JP2002006934A - Worker allocation adjustment method on production line and its system - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an allocation adjustment method of a worker on a production line with a high productivity and growth potential according to a result from the productivity evaluation of the worker, its feedback to the ongoing production and a calculation of the productivity on line by line and product class by product class basis based on the actual result of the work. SOLUTION: The actual result of the work activity from a task start to its end on the production line is prepared as a work progress table 22, 23 and every time when a working efficiency at each production line is evaluated based on a designated evaluation criterion mainly consisting of balance of the number of the product yet to be manufactured and a remaining work hour as the evaluation items, a change order is issued to the worker required and the capability master table 21 is updated after the work is completed based on the performance at work written to performance at work progress table 22, 23.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for adjusting the distribution of workers on a production line and an improvement of the system.

[0002]

2. Description of the Related Art In recent years, in a production line including manual operations such as processing and assembly in a factory or the like, in order to efficiently produce a product, a work plan relating to worker arrangement by a computer system such as Japanese Patent Application Laid-Open No. Hei 5-2594 is prepared. Is used. In addition, during production, the distribution of workers is generally adjusted manually by comparing a planned value and an actual value of the production quantity.

[0003]

However, in the conventional work plan, only an appropriate number of workers is allocated according to the production quantity, and the work plan cannot be established based on the productivity of the workers. In addition, the adjustment of worker distribution during production is based on the evaluation of worker productivity, merely moving the worker on the line that is advancing to the line that is behind according to the progress of the work. Was not.

[0004] Therefore, even if a work plan is made, the work does not proceed according to the plan, causing a loss of movement of the worker between lines.

The present invention has been made in view of the above problems, and evaluates the productivity of an operator, feeds it back to the current production, and, based on the operation results, the productivity of each line and each product. It is an object of the present invention to provide a method for adjusting the distribution of workers on a production line having high productivity and high growth potential.

[0006]

According to a first aspect of the present invention, there is provided a method for adjusting the distribution of workers in a production line, comprising the steps of: Is created as a work result progress table, and the work efficiency in each line is
In accordance with the predetermined conditions, each time the evaluation is performed according to the predetermined evaluation criteria, which mainly includes the number of unprocessed products remaining and the remaining work time, etc., the necessary instructions for changing the worker are issued, and the ability master table indicates that the work has been completed. Later, the work result is updated based on the work result written in the work result progress table.

According to a second aspect of the present invention, the distribution of the workers in the production line is adjusted by collecting the results of work activities from the start of the work to the completion of the work on the production line and creating a work result progress table. Work progress table creation means, work performance in each line, according to predetermined conditions, work performance evaluation means to evaluate according to a predetermined evaluation criteria and the main evaluation items such as the number of unprocessed product remaining and remaining work time, A change instructing means for receiving an instruction from the work performance evaluation means and instructing a field worker to change a required worker, and a work performance progress table creating means, after completion of the work, The ability master table is updated based on the work results written in the progress table.

According to the first and second aspects, after the completion of the work, the ability master table, that is, the parameters based on the factors of the worker and the like are updated based on the work results, so that a more accurate line tact value is utilized. The distribution can be adjusted.

According to a third aspect of the present invention, when the worker on the manufacturing line is a new person or the like who is not sufficiently used to work,
The capability master table is referred to by taking a predetermined correction rate into consideration, and after the work is completed, the capability master table is updated taking into account the predetermined correction factor.

According to a fourth aspect of the present invention, when a product to be worked on a manufacturing line is a new product, the capability master table is referred to by taking a predetermined correction rate into consideration, and after the work is completed, The capability master table is updated in consideration of a predetermined correction rate.

Therefore, according to the method for adjusting the distribution of workers according to the third or fourth aspect, the distribution can be adjusted in response to a change in the situation such as new employee introduction or new product introduction.

According to the fifth aspect, the man-hour load factor for determining the number of workers to be distributed to the production line is sequentially updated by a learning function in consideration of the actual work performed. As a result, it is possible to sequentially cope with a fluctuating environmental change of the production line.

According to the present invention, each time a work efficiency is evaluated for each of the production lines, a load accumulation simulation is performed, and a change notice is notified to a line requiring a change in worker distribution. I have.

