PATENT ABSTRACT
A wire harness manufacturing system which issue a working instruction for manufacturing a wire harness to a worker using a network composed of an upstream network and a downstream network, comprising: a clamping pole having a plurality of wire clamps; a jig having a designating portion corresponding to each clamp; a first computer for managing data necessary to manufacture wire harnesses; a second computer for creating an operation instruction file; a third computer for checking the operation instruction file against a master file to create data available for all manufacturing steps; a fourth computer for allotting the file data processed by the third computer to each wire clamping pole, a server for supplying the operation instruction file data to the downstream network; a plurality of information terminal devices which are connected to the servers to requite data necessary for actual operations and provide each designation signal to said designating portion; and a scanner for supplying the number of the claiming pole to a certain information terminal device. In this wire harness manufacturing system, any beginner can manufacture the wire harness easily.

PATENT DESCRIPTION
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to a wire harness manufacturing system which can give instructions to workers to manufacture a wire harness through a network. 
     2. Description of the Related Art 
     A conventional wire harness system, as shown in FIG. 27, includes steps of ( 1 ) preparation (set-up), ( 2 ) wire cutting, ( 3 ) combining of accessory, ( 4 ) terminal crimping, ( 5 ) wire jointing, ( 6 ) assorting, and ( 7 ) “sub-assy(assembly)”. 
     The preparation step of ( 1 ) includes “OEF” processing, instruction outputting, instruction needle (metallic wire)-threading for an instruction card, and assorting of the instruction cards. 
     The OES (Order Entry System) is a method of batch-producing sub-wire harnesses in accordance with job or task instructions. The batch production is to cut a single electric wire into a number of wire segments each having a predetermined length within a single lot and successively crimp the same terminal on each wire to manufacture the electric wires each equipped with the same terminal in lots. The OES refers to inputting processing for this purpose. The instruction outputting is to issue an instruction card on the basis of the OES processing. The instruction cards each with a needle-threaded tied to a product is sequentially transferred to each manufacturing step. In the instruction assorting step, the instruction cards are assorted in accordance with sizes of products. 
     The step ( 2 ) of wire cutting includes “cutting”, “assorting”, “peeling preparation”, and “peeling”. 
     Specifically, in this step, an electric wire is cutting into segments each having equal lengths, The wire segments (simply referred to as “wires”) are assorted in terms of a peeling length, peeling position, etc. Using a peeling machine adjusted in accordance with the peeling length, the insulating covering of each wire is peeled at its end position or middle position. 
     The step ( 3 ) of accessory combining includes “assorting” and “combining of accessory”. 
     Specifically, the wires are assorted in accordance with a kind of accessory, and they are combined with the same accessory. 
     The step ( 4 ) of “terminal crimping” includes “assorting”, “A/P (applicator) preparation”, “crimping”, “testing”, and “marking”. 
     In this step, the wires are assorted in accordance with the kind of a terminal. The A/P preparation is to replace an A/P (applicator) in accordance with a terminal crimping machine and adjust a crimping height. The A/P includes an up-and-down upper die (crimper) and fixed lower die (anvil). After the end of the wire is crimped with a terminal, the crimping state is tested by naked eyes or a television camera, and the terminals are marked with marks for identification in the terminal insertion step described above. 
     The step ( 5 ) of wire jointing includes “joint assorting”, “joint peeling”, “A/P preparation”, “joint crimping”, “testing” and “joint tape winding”. 
     The wires each equipped with the terminal in the step of ( 4 ) are assorted in accordance with the kind of a joint terminal or joint position. The insulating covering at the middle portion of the wire is peeled using a peeling machine. In the same manner as the terminal crimping, the A/P for the joint crimping machine is prepared in accordance with the joint terminal. The terminal of another wire is branch-connected to the peeling position of the wire at issue through the joint terminal. After the crimping state is tested, the joint portion is wound by an insulating vinyl tape. 
     The step ( 6 ) of assorting is to set the terminal-crimped wires and jointed wires for each product number. 
     The step ( 7 ) of “sub-assy” is to insert the terminal of each wire in a connector housing, thereby assembling a sub-assy (sub-wire harness). 
     The sub-assys are arranged in the form of a wire harness on a wire harness board, and subjected to a protector combining and a tape winding to complete a wire harness. 
     The manufacturing system described above does not suffer from the problem when the sub-assembles with the same product (item) number are mass-produced. However, this system requires a large number of tooling changes (replacement of preparation or set-up) in flexible manufacturing (a small amount and a wide variety of products). This leads to poor efficiency and a longer time of work. A worker is required to have knowledge of the wide variety of products, and higher skill. 
     Particularly, in recent years, manufacturing locations of wire harnesses for Japanese motor vehicles have been shifted to overseas factories. The mass-produced products are preferentially shifted, whereas the percentage of the non-mass-produced products is increasing performed in Japanese. Therefore, it is important to manufacture the non-mass produced products effectively. Further, the strategy of a car maker moving abroad has developed the localized production of motor vehicles. Therefore, the production of the non-mass-produced products is increasing in overseas factories for wire harnesses. 
     SUMMARY OF THE INVENTION 
     An object of the present invention is provide a wire harness manufacturing system which permits any person to carry out flexible production of wire harnesses effectively. 
     More specifically, an object of the present invention is to a wire harness manufacturing system which can satisfy the requirements of (1) shortening the lead time to enable the production by a firm order (final order from a car maker), (2) reduce attendant works to increase the production efficiency, (3) improve a work instructing method to enable any person to carry out the work easily, and (4) improve the efficiency of work preparation to prevent the analysis processing in an indirect department from increasing. 
