JP3106736B2 - Work load display method - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a work load display system, and more particularly to a work load display system suitable for use in line management in which a variety of products is varied and the types and the production amounts are varied.

[0002]

2. Description of the Related Art For example, in an automobile production line, a number of processing steps are performed on a work. In such a line, it is important to perform economical and efficient process management. In particular, in a line where multi-variety, variable and variable production is carried out as in recent years, the process becomes complicated and the types of workpieces also become diverse, so it is important to accurately control the process from the viewpoint of improving production efficiency. Becomes

One of the means for performing the process control is load management. In this load management, the time required for each process performed on the work is obtained, and based on this, the operation adjustment of the general-purpose machine group and the personnel planning are performed, thereby improving production efficiency. .

Conventionally, load management of a single line composed of a group of general-purpose machines in multi-product variation / variable production involves individually calculating a load for each process in the line, multiplying the calculated load by the number of input workpieces, Based on the results, the operation of the general-purpose machine group was adjusted and the number of personnel was planned. That is, the conventional load management is a management focusing on a line process (management in a lot unit), and a management in a work unit is not performed.

On the other hand, load management is often performed using a computer. In this case, a method of displaying a work load is to display a load (work time) by a bar for each process and each day when the process is performed. Was to be done.

[0006]

Unlike a dedicated line (a line for processing only the same work), it is composed of a group of general-purpose machines in a multi-kind, variable and variable production in which a work cannot be produced in a constant tact time. On the line,
There is always a bottleneck process (a process with a high priority or a process with a long processing time). Also, since there are many types of input work, the number of daily inputs often differs even for the same work.

[0007] Therefore, manual setup changes frequently occur every day, and work of connecting works between processes and work of attaching and detaching works to and from a machine (this work is manual work).
Also occur frequently every day.

However, as described above, the conventional load management focuses on the line process, so that it is not possible to perform the management in units of work, and to perform the various types of work that occur frequently every day as described above. There was a problem that it was not able to reflect on. If the accuracy of load management deteriorates in this way, it is not possible to carry out accurate personnel planning, and it is necessary to cope with such situations that the number of people will be stagnant at the time of machine neck or the production volume will not increase at the time of man neck, etc. Various inconveniences that cannot be performed occur, and the productivity of the line is reduced.

Further, in the conventional method of displaying the work load, the load (work time) is displayed as a bar for each process and each day when the process is carried out. It was not possible to judge whether the work was completed only by looking at the workload display. Therefore, in order to make the above determination, the operator has to judge again whether the work is completed on a predetermined date, which requires many man-hours and lacks accuracy and speed. there were.

The present invention has been made in view of the above points, and an object of the present invention is to provide a work load display method capable of improving the accuracy and speed of work load management by displaying a load on a work basis. Aim.

[0011]

FIG. 1 is a diagram illustrating the principle of the present invention.

In order to solve the above-mentioned problems, in the method of the present invention, at least the date of scheduled work completion of the work, the identification data for identifying the work, and the time required for working the work in each process performed on the work. Input means (A) for inputting production plan information having reference time data
1), a production plan information memory (A2) that stores the production plan information input from the input means (A1) , and a reference in which reference information having a past machining result for various workpieces is stored and stored in advance. Based on various data stored in the information storage memory (A3) and the production plan information memory (A2), the man-hour load and the machine load required for machining the work are calculated , respectively.
Compare the man-hour load and the mechanical load and select the one with the higher load rate.
Based on the load calculation means (A4) to be selected and the data stored in the production plan information memory and the reference information storage memory , a negative
Includes the processing required time calculating means for calculating a load (A5), display means for displaying the computed results and (A6), the man-hour load
Load selected by the load calculation means from
While displaying based on the higher rate, the above man-hour load and
Identification that indicates which of the mechanical loads is higher
For each zone composed of one or more processes
It displayed, and the value of the load which is calculated by the processing required time calculating means (A5), in the column corresponding to the machining completion date of the work, stacked in order of priority of the process to bar display It is a feature.

