WO2019017061A1

WO2019017061A1 - Progress/operation monitoring system and method

Info

Publication number: WO2019017061A1
Application number: PCT/JP2018/019091
Authority: WO
Inventors: 禎生菅原; 悠太本田; 英憲橋本; 隆之門間; 隆之武澤; 君賀; 渉川合
Original assignee: 株式会社日立製作所
Priority date: 2017-07-18
Filing date: 2018-05-17
Publication date: 2019-01-24
Also published as: JP6945369B2; CN110832415A; JP2019021014A

Abstract

The present invention provides a progress/operation monitoring system and method which enable a user to monitor a state of progress and an operation state at a production site through a production monitoring screen that is convenient for use. The progress/operation monitoring system 1, which monitors a state of progress and an operation state at a production site 2 in which a plurality of working processes P1-Pn are included, is provided with: an actual production management unit 14 which manages actual production data acquired from each working process; a production plan management unit 13 which manages a per process production plan in each working process; and a production monitoring unit 15 which displays a problem in working capacity in each working process, which is analyzed on the basis of each piece of the actual production data managed by the actual production management unit and the per process production plan managed by the production plan management unit, and provides, to the user, a production monitoring screen 16 which receives an instruction for changing the allocation of workers to each working process.

Description

Progress and operation monitoring system and method

The present invention relates to a progress and operation monitoring system and method.

Products such as control panels, office equipment, automobiles, aircraft, industrial machines, construction machines, etc. are manufactured using a production method such as line method, cell method and dynamic cell method. One product is produced, for example, through a plurality of work processes such as preparation of parts and materials, sheet metal, painting, assembly of main parts, assembly of main parts to the main body, inspection and the like. At a production site, products are produced according to a pre-planned production plan, but due to various circumstances, production plan and production performance often deviate. Then, the technique which monitors a production progress condition and optimizes worker arrangement is proposed (patent documents 1).

Japanese Patent Application Laid-Open No. 11-300585

In Patent Document 1, “The creation of a worker layout plan for determining the number of workers in each process of the production line and the automatic execution according to the progress of production collected from each worker in the scene of executing it, In accordance with the progress of production, the worker layout plan is changed and the worker is notified of the layout change information promptly. ”(Patent Document 1 paragraph 0022) The operator layout plan is automatically drawn up and instructed to the workers.

However, in an actual production site, the environment and condition of each worker, such as the worker's physical condition, convenience, and willingness to work, change dynamically. Therefore, automatically optimizing the worker arrangement may not meet the actual situation of the production site, and the usability is low.

The present invention has been made in view of the above problems, and its object is to provide a progress / operation monitoring system and method which can monitor the progress status and operation status of a production site through a user-friendly production monitoring screen. It is to provide.

In order to solve the above problems, a progress / operation monitoring system according to the present invention is a progress / operation monitoring system for monitoring the progress status and operation status at a production site including a plurality of work steps, which is obtained from each work step Production performance management unit managing performance data, production plan management unit managing production plan according to each work process, each production performance data managed by production performance management unit, and each process managed by production plan management unit A production monitoring unit that provides the user with a production monitoring screen that displays the problem of work capacity in each work process analyzed based on the separate production plan, and receives an instruction to change the assignment of the worker to each work process And.

According to the present invention, the display of the problem of the work capacity in each work process and the assignment change of the worker to each work process can be centrally performed on the production monitoring screen.

It is an explanatory view showing the whole outline of this embodiment. It is a functional block diagram of a progress and operation monitoring system. It is a flowchart which shows progress and operation monitoring processing. The example of the setting screen for allocating a worker to a work process is shown. It is a flowchart which concerns on 2nd Example and which shows the process which instruct | indicates a worker's assignment change. It is a flowchart which concerns on 3rd Example and which shows the process which displays the worker candidate added to a work process. It is a flowchart which concerns on a 4th Example and shows the display process of a worker candidate.

Hereinafter, embodiments of the present invention will be described based on the drawings. In the progress / operation monitoring system 1 according to the present embodiment, as described later, work problems in each work process P1 to Pn of the production site 2 are visualized and displayed on the production monitoring screen 16 in a centralized manner. Workers can be assigned through the production monitoring screen 16.