     In order to attain the above object, there is provided a wire harness manufacturing system which issue a working instruction for manufacturing a wire harness to a worker using a network composed of an upstream network and a downstream network, comprising: a plurality of wire clamping poles each having a plurality of wire clamps; a jig having a designating portion corresponding to each clamp; a first computer for managing data necessary to manufacture wire harnesses; a second computer for supplying the data received from the first computer with several kinds of designation data to create an operation instruction file; a third computer for checking the operation instruction file against a master file to create a data file available for all manufacturing steps; a fourth computer for allotting file data processed by the third computer to each wire clamping pole, a plurality of servers for supplying the file data to the downstream network; a plurality of information terminal devices which are connected to the servers to requite data necessary for actual operations and provide each designation signal to the designating portion; and a scanner connected to each of said information terminal devices, for supplying the number of the claiming pole to a certain information terminal device , wherein said first, second, third and fourth computers are connected to the server through a bus line and constitute the upstream network. In this configuration of the wire harness manufacturing system, data necessary to manufacture a wire harness are distributed to each information terminal device from an upstream network through a server. The item number of the wire clamping pole is read to designate a wire to be used in the wire clamping pole. Each information terminal device issues an instruction of the task to be effected by a worker. If the worker effects the task in accordance with the instruction, he can carry out flexible production of a sub-wire harness easily and flexibly with no skill. 
     The above and other objects and features of the present invention will be more apparent from the following description taken in conjunction with the accompanying drawings. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a system diagram showing an embodiment of a wire harness manufacturing system according to the present invention; 
     FIG. 2 is a front view of a wire clamping pole; 
     FIG. 3 is a perspective view of a jig for designating a wire clamp position; 
     FIG. 4 is a view for explaining the state where the detailed data for a wire is divided for each pole; 
     FIG. 5 is a view for explaining the data flow in a system; 
     FIG. 6 is a perspective view of am automated wire cutting machine; 
     FIG. 7 is a front view of am automated peeling machine; 
     FIG. 8 is a front view of a main part of an automated peeling machine; 
     FIG. 9 is a perspective view of an accessory combining step; 
     FIG. 10 is a perspective view of a wire stocker; 
     FIG. 11 is a perspective view of a multiple-die crimping machine; 
     FIG. 12 is a perspective view of a moving cart in a terminal crimping step; 
     FIG. 13 is a plan view of one example of a step layout; 
     FIGS.  14 A- 14 G are plan views of manufacturing formats of sub-wire harnesses in respective steps; 
     FIG. 15 is a flow chart of an SPC step; 
     FIG. 16 is a flowchart of a wire cutting step; 
     FIG. 17 is a flowchart of a wire peeling step; 
     FIG. 18 is a flowchart of an accessory combining step; 
     FIG. 19 is a flowchart of a wire shooting step; 
     FIG. 20 is a flowchart of a terminal crimping step using a servo press; 
     FIG. 21 is a flowchart of a terminal crimping step using a multiple-die press; 
     FIG. 22 is a flowchart of a wire jointing step; 
     FIG. 23 is a flowchart of a soldering step; 
     FIG. 24 is a flowchart of a marking step; 
     FIG. 25 is a flowchart of a terminal inserting step; 
     FIG. 26 is a table showing the summary of an FPS system; and 
     FIG. 27 is a table showing the summary of a conventional system (OES). 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Now referring to the drawings, an explanation will be given of embodiments of the present invention. 
     FIGS. 1 to  14  show an embodiment of a wire harness manufacturing system according to the present invention. 
     Through a network as shown in FIG. 1, this manufacturing system transmit manufacturing instruction data according to product (item) numbers of sub-wire harness for each of steps of cutting  2 , peeling  3 , accessory combining  4 , terminal crimping  5 , wire jointing  6  and terminal inserting so that works to be done are instructed to workers using a wire clamping pole  9  having a bar code (identifying portion)  8  as shown in FIG. 2, a wire clamp position designating jig (pole LED) in which the wire clamping pole  9  is set, etc., and automatic setup for a terminal crimping machine can be made. 
     As shown in FIG. 2, the wire clamping pole  9  is composed of a lengthy straight base plate  55  of aluminum and clamps  42  of synthetic resin arranged at regular intervals on the base plate  55 . Such a wire clamping pole  9  has been used as a wire harness manufacturing jig. A bar code seal  8  is pasted on the base plate  55 . The clamp  42  is composed of a pair of sandwiching members spring-urged in a closing direction between which a wire can be inserted or implanted by a hand from above. Another identifying means can be used in place of the bar code  9 , and another reading means such as a television camera can be used in place of a bar code scanner  36  in FIG.  1 . 
     As shown in FIG. 3, the wire clamping pole  9  is fixed on a wire clamp position designating jig  10  by a manual clamp  56 . On the designating jig  10 , LEDs (light emitting display lamps)  43  are arranged corresponding to the respective clamping positions. The wires  53  are sequentially implanted in the clamps  42  designated by the LEDs  43  so that one or plural wire clamping poles  9  constitute a set of sub-wire harnesses. 
     As seen from FIG. 1, in the network  1 , a bus line (e.g. coaxial cable) is connected to a host computer (first computer)  11 , a receiving personal computer (second computer)  12 , a file server  13 , a master personal computer (third personal computer)  14  and a subsidiary personal computer (fourth personal computer)  15 . Further, the bus line  16  is connected to personal computers (PC)  17  and  18  for the cutting step  2  and peeling step  3  through signal lines  19  and  20 , and also connected to accessory combining step 4, terminal crimping/wire jointing steps 5, 6 and terminal inserting step 7 through LON servers  21 - 23 , and signal lines  24 - 26 , respectively. The LON servers  21 - 23  are connected to a downstream LON network. The LON (Local Operating Network) is mainly directed to the transmission/reception of control command statuses whereas the LAN (Local Area Network)is mainly directed to movement of a large amount of messages. 
     LON servers  21 ,  22  and  23  are connected to information terminal devices  27 ,  29  and  32  for control (ACE III) respectively, which are in turn connected to bar code scanners  36 ,  37  and  38  on the input sides and the wire clamp position designating jigs (pole LEDs)  10   1 - 10   3  (LEDs  43  in FIG. 3) on the output sides and monitors  44 ,  45 . The information terminal devices  27 ,  29  and  32  are connected in parallel to other information terminal devices  28 ;  30 ,  31 ; and  33 . These information terminal devices  28 ;  30 ,  31 ; and  33  are connected to an accessory shelf LED  46 , terminal crimping machines  48 ,  49  and monitor  50 , respectively. 