[0013]

According to the above-mentioned method, since the load is displayed for each work, it is possible to immediately judge whether or not the work is completed on the scheduled processing completion date. Further, since it is possible to immediately determine whether the step that becomes a neck is a man-hour load or a mechanical load, the neck can be eliminated accurately and quickly.

[0014]

Next, an embodiment of the present invention will be described with reference to the drawings. In this embodiment, a case where a load is displayed on a production line of an automobile will be described as an example.

FIG. 2 is a schematic configuration diagram of a computer 1 used for a workload display method according to one embodiment of the present invention. In the figure, reference numeral 2 denotes graphics (GF) for inputting production plan information from an order sheet or the like by an operation of an operator.
X) an input / output device, 3 is a production plan information memory for storing production plan information, 4 is a load information memory for storing created load information, and 5 is a reference information that has been created in the past and has been processed. 2 shows a reference information storage data memory that stores data. The production plan information memory 3 and the load information memory 4 are built in a first storage device 6, and the reference information storage data memory 5 is built in a second storage device 7. Reference numeral 8 denotes a main controller (CPU) which is connected to each of the devices 2 to 7 described above and executes a series of processing described later;
Reference numeral denotes an output device such as a printer for outputting a result calculated by the CPU 8.

The production plan information and the reference information used in the description of the schematic configuration of the computer 1 will be described later.

FIG. 3 is a flowchart for executing the workload display method according to one embodiment of the present invention. Hereinafter, C for displaying the workload based on this flowchart will be described.
The processing executed by the PU 8 will be described. The load calculating means (A4) and the required processing time calculating means (A5)
It is configured as software executed by U8.

When the workload processing shown in FIG.
An operator inputs production plan information to the computer 1 using the input / output device 2 in step 10 (hereinafter, step is referred to as S). Here, the production plan information will be described. The production plan information refers to a set of various data required when performing a plurality of processes on a workpiece in a line.

A specific procedure for inputting production plan information is as follows. First, a worker interprets the contents based on an order sheet describing a processing order for a work as shown in FIG. 4A, and then creates a production plan information book shown in FIG. 4B. As shown in the figure, the production plan information document includes a product number, a reference time data type (in this example, A), an operation order, a plan No, a quantity, a priority, a use,
Various data such as difficulty level and delivery date are described in an organized state. The operator inputs the above data to the computer 1 using the input / output device 2 based on the production plan information book.

When the production plan information is input in S10, the CPU 8 stores this data in the production plan information memory 3 in S12.

After confirming that the production plan information has been stored in the production plan information memory 3, the CPU 8 issues a load information creation instruction in the following S14, and the creation of load information is started. Here, the load information is information on which the work load display according to the present invention is based, and is information indicating a load (work time) required in each process. In the present invention, this load is required manually (hereinafter, this load is referred to as a man-hour load), and the load required by the machine (hereinafter, referred to as man-hour load)
This load is referred to as a mechanical load).

In step S16, the production plan information stored in the production plan information memory 3 is extracted by the processing in step S12. In step S18, the reference information stored in the reference information data memory 5 is compared with the production plan information. Specifically, the type of the reference time data included in the production plan information (FIG. 4)
(A) in the example shown in (B) and the delivery date (5/10 in the example shown in FIG. 4 (B)) are collated with the reference information stored in the reference information data memory 5.

Here, the reference information data is data that is created by storing reference information that has been created in the past and that has been processed, and includes various data shown in FIG. The reference information includes the type of the reference time data and the factory operation day calendar as shown in the figure. Therefore, whether the type of the reference time data of the production plan information matches, and the Whether the delivery date is included in the factory operation day calendar of the reference time data is collated.

In subsequent S20, as a result of collating the reference information with the production plan information, it is determined whether or not the reference information corresponding to the production plan information is registered in the reference information data memory 5. Reference information data memory 5
The reference information registered (stored) in the server is extracted (S2).
4) A load calculation is performed in S26 based on the data.