Thereby, according to the present embodiment, for example, the user who is the leader of the production site can grasp the progress status and the operation status of the production site through one production monitoring screen 16, and further, the worker The worker's assignment change can be determined in consideration of individual circumstances of As a result, the user can relatively easily reduce the deviation between the production plan according to each process and the production result data, or detect and eliminate the bottleneck work. Thereby, according to the present embodiment, it is possible to solve the problem on the production site on the spot through the easy-to-use production monitoring screen 16, and the production efficiency can be improved.

A first embodiment will be described using FIGS. 1 to 4. FIG. 1 is an explanatory view showing an outline of the progress / operation monitoring system. The progress / operation monitoring system 1 monitors the progress status and the operation status of the production site 2 and provides the monitoring result to the user.

The progress / operation monitoring system 1 can be configured, for example, using at least one computer. The progress / operation monitoring system 1 includes various functions 11 to be described later from an arithmetic unit as a computer resource, a memory unit, an auxiliary storage unit, an input / output interface circuit, a communication interface circuit (all not shown) and a predetermined computer program. Realize 15.

The production site 2 will be described first. The production site 2 produces the product 23 by a plurality of work processes P1 to Pn. The product 23 is usually composed of a plurality of parts 22. The production method of the production site 2 may be any of a line method, a cell method, and a dynamic cell method. The production site 2 of the present embodiment is suitable for so-called high-mix low-volume production, but is also applicable to low-mix high-volume production and low-mix low-volume production. Hereinafter, the work process may be abbreviated as a process.

Each of the processes P1 to Pn includes an RFID reader 21 that reads out identification information of a worker from an RFID (Radio Frequency Identifier) tag 24. One or more workers W1 to Wn are disposed in each of the processes P1 to Pn. The placement destination of the worker can be determined in advance by a user who is, for example, a leader of the production site 2.

When the worker arrives at the process assigned to him / her, he / she causes the RFID reader 21 to read the worker identification information stored in the RFID tag 24.

Here, as shown in FIG. 2, the RFID tag 24 includes a worker tag 24-1 storing worker identification information and a work instruction slip tag 24- storing information indicating the process of the worker's location. It can be divided into two. The RFID reader 21 installed in each process reads identification information identifying the worker from the worker tag 24-1 and reads identification information identifying the process from the work instruction slip tag 24-2. Based on the information read by the RFID reader 21, the progress / operation monitoring system 1 can grasp which worker is disposed at which process.

The worker tag 24-1 and the work instruction tag tag 24-2 may be integrated, and the process identification information specifying the process the worker takes charge may be rewritten by the RFID reader / writer according to the user's instruction. .

A work instruction terminal 25 is installed in each process. The work instruction terminal 25 displays a screen for teaching the work procedure in the process to the worker. When the worker completes one work procedure, the worker operates a work completion button indicating the completion of the work procedure or a next button requesting the display of the next work procedure on the work instruction terminal 25. Every time the worker finishes each work procedure or calls the explanation of the next work procedure, the button is operated as "predetermined operation". The progress / operation monitoring system 1 can grasp the progress of the work procedure to be performed in each process in real time by monitoring the operation to the work instruction terminal 25.

The configuration of the progress and operation monitoring system 1 will be described. The progress / operation monitoring system 1 includes, for example, a work status monitoring unit 11, a worker management unit 12, a production plan management unit 13, a production performance management unit 14, and a production monitoring unit 15.

The work status monitoring unit 11 monitors the progress of the work of each process based on the identification information read by the RFID reader 21 of each process and the operation to the work instruction terminal 25, and transmits it to the production record management unit 14. Do.

The worker management unit 12 manages, for example, the worker number of each worker, the name, the type of work, the working hours, the history of the assigned process, the presence or absence of skills required in each process, and the like. Information managed by the worker management unit 12 is written in the worker tag 24-1.

The production plan management unit 13 manages the production plan of the production site 2. The production plan management unit 13 manages a production plan for the entire production site and a production plan for each process.

The production track record management unit 14 manages the production track record for each process based on the data from the work status monitoring unit 11.

The production monitoring unit 15 analyzes the problem of work capacity in each work process based on the production performance data of each process managed by the production performance management unit 14 and the production plan for each process managed by the production plan management unit 13. Do. The problem of the working capacity is, for example, the difference between the production plan and the production performance, the presence or absence of the bottleneck work, and the excess or deficiency of the working capacity.

