KR102234368B1 - System for managing dcs productivity - Google Patents

Abstract

The present invention relates to a management system, and more specifically, in the process of mass-producing products through a DCS (Distributed Control System) facility, all documents and instructions required for production management of workers and products are converted into a database, and a productivity analysis system is established. It relates to a DCS productivity management system that enables efficient product production management by making it possible to establish.
To this end, the present invention includes a time and attendance status management unit for managing the time and attendance status of each worker at a production site using a DCS (Distributed control system), a work status management unit for managing the work status of a group belonging to a worker including the worker, The production status management department to manage the production status of products at the production site using DCS, the productivity management department to manage the productivity and defect rate of products according to at least one or more of the worker's group and product, and the worker's group and product. A manager server comprising a production instruction performance management unit that manages performance results for at least one production instruction; It characterized in that it comprises a; and a person in charge terminal for transmitting and receiving data with at least one or more of a time and attendance status management unit, a work status management unit, a production status management unit, a productivity management unit, and a production order performance management unit by communicating with the manager server.

Description

DCS productivity management system {SYSTEM FOR MANAGING DCS PRODUCTIVITY}

The present invention relates to a management system, and more specifically, in the process of mass-producing products through a DCS (Distributed Control System) facility, all documents and instructions required for production management of workers and products are converted into a database, and a productivity analysis system is established. It relates to a DCS productivity management system that can promote efficient product production management by making it possible to establish.

In the early days, the concept of control using a computer was mainly based on a direct digital control (DDC) system by one computer and a control method by analog connection in the field.

In the case of such a DDC, since all control functions are concentrated on one computer, there is a problem that the entire process is out of control when an error occurs in the computer.

The DCS (Distributed Control System), developed to compensate for this, separates several small central processing units for each function and connects each to a communication network to form an entire system.

As described, the efficiency of DCS is gradually increasing due to the improvement of semiconductor manufacturing technology, and the application power of the field is also continuously increasing, and the demand is increasing day by day, such as being installed and operated at various types of process control sites. to be.

Due to the active market demand for DCS, competition among peers is also fierce. Therefore, in this trend, it is essential to continuously and quickly produce high-quality products as a condition for a company to secure competitiveness. Efficient management of productivity is essential, but due to the lack of technology related to productivity management of DCS, research on this needs to be continued.

Republic of Korea Patent Publication No. 10-0269785 Korean Patent Application Publication No. 10-1997-0007687

The present invention was conceived to solve the problems of the prior art described above, and when mass-producing a product through a DCS facility, information and instructions necessary for the operator and product production management were converted into a database to facilitate convenience and productivity analysis. Its purpose is to provide a DCS productivity management system that can increase the efficiency of product production management.

In order to achieve the above object, the present invention provides a T&A status management unit for managing T&A status for each worker at a production site using a Distributed Control System (DCS), and a work status of a worker's group including the worker. The work status management department, the production status management department to manage the product production status at the production site using DCS, the productivity management department to manage the productivity and defect rate of products according to the worker's group and product, and the worker's group and product A manager server comprising a production instruction performance management unit that manages the performance of the production instruction; It is possible to communicate with the manager server and configured to include; a T&A status management unit, a work status management unit, a production status management unit, a productivity management unit, and a person in charge terminal for transmitting and receiving data to and from the production order performance management unit, wherein the T&A status management unit , A T&A status management module for managing T&A of workers according to the T&A classification according to name, work date and working time, T&A classification according to other work assignments, and vacation classification information, and the work status management unit is equipped with the work plan status. A work plan to manage the work group, the name of the worker, the date of the worker, the product produced, the product code, the product production schedule and the work division according to the work time, work start time, work end time, and other matters (special details) Equipped with a management module, the production status management unit is the production period for the product production plan and performance, worker affiliation group, manufacturing instruction number, product model number, product model name, production instruction quantity, production completed quantity, defective quantity and defective product information After the product production plan including manufacturing instructions is set, and product production is completed, a product production status management module for setting production completion quantity, defective quantity and defective product information in addition to information on the product production plan, and for each project Calculate the progress rate for product production by the following equation, multiply the number of times of recovery by the standard labor rate to obtain the standard labor cost of the product produced, and compare the production scale during the period through the number of times of recovery for all products produced by period. The production status management module for the project is provided, and the productivity management unit provides information on the productivity of each worker's group including the productivity status and lost labor status information for the product, and the process defect rate information including the productivity of each product and the defect status of each product by period. And a productivity management module that enables management by using and a productivity reporting module for each period for providing information of the productivity management module in the form of a file that can be displayed while dividing and displaying information by period through graphs and figures, and the production instruction performance management unit Product and worker Production order performance management module for managing production order number, product model number, product model name, production order quantity, production completion quantity, work start date and work completion date for production ordered products by affiliated group, and production ordered products by worker affiliated group It is characterized in that it comprises a capacity analysis module for analyzing the number of man-hours, instruction man-hours, and recovery man-hours based on information on normal working hours, number of workers, overtime hours, and extra work days for the production.

