JPH0652178A - Assembly line work plan generation support system - Google Patents

Abstract

PURPOSE:To support the generation of an efficient allocation work order by means of considering machine type switching on a main assembly line and the appropriate allocation of workers. CONSTITUTION:This system is provided with an assembly order decision device 2 deciding an assembly order by considering the assembly workability of parts at the time of assembling a product on the line where automatic machines and the workers are mixed, a work order decision device 3 deciding the work order for the assembly order and a work allocation device 4 distributing work by considering workability from worker information to the work order. Thus, the generation of the efficient allocation work order by considering machine type switching and the appropriate allocation of the workers are supported.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention considers the workability of assembling by a worker when a plurality of types of products such as industrial machines and household appliances are continuously assembled by a main assembly line and a subassembly line. The present invention relates to an assembly line work plan creation support system that supports the creation of an assembly line work plan to achieve the specified work content.

[0002]

2. Description of the Related Art When a plurality of models flow on an assembly line, it is important to create efficient allocation work in consideration of model switching and to appropriately assign workers to the production efficiency on the assembly line. It greatly contributes to.
In other words, when multiple models flow on the assembly line, it is a major issue to avoid setup changes due to worker changes due to model changes, and reduction in production efficiency due to lack of experience and capability of workers. . Conventionally, the assignment of the assembly work to the current line is done by the workers on the production site, such as the constraint conditions such as the configuration of the assembly line and the arrangement of the automatic machine, the content of the assembly work such as the product component configuration and the assembly method, and the worker. The actual situation is that it is done after comprehensively considering individual experiences and abilities. However, the number of parts to be assembled per model is large, and since the processing information is too much on a line with many types of assembly per part, not only is assignment work a heavy labor task, but there is also a change in workers between multiple models. It is difficult to make proper allocation in consideration of setup.

As a means for solving the above-mentioned problems, for example, Japanese Laid-Open Patent Publication No. 1-251279 can be cited. In this case, a work order is input and a simulation is used to confirm the work interference state. , The work process in which the interference is avoided is supported without any inconsistency with a light labor.

[0004]

However, in the case of the above publication, the above problems at the time of creating the work sequence are still unsolved. In other words, it is still in the mind of a person to perform setup change due to worker changes accompanying model change at the time of work assignment, and to create work assignment plans considering the experience and ability of the workers. Therefore, it was difficult to optimize the work assignment while keeping all the items consistent.

An object of the present invention is to provide an automatic machine and a worker on a subassembly line or a main assembly line in a mixed manner, and on a main assembly line in which one or more subassembly lines are directly connected to each other, Efficient in consideration of model switching when a plurality of models flow into the main assembly line when assembling a finished product by assembling parts by an operator and sequentially assembling the parts obtained by the assembling work. The present invention provides an assembly line work plan creation support system capable of creating a proper allocation work sequence and assisting in assigning workers appropriately.

[0006]

Specifically, the above object is to provide a code storage device for storing a grouped part code as a part code system and a grouping work code as an assembly work code system, and the present situation. Change the assembly order of parts between models based on the constraint condition storage device that stores various constraint conditions in the line, the assembly preceding sequence information on the drawing number of the part, and the grouping part code from the code storage device And an assembling order determining apparatus for determining an optimal assembling order of the parts, and a grouping work code from the code storage device for the determined assembling order from the assembling order determining apparatus is used. With respect to the determined assembly work order from the work order determination device and the work order determination device that determines the optimum assembly work sequence that minimizes the change of the assembly work sequence in In consideration of various constraints in the constraint condition storage device, a work allocation device that creates an optimum assembly work distribution that minimizes worker movement between models as an assembly line work plan is configured. Can be achieved.

[0007]

In the assembling order determining device, the parts are represented in the order of assembling based on the drawing number by using the grouped part codes classified from the process contents. On the other hand, while it is possible to create, the distribution information of the assembly line, which is a constraint condition of the current assembly line, is stored in advance as a grouped part code, and parts can be automatically expanded by line,
The labor of the operator can be reduced. Further, since the assembly order change rule data includes the installation order of the automatic machines, which is a constraint condition, it is possible to automatically create the assembly order candidate group while having a rule in developing the assembly order. Furthermore, by extracting a group of workers in the assembly sequence and making the configurations of the models similar to each other, it is possible to positively reduce the setup change due to the change of the workers.

