JP6020176B2 - Production management apparatus and production management method - Google Patents

Description

  The present invention relates to a production management device and a production management method.

  Currently, many production lines for industrial products employ a line production system in which products to be produced are conveyed by a conveyor, etc., and each worker sequentially performs each process operation such as assembly work on the conveyed products. . In the line production method, a tact time is assigned to each process, and each worker needs to finish the work within the tact time assigned to the own process.

  In the line production system, if the work in one process does not end within the tact time for some reason, the entire line is stopped. Many production methods have been adopted in which a support worker dedicated to handling is called to receive support for the work. When trouble occurs in a plurality of processes, the support worker determines which process should be supported, for example, supports in the order in which calls are made, or determines the delay time of the process in which the trouble occurred. I guessed from the experience, and prioritize support.

  Further, in the line production system, a production management device is known that performs production adjustment in each process when equipment failure occurs (for example, Japanese Patent Laid-Open No. 7-129672).

JP-A-7-129672

  However, in the conventional line production method, when trouble occurs in a plurality of processes, the support worker sometimes makes a mistake in the determination of the priority order of support, and the production line stop time may be lengthened.

  In view of this, an object of one aspect is to provide a production management apparatus and a production management method that automatically determine the priority of a process to be supported when trouble occurs in a plurality of processes.

  In one proposal, the production management device is arranged for each process of the production line composed of a plurality of processes, a notification means for requesting work support, a recording means for recording a past stop time for each process, Priority generation means for calculating the expected stop time by reading the past stop time of the process requested for support by the notification means from the recording means, and creating priority order for support for the process requested for support, and priority Informing means for informing a process of supporting according to the priority order created by the order creating means.

  According to one aspect, when trouble occurs in a plurality of processes, it is possible to provide a production management apparatus and a production management method that automatically determine the priority order of the processes to be supported.

Overall block diagram of production management equipment The figure explaining process DB DB Flow chart explaining operation of production management device Diagram explaining the operation of the production management device in the production line Time chart explaining process operation status using production management device Time chart explaining process operation status without using production control equipment

  Hereinafter, embodiments of the present invention will be described with reference to the drawings.

  FIG. 1 is an example of an overall block diagram of a production management apparatus. In FIG. 1, the production management apparatus includes priority order creation means, a stop time measurement timer, and a process-specific record DB. A line operation / stop notification unit, call notification units 1 to n, and an instruction unit are connected to the priority generation unit. Display means 1 to n are connected to the instruction means.

  The call notification means 1 to n are call notification means that are arranged in each process of the production line and operated when calling a support worker in each process. For example, a push button switch or a wire pressed by the worker For example, a connected limit switch. The call notification means 1 to n are input to the priority order creation means and notify from which process the support worker has been called. If the call notification means 1 to n are switches that perform an alternate operation, for example, they can be turned on when the support worker calls and turned off when the support work starts. Further, as a call notification means, a push button switch for starting or ending the support work may be separately installed.

  The line operation / stop notification unit notifies the priority level generation unit whether the line is operating or stopped. When trouble occurs in the production line and the line is stopped, the line stop information is input to the priority order creating means. The stop time measurement timer measures the line stop time by measuring time based on the line stop information notified by the line operation / stop notification means. The measured line stop time is recorded as a cumulative stop time in the process-specific record DB, which will be described in detail with reference to FIG.

  The instruction means is arranged between the priority order creating means and the display means 1 to n, and transmits a support instruction for the support worker from the priority order creating means to the display means 1 to n. The display means 1 to n are, for example, an indicator lamp or a rotating lamp, and are notification means for notifying a support worker of a process to be supported. The display means 1 to n can be used together with, or can be replaced with, a notifying means using a voice such as a chime or voice guidance.

  Next, details of the process-specific record DB connected to the priority order creating means will be described with reference to FIG.

  FIG. 2 is an example of a diagram illustrating the process-specific record DB. In FIG. 2, the process-specific record DB includes information on “process NO.”, “Product”, “number of calls”, “cumulative stop time”, and “skill level”.