Equation: Progress rate = (working time/recovery man-hour)*100 (recovery man-hours are calculated as standard man-hours*production amount of the product produced)

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In addition, the work status management unit includes the worker's affiliation group, worker name, date, production product, production product code, product production completion quantity, work classification according to work time, work start time, work end time, and others regarding the work performance status. It characterized in that it comprises a work performance management module for managing at least one or more of the matters.

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The DCS productivity management system according to the present invention as described above, when mass-producing a product using a DCS facility, converts a database of worker attendance status, productivity, defect rate, performance against work orders, etc., and makes it possible to analyze productivity to produce optimized products. Management can be made possible.

In addition, by enabling direct transmission and reception of information related to production management between the manager and the person in charge of the field, it is possible to increase product production efficiency through real-time rapid communication between production personnel.

1 is a diagram schematically showing a DCS productivity management system according to the present invention.
Figure 2 is a block diagram schematically showing a manager server in the DCS productivity management system according to the present invention.
Figure 3 is a block diagram showing the sub-elements of the manager server in the DCS productivity management system according to the present invention.

The terms or words used in the specification and claims should not be construed as being limited to their usual or dictionary meanings, and the inventor may appropriately define the concept of terms in order to describe his own invention in the best way. It should be interpreted as a meaning and concept consistent with the technical idea of the present invention based on the principle that there is.

Accordingly, the embodiments described in the present specification and the configurations shown in the drawings are only the most preferred embodiments of the present invention, and do not represent all the technical ideas of the present invention, so that they can be replaced at the time of application. It should be understood that there may be various equivalents and variations.

Hereinafter, a DCS productivity management system and method according to the present invention will be described with reference to the drawings.

1 is a diagram schematically showing a DCS productivity management system according to the present invention.

The present invention is basically composed of a manager server and a person in charge terminal.

More specifically, the present invention provides a T&A status management unit for managing T&A status for each worker at a production site using a Distributed Control System (DCS) by an administrator server, and a work status for managing the work status of a worker's group including workers. The management department, the production status management department to manage the product production status at the production site using DCS, the productivity management department to manage the productivity and defect rate of the product according to the worker's group and product, and the worker's group, production of products, etc. It consists of a production order performance management department that manages the performance of orders, and the terminal in charge can communicate with the manager server for DCS productivity management, so data such as time and attendance status management department, work status management department, production status management department, productivity management department, production order performance management department, etc. Is sent and received.

The manager server may be constructed to serve as a kind of web server or web service server. For example, the processed result can be displayed on a web page or required input data can be transmitted through a web page, where the web page is a simple In addition to text, images, sound, and video, it should be interpreted as including software for performing specific tasks such as web applications, and may also be constructed to provide an interface with applications installed on desktops, laptops, smartphones, and tablet PCs. have.

The person in charge terminal is for transmitting and receiving information on worker attendance status, productivity, defect rate, performance against work orders, productivity analysis, etc. in relation to mass production of products through DCS facilities by accessing the manager server on the online network, It should be interpreted as including various communication means such as tablets, netbooks, personal digital assistants (PDAs), portable multimedia players (PMPs), smart phones, and wearable smart devices. Software, applications, etc. for interworking may be provided.