According to the present invention, each time the work efficiency is evaluated for each of the production lines, it is necessary to carry out load accumulation simulation means for performing load accumulation simulation, and to change the worker distribution by the load simulation. The line includes a change notice notification means for notifying change notice.

Therefore, according to the sixth or seventh aspect, it is possible to prompt the operator to prepare for the rearrangement, thereby realizing a quick rearrangement.

According to the present invention, each time a predetermined operation on the production line is completed, the operation result and the distribution history of the distribution of workers are totaled, and the capability evaluation data for each worker is generated and output. According to the ninth aspect of the present invention, each time a predetermined operation on the production line is completed, the operation result and the worker distribution change history are totaled, and the capability evaluation data for each worker group is generated and output.

As a result, an appropriate work plan in the future can be easily set by using the capability evaluation data.

[0018]

Embodiments of the present invention will be described below with reference to the drawings.

FIG. 1 is a flowchart showing the basic operation of the system for instructing distribution adjustment of workers in a production line.

The distribution of the workers may be adjusted as an initial setting at the start of the work or in real time during the work. In the description of the embodiment, the former is referred to as the work for convenience. Worker distribution, and the latter is called worker distribution adjustment.

First, at the stage of starting production, order data for instructing which type of product is to be produced in which line, a capacity master table (the minimum number of people required for production and the tact per unit production) for each type code are stored. 4), the worker distribution is executed, and an instruction is output to a display device or the like (initial setting portions 101 to 103).

When the production is started, the worker distribution is adjusted in accordance with a predetermined evaluation criterion every hour or at a review timing such as lunch break, and an instruction is output to a display device or the like. This is repeated until the production ends, and when the production ends, a new ability master table is created based on the results and evaluations during the production (real-time portion of 104 to 110).

The worker distribution in the initial setting and the distribution adjustment instruction to be performed in real time will be described later in detail with reference to the drawings.

FIG. 2 is a block diagram showing a main configuration of a system for instructing distribution adjustment of workers in a production line.

In FIG. 2, a worker distribution adjustment instruction system 10 controls the following units, and includes a main control unit 1 composed of a CPU, a production line progress record table (FIG. 5) described later, and a worker arrangement. Work result progress table creating means 2 for updating a result table such as a result table (FIG. 6) and a capability master table (FIG. 4) described later; work result evaluating means 3 for evaluating a work state based on work results; Change instructing means 4 for instructing a change by the evaluation of evaluation means 3,
It mainly comprises a simulation means 5 for performing a load accumulation simulation for notifying a work instruction in advance, and a change notice notification means 6 for notifying a notice of a change in worker distribution by the load accumulation simulation.

Next, calculation of the distribution instruction in the initial setting,
And the distribution adjustment instruction performed in real time, FIG.
4 will be described.

FIG. 3 is a conceptual diagram showing a mechanism for determining a line tact per unit production.

When a plurality of workers are arranged on a certain line, the line tact is represented by the maximum tact among the tacts per unit production (unit work time) for each worker.
That is, if three workers are placed on a certain line,
Assuming that the tact time of each step is 20, 16 and 11 seconds, the line tact time of the line is 20 seconds (FIG. 3A).

Next, when a new worker is put into this line, the worker who takes the longest time has two tacts.
It is placed in a 0 second step. As a result, the tact of this process is 10 seconds, and the maximum tact, that is, the line tact is 16 seconds (FIG. 3B).

When one more person is put in, the arrangement is made as shown in FIG. 3C, and the line tact becomes 11 seconds.

As described above, the relationship between the number of workers put into a line and the line tact is not linear, and a line tact value obtained based on past results is determined for each line. The table storing the line tact value is the ability master table.

FIG. 4 shows the internal structure of the capability master table 21. This table 21 is divided into product codes 21a, a line code 21b indicating which line is used for production, and a minimum number of workers 21c required for production.
And the respective line tact values 21d for the number of workers to be added.

Using this ability master table 21 and order data for instructing which product is to be produced on which line, the distribution instruction of the worker is calculated. Specifically, for example, in the case of an order for producing 100 varieties a on the line 1, the number of workers to be arranged on the line 1 is determined in view of the operable time of the line 1, and the display provided in the system 10 is determined. The information is displayed on a device (not shown) and instructed to a worker at the site.

