CN101667283A - Operation analysis apparatus - Google Patents

Abstract

The present invention relates to a work analyzing device capable of accurately adjusting the process allocation of workers to improve production efficiency. It has: its data acquisition unit, which acquires job record data D including operator ID, process ID and takt time data from each sewing machine; job required time calculation unit, which calculates the whole or part of each job record data Within the range, the takt time of each operator is obtained for each work process; and the actual work time calculation unit calculates the actual work time by summing up the tact time of each work process for each operator, and the actual work time The calculating means calculates the time required for the work of the work steps of these operators by means of a reconciliation average, if there is work time specific information in the case where one work process is divided into tasks by a plurality of operators in each work record data. Averaging is performed to calculate the actual work time based on the time required for each work.

Description

job analysis device

technical field

The present invention relates to a work analysis device which collects and analyzes work record data involved in the production of products manufactured by performing shared work processes simultaneously, and displays or outputs the analysis results to the outside.

Background technique

For example, in a sewing factory, a sewing operation process is generally divided for each part of a sewn product, and each sewing operation process is shared by a plurality of operators, and the sewing operation is performed by operating a sewing machine.

In the case of dividing the sewing operation involved in one product into a plurality of operation procedures, it is preferable to carry out all the operation procedures at the same time, so as not to cause delays in the operation procedures shared by only a part of the operators. In order to improve efficiency, it is necessary to reduce fluctuations in time required for each operator's work.

Therefore, as described in Patent Document 1, for example, a conventional work analysis device uses operator-specific information for specifying a worker, process-specific information for specifying a work process, and the time required for each work process , to record a certain operation procedure performed by each operator and the time required for each operation procedure one by one, collect the data, summarize and analyze them through the operation analysis device, and display the analysis results.

As shown in FIG. 16 , in the manufacture of a sofa, an example is shown in which five workers each perform sewing work for the work steps of the assigned parts.

In FIG. 17, the summary data of the following data are displayed in tabular form, that is, the process ID (process specific information) of the process assigned to each operator, the takt time (tact time) required for each process to perform a sewing operation (tact time). required time) and the actual work time for each operator by summing up the takt time of each process, the data D1 represents the state before the process allocation adjustment, and the data D2 represents the state after the process allocation adjustment.

In addition, FIG. 18 shows the relationship between the operator and the actual working time, the broken line L1 is based on the data D1, and the broken line L2 is based on the data D2.

Here, the "actual work time" refers to a value obtained by summing up the takt time of each process when a plurality of operators share work processes belonging to a certain product. That is, the actual working time is a value representing the working time of each operator for the entire sewing operation required for one product, and by allocating each process to each operator so that the actual operating time is evenly distributed, the Delays in product completion due to delays in some processes enable efficient joint operations to achieve line balance.

As can be seen from broken line L1, among all the operators, the actual working time of the operator with operator ID 1113 is longer, the actual working time of the operator with operator ID 1106 is shorter, and the production line balance is poor. In this case, adjustment is made by assigning part of the work steps assigned to the operator (1113), for example, the step 71, to the operator (1106). Thereby, as shown by the broken line L2, the difference in the actual working time of each operator is greatly reduced, and the line balance becomes favorable.

In order to perform the above-mentioned analysis and adjustment smoothly, the existing operation analysis device has the following functions, that is, it collects the operation record data collected from each sewing machine, performs the generation and display of the above-mentioned data D1, and performs data analysis. Edit assignment. In addition, in the summary data processed by the job analysis device, the tact time of each process is calculated by dividing the working time of multiple sewing operations by the number of pieces to calculate the average value, and then generating data D1. Takt time is calculated by adding and averaging.

However, at the sewing site, when a part of the process assigned by a certain operator is delayed, an operator who has no work at hand will temporarily help a part of the number of sewing plans in the delayed process. In this case, the operator who assists inputs the process ID of the process to be assisted, and includes the assisted part in the work record data.

