JPH04289063A - Assembly line construction supporting device - Google Patents

Abstract

PURPOSE:To provide an assembly line analyzing device for extracting a problem based on results of simulatiorn of an assembly line, an assembly line construction device capable of formation of a substitute idea corresponding to it even by an unskilled operator easily, and a filing device for an assembly line capable of searching and outputting examples of past assembly lines by inputting use of the assembly line to be constructed. CONSTITUTION:A problem of a line is extracted based on output data of simulation using an assembly line analyzing device 1 in a first stage. If there is no problem, an assembly line construction device 2 is taken for a second stage, and a substitute idea for resolving the problem is outputted. Corresponding to it, an operator modifies model data (file of condition values) of simulation, and makes simulation again. These procedures are repeated, and an assembly line filing device 3 is taken for a third stage when there are no problems left. For reusing examples of past assembly lines for intellectual property here, proper assembly lines are registered in a data base, and the past examples similar to an assembly line which the operator is constructing are searched and outputted.

Description

[Detailed description of the invention]

0001

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an apparatus for supporting the construction of an assembly line using a continuous flow conveyor or a free flow conveyor.

0002

BACKGROUND OF THE INVENTION Conventionally, assembly lines have been constructed by skilled workers with many years of experience, relying on their experience and making mistakes. However, as assembly lines are currently being forced to produce high-mix, low-volume production, system construction has become complex, and it has become difficult to construct an appropriate line using only the experiential knowledge of experts. In addition, line construction and modification are becoming more frequent as products have shorter lifespans, making it urgent to build assembly lines as quickly as possible, but this is not easy with conventional manpower tactics alone. Furthermore, since building an assembly line requires a large amount of investment, it must be highly practical and reliable, but it is not possible to build an appropriate assembly line based solely on qualitative judgments such as empirical knowledge. For this reason, simulators have been developed as quantitative evaluation methods for assembly lines, production systems, etc., but as seen in JP-A-62-277250 and JP-A-63-136249, Many of them deal with the development of technology to facilitate simulations, and methods for analyzing output results, countermeasures for problems, and methods for using past construction examples remain unresolved.

0003

[Problems to be Solved by the Invention] In the above-mentioned conventional technology, the time and quality required to construct an assembly line depend on the quality of skilled workers. Furthermore, as assembly lines have become more complex, it has become difficult to identify problems and analyze alternatives and diagnostic methods from multiple angles. Furthermore, when constructing an assembly line, there are many cases in which cases of assembly lines that have been built in the past are referred to. , construction, and search methods have not been established, so experts are required to use their know-how.

[0004] An object of the present invention is to provide an apparatus that allows anyone, not only an expert, to easily extract problems and create alternative solutions based on the results of simulating an assembly line. Furthermore, it is an object of the present invention to provide a device that, when inputting the use of an assembly line to be constructed, easily searches for and outputs examples of past assembly lines.

[0005]

[Means for Solving the Problems] In order to achieve the above object, the present invention provides an operating ratio for parameter values indicating characteristics of an assembly line such as production amount, number of model changeovers, etc. in order to extract problems in an assembly line. , a standard value table for assembly lines in which the standard value ranges of abnormal stop time rate and product waiting time rate are registered;
An input section for selecting a suitable standard value table for an assembly line, a data conversion section, a condition storage section, a table determination section, a table storage section, a detection section for detecting a problem work station from the simulation output data and the standard value table. An assembly line analysis device having an output section and a problem selection section.

[0006] An assembly line construction database that stores assembly line construction know-how possessed by experts in an IF-THEN format, a concept input section for inputting operator concepts, and work output from an assembly line analysis device. An assembly line construction device that has a storage section that inputs stations and concepts as initial values from a data change section, stores inference processes, and a drive section that utilizes the know-how of experts in assembly line construction databases for the data in the storage section.

[0007] As a result of constructing an appropriate assembly line, a memory unit is used to register the characteristics of the assembly line such as the target product, production plan, takt time, work process, equipment configuration, specifications of each equipment, number of workers, and constraints. , DB data creation section, DB data conversion section, DB registration section, and assembly line database. The assembly line filing device further includes an input section, a storage section, a search section, and an output section for searching an assembly line similar to a desired assembly line from an assembly line database.

[0008]

[0009]

[Operation] The assembly line analysis device displays the standard value ranges of operation rate, abnormal stop time rate, and product waiting time rate for characteristic parameter values that indicate assembly line characteristics such as production volume and number of model changeovers in table format for assembly lines. Register it in the standard value table. The selection of an appropriate assembly line table for the assembly line under analysis is performed by the table determination section using the simulation input data from the data conversion section and the characteristic parameters from the operator input data from the input section, and is imported into the table storage section. It will be done. The detector then compares the simulation output data of the operating rate, abnormal stop time rate, and product waiting time rate at each work station with the standard value range in the table storage unit, so that the performance of each work station is within the standard range. , below the standard range, and above the standard range, and the output section can visually display the results on the display output device.