On the other hand, if it is determined in S20 that the reference information corresponding to the production plan information is not registered in the reference information data memory 5, the process proceeds to S22, and the CPU 8 instructs the worker to correspond to the production plan information. It informs via the input / output device 2 or the output device 9 that the reference information to be registered is not registered in the reference information data memory 5. If no registration is output, the operator manually inputs each data included in the reference information data. When this data input is completed, the process proceeds to S26, where a load calculation is performed.

Here, the specific processing of the load calculation performed in S26 will be described below.

In order to perform the load calculation, first, the human acceptance frame T
_m and the machine acceptance slot T _M are calculated. Here, means a human hand can total time the receiving frame T _m of a human, the receiving frame T _M of the machine zone (e.g., processing order of progress of, is composed of a plurality of processes defined by the type of machining )
Means the operating time of the machine in the neck process (the process requiring the most time). Human acceptance frame _Tm and machine acceptance frame T
_M is obtained by the following equation.

T _m = h × α ₇ × m ₀ × ｛(m ₀ + mα × α ₄ ) /
m ₀ ｝ × (h + α ₅ ) / h−α ₆ (1) T _M = h × α ₇ × M × α ₈ (2) The items and numerical values of the parameters in the above equation are shown in FIG.
This is as shown in FIG. In the above equation, (h ×
α ₇ × m ₀ ) indicates the total man-hours for day and night, and ｛(m ₀ +
mα × α ₄ ) / m ₀ } indicates the ratio of the number of supporters, {(h + α ₅ ) / h} indicates the ratio of overtime hours,
(H × α ₇ × M) indicates the total operation time of day and night.

Subsequently, the man-hour load t _m is obtained. The man-hour load t _m is obtained by the following equation, where n is the number of works.

T _m = A _m + B _m × n (3) In the equation (3), _Am and B _m are represented by the following equations.

A _m = (a ₁ + a ₂ ) × α ₁ (4) B _m = b ₁ × α ₂ (5 ) In the equations (4) and (5), a ₁ is an inner setup.
You. Generally, the inner setup means that the machine is stopped when the first
Necessary for attaching jigs to machines, centering workpieces, changing blade tools, etc.
It refers to the working time of the manual worker. However, here
The inner setup a ₁ is particularly the inner setup for each machine through which the workpiece passes.
Total time, i.e., the processes other than the neck process and the neck process.
Shows the sum of the internal setup time in all processes including the process
ing. Also, a ₂ is the off-line setup, during Hatsumono machining, jig prepared outside the machine during machine operation refers to the manual work time required for the jig adjustment. In particular, a ₂ refers to the sum of the off-line setup time of the machine each time the workpiece passes. In addition, b ₁ is a manual, refers to consuming manual work time to work desorption of the machine each time the work is through. In particular, b ₁ indicates the sum of the manual machine each time the workpiece passes.

As is clear from the above description, the inner setup a ₁ and the outer setup a ₂ are constant terms relating to one initial product, and manual work b ₁ is a proportional term requiring the same number as the number n of works. However, manually by the improvement b ₁ and the inside and outside set-up a
_A setup improvement coefficient α ₁ and a processing improvement coefficient α ₂ are provided as evaluation scales in order to cope with the case where the times of a _and a ₂ become smaller than the initial set values.

After the man-hour load t _m is obtained as described above, the mechanical load t _M is subsequently obtained. The mechanical load t _M is obtained by the following equation.

T _M = A _M + B _M × n (6) In the equation (6), A _M and B _M are represented by the following equations.

A _M = C ₁ × α ₁ (7) B _M = (d ₁ + d ₂ ) × α ₂ (8 ) In the equations (7) and (8), C ₁ is an internal setup.
You. In particular, arrangements C ₁ among here, the workpiece is passing
During the process, the inner stage of the machine with the longest machining time in the zone
Indicates the take time. That is, the inner setup C ₁ here
Indicates the internal setup time in the neck step. In addition, d ₁ is the processing time, refers to the time required for the processing end from the start of the machining of the workpiece. In particular, d ₁ denotes the ones in the same manner as in C _1, long processing time is best in that zone. Further, d ₂ is a manual operation, and after the machining of the workpiece,
This refers to the time that the machine is occupied by the attachment and detachment of the work. d ₂
Also shows the manual work time on the machine with the longest processing time.