FIG. 19 shows an example of summary data D3 after the job analysis device put together the job record data in a tabular form. The aggregated data D3 uses the above-mentioned data D1 as a process reference, that is, the contents of the aggregated work record data are aggregated for each process.

The area A1 of the summary data D3 shows an example in which operators (1106), (1067), and (1105) work on the process (45). In addition, in the summary data D3, "average tact time (1)" is the average tact time of each process performed by each operator (it can also be called the average tact time based on the operator), and "average tact time Time (2)" is the average production takt time of each process (it can also be called the average production takt time of the process benchmark), and the two average production takt times (1) and (2) are operated by a single operator in each process In the case of , it is the same value, but as shown in the process (45), it is a different value when one process is performed by a plurality of workers in division of tasks.

In addition, in the conventional job analysis device, the calculation of the process-based average tact time (2) in the case where a plurality of operators perform separate tasks for one process is calculated by adding and averaging processing. Specifically, as shown in the area A1 of the summary data D3, when the average takt time (1) of the three operators is 85 [s], 103 [s], and 69 [s], respectively, the process-based The average tact time (2)=(85+103+69)/3=86[s] is obtained by adding and dividing the "average tact time (1)" of each operator in charge of the division of work by the number of people calculate.

In addition, the conventional work analysis device also calculates the summary data D4 based on the operator, as shown in FIG. 20 . This aggregated data D4 is data that aggregates, for each operator, the process ID of the assigned process, the production quantity of each process, the average tact time (2) of each process, and the actual work time of each operator.

The area A2 of this summary data D4 represents the average tact time (2) of the process (45) of the operation (45) divided by the three operators (1106), (1067), and (1105). The average tact time (2) (= 86 [s]) obtained by adding the average tact time (1) of the two to each other.

In addition, as shown in the summary data D4, in the existing work analysis device, when calculating the actual work time for each operator, for the process (45) of the work divided by a plurality of operators, the above-mentioned The average tact time (2)=86 [s] obtained by adding the average is used as the common average tact time for each operator in charge of the division of work.

Patent Document 1: Japanese Patent Application Laid-Open No. 04-13546

Contents of the invention

However, as described above, whenever the process-based average tact time (2) is calculated for a process in which a plurality of people work separately, the correct tact time cannot be obtained only by adding and averaging the tact time of each person. average value. That is, the correct average value mentioned here refers to the necessary time required for an operator who has the average ability of a plurality of operators who perform divisional work on the same process work to complete the process.

但上述相加平均值为86[s]，与正确的所需时间83[s]不一致。The takt time of the operators (1106), (1067), and (1105) is taken as an example for illustration. If the unit of the average takt time (1) shown in the summary data D3 is seconds ([s]), the processing speed [pieces/s] of each person’s process (45) is (1/85) [pieces/s] s], (1/103)[pieces/s], (1/69)[pieces/s], so if the process (45) is carried out together, the required time is ((1/85)+(1/ 103) + (1/69)) ^-1 = 27.8 [s]. Therefore, if a single operator with average ability performs process (45), it will take 3 times as long, so the correct average takt time (2) should be

However, the above added average value is 86[s], which is inconsistent with the correct required time of 83[s].

As a result, there is a problem that, when one process is divided into tasks, the actual working time for evaluating the balance of the line cannot be accurately calculated, and even if the operator's process assignment is adjusted based on the actual working time, there is no problem. Will increase production efficiency.

In addition, in the conventional calculation method of the actual working time, the work ratio of each operator is not taken into consideration when the work is divided into one process. If the above-mentioned operator (1106), (1067), (1105) carries out the situation of division of work as an example to illustrate, then for example, as shown in summary data D4, the operator (1105) for the process (41), (42 ), (44) carried out sewing of 30 pieces, but only sewed 5 pieces for process (45). That is, although one-sixth of the sewing quantity of other processes is carried out, the average takt time (2) is obtained by addition as the same number of sewn products as other processes in the calculation of actual operation time.