[0010] In the assembly line construction device, if the assembly line construction know-how of experts is stored in an assembly line construction database in an IF-THEN format,
The driving unit searches the database for know-how that matches the problem output from the assembly line analysis device, adds new countermeasures to the storage unit, continues until the drive stops, and outputs an alternative solution to the problem. If other data is required, the driver refers to the simulation input/output data or asks the user interactive questions. If there is no match between the data in the storage section and the assembly line construction database, this is considered a termination decision, and the data in the storage section is output as an alternative plan.

As a result of constructing an appropriate assembly line, the characteristics of the assembly line such as the target product, production plan, tact, work process, equipment configuration, specifications of each equipment, number of workers, and constraints are stored in the storage section and DB. Data creation section, DB data conversion section,
It is stored in the assembly line database section via the DB registration section. Furthermore, by inputting the characteristic parameters of the required assembly line at the input section, a similar assembly line can be selected at the search section and outputted to a display output device or a printer output device at the output section.

0012

DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of the present invention will be described below with reference to FIGS. 1 to 4.

FIG. 1 shows the configuration of an embodiment of the present invention, in which an assembly line analysis device 1, an assembly line construction device 2, and an assembly line filing device 3 are provided, each of which is organically driven. It consists of a support device 4.

[0014] With this configuration, the operation is as follows. In the first step, the assembly line analysis device 1 is used to extract line problems from the simulation output data. If there is a problem, the process moves to the second stage assembly line construction device 2 and outputs an alternative plan for solving the problem. Accordingly, the operator modifies the simulation model data (condition value file) and performs the simulation again. This series of operations is repeated, and when the problem is resolved, the process moves to the third stage, the assembly line filing device 3. Here, in order to reuse past assembly line cases as intellectual property, appropriate assembly lines are registered in a database, and past cases similar to the assembly line that the operator is trying to construct are searched and output. It is. The assembly line construction support device 4 has these three devices and organically drives them.

The configuration of the assembly line analysis device will be described below with reference to FIG. First, from the simulation input data file (condition value file 100), the data conversion unit 10
2 extracts the data necessary for selecting an appropriate assembly line standard value table, converts the data format into all parameters that affect construction, and stores the data in the condition storage unit 105.
Register to. For example, based on the production plan data of the condition value file 100, the data conversion unit 102 determines the number of times the model is switched. This process is performed to account for variations in assembly ST (standard time) for each model, production tact, etc. Also,
Input device 104 and input unit 10 input parameter values indicating assembly characteristics such as product weight, assembly accuracy, assembly ease evaluation method (for evaluating ease of assembly), and FA rate that are not in the condition value file.
3 and is registered in the condition storage unit 105. next,
The table determining unit 106 selects an assembly line standard value table 107 that meets the conditions from the values in the condition storage unit 105, and the table storage unit 108 imports the standard value table 107. The standard value table registers the standard value ranges of operation rate, stop time rate, and product waiting time rate for parameter items that indicate the characteristics of the assembly line set in the condition storage section. The value range is set to the data of the actual assembly line currently in operation.

[0016] The selection is based on weighted evaluation.

For example, weights are given to parameters indicating features, such as a weight Wc for the number of model changes and a weight Wp for assembly accuracy. Then, the difference between the parameter values such as the number of model switching times and assembly accuracy in the condition storage unit 105 and the parameter values in the standard value table is multiplied by a weight, and the one with the smallest sum is set as the standard value.

In addition, the standard value may be set by approximating changes in the operating rate, abnormal stop time rate, and product waiting time rate due to changes in individual parameters such as the number of model changes and assembly accuracy using functions. You can also do it.

The assembly line standard value table can be easily maintained as technology advances. On the other hand, input the line equipment configuration, production method, production plan, etc.
The operation rate, abnormal stoppage time rate, product waiting time rate, etc. are simulated, and the data conversion unit 109 calculates the operation rate, abnormal stoppage time rate, product waiting time rate of each work station from the simulation output result file 101 of this simulation. The data is taken out and imported into the storage unit 110. The data in the storage unit 110 and the values in the table storage unit 108 are compared by the detection unit 111, and the output unit 112 determines whether the simulation result at each station is below the standard value range, within the standard value range, or above the standard value range. The image is visually displayed on the display output device 113. Figure 9 shows an image of the output regarding the operating rate. In addition, the abnormal stop time rate and product waiting time rate are similarly output. Based on this result, the operator determines the problematic station in the problem selection section 114, and if no problem is selected, all work stations below the standard value range are selected. The selected work station is analysis file 11
5 is output. The flow of these operations is shown in FIG.

Next, the system configuration of the assembly line construction device is shown in FIG. First, the analysis result file 115, which is the data of the work station in question, is imported into the storage unit 203 by the data conversion unit 200 from the assembly line analysis device. In addition, the concept input section shortens lead time.
By weighting the operator's design concepts such as eliminating the number of workers and eliminating space on the assembly line,
02 and fetched into the storage unit 203.