In this case, the inner setup C₁Is the first
It is a constant term concerning one piece, and processing d ₁And manual work_TwoIs
This is a proportional term requiring the same number as the number n of works. Also, setup
Improvement coefficient α₁, Machining improvement factor α_TwoIs explained by man-hour load
The contents are the same.

After the man-hour load t _m and the mechanical load t _M are obtained, the difficulty levels T _{1 (m)} and T _{1 ( M)} are subsequently obtained. Here, T _{1 (m)} is the difficulty for the man-hour load t _m ,
_{1 (M)} is the difficulty for the mechanical load t _M. Each difficulty level T
_{1 (m)} and T _{1 (M)} are obtained by the following equations.

T _{1 (m)} = t _m × α ₀ (9) T _{1 (M)} = t _M × α ₀ (10) In the expressions (9) and (10), α ₀ is a difficulty coefficient It is. When processing a workpiece for the first time, it usually takes longer than a workpiece that has been processed once. For this reason, all the loads of the man-hour load t _m and the mechanical load t _M are multiplied by a coefficient, and the first product is weighted. The coefficient at this time is referred to as a difficulty coefficient α ₀ .

As described above, the difficulty level T_{1 (m)}, T_{1 (M)}Sought
Then, the dimension is corrected. This dime
The correction of the load, including the unit correction, is
The overall correction is performed. Dimension correction is below
The difficulty level T as shown in the equation _{1 (m)}, T_{1 (M)}Dimensi
Correction coefficient α_ThreeIs performed by multiplying

T _{2 (m)} = T _{1 (m)} × α ₃ (11) T _{2 (M)} = T _{1 (M)} × α ₃ (12) After the dimension correction is performed, the daily load is subsequently calculated. Is calculated. The daily load is calculated by the following formula.

ST _{2 (m)} = ΣT _{2 (m)} (13) ST _{2 (M)} = ΣT _{2 (M)} (14) In equations (13) and (14), ST _{2 (m)} is ST2 _(M) indicates the total sum of the machine occupation time of the neck process in the lot unit to be input per day.

When the daily load is calculated as described above, the human acceptance frame T _m and the machine acceptance frame T _M obtained by the above equations (1) and (2) are calculated by using the equations (13) and (13). The comparison with the daily load obtained by the equation (14) is performed.

The man-hour load _{factor: w m = ST 2 (m} ) / T m ... (15) Machine Load factor: Load operation by _{w M = ST 2 (M)} / T M ... (16) over a series of processing Ends.

Returning to FIG. 3 again, the description of the processing executed by the CPU 8 for displaying the workload will be continued. The calculated values (the calculated values are collectively referred to as load information) obtained by the above equations (1) to (16) are temporarily stored in the load information memory 4 in S28.

Thereafter, the operator operates the input / output device 2, and
When the display of the load information is instructed, the load information stored in the load information memory 4 is taken out by the CPU 8 (S3).
2) In addition, the factory operation day calendar (see FIG. 5) is read from the reference information storage data memory 5, and the accepting frame data T _m and T _{M are associated} with the factory operation day calendar (S34).

In S36, the CPU 8 calculates the graph display based on the data taken in S32 and S34, and the GFX screen of the input / output device 2 and the output device 9 display the graph. FIG. 7 shows an example of a graph display, and the load is displayed as a bar as shown in FIG.

As described above, there are two types of loads, man-hour load and mechanical load. In the load display method of the present invention,
Load factors w _m , w determined by equations (15) and (16)
It is configured to compare _M and display the one with the higher load factor. This will be described with reference to FIG. FIG accepts frames T _m and the machine of the receiving frame T _M and day load aggregate ST 2 _(m), in which ST 2 _{(M) is} the bar display. In the example shown in the figure, the man-hour load factor (w _m = ST _{2 (m)} / T _m ) is higher than the mechanical load factor (w _M = ST _{2 (M)} / T _M ). Displays a graph based on the man-hour load.