Also for this reason, the actual working time cannot be calculated correctly, and thus the production efficiency cannot be improved by adjusting the process assignment of the operator.

An object of the present invention is to accurately adjust the process allocation of workers to improve production efficiency.

The invention described in claim 1 is to collect and analyze the operation record data related to the production of the following products, which are produced by a plurality of operators, and analyze them, and display or output the analysis results to the outside. Produced by simultaneously executing the work of the work steps shared by each of them, it is characterized in that it has: a data acquisition unit that obtains work record data, and the work record data includes the operator-specific information and work-process-specific information for each of the above-mentioned work steps. , and specific information on the work time required for each work process; a work time calculation unit that calculates the work time of each operator for each work process within the range of all or part of the work record data. required time; and an actual working time calculation unit, which, for each of the operators, sums up the required working time of the work process performed by the operator to calculate the actual working time, and the actual working time calculation unit is When there is work time specific information in the case where one work process is divided into tasks by a plurality of workers in each of the work record data, the work time required for the work process of these workers is calculated using a harmonic average. This is averaged, and based on the averaged work required time, the actual work time of each worker is calculated.

The invention described in claim 2 is characterized in that it has the same configuration as the invention described in claim 1, and at the same time, the production quantity information of each operator in each operation process is included in the above-mentioned each operation record data, so The actual work time calculation unit calculates the actual work time by averaging using the harmonic mean when there is time-specific information on the time required for work in the case where one work process is divided into work by a plurality of workers in the work record data. Multiply the time required for the operation by multiplying the ratio of the production quantity of each operator to the production quantity of the entire operation process of the division of work, and on this basis, calculate the time required for other operations In total, the actual working time of each operator is calculated.

In addition, the contents of the "job required time specific information" and "production quantity information" of the "job record data" are not limited to directly displaying the required time or production quantity, but may obtain the required time as a result by performing calculation processing. An indirect result of time and production quantities. For example, it is the information indicating the start or end time of each sewing of the sewing machine, etc., and the required time is calculated according to the difference between these times, or it is also possible to record some information that must be recorded for one sewing, by checking the time required within a specified period The number of pieces of this information is counted to obtain the production quantity.

In addition, the above-mentioned "operation process identification information" is, for example, identification information indicating all classifications of sewing operations of sewing machines (as long as the identification information is ID and other information that can be identified by a device that performs data processing), for example, in Identification of Various Sewing When the operation is managed in units of batches, it is only necessary to include information capable of identifying each batch.

The effect of the invention

In the work analysis device of the invention described in claim 1, by acquiring work record data and using the worker-specific information, work-process-specific information, and work-required time-specific information contained in the work record data by the work required time calculation means, Which operator performs which work process and how much work time is required in the work process is summarized.

Furthermore, the actual work time calculating means calculates the actual work time by summing up, for each worker, the time required for the work of the work steps performed by the worker.

Then, when there is a work process performed by a plurality of workers in a plurality of collected work record data, the time required for the work of each worker is averaged based on the harmonic mean for the work process.

For example, when operators A, B, and C perform the same operation process with the time required for the operation being t1, t2, and t3, respectively, according to the concept of harmonic mean, the average value is calculated by ta=3/((1/t1) +(1/t2)+(1/t3)) is calculated. Since this value is exactly equivalent to three times the required time when operators A, B, and C jointly perform the above-mentioned operation process, it is possible to become an operator with the average ability of operators A, B, and C to perform the operation. The time required for the operation required by the operation process.

As mentioned above, even if all the work steps are shared by a plurality of workers, and some of the work steps include common work, since the time required for work is averaged by reflecting the work ability of each worker, in order to When the actual work time of each worker is adjusted to be as equal as possible in accordance with the work ability, the actual work time can be calculated more appropriately, and by using the work analysis device of the present invention, the operator's work time can be accurately adjusted. Process allocation, to achieve the improvement of production efficiency.