  “Process No.” is the number of each process in the production line. In FIG. 2, the case where a process is 1 to 3 is illustrated. This step No. corresponds to the call notification means shown in FIG.

  “Product” is information corresponding to the work carried on the production line. FIG. 2 illustrates a case where two types of products A and B are recorded as products. For example, when a plurality of types of products are mixed and flowed on the same production line, information for each product in each process may be recorded in the process-specific record DB. FIG. 2 illustrates a case where a plurality of processes and a plurality of products are recorded in one table. However, for example, the table may be recorded separately for each process or each product.

  The “number of calls” is the cumulative number of times the support worker has been called in the process during a predetermined period. When the call notification means 1 to n described in FIG. 1 are operated by the operator, the number of calls is counted. Although FIG. 2 illustrates the case where the number of calls is counted for each process and each product, for example, a total for each worker (not shown) may be performed. Because work skill and speed differ depending on the worker. More accurate information can be collected.

  The “cumulative stop time” is a cumulative stop time for each process. The accumulated stop time is the total stop time for each process in a predetermined period. The stop time is measured and recorded by the information from the line operation / stop notification means described with reference to FIG. 1, the input from the call notification means, and the time measurement information by the stop time measurement timer. The call is stopped by the call notification means within the accumulated stop time, and the call state cannot be canceled by the tact time and the line is stopped is called “call stop”. In this embodiment, the stop time accumulated by the accumulated stop time is accumulated by the accumulated time due to the call stop. Although FIG. 2 illustrates the case where the accumulated stop time is accumulated for each process and each product, for example, as with the number of calls, a total for each worker (not shown) may be performed.

The predetermined period recorded by the number of calls and the accumulated stop time can be set to a predetermined fixed period such as 3 months, 1 month, or 1 week, for example. Records after a predetermined period may be erased sequentially from the oldest one. The accumulated stop time may be weighted by multiplying the recorded value by a predetermined coefficient according to the newness of recording. For example, when there is a stop of 100 seconds, 1/10 is subtracted every day, 100 × (0.9) ¹ = 90 seconds if the previous day's stop, 100 × ( 0.9) ² = 81 seconds, if 30 days ago, 100 × (0.9) ³⁰ ≈4 seconds may be integrated. By assigning weights to newly generated stops, it is possible to perform more accurate stop predictions, for example, when the process is improved daily and workability is improved.

  “Proficiency” represents the proficiency level of an operator who is currently working in the process. In this embodiment, the proficiency level of 1.0 is the highest proficiency level, and the proficiency level decreases as the numerical value increases. For example, when the proficiency level is 1.5, the expected stoppage time described later is multiplied by 1.5. To calculate. In FIG. 2, the worker in the process 1 has a proficiency level of 1.0 for the products A and B. On the other hand, the worker of the process 2 has a proficiency level of 1.5 for the product A, 1.3 for the product B, 1.5 times the expected stop time for the product A, and 1. for the product B. Calculated as 3 times. It should be noted that whether or not the proficiency level is used for calculating the estimated stoppage time can be arbitrarily set.

  Since the process-specific record DB is implemented by software built on hardware resources, the process record DB in this embodiment is a hard disk, for example, when a single DB is constructed with a plurality of hard disks. The configuration of the wear is not limited. In this embodiment, the process-specific record DB is expressed as one DB, but the DB may be divided into a plurality of records depending on the recorded contents. For example, the number of calls and the accumulated stop time may be recorded in separate DBs, and data may be read from each DB when used. Further, a process-specific record DB may be constructed in a storage device via a network, and data may be shared with other production management devices (not shown).

  Next, the operation of the production management apparatus will be described with reference to FIG.

  FIG. 3 is an example of a flowchart for explaining the operation of the production management apparatus. In FIG. 3, it is checked whether or not a line call has occurred (S1). If there is no line call (No in S1), it is checked whether a line call stop has occurred (S5). If no line call stop has occurred (No in S5), the loop is repeated.

  When a line call occurs (Yes in S1), the number of calls of the process for which the process-specific record DB is called is incremented by 1 (S2). As a result, the numerical value of “number of calls” described in FIG. In FIG. 2, since the number of calls is counted for each product, in this embodiment, the product flowing in each process can be grasped by a method not shown.