Here, the operable time is the actual operating time ×
It means the net operating time calculated by the man-hour load factor. As the man-hour load factor, a value obtained by storing a past average value in a man-hour load factor master table (not shown) may be used. The man-hour load factor will be described later with reference to FIG.

At the time of reviewing the worker distribution at a predetermined cycle or during a lunch break, the work performance evaluation means 3
Calculates the ratio (remaining time / remaining production number) of the remaining time until the end of the operation of the line to the remaining production amount obtained by subtracting the already produced number from the planned production number (remaining time / remaining production number) as an evaluation value. This evaluation value is calculated for each line, distribution adjustment for moving one or more workers from the line with the largest evaluation value to the line with the smallest evaluation value is performed, and this is instructed by the change instruction means 4 such as a display device.

The evaluation method is not limited to the above method, and a value obtained by subtracting the remaining load time from the remaining time may be used as the evaluation value. The remaining load time is a value obtained from the number of remaining productions and the number of workers, and is specifically represented by a line tact value corresponding to the number of workers × the number of remaining productions.

In the distribution adjustment, for example, a plurality of workers may be moved between one or more lines having a larger evaluation value and one or more lines having a smaller evaluation value. Good.

The worker distribution instruction performed in the initial setting and the distribution adjustment instruction performed in real time are realized by storing and referring to the planned data and the actual data in the production line progress actual table 22 shown in FIG. You.

As shown in FIG. 5, the production line progress record table 22 is divided for each line code 22a, and includes order data 22b relating to product types such as a product code and a quantity produced in the line, a planned total and a result. It includes progress data 22c such as a cumulative total, headcount data 22d such as the number of arranged workers, and line operation time data 22e such as start and end times. In some cases, a plurality of types are produced on the same line.
b includes data of a plurality of types 1 to N.

Further, at the timing of adjusting the distribution of the workers,
Further, a load accumulation simulation is performed, and a change notice of the progress status is output. This is realized by the simulation means 5 and the change notice notification means 6 of FIG.

Specifically, (1) the estimated required time obtained from the remaining production number is calculated for each line by using the production line progress result table 22 and the capacity master table 21;
(2) Lines where progress is likely to be delayed by the next review timing and lines where progress is not likely to occur are divided into lines, and delays and advancements are calculated for each time, and (3) display devices provided for each line (change notice) The notifying means 6) displays the predicted progress including the predicted time.

By giving the advance notice of change in this way,
It is possible to prompt the operator to prepare for the rearrangement, and a quick rearrangement can be realized.

At the distribution adjustment timing of the worker distribution, evaluation data such as throughput is output for each worker or for each worker group based on the performance of the worker, and is fed back to the worker.

FIG. 6 is a diagram showing an internal structure of the worker arrangement result table 23 used for evaluating workers and the like.

As shown in FIG. 6, the worker arrangement result table 23 shows what kinds of workers were allocated to the operation time from the review timing to the next timing. The time data of the time 23b, the worker code 23c of the placed worker, the quantity 23d produced during that time, and the line tact value 2
3e, net operating time 23f, number of workers 23g,
Other information necessary for processing is configured.

Specifically, the total work time for each worker and the quantity produced as a result of the work are obtained from the table 23, and the time required for producing one, that is, the throughput is calculated.

In the case of a worker group, a line tact value is calculated for each combination that actually occurs, for example, a combination of workers A and B or a combination of A and C.

The calculated evaluation value is output from a display device or a printer connected to the present system.

As described above, by evaluating each worker or each worker group, not only an appropriate work plan in the future can be made, but also the worker himself / herself can be notified to improve the willingness to work. it can.

Next, a method of updating the ability master table 21 based on the worker arrangement result table 23 will be described. By updating the ability master table 21, an appropriate future work plan is realized.

FIG. 7 is a diagram showing a flow of updating the ability master table 21.

Based on the worker arrangement result table 23,
(1) The work time and the production quantity are summed for each line and each worker combination. (2) The average line tact value is calculated by the following equation: The obtained average line tact value is replaced with the line tact value in the ability master table 21.

At this time, if the workers include a new employee or the like and the work efficiency is different, the worker arrangement result table 23
Are converted to the average worker and totaled.