     These information terminal devices  27 - 33 , which are directed to dispersion control, may preferably be e.g. Oppen Map (trade name) available from TOSHIBA ELECTRIC CO. LTD, which may be replaced by a controller or sequencer. The information terminal devices  27 - 33  can instantaneously collect/monitor information on the shop floor inclusive of facility operating status data, production quantity data, quality monitoring data, etc. The information terminal devices are particularly preferable in the case where an information source and an information destination are dispersed in several branches and where a present intensive control system is shifted to a dispersion control system. The information terminal devices  27 - 33  are connected to steps or devices so that they are integrated to monitoring personal computers and POP terminals (bar code scanner). In this way, while an operator is present in an office, he can easily effect the information management on the production floor, recognize the track record in the production line in real time in comparison to planed production information. The use of the POP terminal makes a handwritten slip unnecessary. Thus, these information terminal devices can be easily connected to upstream computers. 
     The LON servers (data converters for the information terminal devices)  21 - 23  manages the LON network, particularly information terminal devices  27 - 33 . The information terminal devices  27 - 33  request data necessary for each work from the LON servers  21 - 23  and display the data on the monitors  44 ,  45  and  50 . 
     The host computer  11  manages the data necessary to produce wire harnesses. The receiver personal computer  12  adds the wire clamp position data or other data in the wire clamping pole  9  to the data received from the host computer  11  to create pole-classified data. The other data than the wire clamping position data include accessory shelf position (address) data and machine number designation data of machines such as crimping machines or soldering machines. 
     The pole-classified data includes the following contents. Now it is assumed that the detailed data (wire product No. size, cutting length, etc.) received from the host computer  11  are data of a product of 100 circuits (e.g. product No. A). In this case, for example, if only 25 circuits can be set in the wire clamping pole  9  (FIG.  2 ), the data must be distributed for four wire clamping poles  9   1 - 9   4 . For this purpose, the data processed for the “sub-assy” are automatically divided into four components and distributed to the wire clamping poles  9   1 - 9   4 . These data refer to “pole-distributed data”. The pole-distributed data include the detailed data (wire product No. size and cutting length, etc.) for 25/100 circuits and the position data of the clamp  42  in any of the wire clamping poles  9   1 - 9   4  where the wire  53  is to be clamped. 
     In FIG. 1, the file server  13  manages the upstream network and also manages the data necessary for production. The master personal computer  14  checks each master file or data against the data allotted to the wire clamping by the receiver personal computer  12 . The printer  54  outputs the list necessary for work. The subsidiary personal computer  15  allots the data processed by the master personal computer  14  to the wire clamping poles  9 . 
     Where the system of FIG. 1 is used within a comparatively narrow area such as a single factory, the host computer  11  is replaced by a locating server (first computer), the receiver personal computer  12  is replaced by a data server (second computer) and the file server  13  can be omitted. In FIG. 1, the components located above from the bus line  16  or the LON servers  21 - 23  constitute the upstream network. 
     FIG. 5 shows the flow of data signals in the network as shown in FIG.  1 . 
     First, the data (work designation file) supplied with the clamping positions by the receiver personal computer  12  are stored in the file server  13 . On the basis of the data  57 , three data of cutting data  58 , peeling data  59  and LON files  65 ,  66  are created by the master personal computer (data creator for the entire process)  14  and the subsidiary personal computer  15 . 
     The cutting data  58  is sent to the cutting machine  63 , and the peeling data  59  is sent to the peeling machine  64 . Since the machines (cutting machine  63  and peeling machine  64 ) are provided with control personal computers  17  and  18 , respectively, the cutting data  58  and peeling data  59  are directly supplied to the control personal computers  17  and  18 , respectively. The control personal computers  17  and  18  process the data  58  and  59  in accordance with the necessary data and order and directly transfer the data thus processed to the cutting machine  63  and the peeling machine  64 . 
     Using the file creating software&#39;s (“A” and “B” file creating software&#39;s  67  and  68 ) for the LON servers  21 - 23 , the LON files  65  and  66  are processed into data (“A” and “B” file data  69  and  70 ). The data  69  and  70  are sent to the devices (e.g. accessory shelf LED  46  and terminal crimping machine  48 ) using the softwares  71  and  72  in the information terminal device (ACE III), respectively. Incidentally, the LON files  65 ,  66  are general irrespectively of the facility and process, and the step specification (specified facility) using the information terminal devices  27 - 33  can be modified by a user. 
     A detailed explanation will be given of each of the steps as shown in FIG.  1 . 
     In the wire cutting step  2 , with a bar code scanner  34  connected to the personal computer  17  and with the personal computer  17  connected to the automated cutting machine  61 , the cutting machine  61  carries out sizing, cutting and cover peeling (middle position) of the wire and implanting of the wire into the wire clamping pole  42  (FIG.  2 ). 
     The automated cutting machine  61 , as shown in FIG. 6, a sizing reel unit  72  for sizing wires supplied from  120  wire selecting nozzles, a peeling unit  74  for peeling the middle portion of the sized wire, a cutting/implanting unit  75  for cutting and implanting the wire into the wire clamping pole  9 , and a setting portion  76  in which the wire clamping pole  9  is set. The cutting/implanting unit  75  or setting portion  76  is moved horizontally by servo control so that the wire is implanted in the required clamp. 
     In the peeling step  3  in FIG. 1, like the wire cutting step  2 , with the bar code scanner  35  connected to the personal computer  18  and with the personal computer  18  connected to the automated peeling machine  62 , the automated peeling machine  62  peels the end portion of the wire. 