Next, the drive unit 204 matches the storage unit with the assembly line construction database 205 in which the know-how of experts is stored in an IF-THEN format, and if there is a match, Rewrite the data in the storage unit 203. For example, if there is data (a, c) in the storage unit, the drive unit searches for know-how that matches (a) from the assembly line construction database, and
a) Zen (s)” matches, the storage unit stores (s, c)
can be rewritten as Further, the driving section proceeds while referring to the condition value file 100, the simulation output result file 101, and the operator as necessary. If there is no matching item in the storage unit and the assembly line construction database, this is determined to be the end, and the output unit 206 outputs to the printer output device 207. A flowchart of these operations is shown in FIG.

Next, a system block diagram of a filing device for an assembly line is shown in FIG. This device has a registration function and a search function, and the operation flow for the registration function will be explained first. For an appropriate assembly line, the database creation unit 301 assembles the target product, production plan, tact, work process, equipment configuration, specifications of each equipment, number of workers, constraint conditions, etc. from the condition value file and simulation output result file. Extract parameters that indicate line characteristics. The database data conversion unit 302 converts this into a data format to be registered in the assembly line database 304.
The database conversion registration unit 303 allocates and executes a registration area. The conversion format in the data conversion unit 302 is shown in FIG. The features of the assembly line extracted by the database data creation unit 301 are constructed hierarchically as shown in FIG. This makes data construction economical and flexible. On the other hand, in the search, first enter the characteristic parameters of the assembly line you want to search using the input device 305.
Input from 6. This parameter value is registered in the storage unit 307, and the search unit 308 searches for an assembly line similar to the data in the storage unit. The search results are prioritized and output from the output unit 309 to the display output device 310 or the printer output device 311. The search method in the search unit 308 is as follows.
Weights are set for the feature parameters, multiplied by the difference between the parameter values in the storage unit and the parameter values in the database, and the one with the smallest total when this is applied to all parameters is output first. For example, for a characteristic parameter such as the number of model switching, the data in the database is Di times/
Assuming that the data in the storage unit is Si times/year, and the weight Wi is, |Si−Di|/Si×Wi is the similarity amount in the number of model switching, and the total sum S = Σ for all feature parameters.
(|Si−Di|/Si×Wi) is determined and outputted in ascending order of S. An operational flowchart for these registrations is shown in FIG. 7, and an operational flowchart for search is shown in FIG.

[0023]

[Effects of the Invention] According to the present invention, the following effects can be achieved.

The assembly line analysis device can quickly evaluate whether the performance of each work station is within the standard range, below the standard range, or above the standard range. Since the standard value table for evaluation is selected on the system side by the table determination section, the know-how of an expert is not required for evaluation. In addition, the output results are displayed visually, allowing the operator to grasp problems on the entire line from a macroscopic perspective.

[0025] With the assembly line construction device, anyone can easily modify the assembly line using the know-how of an expert, and the time required to construct the assembly line can be greatly reduced when modifying an assembly line with a huge number of combinations. It is shortened to .

Furthermore, the assembly line filing device allows past assembly line cases to be easily reused. In addition, since past case searches are performed on the system side, it can be used by not only experts, and materials for building an assembly line can be quickly supplied to operators.

[Brief explanation of the drawing]

FIG. 1 is a system flowchart of an assembly line construction support device.

FIG. 2 is a system block diagram of an assembly line analysis device.

FIG. 3 is a system block diagram of an assembly line construction device.

FIG. 4 is a system block diagram of a filing device for an assembly line.

FIG. 5 is an operation flowchart of the assembly line analysis device.

FIG. 6 is an operation flowchart of the assembly line construction device.

FIG. 7 is an operation flowchart of a registration function in an assembly line filing device.

FIG. 8 is an operation flowchart of a search function in the assembly line filing device.

FIG. 9 is an explanatory diagram of an output screen of the assembly line analysis device.

[Figure 10] DB in filing device for assembly line
Data format explanatory diagram.

[Explanation of symbols]

1...Assembly line analysis device 2...Assembly line construction equipment 3...Filing device for assembly line 4...Assembly line construction support device

Claims (3)

[Claims] Claim 1: A standard value table for an assembly line in which standard values are registered, and a table for selecting a table, in order to analyze problematic work stations based on the operation rate, abnormal stop time rate, and product waiting time rate from the simulation results. An input section, a data conversion section, a condition storage section, a table determination section, a table storage section, a data conversion section that extracts and stores data necessary for analysis from simulation results, a storage section, and a storage section that analyzes the station in question. detection unit for output,
An assembly line analysis device characterized by including an output section and a problem selection section. 2. A database for constructing an assembly line according to claim 1, in which the know-how of experts is accumulated, in order to output an alternative plan for the problematic work station;
An assembly line construction device comprising a concept input section, a data conversion section, a storage section for inputting and storing an operator's concept and problems, and a drive section for utilizing the know-how of the expert. 3. An assembly line database that systematically stores assembly line characteristics in order to reuse past knowledge of appropriate assembly lines, a storage unit for registering the assembly line, and a DB data creation unit. , DB data conversion unit, DB
1. A filing device for an assembly line, comprising a registration section, an input section for searching for a required assembly line, a storage section, and a search section output section.