In the invention described in claim 2, the work record data includes the production quantity information for each work process of each operator, and when one work process is divided into operations by a plurality of workers, the actual work time calculation means When calculating the actual working time of each worker, for the working time of the common working process, the value averaged by the harmonic mean is not directly summed up with the working time of other working processes. It is calculated by multiplying the time required for the operation after the harmonic average by the ratio of the production quantity of one operator to the production quantity of the entire joint operation, and then summing it up with the time required for other work processes. And calculate the time required for the job.

The concept of the actual work time is to quantify the time ratio shared by each worker among the total required time required for the entire work including all the work steps.

On the other hand, for the work process that works together, since the whole process is not carried out by a single operator, and the same amount of work as other processes is not performed, in the calculation of the actual work, it cannot be added in the same way as other processes operation. Therefore, as shown in the above-mentioned actual working time calculation unit, by multiplying the ratio of the production quantity of the individual worker to the total quantity by the time required for the work, it is possible to more reliably reflect the total time required for the entire work. The proportion of time shared by individual operators.

Therefore, by using the work analysis device of the present invention, the actual work time can be obtained more reliably, and the process allocation of the worker can be adjusted accurately, thereby improving the production efficiency.

Description of drawings

FIG. 1 is a block diagram showing a schematic configuration of a sewing machine operation analysis system.

Fig. 2 is a block diagram showing a schematic configuration of a work analysis system including production management sewing machines.

Fig. 3 is an explanatory diagram showing a recording structure of sewing operation time data as operation recording data.

Fig. 4 is a flowchart showing processing based on a recording processing program of job recording data executed by the CPU of the production management sewing machine.

Fig. 5 is a display example of a main screen.

FIG. 6 is a flowchart showing display processing performed by the CPU on the main screen.

FIG. 7 is a flowchart showing selection processing performed by the CPU on the main screen.

Fig. 8 is a display example of a process list screen based on a process.

FIG. 9 is a flowchart showing display processing of a process list screen.

FIG. 10 is a flowchart showing an averaging process of tact times performed in the display process of the process list screen.

Fig. 11 is a display example of a graph display screen of the average takt time (2).

Fig. 12 is a display example of a process list screen based on an operator ID.

FIG. 13 is a flowchart showing display processing of the process list screen.

FIG. 14 is a flowchart showing calculation processing of actual work time performed in display processing of the process list screen.

Fig. 15 is a display example of a graph display screen of actual working time.

Fig. 16 is an explanatory diagram showing an example of a case where five workers share each step of the sofa sewing operation.

FIG. 17 is a graph showing summary data of each process belonging to an operator in the work log data of the process shown in FIG. 16 , the time required for each process, and the actual work time of each operator in tabular form.

Fig. 18 is a line graph showing the relationship between the operator and the working time in the sewing work shown in Fig. 16 in broken lines.

FIG. 19 is a graph showing aggregate data that aggregates work log data for each process.

FIG. 20 is a graph showing summary data that summarizes work log data for operators.

Detailed ways

(Overall structure of the embodiment of the invention)

Next, a sewing machine work analysis system 100 including a work analysis device 101 according to the present invention will be described based on FIGS. 1 to 15 with reference to the drawings.

As shown in FIG. 1, this job analysis system 100 has: a plurality of production management sewing machines 10; Log data transmission/reception.

A personal computer or a workstation is used as the above-mentioned job analysis device 101 . In addition, wireless or wired communication means such as wireless LAN and wired LAN may be used for transmission/reception of job log data between job analysis device 101 and each production management sewing machine 10 .