The production monitoring unit 15 displays the problem of the working capacity on the production monitoring screen 16. The production monitoring screen 16 may be displayed on a display connected to the progress / operation monitoring system 1 or may be displayed on a screen of a terminal owned by a user such as a site reader. As a user's terminal, a portable information terminal, a mobile telephone, a virtual reality headset, etc. can be mentioned, for example.

In the production monitoring screen 16, each process is displayed on the horizontal axis, and time is displayed on the vertical axis. The production monitoring screen 16 contrasts and displays a display element (for example, bar graph) 161 indicating a production plan and a display element (for example, bar graph) 162 indicating production results for each process.

Furthermore, on the production monitoring screen 16, a display element indicating the current time T1 and a display element indicating the predetermined work end time T2 are displayed. The time T3 is the scheduled work end time of the process P5 which is the most delayed work. The display element indicating the scheduled work end time can be displayed for each process, but only the process with the latest work is illustrated here.

The user can easily grasp the progress status and operation status of the production site 2 by viewing the production monitoring screen 16 that displays the status of each process in a unified manner. The user notices that the scheduled work end time T3 of the process P5 greatly exceeds a predetermined work end time T2 (for example, a so-called leaving time at a fixed time). That is, it can be considered that the process P5 is a process in which the production plan and the production result are diverged, a process having a bottleneck operation, and a process in which the shortage of working capacity has occurred.

The user changes the assignment of the worker on the production monitoring screen 16 in order to solve the problem of the process P5, that is, to bring the scheduled task end time T3 of the process P5 closer to the predetermined task finish time T2.

For example, the user operates the assignment change button 164 disposed on the production monitoring screen 16 to display the worker assignment setting screen 19 as the “setting screen” on the production monitoring screen 16. A detailed example of the setting screen 19 will be described later with reference to FIG.

The user uses the setting screen 19 to designate a worker to be additionally arranged in the process P5. Here, for example, as shown by a two-dot chain line arrow 163, it is assumed that one worker is transferred from the process P2 to the process P5. The process P2 is an allocation source process for providing the worker, and the process P5 is an allocation destination process supplied by the worker. In the allocation source process P2, since the difference between the production plan and the production results is small according to the prediction result of the current time T1, it can be determined that the work end time will not increase so much even if the worker of the process P2 is reduced. Not only the process P2 but also another process can be selected as the allocation source process. The user can determine which process worker should be assigned to the assignee process each time.

As in another embodiment described later, when the user selects the assignment destination process P5 and the assignment source process P2, a list of workers who can move from the assignment source process P2 to the assignment destination process P5 is displayed on the setting screen 19 You may display it. Also, for example, as shown by the two-dot chain line arrow 163, when the assignment destination process P5 is selected with the user still selecting the assignment source process P2, the worker candidate who can move from the process P2 to the process P5 is set. It may be displayed on the screen 19.

FIG. 2 is a functional block diagram of the progress / operation monitoring system 1. The worker management unit 12 includes, for example, a worker tag management unit 121, a work instruction slip tag management unit 122, and an RFID management database 123. The worker tag management unit 121 manages identification information of the worker stored in the worker tag 24-1. The work instruction slip tag management unit 122 manages identification information for each process stored in the work guidance slip tag 24-2. The RFID management database 123 stores the correspondence with the identification information of the worker, the identification information for each process, the number (production number) of the product manufactured by the worker, and the like.

The work status monitoring unit 11 includes, for example, an RFID reader 21, a work instruction terminal 25, an RFID management system 111, and an RFID dynamic database 112. The RFID management system 111, for example, information read from each of the tags 24-1 and 24-2 via the RFID reader 21, operation information acquired from the work instruction terminal 25, and date and time information acquired from a clock not shown. The process identification information and the serial number acquired from the RFID management database 123 are managed in association with each other. The RFID management system 111 stores the associated data in the RFID dynamic database 112.

The production performance management unit 14 reads data indicating the progress status of the production site from the RFID dynamic database 112 and grasps the production performance.