On the other hand, in the work order determination device, the work order is expressed from the similarity of workability between models by expressing the work order using a grouping work code classified from the similarity of work. It is possible to perform pre-setup (jig set, work on assembled parts, etc.), post-setup (check, shaping, adjustment, etc.), and test work items (assembly) when assembling parts to the assembly order. The same effect as above can be obtained by entering a code such as a work quality test or a commercial test. In addition, by assembling parts into three series of operations, that is, parts supplying operation, auxiliary operation, and assembling operation, and inputting each operation by a code, the parts code can be automatically expanded into a work code. , Will lead to a reduction in labor.

Further, in the above work allocating device, since the standard time for the grouping work code is stored in advance, it is possible to automatically add the work time information to the work. Automatically allocates work to reduce labor, and in addition, workers are assigned in consideration of the experience and ability data of workers, which makes the work plan of the assembly line highly workable. A plan can be created.

[0010]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An assembly line work plan creation support system according to the present invention will be described below with reference to FIGS. First, its configuration will be described. FIG. 1 shows an outline system configuration as an example. As shown in the figure, the whole is composed of an assembly order determination device 2, a work order determination device 3, a work allocation device 4, a code storage device 5, and a constraint condition storage device 6. Of these, the assembly sequence determination device 2 is from the assembly sequence input unit 7, the assembly sequence group expansion unit 8 and the assembly sequence determination unit 9, and the work sequence determination device 3 is the work sequence input unit 10 and the work sequence group expansion unit. 11 and the work order determination unit 12 further includes the work allocation device 4
Are composed of only the work allocating section 13. Now, regarding the processing in that system, the outline is that the assembly order determination device 2 determines the assembly order based on the assembly order data 1 of the type indicating the assembly preceding order of parts, but based on the assembly order. The work order is determined by the work order determining device 3, and the work allocating device 4 allocates the work within the set takt time based on the work order, assigns a worker to each work, and sets the assembly line work plan to the work process. It is designed to be output as vote 14. In the series of processing flows, various data (grouped component code, grouped work code, assembly line distribution data, worker data, standard time (ST) are stored in each of the code storage device 5 and the constraint condition storage device 6 as needed. ) Data, takt time data, etc.) are referred to.

More specifically, FIG. 2 shows the function of the assembly sequence input section 7. If this is the case,
In the function S10, the assembly sequence data 1 expressing the preceding order of the drawing numbers of the parts is input from the outside, and in the function S11, the drawing number is referred to while referring to the grouped part code stored in the code storage device 5 in advance. And the grouping part code matching process is performed. Further, in function S12, the assembly sequence data of the drawing number is replaced with the grouping part code from the matching process result, and the function S1
3 is output to the assembling order developing unit 8. At that time, as the assembly sequence data, data having the assembly preceding sequence information shown in FIG. 3 is input.
These data are an array of model names or drawing numbers. However, from these information, it is not possible to examine the similarity in terms of assembly process of parts between models, so as shown in FIG. It corresponds to. As a result, the assembly sequence data shown in FIG. 3 is replaced with the assembly sequence code data shown in FIG. As described above, the order of assembling the parts between the models can be processed on the same code in consideration of the similarity of assembling.

Next, the function of the assembly sequence group expansion section 8 will be described. In the assembly sequence group expansion section 8, the information of the assembly line is set as a constraint condition so as to be expanded to the assembly sequence on the current assembly line. As a result, the information is added to the data (assembly preceding order information of the grouped part code), and a candidate group whose order can be changed is created in the information. Specifically, as shown in FIG. 6, in the function S20, the array of the grouped component codes obtained in FIG. 5 is obtained from the classification data of the components assembled on the main assembly line (total assembly line) and the assembly line. It is divided into parts to be assembled for each line, and in function S21, information on parts to be assembled by the automatic machine is added from information on the automatic machine on the assembly line. Further, in the function S22, a rule is set in the assembling precedence order from the arrangement order of the automatic machines in order to follow the automatic machine target parts, and in the function S23, the possible assembly order is performed while satisfying the rules for each line. Has been developed as a candidate group of. This result is output to the assembly order determination unit 9 by the function S24.