     As shown in FIG. 7, the automated peeling machine  52  shifts the wire clamp position designating jig  10  along a horizontal rail  78  by drive of a belt  77  so that the wire  53  in the desired clamp  42  of the wire clamping pole  9  is located between and peeled by a pair of peeling blades  79 . The peeling state of the wire  53  is automatically tested by a television camera  80 . As shown in FIG. 8, the pair of peeling blades  79  are located on both sides of the terminal of the wire  53 , and is moved to the wire by rotation of a screw shaft  82  by a first servo motor  81  to make an incision on the covering of the wire  53 . Subsequently, the blades  79  are moved backwards together with the base plate  84  by rotation of a second servo motor  83  so that the covering is removed off from the wire  53 . 
     In FIG. 7, the wire clamping pole  9  is set in the wire clamp position designating jig  10  by an operator. The bar code of the wire clamping pole  9  is read using the scanner  35  in FIG. 35 so that the personal computer  18  reads the product number of the sub-wire harness relative to the wire clamping pole  9  and receives the manufacturing instruction for the sub-wire harness from the upstream network. Thus, the belt  77  of the automated peeling machine  62  in FIG,.  7  is driven by a servo motor  85 so that the required wire  53  is located between the peeling blades  79  and its end portion is peeled. 
     In FIG. 1, between the automated cutting machine  61  and automated peeling machine  62 , a rail (not shown) is provided for moving the wire clamping pole  9 . 
     Additionally, in the peeling step in FIG. 1, a plurality of different kinds of peeling machines (not shown) are arranged and any of them may be automatically selected in such a manner that the wire clamp position designating jig  10  and the operation display lamp of each peeling machine are connected to each other by the same information terminal device  29  as in the terminal crimping step  5  described later. In the cutting and peeling steps  2  and  3 , personal computers  17  and  18  are sufficient to handle the required communication volume. 
     In the accessory combining step in FIG. 1, the first information terminal device  27  is connected to the first LON server  21  through an interface  86 , to a bar code scanner  36  on the input side, and to the pole LED on the output side, i.e. wire clamping position designating jig  10   1 . The first information terminal device  27  is also connected to a monitor  44  in parallel to the pole LED  10   1 . Using the moving cart  88 , the first information terminal device  27 , bar code scanner  36 , interface base plate  87 , pole LED  10   1  and monitor  44  can be moved simultaneously. 
     The second information terminal device  28  is connected in parallel to the first information terminal device  27 . The second information terminal device  28  is also connected to an accessory shelf LED  46  through a sequencer  89  and a wire stocker LED  47  through an interface base plate  90 . 
     As shown in FIG. 9, the accessory shelf  46  is located in front of the wire clamp position designating  10   1 . The wire clamp position designating jig  10   1  is provided with LED&#39;s  43  arranged corresponding to the positions of the respective clamps  42  of the wire clamping pole  9 . The wire clamping pole  9  is set in the wire clamp position designating jig  10   1  via the peeling step  3 . The accessory shelf  46  is provided with different accessory boxes  91  in which different accessories are housed and LED&#39;s  43  arranged correspondingly to the accessory boxes  91 . 
     The wire clamp position designating jig  10   1  is located on a fixed stand or a moving cart  88  used in the crimping step described below. In FIG. 1, between the automated peeling machine  62  and the wire clamp position designating jig  10   1 , a rail (not shown) may be arranged for moving the wire clamping pole. 
     A wire stocker  47  as shown in FIG. 10 is located beside the accessory shelf  46 . The wire stocker  47  has a plurality of wire housing cylinders  92  arranged in parallel and in plural stages. Each wire housing has an opening  93  in its front, and the LED  43  is provided on the upper side of each opening  93 . Within the wire housing cylinder  92 , several kinds of special electric wires such as a twisted wire or shielded wire are housed. A worker pulls out the wire  94  from the opening  93  designated by an LED  43 , and implants it in the clamp  42  designated by the LED  43  of the wire clamping pole  10   1  shown in FIG.  9 . 
     In FIG. 1, the manufacturing designating data are sent to the pole LED  10   1 , accessory shelf LED  46  and wire stocker LED  47  from the upstream network through the information terminal devices  27 ,  28 . Then, each LED illuminates. The worker picks up the electric wire  53  from the clamp  42  with the LED illuminated in the pole LED  10   1  and the accessory  95  from the accessory box  91  with the LED illuminated in the accessory shelf LED  46  and mounts the accessory  95  to the wire  53 . Otherwise, the worker takes out a special wire  94  from the wire housing cylinder  92  with the LED illuminated in the wire stocker LED  47  and the accessory  95  from the accessory box  91  with the LED emitted light, and combines the accessory  95  with the special wire  94 . 
     In the terminal crimping/wire jointing steps  5  and  6  as shown in FIG. 1, the second LON server  22  is connected to the third information terminal device  29 . The third information terminal device  29  is connected to a bar code scanner  37 , a pole LED  10   2  (i.e. wire clamp position designating jig) through an interface base plate  96 , and a monitor  45 . These components can be simultaneously moved by a moving cart  97 . 
     The third information terminal device  29  is connected in parallel to a fourth information terminal device  30 . The fourth information terminal device  30  is connected in series with a crimping monitor  98  and a servo press (crimping machine)  48 . The servo press  48  is connected in parallel to the fourth information terminal device  30  through a signal line  99 . A task display lamp  100 , which is located beside the servo press  48 , is connected to the fourth information terminal device  30 . 
     The fourth information terminal device  30  is connected in parallel to a fifth information terminal device  31 . The fifth information terminal device  31  is connected in series with a crimping monitor  10   1  and multiple die press (crimping machine)  49 . The multiple die press  49  is connected in parallel to the fifth information terminal device  31  through a signal line  102 . A task display lamp  103 , which is located beside the servo press  49 , is connected to the fifth information terminal device  31 . 
     A second servo press (not shown) may be arranged beside the multiple die press  49 . In this case, the fifth information terminal device  31  is connected in parallel to the other terminal device (not shown) through a signal line. The other terminal device is connected to the multiple die press  49 . 
     The servo press  48  may be a known device which rises or falls the shaft of an applicator using a servo motor (not shown) to crimp a terminal on a wire between an upper die (crimper) and a lower die (anvil). 