In addition, the online network referred to in the present invention may be a core network integrated with a wired public network, a wireless mobile communication network, or a portable Internet, and the TCP/IP protocol and various services existing in the upper layer, that is, HTTP (Hyper Text Transfer). Protocol), Telnet, File Transfer Protocol (FTP), Domain Name System (DNS), Simple Mail Transfer Protocol (SMTP), etc.It can mean a global open computer network structure. It refers to a data communication network that can transmit and receive data in a comprehensive manner.

2 and 3 are block diagrams showing sub-elements of the manager server and the manager server, respectively, of the DCS productivity management system according to the present invention.

Detailed matters related to the sub-elements of the manager server will be described below.

<Main components, functions and effects of the time and attendance management department>

* T&A status management module

-T&A classification according to the worker's affiliation group (e.g., class), name, work date, working hours (e.g. normal, absent, overtime, all night, etc.), Dispatch, education, business trip, overseas business trip), vacation category (e.g., normal, annual/monthly, public leave, morning vacation, afternoon vacation, etc.)

-Time can be managed even when working overtime, such as overtime, all night, and overtime or two-part work

-'Repayment' refers to the case of applying from other departments, and during the repayment period, applicants can be managed by the worker's group personnel.

-Support to check the status of employee T&A of individual workers and affiliated groups at once

* T&A status output module

-Supports output of T&A status for each worker's group and individual

-T&A status for a specific period can be output through period setting

<Main components, functions and effects of the work status management department>

* Work plan management module

-Worker's affiliation group, worker name, date (planned work date), product produced, product code (selected from product list), product production schedule quantity, work classification according to work time (e.g., normal, Overtime, overnight work, etc.), work start time, work end time, and other matters (special matters) are entered and managed through inquiry

-Establish a pre-production schedule plan before product production work

* Work performance management module

-Enter and query the worker's group, worker name, date, product produced, product code, product production completion quantity, work classification according to work time, work start time, work end time, and other information regarding the work performance status. Managed through

-Used to check and analyze the work efficiency of workers in comparison with the work plan management module information

<Main components, functions and effects of the production status management department>

* Product production status management module

-Production period (start date and end date of production order) for product production plan and performance, worker affiliation group, manufacturing instruction number, product model number, product model name, production instruction quantity, production completion quantity, defective quantity, defective product information, etc. Management through input and inquiry

-After the information on the product production plan including the manufacturing instruction (production period, worker affiliation group, manufacturing instruction number, product model number, product model name, production instruction quantity) is set, the production plan is completed according to the corresponding production plan. In addition to the information on the product, production completed quantity, defective quantity, defective product information, etc. are set.

* Project production status management module

-By project (e.g., weekly, monthly, quarterly, semiannual, etc.), the progress rate for product production is calculated and managed by the equation (progress rate = (work time/recovery number)*100)

-'Recovery man-hours' can be calculated as each standard man-hour * production volume of the produced product, and it allows you to assess the production efficiency of each project. If you calculate the cost of materials, you can get the product cost, and if you check the number of times of recovery for the entire product produced by period, you can compare the production scale during the period.

<Main components, functions and effects of the productivity management department>

* Productivity management module

-Productivity by worker's group, productivity by product, process defect rate information, etc. are managed by period

-For example, if you want to check the productivity of each worker's group, if you select a specific group after setting a period, the productivity status of the group by date, lost labor status information, etc. will be displayed, and if you want to check the productivity by product, set the period. After selecting a specific product, the product's productivity status by date and lost labor status information are displayed.

-In the case of process defect rate, if you select a group to which the worker belongs after setting the period, the defect status of each product of the group is displayed.

* Productivity reporting module by period

-Information of the productivity management module is displayed by dividing it by period through graphs, figures, etc.

-Through period setting, you can see the status of productivity, status of lost labor, status of quality, etc.

-Information of this productivity management module can be provided in the form of a file that can be printed like an Excel report.

<Main components, functions and effects of the production order performance management department>

* Production order performance management module

-Manages the production order number, product model number, product model name, production order quantity, production completion quantity, work start date, work completion date, etc. for production ordered products by product and worker affiliation group

-If you select a product and a group to which the worker belongs, you can check the performance against the order of manufacture by product, and by adding a period setting, you can also check the performance against the order by group, and you can print the performance report against the order for the period.