In the processing of the system, the latest tact value table as shown in FIG. 7 may be used, but the present invention is not limited to this method.

This updated ability master table 21
However, it is applied to the distribution of workers in the next operation, and more efficient work can be expected.

Since the line tact value in the ability master table 21 is applied to an average worker, if the worker is a person new to the work such as a new employee, the line tact value is corrected by the correction coefficient. What was done is used.

FIG. 8 shows an example of a new face growth history table storing the correction coefficients.

The newcomer growth history table 24 shows the past newcomers on the first day, the second day,..., The average actual line tact value 24a for each production line, and the line tact for each elapsed day. And a correction coefficient 24b obtained from the value. When arranging workers, the line tact value 21d of the ability master table 21 × the correction coefficient 24b
And the corrected line tact value is used.

In this example, the average value is obtained and stored in the table 24. For example, the table 24 'is classified into cases for all newcomers in the past year, and the correction of the case table having the highest degree of coincidence is performed. A coefficient may be employed (FIG. 8B). Specifically, for example, in the case of the work on the fifth day of the newcomer, the line tact value on the first to fourth days of the newcomer is sequentially compared with the line tact value on the first to fourth days in each case table. The case in which the number of days that match (approximately) match the most is sufficient.

As in the case of a new employee, a table (not shown) for an operator who has been changed due to a change of location or transfer.
May be provided to correct the line tact value.

Although not shown in the figure, as in the case of a newcomer,
When a new product is produced, a new product growth history table is provided, a correction coefficient is stored for each line, and the line tact value of the capability master table 21 is corrected using this.

As described above, the line tact value is corrected from similar past results, so that the situation change over time that cannot be performed by ordinary adjustment such as the introduction of a new employee or the introduction of a new product. Can also be accommodated.

FIG. 9 is a diagram showing an example of the internal structure of the man-hour load factor history table.

This table 25 has a line code 25a.
The actual man-hour load ratio 25c for each combination of the man-hour and the number of people 25b is stored. By using the saved man-hour load ratio as the man-hour load ratio of the next operation, the change in the environmental change of the production line can be prevented. Yes, it is. That is, the varying man-hour load factor plays a role of the learning function.

The man-hour load rate 25 c in the table is obtained from the actual value of the worker arrangement actual table 23. Specifically, although the combination of the line code and the number of workers match, the operation time and the net operation time are totaled,
The man-hour load factor 25 is calculated by the sum of the net operation time and the operation time. In addition, in the case of totaling, when a new person or the like is included in the workers, a net operation time converted into an average worker is used in consideration of work efficiency.

[0066]

As can be understood from the above description, according to the method for adjusting the distribution of workers in the production line according to the first aspect or the system for adjusting the distribution of workers in the production line according to the second aspect. After completion of the work, the ability master table, that is, the parameters based on the factors of the worker and the like are updated based on the work results, so that the distribution can be adjusted using the line tact value with higher accuracy.

According to the third aspect of the present invention, since the line tact value of the ability master table is used in consideration of the correction rate for a new worker, the new worker is input. The distribution adjustment can be performed in response to a situation change that cannot be performed by the normal adjustment by the user.

According to the method for adjusting the distribution of workers according to the fourth aspect, the line tact value of the ability master table is used in consideration of the correction rate for new products. In response, the distribution can be adjusted.

According to the worker distribution adjusting method according to the fifth aspect, the man-hour load factor for determining the number of workers to be distributed is sequentially updated and updated by the learning function in consideration of the work results. Since the man-hour load factor is adopted for the next operation, it is possible to sequentially cope with a fluctuating production line environment.

The method for adjusting the distribution of workers according to claim 6,
According to the worker distribution adjusting system of the present invention, the load stacking simulation is performed each time the work efficiency is evaluated at a predetermined timing. It becomes possible, and quick rearrangement can be realized.

According to the worker distribution adjusting method described in claim 8 or 9, the capability evaluation data is generated and output for each worker or each work group, so that an appropriate future work plan can be established. Instead, by notifying the worker himself / herself, motivation to work can be improved.

[Brief description of the drawings]

FIG. 1 is a flowchart showing a basic operation example of a distribution adjustment instruction system for workers in a production line according to the present invention.

FIG. 2 is a block diagram illustrating a configuration example of a main part of a distribution adjustment instruction system for workers in a production line according to the present invention.