The operation contents of the assembling sequence expanding section 8 will be described in more detail. As shown in FIG. 7, the distribution information of the assembly line is stored. The parts group to be handled is classified by grouping part code. By referring to this information, the physical distribution information of the current line can be added to the assembly preceding sequence information of the part code obtained by the assembly sequence input unit 7. In other words, it can be considered that it has been disassembled into the shape of the current assembly line. FIG. 8 shows the result of adding the physical distribution information of the line to the assembly sequence data. Next, as the information of the automatic machines on the current line, the arrangement order of the automatic machines is added to the parts handled by the automatic machines. FIG. 9 shows the result of adding the automatic machine order information to the assembly order data. It is shown.
As a result, since the arrangement order of the automatic machines is determined, it becomes a rule for developing the assembly preceding order. In other words, in the line that is lined up with the automatic machines 1 and 2, it is possible to assemble the parts 17 after the parts 3 have been assembled from only the information of the assembling order, but the information is added to the current line. It becomes impossible by doing. Next, by expanding the possible assembling order in a manner that satisfies the rule, a candidate group of assembling order data is obtained as shown in FIG.

Further, the function of the assembling order determining unit 9 will be described. Here, in order to determine one assembling order for each model, one having the most similar assembling order among the models is selected. It has become one. Specifically, as shown in FIG. 11, in the function S30, one assembly sequence data is extracted from the candidate group data for each model, and a combination of the assembly sequence data is created. A group (hereinafter, referred to as a cell) in which other workers are to be assembled with the automatic machine target component fixed is extracted from the assembly sequence data. Then function S3
In 2, the grouping rate that evaluates the closeness of the component configuration of each cell is calculated. This is because the necessity of worker change due to model switching is different from the difference in the number of component configurations between cells. If there is a change in the worker due to the difference in the work content of assembling the parts, it is possible to minimize both causes by increasing the grouping rate. Function 3
If it is determined in step 3 that the combination has the highest grouping rate than the grouping rate, the function 34 determines the assembly sequence data on the assembly line. The determination of such assembly sequence data is performed for all the assembly lines by the function S35, and the determined assembly sequence data is output to the work sequence input unit 10 by the function S36. The operation contents of the assembly sequence determination unit 9 will be described in more detail. As shown in FIG. 12, the assembly sequence candidate group has the parts 3 and 9 to be assembled by the automatic machine fixed and the cells to be operated by the worker. A combination that has been extracted and most similar in order to the cell component parts (maximum grouping rate) is obtained as shown in FIG.

As described above, the internal functions of the assembly sequence determination device 2
The processing has been described. Next, the internal functions and processing in the work order determination device 3 will be described below.
That is, first, the function of the work sequence input unit 10 will be described with reference to FIG. 14. Here, since the assembly sequence data is an array of component codes, this is converted into work sequence data in order to reduce it to the work allocation level. Therefore, in each line, other than the current assembly work, parts supply work,
Four pieces of information, an auxiliary work for assembling and an assembling work, are input. These pieces of information are items that depend on the current production method on the line, and also serve to input the constraint conditions of the line to the work order. Specifically, in the function S50,
Other than assembling work, pre-setup work including jig loading / collection and work on assembled parts, post-setup work including adjustment / shaping work of parts after assembly, and tests performed in commercial tests A grouping work code is input for each work item. This input method using the grouping work code has the same effect as the grouping part code described above, and it becomes possible to evaluate the similarity of the work and positively group the work, and it is possible to perform the setup change and the work of the worker. It would be possible to create a plan with reduced changes. Next, a part supply work for each part, an auxiliary work, and an assembling work are regarded as a series of operations. In function S51, a part supply work method is applied to a part code, and in function S52, an auxiliary work for assembling work. The method further includes function S53.
In, the auxiliary work method at the time of assembling is input by each grouping work code. Such a series of processing is performed for all parts and all lines by the functions S54 and S55, and the processing result is the function S56.
Is output to the work order group expansion unit 11.

The operation contents of the work sequence input section 10 will be described in more detail. As shown in FIG. 15, the parts to be assembled are developed in the current line shape by the function as shown in FIG. , Inserting jigs required for pre-setup, peeling off peeling paper from seals, reversing the work, etc., and performing post-preparation work such as adjusting work and shaping parts, and test work in commercial tests as test work items. Etc. are added as the information of the component codes, respectively.
Next, as shown in FIG. 16, a component supplying work, an auxiliary work, and an assembling work are set for one component code. Such a setting process is performed for all the components. Has become. As a result, the information for converting the grouped part code into the grouped work code is added. The grouping work code shown in FIG. 17 is for assembly work, auxiliary work, and component supply work,
Depending on the work specifications, different groups are divided into more detailed groups.