     As shown in FIG. 11, the multiple die press  49  is provided with a plurality of applicators  104  arranged radially, and can select a required applicator  104  by drive of a servo motor  105 . The applicators  104  are automatically selected using a signal transferred to the fifth terminal device  31  through the LON server  22  as shown in FIG.  1 . The multiple die press  49  is connected to the crimping monitor  45  which can recognize the crimping state of the terminal. Terminals (located at random)  106  are housed according to a kind in each housing portion  107 . When a certain applicator  104  is selected, the corresponding housing portion  107  is rotated together therewith to select the terminal automatically. 
     As shown in FIG. 12, the crimping machines  48  and  49  are arranged on a supporting stand  108 , and in front of the supporting stand  108 , a moving cart  97  is arranged movably in a horizontal direction on a rail  109 . The moving cart  97  carries the wire clamp position designating jig  10   2 , information terminal device  29  and bar code scanner  37 . The wire clamping pole  9  is set in the wire clamp position designating jig  10   2 , and the wires  53  and  94  are implanted in the clamps  42  of the wire clamping pole  9 . On the wire clamp position designating jig  10   2 , an LED  43  is arranged corresponding to each clamp  42 . 
     Instruction data are directly transferred from the upstream network shown in FIG. 1 to each crimping machine  48 ,  49  through the information terminal devices  29 - 31 . The worker takes out the wire  53 ,  94  from the clamp  42  with the LED illuminated and crimps the terminal on the wire taken out using the designated crimping machine  48  or  49 . Thereafter, the wire is put back to the clamp  42 . 
     Both the terminal crimping and wire jointing can be effected by the same servo press  48 . Otherwise, in FIG. 1, the fifth information terminal device  31  is connected in parallel to one or plural other information terminal devices (not shown) which are in turn connected to a joint servo press (not shown) like the servo press  48 . 
     In the terminal insertion step in FIG. 1, the third LON server  23  is connected to a sixth information terminal device  32  which is in turn connected to a bar code scanner  38  and a pole LED  10   3  (wire clamp position designating jig) through an interface base plate  110 . These components can be simultaneously moved by a moving cart  111 . 
     The sixth information terminal device  32  is connected in parallel to a seventh information terminal device  33  which is in turn connected to a monitor  50 . The monitor displays which terminal chamber of a connector housing (not shown) a terminal is to be inserted into. Instruction data are directly transferred from the upstream network shown in FIG. 1 to the pole LED  10   3  and monitor  50  through the information terminal devices  32 - 33 . 
     In the embodiment of FIG. 1, the LON servers  21 - 23  are arranged for the steps  4 ,  5 / 6 , and  7  of accessory combining, terminal crimping/wire jointing and terminal insertion to increase the processing speed. However, the same LON server may be shared between e.g. the accessory combining step  4  and the terminal insertion step  7 . In this case, the signal line  112  in the accessory combining step  4  in FIG. 1 is directly connected to the sixth information terminal device  32  in the terminal insertion step  7  to exclude the third LON server  23  so that the first LON server  21  can control the accessory combining step  4  and terminal inserting step  7  and the second LON server  22  can control the terminal crimping/wire jointing steps  5 / 6 . 
     In FIG. 1, an additional cutting machine (not shown) for wires used with a low frequency may be arranged in parallel to the automated cutting machine  61 . In this case, this additional cutting machine is connected to a sequencer (not shown) which is in turn connected to a wire shelf LED (not shown). The additional cutting machine and sequencer are connected to a personal computer (not shown) which is in turn connected to the bar code scanner and the pole LED. 
     FIG. 13 shows an example of the layout of the steps as described above. FIGS.  14 A- 14 G show formats of the sub-wire harnesses in the respective steps. An explanation will be given of the respective steps. 
     The wires  53  used with a high frequency each having a sectional area of 0.3-3.0 mm 2  are transferred from a wire shelf  113  to an automated cutting machine  61 , and cut to have a required length. Their middle portions are peeled ( 114 ) and the wires thus created are implanted in the wire clamping pole  9  (FIG.  14 A). Beside the automated cutting machine  61 , a cutting machine (not shown) may be arranged for cutting, peeling and implanting the wires used with a low frequency each having 0.3-3.0 mm 2 . 
     The wire clamping pole  9  with the wires each having a prescribed length implanted is transferred to a pole-setting automated peeling machine  62 . The ends  53   a  of the wires are peeled by the automated peeling machine  62  (FIG.  14 B). The wire clamping pole  9  is transferred to the accessory combining step  4  along the rail  116  and carried on a moving cart. In the accessory combining step 4, accessories such as a tube and water-proofing rubber stopper are taken out from the accessory shelf  46  and combined with the wires  53 . At the same time, a required wire(s) is taken out from the wire stocker  47  for a special wire step  117  by which a special wire (inclusive of a heavy wire of 5 sq or larger, shielded wire and twisted wire) is subjected to several kinds of processing such as cutting and peeling, and is implanted in the clamp of the wire clamping pole  9  (FIG.  14 C). 
     The wires  53  and  94  combined with the accessories are transferred, together with the wire clamping pole  9 , to the terminal crimping step  5  along the rail  16  and carried on a moving cart. Terminals  106  are crimped on the ends of the wires  53  and  94  using the servo press  48  and multiple die press  49  (FIG.  14 D). The moving cart is installed for each of the steps, and the information terminal device is mounted on each moving cart. 
     The wires subjected to the terminal crimping are transferred to the adjacent soldering/marking step  118 . In this step, soldering  119  is made for the crimping portion of a required terminal  95  and jointing portion of the wire to reinforce the crimping portion and jointing portion (FIG.  14 E). A soldering machine is classified in uses of thin and thick solders, or iron soldering and jab soldering. Each soldering machine is equipped with an LED for designating the machine number to be used. The LED receives a signal from the upstream network through the same personal computer as in the wire cutting step  2  and through the same information terminal device as in the accessory combining step  4 . This applies to the marking step. 