The data collection unit 17 periodically or irregularly acquires production result data from the production result management unit 14, and acquires a production plan by process from the production plan management unit 13. The data collection unit 17 does not have to periodically acquire the process-based production plan, and may obtain the process-based production plan from the production plan management unit 13 when the production plan is changed. The data collection unit 17 stores the production result data of each process acquired from the production result management unit 14 and the process-specific production plan acquired from the production plan management unit 13 in the data pool 18.

The production monitoring unit 15 reads the production plan by process and production result data from the data pool 18, analyzes the progress status and operation status of the production site, extracts the problem of working capacity, and produces the production monitoring screen 16. indicate.

In the production monitoring screen 16, when the user instructs to change the assignment of the worker, the production monitoring unit 15 notifies the worker management unit 12 of the instruction. As a result, the identification information of the worker to be changed is associated with the identification information of the process (assignment destination process) of the movement destination, and is registered in the RFID management database 123.

FIG. 3 is a flowchart showing the progress / operation monitoring process. The production monitoring unit 15 acquires a production plan by process from the production plan management unit 13 (S10), and acquires production results (production performance data) from the production result management unit 14 (S11).

The production monitoring unit 15 calculates the progress of the work in each process by comparing the production plan and the production results (S12). Then, the production monitoring unit 15 generates and displays the production monitoring screen 16 using the calculation result of step S12 and the data acquired in steps S10 and S11 (S13).

The production monitoring unit 15 determines whether the user has instructed the change of assignment of the worker through the production monitoring screen 16 (S14). When the production monitoring unit 15 determines that the user has instructed the assignment change of the worker (S14: YES), the production monitoring unit 15 calculates the candidate of the worker to be changed and displays it on the setting screen 19 on the production monitoring screen 16 ( S15). The production monitoring screen 16 and the setting screen 19 may be displayed on separate displays.

The production monitoring unit 15 determines whether the information indicating the change content of the worker assignment is input from the user through the setting screen 19 (S16). When the information indicating the change content of the assignment of the worker is input (S16: YES), the content is stored (S17).

The production monitoring unit 15 determines whether or not the user operation on the production monitoring screen 16 has ended (S18), and if it is determined that the operation has ended (S18: YES), the contents of the assignment change of the worker saved in step S17 It outputs (S19). If the operation is not ended (S18: NO), the production monitoring unit 15 calculates the progress status based on the assignment change contents of the worker stored in step S17 (S12) and displays it on the production monitoring screen 16 (S13) ). Therefore, every time the user assigns the worker to the assignment destination process, the user can confirm that the deviation between the production plan and the production result (predicted value) in the assignment destination process decreases.

The content of the assignment change of the worker output from the production monitoring unit 15 is notified to the worker management unit 12 via the production plan management unit 13, for example. The content of the assignment change of the worker may be notified from the production monitoring unit 15 directly to the worker management unit 12.

After this, the worker to be changed is instructed to move to the assignment destination process. There is no particular limitation on the instruction method. For example, the identification information of the process to be assigned may be written in the tag 24-1 possessed by the worker, or the process to be assigned may be displayed on the operation management board that the worker visually confirms. Alternatively, information on the process to be assigned may be displayed by sending an e-mail to a terminal owned by the worker. Furthermore, information on the assignment destination process may be displayed on the work instruction terminal 25 currently referred to by the worker to be changed.

FIG. 4 shows an example of the worker assignment setting screen 19. The setting screen 19 has, for example, a list of workers 191 displaying a list of workers,

buttons

192 and 193 for specifying work date and time to be assigned, a screen 194 for closing the setting screen 19, and confirmation of assignment contents. A button 195, a button 196 for adding a worker to the worker list 191, a button 197 for deleting a worker displayed in the worker list 191, and the number of workers to be assigned to be assigned to the assignment destination process are displayed. And a display unit 198.

The worker list 191 includes, for example, a check box portion 1911, a serial number 1912, a name 1913, an identification number 1914 specifying a line in charge, a name 1915 of a process in charge, work information 1916, and overtime work. And time 1917. The worker list 191 may include items other than these, such as information on possessed skills.

The user confirms the worker list 191 and checks the check box portion 1911 to select at least one worker to be moved to the assignment destination process. When the user operates the confirmation button 195, the assignment change content of the worker is confirmed and stored.