Next, the function of the work sequence group expansion unit 11 is shown in FIG.
8, the information obtained by the work order input unit 10 is used as an array of work codes in the shape of the current line, and all possible work orders are obtained as a work order candidate group. Has become. Specifically, the function S6
In 0, the information added to the component code is replaced with the work code instead of the component code. However, after performing such processing for all the components from the function S61, the function S
In 62, a work sequence candidate group is created and created from the possibility of changing the assembly work sequence per component. After this is processed for all the parts by the function S63, the same processing is repeated for all the lines by the function S64. The result thus obtained is output from the function S65 to the work order determination unit 12. is there.

Continuing with FIG.
9, the work sequence group expansion unit 11 will be described here.
In order to determine one work order for each model from the work order candidate group obtained in step 1, a procedure similar to that of the assembly order determination unit 9 in the assembly order determination device 2 is performed. Specifically, in the function S70, one work order data is selected for each model from the work order candidate group, and a combination of work order data is created. Next, in function S71, the target work in the automatic machine is fixed and cells are extracted.
2, S73 and S74 determine the combination of the work sequence data having the highest grouping rate. After such determination processing is performed for all lines by the function S75, the results are determined by the function S76. , Is output to the work allocation unit 13.

The function of the work allocating section 13 is shown in FIG.
In this case, standard time (ST) information is added to the work code in order to assign the work data to the worker, and the work is assigned based on this and the set takt time. Workers are assigned based on their abilities. Specifically, in the function S100, the standard time data in the constraint condition storage device 6 is referred to, and the work time is added to each work code.
Next, in function S101, the takt time data in the constraint condition storage device 6 is referred to, and the work is divided into elements so that the takt time set in the allocation target model is reached. Further, in the function S102, the worker order data is created by assigning the worker to each work element in consideration of the experience and ability of the worker from the worker data. After that, function S10
3, the same processing is performed for all lines and all target models by S104, but the functions S105, S
In 106, a cell is created in the worker order data of each model, and the change status of the worker between cells due to model switching is output. Whether or not there is a need to change the allocation is determined by the function S107 based on the result of this change situation. If there is no need, the assembly line work plan including the work allocation result is output as the work process slip 14 by the function S108. Is.

[0020]

As described above, according to the first to third aspects, the automatic machine and the worker are mixed on the subassembly line or the main assembly line, and one or more subassembly lines and the subassembly lines are provided. On the main assembly line where the lines are directly connected, when assembling a finished product by assembling the parts by the worker and sequentially assembling the parts obtained by the assembling work, a plurality of models flow on the main assembly line. For cases,
Create an efficient assignment work order considering model switching,
Moreover, it is possible to support the appropriate assignment of the workers.

[Brief description of drawings]

FIG. 1 is a diagram showing a schematic system configuration of an example of an assembly line work plan creation support system according to the present invention.

FIG. 2 is a diagram showing a function of an assembly sequence input unit in the assembly sequence determination device as one of the components.

FIG. 3 is a diagram showing assembly order data at a part name level.

FIG. 4 is a diagram showing a grouped part code.

FIG. 5 is a diagram showing assembly order data at a grouped part code level.

FIG. 6 is a diagram showing a function of an assembly sequence expanding unit in the assembly sequence determination device.

FIG. 7 is a diagram showing assembly line physical distribution data.

FIG. 8 is a diagram showing a result of adding physical distribution information of a line to assembly sequence data.

FIG. 9 is a diagram showing a result of adding automatic machine order information to assembly order data.

FIG. 10 is a diagram showing an assembly sequence candidate group.

FIG. 11 is a diagram showing a function of an assembling order determining unit in the assembling order determining device.

FIG. 12 is a diagram showing a result of extracting cells from assembly sequence data.

FIG. 13 is a diagram showing assembly order data which is an output result.

FIG. 14 is a diagram showing a function of a work order input unit in the work order determining apparatus as one component.

FIG. 15 is a view showing a result of adding information on setup work and test work to assembly sequence data.

FIG. 16 is a diagram showing a result of adding parts supply work, auxiliary work, and assembly work information to a part code of assembly order data.

FIG. 17 is a diagram showing a grouping work code.

FIG. 18 is a diagram showing a function of a work order group expansion unit in the work order determination device.

FIG. 19 is a diagram showing a function of a work order determination unit in the work order determination device.

FIG. 20 is a diagram showing a function of a work allocating device or a work allocating unit as one component.