     The marking step serves to identify the terminal  95  crimped on the same kind of wire  53  in the terminal inserting step, and makes a marking  119  on the crimping portion of the terminal using a marker. The marker is selected by the LED through an instruction from the high order network. 
     The terminal-equipped wires  53  and  94  subjected to the soldering/marking are sent, together with the wire clamping pole  9 , to the adjacent wire jointing step  6 . The servo press  48  and a tape winding machine  120  are arranged for the wire jointing step  6 . The end of another wire  53   2  is branch-coupled with the middle peeled portion of the wire  53   1  at a joint terminal  201  (FIG.  14 F). An insulating tape is wound around the joint portion. The required joint portion is subjected to the soldering step before the tape winding step. The soldering step is monitored in the jointing step  6 . 
     The terminal-equipped wires  53  and  94  subjected to the jointing are sent, together with the wire clamping pole  9 , to the terminal insertion step  7 . In the terminal insertion step  7 , the terminals of  95  on the one or both sides of the wires  53  are inserted in a connector housing  202  (FIG.  14 G). The connector housing  202  to be used is designated by the LED arranged on a component shelf  203  to which a designation signal is supplied from the upstream network. 
     Using the flowcharts, an explanation will be given of the working procedure in each step. 
     FIG. 15 is a sub-personal computer step in which a wire clamping pole  9  is registered. 
     First, a worker places a switch of a cutting machine in a pole input mode ( 205 ). Where a component number is displayed on a monitor ( 206 ), he reads the bar code of the wire clamping pole using a bar code scanner ( 207 ). Thus, the number (No) of the wire clamping pole is registered on a data base of received data ( 208 ) to indicate the correspondence between the number of the wire clamping pole and the product number of the sub-wire harness. The pole-allotted received data ( 209 ) are created on the basis of the received data ( 208 ). After having read the bar code, the wire clamping pole data is read to a subsequent step, e.g. wire cutting step ( 210 ). 
     FIG. 16 shows a wire cutting step. 
     First, a worker takes the wire clamping pole ( 211 ) and its bar codes using the bar code scanner ( 212 ). With the wire clamping pole set in the automated cutting machine (FIG.  6 ), he may read the bar code. Thus, the item number of the wire clamping pole is input in working order data ( 213 ). A product or design number is displayed on the monitor on the basis of the working order data. The signals indicative of the number of a wire introducing nozzle, cutting length, middle-peeling position, middle-peeling size and clamping number of the wire clamping pole (two clamping numbers of both ends of a single wire) are supplied to a personal computer for the automated cutting machine ( 215 ). 
     The worker, as long as he does not hear a finish buzzer ( 216 ), sets the wire clamping pole in the automated cutting machine and turns on an operation switch ( 218 ). Thus, the cutting, middle-peeling and implanting of the wires into the wire clamping pole are carried out automatically ( 219 ). After the worker recognizes the completion of operation of the automated cutting machine, he takes out the wire clamping pole from the automated cutting machine( 221 ), carries it on the rail ( 222 ) and send it to the subsequent step (peeling step). 
     FIG. 17 shows the film peeling step. 
     First, a worker sets the wire clamping pole in the automated peeling machine ( 223 ). He reads the bar code of the wire clamping pole using the bar code scanner ( 224 ). Thus, the number of the wire clamping pole is supplied to a file of film-peeling data of a personal computer. The peeling data inclusive of a wire number, wire size, clamping number (two clamping numbers of both ends of a single wire) and film-peeling size of each terminal are supplied to the automated film-peeling machine ( 226 ). 
     The start switch of the automated film-peeling machine is turned on ( 227 ). The ends of each wire are automatically peeled ( 228 ). The peeling state is monitored automatically by image processing. After completion of the peeling is confirmed ( 230 ), the worker carries the wire clamping pole on a shifting rail ( 231 ), and sends the wire clamping pole to the subsequent step (accessory combining step). 
     FIG. 18 shows an accessory combining step. 
     First, a worker sets the wire clamping pole in the wire clamp position designating jig ( 232 ). He reads the bar code of the wire clamping pole ( 233 ). Thus, the number of the wire clamping pole is supplied to an accessory data file ( 234 ). The product number, design number and task name of the sub-wire harness are displayed on the monitor ( 235 ). A component shelf address signal is outputted from the accessory data to cause the LED of a component shelf to be used illuminates ( 236 ). A clamping number signal is outputted to cause the LED of a wire clamp position designating jig to illuminate ( 237 ). 
     The worker recognizes the presence of a task from the display of the monitor and lighting of the LED. He takes the component (water-proofing stopper, insulating tube, etc.) with the LED emitted in the component shelf ( 239 ), pulls out the wire from the clamp with the LED illuminated, and combines the component with the wire ( 241 ). Thereafter, the component-equipped wire is manually implanted in the clamp with the LED illuminated ( 242 ). He turns on a stepping switch ( 243 ) to confirm the presence or absence of a task. If no task is present, the buzzer sounds ( 244 ). Then, he carries the wire clamping pole on the shifting rail ( 245 ) and sends to the subsequent step (implanting step of a special wire). 
     FIG. 19 shows the wire implanting step. 
     First, a worker sets the wire clamping pole in the wire clamp position designating jig ( 255 ), and reads the bar code of the wire clamping pole ( 257 ). Thus, the item number of the wire clamping pole is supplied to an implanting data file ( 257 ). The product number, designing number, lot number and wire color of a sub-wire harness are displayed on a monitor ( 258 ). In addition, the clamp number signals indicative of the positions where both ends of the wire are to be clamped are outputted sequentially by the operation of the stepping switch so that the LED&#39;s of the two clamps of the wire clamp position designating jig illuminate sequentially ( 259 ,  260 ). 