Next, the expected stop time for each process is calculated for all processes in which calling has occurred (S3). A method for calculating the expected stop time is exemplified below.
・ Expected stop time = Cumulative stop time / Number of calls ... (Formula 1)
-Expected stop time = Cumulative stop time x Proficiency / Number of calls ... (Formula 2)
For example, in FIG. 2, when the product A is produced on the production line, if the line is called from step 1 and step 3, the number of calls in step 1 is 2, and the accumulated stop time is 100 seconds. In the calculation formula 1, expected stop time = cumulative stop time / number of calls = 100/2 = 50 seconds. On the other hand, in the step 3, similarly, the expected stop time = 50/2 = 25 seconds.

  Next, the operation to the display means is instructed to the process having the longest expected stop time by process (S4). In the above example, the expected stop time of process 1 is 50 seconds, whereas the expected stop time of process 3 is 25 seconds. Since the expected time becomes the maximum, a support request is displayed so that the support worker enters support on the display means 1 which is the display means of step 1 shown in FIG. In this embodiment, the case where there is only one cheering worker is explained. For example, when there are two cheering workers, the request for cheering is displayed on the display means of the upper two processes having the longest expected stoppage time. May be.

  Next, the operation when line call stop occurs (S5 is Yes) will be described. When the line call is made and the occurrence of the line stop is notified by the line operation / stop notification described later with reference to FIG. 1, the priority generation means starts measuring the line stop time by the stop time measurement timer ( S6). In this embodiment, the line stop time is measured in units of seconds, but the unit of measurement may be in units of 0.1 seconds, for example. The line stop time is counted until the line stop is completed (Yes in S6).

  Next, the measured stop time is added to the accumulated stop time of the process-specific record DB (S8). The stop time to be added is calculated by the following calculation method.

  First, when the support worker does not support the process at all, the measured line stop time is added as it is to the accumulated stop time of the process in which the stop is generated.

However, the following calculation is performed when the support worker stops support.
Stop time to be added = α + (line stop time−α) × β (Equation 3)
(Α: Time until the support worker reaches the support process, β: Work speed-up factor by the supporter)
For example, when α = 20 seconds and β = 1.5 and the line stop time is 60 seconds, the stop time to be added = 20 + (60−20) × 1.5 = 80 seconds.

  The values of α and β can be set and stored in advance in the priority order creating means. As a result, in the case of a long distance process, the corrected line stop time will be accumulated even if the speed of the work speed up by the support varies depending on the skill of the support worker, etc. The expected time can be calculated.

  The operation on the production line of the embodiment described above will be described with reference to FIG.

  FIG. 4 is an example of a diagram illustrating the operation of the production management device in the production line. In FIG. 4, the workpiece | work thrown into the conveyor is conveyed as process 1-> process 2-> process 3, and is discharged | emitted from a conveyor. Each process is provided with a switch for calling the support worker and a light for notifying the support worker of the process to be supported. The tact time is 60 seconds, and the worker of each process needs to finish the work within the tact time. If a trouble or the like occurs and the work does not end within the tact time, the worker presses the switch at a predetermined timing to call the supporter dealer.

  Now, let us assume that the workers in steps 1 and 3 are pressing the switch. As described above, the expected stop time in each process is 50 seconds for process 1 and 25 seconds for process 3. Further, although the switch is not pressed, if the switch of step 2 is pressed, the expected stop time of step 2 is 17 seconds. The priority creating means determines that the stop time of the process 1 is the maximum, turns on the light of the process 1, and prompts the support worker for support. On the other hand, in step 3, although the switch is turned off, the light is not turned on, and the worker in step 3 continues the work without the support of the support worker.

  Next, an example of shortening the line stop time by the production management apparatus of this embodiment will be described with reference to FIGS. FIG. 5 is an example of a time chart for explaining a process operating state using the production management apparatus. On the other hand, FIG. 6 is a time chart illustrating a process operating state in which the production management apparatus is not used for comparison. It is assumed that the work in each step described in FIGS. 5 and 6 is the same, and the effect of speeding up the work by the supporter dealer is the same. The production line illustrated in FIGS. 5 and 6 is assumed to include a process a, a process b, and a process c with a tact time of 60 minutes.