* Capa analysis module

-Analyze the number of man-hours, instruction man-hours, and collection man-hours based on information on normal working hours, number of workers, overtime hours, and special working days for the production of production-instructed products by worker group

-By making it possible to check the number of man-hours held by period, man-hours for instruction, and man-hours collected in graph form, it is possible to easily check the production capacity of each worker's group

On the other hand, the DCS productivity management method according to the present invention is a step in which the T&A management unit manages the T&A status for each worker at the production site using DCS, and the work status management unit manages the work status of the worker's group including the worker. Wow, the production status management part manages the product production status at the production site using DCS, the productivity management part manages the productivity and defect rate of products according to the worker's group and product, and the production order performance management part belongs to the worker. Managing the performance of the group and product production instructions, and the terminal in charge transmitting and receiving data with at least one or more of the time and attendance status management unit, the work status management unit, the production status management unit, the productivity management unit, and the production order performance management unit. It can be done by doing.

According to the present invention as described, when mass-producing products based on DCS facilities, it is possible to computerize and manage worker attendance status, productivity, defect rate, performance, etc., and productivity analysis can also be checked, so that the accuracy of productivity management, It can support smooth production management of products by promoting convenience, etc.

In addition, as it is possible to transmit and receive information for production management in real time between the manager and the person in charge of the field, it is possible to increase product production efficiency through rapid communication between production personnel.

In the description of the present invention with reference to the accompanying drawings above, a specific shape and direction have been described mainly, but the present invention can be variously modified and changed by those skilled in the art, and such modifications and changes are included in the scope of the present invention. Should be interpreted as.

Claims (10)

A T&A status management unit to manage the T&A status of each worker at a production site using a DCS (Distributed Control System), a work status management unit to manage the work status of a worker's group including the worker, and a production site using DCS The production status management department to manage the product production status of the worker, the productivity management department to manage the productivity and defect rate of the product according to the worker's group and product, and the production order performance that manages the performance of the worker's group and production instructions of the product. A manager server consisting of a management unit;
Consists of including; a staff terminal for transmitting and receiving data with the time and attendance status management unit, work status management unit, production status management unit, productivity management unit, and production order performance management unit by communication with the manager server,
The time and attendance status management unit is provided with a time and attendance status management module for managing the time and attendance of the worker according to the group, name, work date, and time and attendance classification according to the work time, the time and attendance classification according to the assignment of other tasks, and vacation classification information,
The work status management unit includes the worker's affiliation group, worker name, date, production product, production product code, product production expected quantity and work classification according to work time, work start time, work end time, and other matters for the work plan status ( A work plan management module for managing special items),
The production status management unit manages the production period for the product production plan and performance, the worker affiliation group, manufacturing instruction number, product model number, product model name, production instruction quantity, production completion quantity, defective quantity and defective product information, and provides manufacturing instructions. When product production is completed after the product production plan is set, the product production status management module to set the production completed quantity, defective quantity, and defective product information in addition to information on the product production plan, and the progress rate for product production for each project A project production status management module to calculate the standard labor cost of the product produced by calculating with the following equation and multiplying the recovery time by the standard labor wage rate, and to compare the production scale during the relevant period through the recovery time for the entire product produced by period. And,
The productivity management unit includes a productivity management module that enables management of productivity by a worker's group, including productivity status and lost labor status information for each product, and process defect rate information, including productivity by product and defect status by product, by period; A productivity reporting module for each period is provided for providing information of the productivity management module in the form of a file that can be displayed while dividing and displaying the information of the productivity management module by period through graphs and figures,
The production order performance management unit is a production order performance management module for managing the production order number, product model number, product model name, production order quantity, production completion quantity, work start date and work completion date for production ordered products for each product and worker affiliation group. And, it is characterized by having a capacity analysis module to analyze the number of man-hours, instruction man-hours, and recovery man-hours based on information on normal working hours, number of workers, overtime hours, and extra work days for the production of production-instructed products for each group to which the worker belongs. DCS productivity management system.

Equation: Progress rate = (working time/recovery man-hour)*100 (recovery man-hours are calculated as standard man-hours*production amount of the product produced)
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The above work status management unit includes the group of the worker, the worker's name, date, production product, product code, product production completion quantity, work classification according to work time, work start time, work end time, and other matters regarding the work performance status. DCS productivity management system comprising a work performance management module for managing at least one or more.
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