     The worker confirms the presence of a task ( 261 ), and confirms the lot number from the display of the monitor ( 262 ). He takes out the special wire such as a twisted wire and a shielded wire from the wire stocker ( 263 ). He confirms the wire color in comparison with the displayed color ( 264 ). Thereafter, he implants the one terminal (terminal A) of the wire in the clamp on the side of the one illuminated LED in the wire clamp position designating jig ( 265 ). By turning on the stepping switch ( 266 ), he implants the other terminal (terminal B) of the wire in the clamp on the side of the other illuminated LED in the wire clamp position designating jig ( 267 ). The terminal A is located on the forward side within the wire stocker. After implanting, he turns on the stepping switch ( 269 ) to confirm the presence or absence of a task. If no task is present, the buzzer sounds ( 269 ). He carries the wire clamping pole on the shifting rail ( 270 ) and shifts it to the subsequent step (terminal crimping step). 
     FIG. 20 shows the terminal crimping step using a servo press. 
     First, a worker sets the wire clamping pole in the wire clamp position designating jig ( 271 ), and reads the bar code of the wire clamping pole ( 272 ). Thus, the number of the wire clamping pole is supplied to a terminal crimping data file ( 273 ). The signal indicative of the machine number of the servo press is outputted from the crimping data file to illuminate the LED of a required servo press ( 274 ). A plurality of servo presses are arranged. 
     Simultaneously, the crimping data signal designating the terminal product number, wire size, crimp height is outputted from the crimping data file so that the servo press is automatically prepared ( 275 ). Specifically, the servo motor is operated so that the descending stroke of the upper die of the crimping jig is automatically adjusted. The crimping data are displayed on the monitor ( 276 ). The clamp number signal of the wire clamping pole is outputted to illuminate the corresponding LED ( 277 ). Further, another LED indicative of “double-crimping”, i.e. the case where two wires superposed with each other are crimped illuminates in the wire clamp position designating jig ( 278 ). 
     The worker recognizes the presence or absence of the crimping operation ( 279 ), and moves to the servo press designated by the LED ( 280 ). He takes out the wire from the clamp designated by the LED of the wire clamping pole on the moving cart ( 281 ). He confirms whether the LED indicative of the double-crimping illuminates or not. If it is not, the terminal is crimped on the wire ( 283 ). The crimp height is checked automatically ( 284 ) to check the crimping state automatically or visually. If the checking result is OK, he implants the terminal-equipped wire in the clamp in the wire clamping pole designated by the LED ( 286 ). If the subsequent task is present, the above cycle is repeated. If it is not, he turns on the stepping switch ( 288 ) to confirm whether the crimping operation is present or absent ( 279 ). If it is absent, he confirms a finish buzzer ( 289 ). He carries the wire clamping pole on the shifting rail ( 290 ) and shifts it to the subsequent step. The shifting cart is placed for each of the steps. 
     If the checking result of the crimping height is not to standard ( 284 ), for example, he switches the servo press into a manual crimping mode ( 291 ). In this mode, the wire terminal processing such as peeling is carried out referring to a crimping standard table. The crimp height is adjusted ( 293 ) and the crimping is effected ( 294 ). Such a re-crimping operation may be carried out after a series of crimping operations have been completed. 
     FIG. 21 shows a terminal crimping step using a multiple die press (FIG.  11 ). 
     This step is basically the same as the terminal crimping step using the servo press. 
     First, a worker sets the wire clamping pole in the wire clamp position designating jig ( 295 ), and reads the bar code of the wire clamping pole ( 296 ). Thus, the number of the wire clamping pole is supplied to a terminal crimping data file ( 297 ). At the same time,the crimping data signal designating the terminal product number, wire product number, wire size, crimp height is outputted from the crimping data file. 
     The worker shifts the wire clamping jig to the multiple die press with the LED illuminated ( 300 ) and turns on the switch. Then, the lamp of a required multiple die press blinks ( 298 ), and the multiple die press is automatically placed on the basis of the crimping data. When the set-up or placement is completed, the lamp illuminates ( 302 ). Thus, completion of the placement is confirmed ( 303 ). When the signal of the clamp number is outputted from the terminal crimping data file ( 297 ), the LED of the required clamp in the clamp position designating jig illuminates ( 304 ). The worker takes the wire from the clamp ( 305 ), and confirms that the lamp for double-crimping does not illuminate ( 306 ,  307 ). Thereafter, the terminal crimping will be carried out. The subsequent process, which is the same as the case of using the servo press, will not be explained nor illustrated. 
     FIG. 22 shows the wire jointing step. 
     This step is also generally the same as the crimping step described above. 
     First, a worker sets the wire clamping pole in the wire clamp position designating jig ( 309 ), and reads the bar code of the wire clamping pole( 310 ). Thus, the item number of the wire clamping pole is supplied to a joint data file ( 311 ). The LED indicative of the required jointing machine (servo press) illuminates ( 312 ). At the same time, the jointing data signal designating the wire product number, wire size, jointing position, jointing direction, presence/absence of soldering, clamp number, etc. are outputted from the joint data file, and displayed on a joint monitor ( 313 ). Further, the servo press is automatically placed on the basis of the joint data, and the LED in the wire clamp position designating jig illuminates ( 315 ). The LED&#39;s for the two wires to be jointed in FIGS. 14E and 14F illuminate. 
     The worker moves to the machine (servo press) designated by the LED ( 316 ) and sees the monitor ( 317 ). He takes the wires from the clamps with the LED&#39;s illuminated, and joints these wires using the servo press. The measurement of the crimping height and appearance checking are automatically used ( 320 ). If the checking result is OK, the worker re-implants these wires in the initial clamps ( 321 ). The subsequent process, which is the same as the crimping step, will not be explained nor illustrated. If the checking result is NG, he adjusts the servo press ( 322 ). He effects the jointing again, for example by replacing the terminal by a new terminal. 
     FIG. 23 shows the soldering step. 
     First, a worker sets the wire clamping pole in the wire clamp position designating jig ( 323 ), and reads the bar code of the wire clamping pole ( 324 ). Thus, the number of the wire clamping pole is supplied to a soldering data file ( 325 ). Thus, the number of the wire clamping pole is supplied to a soldering data file ( 325 ). The LED indicative of the required soldering machine illuminates ( 326 ). The LED of the wire clamp position designating jig illuminates ( 327 ) to designate the clamping position. 