FIG. 3 is a conceptual diagram illustrating a method of determining a line tact.

FIG. 4 is a diagram showing an example of the internal structure of a capability master table.

FIG. 5 is a diagram showing an example of the internal structure of a production line progress table.

FIG. 6 is a diagram showing an example of an internal structure of a worker arrangement result table.

FIG. 7 is a diagram showing an example of a flow of updating a capability master table.

FIG. 8 is a diagram showing an example of the internal structure of a new face growth history table.

FIG. 9 is a diagram showing an example of the internal structure of a man-hour load factor history table.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 10 Distribution adjustment system of workers in a production line 2 Work result progress table creation means 3 Work result evaluation means 4 Change instructing means 5 Load stack simulation means 6 Change announcement notification means 21 Capacity master table 22 Production line progress result table (Work result progress Table) 23 Worker placement result table (Work result progress table)

Claims (9)

[Claims] An operator is allocated to each of a plurality of manufacturing lines based on a previously created ability master table,
The distribution of workers on the production line is instructed to adjust the required distribution of workers on the way from the start to the completion of the work while evaluating the work efficiency in each line according to a predetermined evaluation standard. In the instruction system, the work efficiency of each production line from the start of the work to the completion of the work is created as a work result progress table for the above production line, and the work efficiency of each line is adjusted according to the specified conditions. Every time evaluation is performed in accordance with the predetermined evaluation criteria with the number and remaining work time as main evaluation items, necessary change instructions of the worker are issued, and the above-mentioned ability master table is written in the above-mentioned work progress table after the work is completed. Based on the work results
A method for adjusting the distribution of workers on a production line, characterized in that the method is updated. 2. A worker is allocated to each of a plurality of production lines based on a capability master table created in advance,
The distribution of workers on the production line is instructed to adjust the required distribution of workers on the way from the start to the completion of the work while evaluating the work efficiency in each line according to a predetermined evaluation standard. In the instruction system, for the above-mentioned production line, a work result progress table creating means for collecting work activity results from the start of work to completion of the work and creating a work result progress table; Work performance evaluation means that evaluates according to predetermined evaluation criteria with the number of unprocessed products remaining and the remaining work time as main evaluation items, and receives instructions from the work performance evaluation means Change instructing means for instructing a necessary worker change, and the work result progress table creating means includes: A system for adjusting the distribution of workers on a production line, wherein the system updates the capability master table based on the work results written in the work result progress table after completion. 3. In the first aspect, when a worker on the production line is a new person or the like who is not sufficiently used to work, the worker refers to the ability master table in consideration of a predetermined correction rate, A method of adjusting the distribution of workers in a production line, comprising updating the above-mentioned ability master table after completion of work, taking a predetermined correction rate into account. 4. The method according to claim 1, wherein when the product to be worked on the production line is a new product, the capability master table is referred to by adding a predetermined correction factor. A method for adjusting the distribution of workers in a production line, wherein the capability master table is updated in consideration of a predetermined correction rate. 5. A learning function according to claim 1, wherein the man-hour load factor for determining the number of workers to be allocated to the production line is determined in consideration of the actual work performed. A method of adjusting the distribution of workers in a production line, wherein 6. The production line according to claim 1, wherein each time a work efficiency is evaluated for each of the production lines, a load stacking simulation is performed, and a line requiring a change in worker distribution is required. A method for adjusting the distribution of workers in a production line, wherein a notice of change is notified. 7. A load-stacking simulation means for performing a load-stacking simulation each time the work efficiency is evaluated for each of the production lines, and a change in worker distribution is required by the load simulation. A distribution adjustment system for workers on a production line, characterized in that the line that has become equipped with a change notice notification means for notifying change notice. 8. The system according to claim 1, wherein each time a predetermined operation on the production line is completed, the operation result and the worker distribution change history are totaled, and the capability evaluation data for each worker is collected. A method for adjusting the distribution of workers in a production line, characterized by generating and outputting. 9. The system according to claim 1, wherein each time a predetermined operation in the production line is completed, the operation result and the worker distribution change history are totaled, and the capacity of each worker group is calculated. A method for adjusting distribution of workers in a production line, characterized by generating and outputting evaluation data.