The buttons for specifying the assignment target work date include a button 192 for specifying the present day (today) and a button 193 for specifying a future date. The staff addition button 196 is used, for example, when registering support from other departments, a worker who has been temporarily employed, or the like in the progress / operation monitoring system 1. The personnel deletion button 197 is used to delete a worker that should not be selected as an assignment target from the worker list 191.

The display unit 198 that displays the additional personnel displays the number of workers expected to be necessary in the assignment destination process as reference information.

According to the present embodiment configured as described above, work problems in each work process of the production site 2 are visualized and displayed on the production monitoring screen 16 in a centralized manner, and the worker's Allocations can be made.

Thereby, according to the present embodiment, the user can quickly grasp the progress status and operation status of the production site 2 through the production monitoring screen 16, and further, considering the individual circumstances of the worker. Thus, it is possible to determine the assignment change of workers.

As a result, according to the present embodiment, it is possible to solve the problem on the production site on the spot through the user-friendly production monitoring screen 16, which leads to the improvement of the production efficiency.

The second embodiment will be described with reference to FIG. Each of the following embodiments including the present embodiment corresponds to a modification of the first embodiment, and therefore, differences from the first embodiment will be mainly described. In this embodiment, an example of the worker assignment change instruction process (S14) described in FIG. 3 will be described.

The production monitoring unit 15 determines whether the user has selected the allocation source process on the graph of the production monitoring screen 16 (S141), and subsequently, the user selects the allocation destination process on the graph of the production monitoring screen 16 (S142).

When production monitoring unit 15 determines that the user has selected the assignment source step and the assignment destination step on production monitoring screen 16 (S141: YES, and S142: YES), an operator's assignment change instruction is input from the user. It is determined that there is an error (S143).

The present embodiment configured in this way also achieves the same effects as the first embodiment. Furthermore, in the present embodiment, the user selects the graph of the scheduled work end time of each process displayed on the production monitoring screen 16 to specify the assignment source process and the assignment destination process related to the assignment change of the worker. Can. For example, as shown by a two-dot chain line arrow 163 in FIG. 1, the user selects an assignment destination process while selecting a graph of the assignment source process (either a bar chart of production plan or a bar chart of production results). It is sufficient to instruct the operator to change the assignment by an intuitive operation. As a result, the usability of the user is improved.

A third embodiment will be described with reference to FIG. In this embodiment, an example of the worker candidate display process (S15) described in FIG. 3 will be described.

The production monitoring unit 15 causes the worker managing unit 12 to extract a worker (for example, a worker who is working today) at the work date and time to be assigned (S151).

The production monitoring unit 15 extracts the worker who holds the skill necessary for the assignment destination process among the workers who go to work (S152).

The production monitoring unit 15 extracts a worker who belongs to a process in which the deviation between the production plan and the production result is within a predetermined time, from among the workers having the necessary skills in the assignment destination process (S153).

The production monitoring unit 15 determines whether the number of worker candidates extracted in steps at steps S151 to S153 is equal to or greater than a predetermined threshold Th1 (S154). The threshold Th1 can be set, for example, to "1".

If the number of workers satisfying all the conditions in steps S151 to S153 is equal to or more than the threshold Th1 (S154: YES), the production monitoring unit 15 sets the production monitoring screen 16 (or setting as the worker candidate) as the worker candidate. The screen 19) is displayed (S156).

When the number of workers satisfying all the conditions in steps S151 to S153 is less than the threshold Th1 (S154: NO), the production monitoring unit 15 is affected even if it is moved among the workers having the skills required in the assignment destination process. The worker who belongs to the process which can be judged that there are few is extracted (S155), and it displays as a worker candidate (S156).

If the number of workers does not satisfy the threshold Th1 even if the target of the worker candidate is enlarged in step S155, an error may be displayed, or the worker list 191 may be displayed without particularly selecting one. Good.

The present embodiment configured in this way also achieves the same effects as the first embodiment. Furthermore, according to the present embodiment, in order to extract a worker satisfying a plurality of extraction conditions as a worker candidate who sends the process to the assignment destination process, the user's judgment can be supported, and the usability is improved.

The fourth embodiment will be described with reference to FIG. In this embodiment, another example of the worker candidate display process (S15) described in FIG. 3 will be described.