     The worker recognizes the presence or absence of task ( 328 ) and the machine number of the soldering machine to be used. He takes the terminal-equipped wire from the clamp with the LED illuminated ( 330 ), and makes the soldering for reinforcement at a terminal crimping portion or jointing portion ( 331 ). Upon completion of the soldering, he re-implants the wire into the initial clamp with the LED illuminated ( 332 ). He confirms the presence or absence of the subsequent task ( 333 ), and turns on a stepping switch ( 334 ). When the completion buzzer ( 335 ) sounds, he carries the wire clamping pole on the rail ( 336 ) and send it to the subsequent step. 
     FIG. 24 shows the marking step. 
     First, a worker sets the wire clamping pole in the wire clamp position designating jig ( 337 ), and reads the bar code of the wire clamping pole ( 338 ). Thus, the number of the wire clamping pole is supplied to a marking data file ( 339 ). The marking address signal is outputted from the marking data file to illuminate the LED indicative of the required marking on a marking shelf ( 340 ). Further, the product number and marking color of the sub-wire harness are displayed on a monitor ( 341 ). The LED of the wire clamp position designating jig illuminates ( 342 ) to designate a required terminal-equipped wire. 
     The worker recognizes the LED of the marker shelf and takes a marker with the LED illuminated. After he confirms coincidence between its color and the marking color displayed on the monitor ( 344 ), he makes a marking on the terminal-equipped wirewith the LED illuminated ( 345 ,  346 ). The worker returns the marker to its initial position (marker shelf with the LED emitted), and turns on a stepping switch ( 348 ). When the completion buzzer ( 349 ) sounds, he carries the wire clamping pole on the rail ( 350 ) and sends it to the subsequent step. 
     FIG. 25 shows the terminal insertion step. 
     First, a worker sets the wire clamping pole in the wire clamp position designating jig ( 351 ), and reads the bar code of the wire clamping pole ( 352 ). Thus, the number of the wire clamping pole is supplied to an terminal insertion data file ( 353 ). A terminal insertion position signal is outputted from the data file so that the monitor displays the item number of a connector housing and wire color, and displays a diagram indicative of the terminal chamber of the connector housing into which the terminal is to be inserted (e.g. a single terminal chamber of the connector housing blinks) ( 354 ). A connector housing designating signal indicative of the connector housing to be used is outputted to illuminate the LED of the connector shelf (component stocker) ( 355 ). A clamp position designating signal is outputted to illuminate the LED of the wire clamp position designating jig ( 356 ). 
     From the illuminated LED, the worker confirms the presence of the connector housing into which a terminal is to be inserted ( 357 ), and takes out the connector housing designated by the LED from the connector shelf ( 358 ). The worker takes out the terminal-equipped wire from the clamp designated by the LED in the wire clamp position designating jig ( 359 ). From the diagram displayed on the monitor, he confirms the position of a terminal chamber into which the terminal is to be inserted and the wire color, and inserts the terminal into the designated terminal chamber in the connector housing ( 361 ). He confirms correctness of the actually inserted terminal in comparison to the diagram displayed on the monitor ( 362 ), and carries out the subsequent terminal insertion operation. When he has inserted all the terminals into the terminal chambers, the sub-wire harness is completed. He turns on the stepping switch ( 363 ) to confirm the completion buzzer ( 364 ). The worker takes out the wire clamping pole from the wire clamp position designating jig ( 365 ), and sends the wire clamping pole with the sub-wire harness being hung on to the subsequent wire harness board step. 
     The operation procedure in the wire harness manufacturing system according to the present invention was described hitherto. 
     This system, i.e. FSP (Flexible Synchronous Production) system can be summarized as follows. 
     (1) The preparation step (from the wire cutting to terminal insertion) is carried out with a set of a wire clamping pole on a line. An ID, namely a bar code seal is pasted on the wire clamping pole. While the ID is being read in each step, data necessary for processing are taken. 
     (2) The facility in each step is controlled so that the tooling change and main operations are effected automatically. 
     In the cutting step, using the automated cutting machine (CS50) having a 120 wire color changing device, the operations of wire changing, cutting, middle-peeling and wire implanting in a wire clamping pole may be automatically carried out. In the peeling step, peeling of both ends of the wire is automatically carried out by a pole-setting peeling machine. In the crimping/jointing step, exchange of the C/H (crimping height) and A/P (applicator) is carried out using the servo press or multiple die servo press. 
     (3) In the steps using no facility (accessory combining and terminal insertion) and subjected to communication control (crimping machine with no servo), necessary data are given to the worker at an appropriate time using a personal computer, monitor and LED. 
     (4) The data necessary for manufacturing are automatically created on the basis of the CAE (Computer Aided Engineering) and data base for each factory (or each step). 
     In accordance with the system, as shown in FIG. 26, the operations can be simplified greatly in comparison to the ordinary OES (Order Entry System) (FIG.  27 ). Specifically, in the preparation step, the operations of outputting of the instruction card, needle-threading for the instruction card, assorting of the instruction cards can be excluded. In the cutting step, the operations of wire assorting and peeling set-up can be excluded. In the accessory combining step, the operation of assorting can be excluded. In the terminal crimping step, the operations of assorting and A/P set-up can be excluded. In the jointing step, the operations of joint assorting, joint middle-peeling and A/P set-up can be excluded. Further, the assorting step can be excluded. 
     More specifically, (1) the manufacturing instruction data for each step are directly supplied to the facility, thus requiring no instruction sheet. This is attributable to use of an information terminal device. (2) Improvement of data transfer to the facility and function of the facility excludes necessity of set-up and human errors. (3) Shifting from the batch production to the set (cycle) production excludes the assorting and intermediate stock. This shortens the lead time in total. Namely, the automatic set-up through the data communication reduces an operation error, the reduction of the attendant operation improves the efficiency, and the production by a firm order is permitted so that the locked up items are reduced.