[Explanation of symbols]

1 ... Assembly sequence data, 2 ... Assembly sequence determining device, 3 ... Work sequence determining device, 4 ... Work allocating device, 5 ... Code storage device, 6 ... Constraint condition storage device, 7 ... Assembly sequence input unit, 8 ...
Assembly order group expansion unit, 9 ... Assembly order determination unit, 10 ... Work order input unit, 11 ... Work order group expansion unit, 12 ... Work order determination unit, 13 ... Work allocation unit

Claims (3)

[Claims] 1. An automatic machine and a worker coexist on a subassembly line or a main assembly line, and on a main assembly line in which one or more subassembly lines are directly connected to each other,
When assembling a finished product by assembling the parts by the worker and sequentially assembling the parts obtained by the assembling work, for supporting the operation so as to make the work contents in consideration of the workability of the worker. An assembly line work plan creation support system, which stores a grouping part code as a part code system and a grouping work code as an assembly work code system, and various constraint conditions on the current line. The optimum assembly sequence of parts is determined in consideration of the assembly workability of parts from the constraint condition storage device to be stored, the assembly preceding sequence information on the drawing numbers of the parts, and the grouped part codes from the code storage device. And a grouping work code from the code storage device for the determined assembly sequence from the assembly sequence determination device. A work order determining apparatus for determining an optimum assembling work order, and an optimal assembling work order from the work order determining apparatus, in consideration of various constraint conditions in the constraint condition storage device. An assembly line work plan creation support system including a work allocating device that creates an allocation work distribution as an assembly line work plan. 2. An automatic machine and a worker are mixed on a subassembly line or a main assembly line, and one or more subassembly lines are directly connected to the main assembly line,
When assembling a finished product by assembling work of components by a worker and sequentially assembling the parts obtained by the assembling work, it is necessary to reduce setup change due to change of worker due to model change of the finished product. An assembly line work plan creation support system for supporting operation, a code storage device that stores a grouping part code as a part code system and a grouping work code as an assembly work code system, and a current line In order to change the assembly order of parts from one model to another, from the constraint condition storage device that stores various constraint conditions, the assembly precedence sequence information on the drawing number of the component, and the grouping component code from the code storage device. An assembly sequence determining device for determining an optimal assembly sequence of the minimum parts, and a code storage device for the determined assembly sequence from the assembly sequence determining device. Using the grouping work code of, the work order determining device that determines the optimum work order for assembling that minimizes the change in the work sequence between models, and the determined work order from the work order determining device. For the order, in consideration of various constraint conditions in the constraint condition storage device, a work allocation device that creates an optimum assembly work distribution that minimizes worker changes between models as an assembly line work plan, Assembly line work plan creation support system including. 3. An automatic machine and a worker are mixed on a subassembly line or a main assembly line, and one or more subassembly lines are directly connected to the main assembly line,
When assembling a finished product by assembling the parts by the worker and sequentially assembling the parts obtained by the assembling work, for supporting the operation so as to make the work contents in consideration of the workability of the worker. An assembly line work plan creation support system, which stores a grouping part code as a part code system and a grouping work code as an assembly work code system, and a constraint condition on the current line. , Assembly line physical distribution data (line-by-line handling part code and automatic machine installation status),
Worker data (worker experience / ability information), standard time data (for each grouped work code)
And a constraint condition storage device that stores set takt time data (for each model), and assembly pre-order information in the drawing number of the part in the product is input, and the pre-assembly order information is a group classified from the process content of the part. The assembly sequence input unit that develops into the assembly part code, the assembly sequence group expansion unit that creates the assembly sequence candidate group by classifying the assembly sequence from the information of the current line for the above assembly preceding sequence information, and the worker An assembly sequence determination unit that consists of an assembly sequence determination unit that classifies the assembly locations as cells, and outputs the assembly sequence with the most similar in-cell component configuration among models to the work sequence determination unit, and the assembly sequence of the components. Using the grouping work codes classified from the assembly work, the pre-setup / post-setup / test work items of the work, parts supply work, assembly assistance work and A work order input section for inputting an assembly work, a work order expansion section for creating a group of assembly work order candidates from a work rule and a change rule of the work order for the grouping work code obtained by the above result, and a work. In addition to classifying the places to be assembled by a worker as cells, a work order determination unit that consists of a work order determination unit that determines the work order in which the cell internal work configurations of the models are the most similar, and the worker's ability or work In order to perform work assignment in consideration of the nature, including work time information using standard time data and adding work time information to the grouping work code, and including a work allocation device that allocates work based on the set tact time and the work priority of the worker Assembly line work plan creation support system.