In the present embodiment, as shown in the display unit 198 of FIG. 4, when displaying the worker candidates, the number Nw of workers required in the assignment destination process is displayed on the production monitoring screen 16 (S150). Then, in the same manner as described with reference to FIG. 6, the operators to be changed are narrowed down in steps S151 to S153, and it is determined whether the number of narrowed workers is equal to or more than the number Nw of workers required in the assignment destination process (S154A) ).

When the number of workers satisfying all the conditions in steps S151 to S153 is equal to or more than the number Nw of workers required in the assignment destination process (S154A: YES), the production monitoring unit 15 selects worker information for the worker candidate. , And is displayed on the production monitoring screen 16 (or setting screen 19) (S156).

On the other hand, when the number of workers extracted in steps S151 to S153 does not reach the number Nw of workers required in the assignment destination process (S154A: NO), the production monitoring unit 15 has the skills required in the assignment destination process. Among the workers, a worker belonging to a process that can be determined to have little influence even if moved is extracted (S 155) and displayed as a worker candidate (S 156).

The present embodiment configured in this way also exhibits the same effects as the third embodiment. Further, in the present embodiment, the number Nw of workers required in the assignment destination process is displayed on the production monitoring screen 16, and a candidate of the worker suitable for the assignment destination process is extracted from among the workers. Further improve.

The present invention is not limited to the embodiments described above. Those skilled in the art can make various additions and modifications within the scope of the present invention. The embodiments described above are not limited to the configuration examples illustrated in the attached drawings. The configuration and processing method of the embodiment can be appropriately changed within the scope of achieving the object of the present invention.

In addition, each component of the present invention can be arbitrarily selected, and an invention having a selected configuration is also included in the present invention. Furthermore, the configurations described in the claims can be combined with combinations other than the combinations specified in the claims.

1: Progress and operation monitoring system 2: Production site 11: Work status monitoring unit 12: Worker management unit 13: Production plan management unit 14: Production results management unit 15: Production monitoring unit 16: Production Monitor screen, worker assignment setting screen, 21: RFID reader, 22: parts, 23: product, 24: RFID tag, 25: work instruction terminal

Claims

A progress and operation monitoring system for monitoring the progress and operation of a production site including a plurality of work processes, comprising:
A production performance management unit that manages production performance data acquired from each of the work processes;
A production plan management unit that manages a production plan by process in each of the work processes;
Display the problem of the working capacity in each work process analyzed based on the production performance data managed by the production performance management unit and the production plan by process managed by the production plan management unit, and A production monitoring unit that provides a user with a production monitoring screen that receives an instruction to change the assignment of workers to each work process;
Progress and operation monitoring system equipped with
The production monitoring screen contrasts and displays the production plan by process and the production result data for each work process, and assigns an operator to each work process according to an instruction from the user. Display the setting screen for instructing,
The progress and operation monitoring system according to claim 1.
The production monitoring screen displays the difference between the production plan according to each process and the production result data as time, and further displays a display element indicating the current time and a display element indicating the predetermined work end time. To be
The progress and operation monitoring system according to claim 2.
The production results management unit
Identification information associated with each worker, the identification information acquired from each worker in each work process;
The respective production results are based on the operation information for the work instruction terminal provided to the respective workers corresponding to the respective work steps, the operation information indicating the predetermined operation regarding the work in the respective work steps. Get data,
The progress and operation monitoring system according to any one of claims 1 to 3.
The production monitoring unit extracts candidate workers who can be assigned to the assignment destination process, when the assignment destination process to which the worker is additionally assigned is selected among the work processes in the production monitoring screen. Display on the setting screen,
The progress and operation monitoring system according to claim 2.
The production monitoring unit displays the number of workers required to achieve the predetermined work end time in the assignment destination process on the setting screen.
The progress and operation monitoring system according to claim 5.
A progress / operation monitoring method of monitoring progress status and operation status at a production site including a plurality of work processes by a computer,
The computer is
Obtain actual production data from each work process,
Obtain a process-specific production plan for each work process,
Analyze the problem of working capacity in each work process based on the production result data and the production plan for each process,
Displaying the analyzed problem of the work capacity on a predetermined screen by comparing the production plan by process and the production result data for each work process;
Receive an instruction to change the assignment of workers to each work process,
Displaying a setting screen for instructing assignment of the worker to each of the work processes in response to the instruction;
Progress and operation monitoring method.