  FIG. 5 (a) and FIG. 6 (a) are time charts when 58 minutes have elapsed.

  At the end of 52 minutes, the worker in step a calls the support worker by pressing the switch. When the switch is pressed, in either case of FIG. 5 (a) and FIG. 6 (a), the light of the process a is immediately turned on, and the support worker recognizes the lighting of the light and the process of the process a is started from 53 minutes. I support the work.

  At the elapse of 54 minutes, the worker in the step b calls the support worker by pressing the switch. In FIG. 6 (a), since the production management apparatus is not used, the light in step b is immediately turned on, and the support worker recognizes it. The support worker plans to support the process b next when the support work of the process a has a target.

  On the other hand, in FIG. 5 (a), when the operator of process b presses the switch in 54 minutes, the production management apparatus will stop the process b for 3 minutes (estimated work completion 63 minutes) with process a. By comparing the expected time of 2 minutes (scheduled work end of 62 minutes), it is determined that the support of the process a having a long line stop time is a priority. The production management device does not turn on the light of the process b, and therefore the support worker continues to support the process a.

  When 56 minutes have elapsed, the operator of step c now presses the switch. In FIG. 6 (a), the light of the process c is turned on immediately, but the support worker cannot determine the priority of the process b and the priority of the process c. And plan to support. On the other hand, in FIG. 5 (a), the production management apparatus calculates the expected stop time for each of the processes a, b, and c. The priority generation means compares the fact that the expected stop time of the process b is 2 minutes and the expected stop time of the process c is 6 minutes, and determines the priority so that the process c enters support from 58 minutes. . In the present embodiment, the priority order of support is determined so that the work end times of the respective steps are as simultaneous as possible. By determining the priority order, it is possible to minimize the stop time in the entire production line. In the present embodiment, the work of the process a is completed before the work of the process b and the process c, but this takes into consideration the movement time between the processes of the support worker described in the calculation formula 3. As a result, it is judged that the stop time of the entire line as a whole can be minimized by supporting only the process c after the work in the process a is completed rather than performing the work in the process b, and the work is not necessarily completed. The case where time is not simultaneous is illustrated.

  After 58 minutes, in FIG. 6 (a), the support worker confirmed that the work of step a is likely to be completed within the tact time by the support of the support worker, and this time there was a support call first. The process b is entered into support. On the other hand, in FIG. 5 (a), in order to encourage support for the process c, which has a longer expected stop time than the process b, the light of the process c is turned on to notify the support worker of the next process to be supported. Note that the timing of lighting the light in step c may be performed in advance 58 minutes before the support work in step c is started.

  FIG. 5 (B) and FIG. 6 (B) are time charts when 60 minutes have elapsed.

  In step a, in both FIG. 5 (b) and FIG. 6 (b), after 58 minutes have passed, the worker in step a has become a single work, and the work has been completed in 60 minutes, which is the tact time.

  In FIG. 6B, a support worker enters the process b after 58 minutes and the work is completed at a tact time of 60 minutes. After the elapse of 60 minutes, the support worker enters support of the process c where the call was last made.

  On the other hand, in FIG. 5B, the support worker does not support the process b, but enters the process c after 58 minutes and supports the work. At the time when 60 minutes have elapsed, the expected stop time of the process b is 4 minutes, and the support stop operator's support has shortened it by 2 minutes from the initial stop expected time of 6 minutes. The expected stop time is calculated in real time even during the work. Therefore, if there is a call from another process, the priority order at that time can be calculated again, so even if there is an additional call, the line stop time is minimized. Can do.

  FIG. 5 (C) and FIG. 6 (C) are time charts when 60 minutes have elapsed.

  In FIG. 6C, the support worker finishes the support work of step b after 60 minutes, supports the last called process c, and finishes the work after 63 minutes. Therefore, when the production management apparatus shown in FIG. 6 is not used, the line stop time is 3 minutes.