In this display, in the load display method of the present invention, an identification display capable of identifying which one of the man-hour load and the mechanical load has the higher load is also displayed. In particular,
In FIG. 7, it is identified by a circle indicated by an arrow A, and in the example shown in FIG.
Unmarked ones indicate that the mechanical load is high. In this way, by displaying an identification display that can identify which one of the man-hour load and the mechanical load has the higher load in accordance with the graph, it is possible to immediately determine whether the neck is caused by the operator or the machine. Can be dealt with immediately, so that the bottleneck can be resolved accurately and quickly.

Further, the load display method of the present invention is characterized in that the values of the loads are displayed in a bar corresponding to the expected completion date of the work (that is, the delivery date) in the order of the priority of the process and displayed in a bar. Is what you do. This display method will be described with reference to FIG. FIG. 1A shows a conventional display method, and FIG. 1B shows a display method according to the present invention.

Conventionally, load management is performed on a lot basis, and accordingly, load display is also performed on a daily basis in accordance with a schedule, as shown in FIG. In the figure, N, N + 1, N + 2 indicate dates, and A
Reference numerals -1, A-2, A-3, and D indicate the steps performed on the workpiece, respectively. In such a conventional display method, if the delivery date is (N + 2) days, the delivery date (N
+2) It was not possible to immediately judge whether or not machining of the workpiece was completed on the day.

Therefore, in the load display method according to the present invention,
As shown in FIG. 7B, the load of the processing performed on each of the processing execution dates N, N + 1, and N + 2 is displayed in a bar on the delivery date (N + 2) date column. Further, the stacking order is such that the stacking is performed in descending order of the priority of the processing steps.

By adopting the load display method according to the present invention, the load display becomes a load display for each work, and it is determined whether or not the stacked bar displays exceed the reference capacity line (acceptance frame). It is possible to immediately and accurately determine whether or not the processing on the workpiece is completed on the delivery date (N + 2). Also, in the order of the priority of the processing step (in FIG.
Since A-3 is displayed with a higher priority), it is easy to deal with this when, for example, the processing of the work is outsourced to meet the delivery date. The priority is included in the production plan information (FIG. 4).
(B)). Further, in the load display method of the present embodiment,
Load display for each processing day when the process is actually performed as follows
The work load on the actual machining date is not
Steps 16 to 24 described with reference to FIG.
Is taken into account. Therefore, it will be implemented on the processing day of writing
The processing load is displayed as a stacked bar,
The work is completed on the delivery date by comparing
It is possible to determine whether or not to do so.

Returning to FIG. 3, the description will be continued. When the graph display as shown in FIG. 7 is performed by the process of S36, the operator determines whether the load output from the graph display exceeds the reference capacity line (acceptance frame). If the load is within the reference capacity line, the processing schedule is determined, and rough material is arranged. Further, the fact that the processing schedule has been determined is also input from the input / output device 2 to the CPU 8 (S40), whereby the CPU 8 displays the bar display indicating the determined load in S42 from white to black (FIG. 7). (The display as shown on the left side of), and the process is terminated.

On the other hand, if the load output from the graph display exceeds the reference capacity line, a plan change process is performed (S44). Hereinafter, specific processing of the plan change will be described. For example, when the load exceeds the reference capacity line as described above, and when there is a bias in the load near the delivery date, the plan change process is performed. This change process is performed by an operator operating the input / output device 2.

When changing the plan, the operator operates the input / output device 2 to instruct the CPU 8 to change the plan. Thereby, the CPU 8 takes out the production plan information stored in the production plan information memory 3 and displays it on the screen of the input / output device 2. Here, the operator changes and inputs, for example, the delivery date was 5/10 to 5/12 in the item column of the production plan information (this process is the same as S10).