  On the other hand, in FIG. 5C, the worker in the step b has finished the work after 62 minutes have elapsed as originally expected in the single work. In step c, support from the support worker enters after 58 minutes, and the work is finished after 62 minutes. Accordingly, the line stop time is 2 minutes, and the line stop time can be shortened by 1 minute compared to the case of FIG. 6 in which the production management apparatus is not used.

  As mentioned above, although the form for implementing this invention was explained in full detail, this invention is not limited to such specific embodiment, In the range of the summary of this invention described in the claim, Various modifications and changes are possible.

The present invention may have the following configurations as described below.
(Appendix 1)
A notification means that is arranged for each process of a production line composed of a plurality of processes, and requests work support;
A recording means for recording a past stop time for each step;
Priority generation means for calculating the expected stop time by reading out the past stop time of the process requested by the notification means from the recording means, and creating the priority of support for the process requested for support;
Informing means for informing the process of supporting according to the priority order created by the priority order creating means;
Production management device with
(Appendix 2)
The recording means records the accumulated stop time obtained by accumulating the past stop time and the number of calls.
The production management apparatus according to appendix 1, wherein the priority order creating means creates the priority order from the accumulated stop time and the number of calls.
(Appendix 3)
The production management apparatus according to appendix 1 or 2, wherein the priority order creating means creates a priority order of support so that the work end time is approximated in each step.
(Appendix 4)
The production management device according to any one of appendices 1 to 3, wherein the recording unit performs correction in consideration of work speeding up by work support during the stop time and records when the support worker is supporting work. .
(Appendix 5)
The production management apparatus according to any one of appendices 1 to 4, wherein the recording unit records the past stop time for each product produced on the production line.
(Appendix 6)
A process of recording a past stop time for each process of a production line comprising a plurality of processes;
A process of receiving a work support request from each of the processes;
A process of reading past stop times for each process for which a support request has been made,
A process of calculating the expected stop time for each process from the past stop time;
A production management method in which a computer executes a process of creating a priority order of support for each process from the expected stoppage time.
(Appendix 7)
The recording process records the accumulated stop time obtained by accumulating the past stop time and the number of calls.
The production management method according to appendix 6, wherein the process of creating the priority order creates the priority order from the accumulated stop time and the number of calls.
(Appendix 8)
The production management method according to appendix 6 or 7, wherein the process of creating the priority order creates a priority order of support so that the work end time is approximated in each step.
(Appendix 9)
The production according to any one of appendices 6 to 8, wherein in the process of recording, when the support worker is supporting the work, the correction is performed in consideration of the work speed-up due to the work support during the stop time. Management method.
(Appendix 10)
The production management method according to any one of appendices 6 to 9, wherein the recording process records the past stop time for each product produced on the production line.

Claims (6)

A notification means that is arranged for each process of a production line composed of a plurality of processes, and requests work support;
A recording means for recording a past stop time for each step;
Priority generation means for calculating the expected stop time by reading out the past stop time of the process requested by the notification means from the recording means, and creating the priority of support for the process requested for support;
Informing means for informing the process of supporting according to the priority order created by the priority order creating means;
Production management device with The recording means records the accumulated stop time obtained by accumulating the past stop time and the number of calls.
The production management apparatus according to claim 1, wherein the priority order creating unit creates the priority order from the accumulated stop time and the number of calls.   The production management apparatus according to claim 1, wherein the priority order creating unit creates a priority order of support so that the work end time is approximated in each step.   4. The production according to claim 1, wherein when the support worker supports the work, the recording unit performs correction in consideration of the work speed-up due to the work support during the stop time, and records the correction. 5. Management device.   The production management apparatus according to any one of claims 1 to 4, wherein the recording unit records the past stop time for each product produced on the production line. A process of recording a past stop time for each process of a production line comprising a plurality of processes;
A process of receiving a work support request from each of the processes;
A process of reading past stop times for each process for which a support request has been made,
A process of calculating the expected stop time for each process from the past stop time;
A production management method in which a computer executes a process of creating a priority order of support for each process from the expected stoppage time.

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