When this input processing is performed, the CPU 8 executes S
The processes of 12 to S28 are executed, and the daily file stored in the production plan information memory 3 is updated using the plan number of the production plan information (see FIG. 4B) as a key.

Thereafter, when the operator operates the input / output device 2 in S30 and instructs the display of the changed graph, the load information stored in the load information memory 4 is extracted (S30).
32) Calculation processing for erasing the load information on 5/10 and displaying the graph on 5/12 is performed, and the load calculated in the column for 5/12 is calculated in the manner described above with reference to FIG. It is output to the input / output device 2 and the output device 7.

Next, the operator looks at the graph display after the schedule is corrected, and determines whether the load is within the reference capacity line (S38). If the load falls within the reference capacity line, a date that is earlier than the processing period by the machining period is determined, and a rough material is requested to the rough material manufacturing department on that date. On the other hand, if it is determined in S38 that the load exceeds the reference capacity line, or if it is determined that the process is biased,
The correction processing described above is performed again. This correction processing is executed until the load falls within the reference capacity line and until the deviation of the process is eliminated.

When a schedule plan based on the load management is created by the above series of processing, a few days later, the rough material production department returns the information on the planned shipping date of the rough material, and the information (schedule) is described above. In the same procedure, input in the answer item column of the production plan information. Hereinafter, the determination of the reference performance line and the like is the same processing as described above. Thereafter, if the load is within the reference capacity line, the same schedule is entered in the item column for determining the production plan information. At the same time, a flag is entered in the inner and outer item columns. With this flag, the order of loading the graph display and the display method are determined.

[0060]

As described above, according to the present invention, since the load is displayed for each work, it is possible to immediately determine whether or not the work will be completed on the scheduled completion date of the work, and the process that becomes a bottleneck will be a man-hour load. It is possible to immediately determine whether the load is a mechanical load or a mechanical load, so that a neck can be eliminated accurately and quickly.

[Brief description of the drawings]

FIG. 1 is a principle diagram of the method of the present invention.

FIG. 2 is a schematic configuration diagram of a computer used for a workload display method according to an embodiment of the present invention.

FIG. 3 is a flowchart for executing a workload display method according to an embodiment of the present invention.

FIG. 4A is a diagram illustrating an example of an order sheet describing a processing order for a workpiece, and FIG. 4B is a diagram illustrating an example of a production plan information book.

FIG. 5 is a diagram illustrating an example of reference information data.

FIG. 6 is a diagram showing an example of symbols and numerical values of respective parameters of an expression indicating a human acceptance frame T _m and a machine acceptance frame T _M.

FIG. 7 is a diagram showing an example of a graph display.

FIG. 8 is a diagram for explaining a comparison between load factors w _m and w _M.

FIG. 9 is a diagram for explaining a load display method according to the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Computer 2 I / O device 3 Production police information memory 4 Load information memory 5 Reference information storage memory 8 CPU 9 Output device

Claims (1)

(57) [Claims] At least the date on which the work is to be completed.
Data, identification data for identifying the work, and
The time required to process the work in each of the steps performed
Production plan information with reference time data indicating
Input means, and production for storing production plan information input from the input means.
Planning information memory andReference information with past processing results
InformationA reference information storage memory storing and storing various data stored in the production plan information memory.
Therefore, the man-hour load and the mechanical load required for machining the work
Arithmetic, Comparing the man-hour load and the mechanical load,
Choose the higher oneLoad calculation means, and stored in the production plan information memory and the reference information storage memory.
Based on each data that has been
Time requiredThe load that isTime required to calculate
And a display means for displaying the calculated result.Of the above man-hour load and mechanical load, select by the load calculation means.
The display based on the selected load factor is displayed.
Determine which of the man-hour load and the mechanical load is higher
The identification mark shown consists of one or more steps.
Display for each zone And, Calculated by the required processing time calculating meansOf the load
valueIn the column corresponding to the scheduled completion date of the work
It is noted that the bars are stacked and displayed in the order of higher priority.
Work load display method.