(Production management sewing machine)

In Fig. 2, each production control sewing machine 10 has: a sewing machine motor 11, which is a driving source for driving a needle bar holding a sewing needle up and down; The driving force for moving up and down is transmitted to the needle bar; the cloth feeding mechanism not shown in the figure; the thread adjusting device not shown in the figure; the cutter drives the solenoid 12, which makes the thread cutter for cutting the suture after sewing is completed. Drive; the operation pedal 13, which inputs the starting instruction of the sewing machine motor 11 by stepping on the front, and inputs the driving instruction of the cutter driving solenoid 12 by stepping on the back; the operation panel 20, which has operation keys 21 for various inputs described later , and a display unit 22 for displaying a specified screen; a count switch 23, which is pressed when the sewing of one operation process is completed; a ROM 32, which stores various programs and initial data for performing various processes described later; CPU 31, which executes various programs; RAM 33, which stores various data related to the processing of CPU 31 in the work area; EEPROM 35, which stores the job record data recorded in the production management sewing machine 10; flash memory card 36 and its reader Taking the writing device 37, the flash memory card 36 is a recording medium used to transmit the operation record data in the EEPROM 35 between the production management sewing machine 10 and the operation analysis device 101.

(job log data)

The above-mentioned production management sewing machine 10 generates the sewing operation time data D as shown in FIG. 3 during the sewing process, and records it in the EEPROM 35. In addition, the sewing operation time data D is copied from the EEPROM 35 to the flash memory card 36 and transmitted to the operation analysis device 101.

The sewing operation time data D is formed in such a manner that the CPU 31 passes the sewing operation time (including the year, month, and day, not shown) every time a sewing operation unit, i.e., an operation process, is sewn. It is generated record by record, and if any one of the operator ID and the process ID is input in the record, it is inserted into the data of each sewing operation time corresponding to the input time. The above-mentioned recording of the sewing operation time is performed when the count switch 23 is pressed at the end of sewing. In addition, the sewing machine ID is recorded in the sewing operation time data D when the main power supply of the production control sewing machine 10 is turned on.

In addition, the sewing machine ID is a code assigned to each production control sewing machine 10 for distinguishing each sewing machine.

In addition, the so-called operator ID is a number assigned to each operator in order to distinguish each operator when a plurality of operators (operators) use each production control sewing machine 10 to perform the sewing operation of the respective operation steps. .

In addition, the process ID is a code assigned to each work process in order to distinguish each work process for each type of to-be-sewn object.

Here, as the work process, the work process is recognized as a different process for each type of the object to be sewn, but when the same type of object is different in size, color, style, material type, etc., Different IDs may be assigned so that these work steps can be identified as different steps.

In addition, in the case where the production of the sewn object is managed in units of batches in order to correspond to the mass production of the sewn object, in the case of different batches, it may be treated as a different operation process. identify.

In addition, in the above-mentioned sewing operation time data D, "operator identification information", "work process identification information", "work required time identification information" and "production quantity information" are respectively recorded. Specifically, the operator ID of the operator in charge of each work process is recorded as the "operator identification information", and the process ID is recorded as the "work process identification information". In addition, the "work required time specific information" is information for specifying the work time for each work process. As this "work required time specific information", sewing operation time data is recorded. The elapsed time from the production of the work time data to the next sewing time data indirectly determines the time required for the work.

In addition, the "sewing operation time data" that can indirectly calculate the production quantity corresponds to "production quantity information". That is, by counting the number of pieces of sewing operation time data within a predetermined period, the production quantity can be specified indirectly.

In FIG. 4, first, when the main power is turned on, a rotational speed recording timer (not shown) counting a cycle for periodically detecting the rotational speed of the sewing machine starts (step S1). Then, the sewing machine ID is recorded in the sewing operation time data D (step S2).

Then, the CPU 31 displays an instruction to input the operator ID and the process ID on the display unit 22, and if these inputs are received from the operation key group 21, the operator ID and the process ID are recorded in the sewing operation time data ID (step S3).

Then, the current time is referred to by a built-in clock not shown, and is recorded in the sewing operation time data D as the sewing operation time (step S4).

In addition, each ID and sewing operation time are recorded in the order in which the recording is performed, and the recorded order can be clarified by referring to each data group which becomes the content of the sewing operation time data D in order.

Then, in step S5, it is judged whether or not a new operator ID has been input due to the shift of the operator, etc., and if not input, the process proceeds to step S7. When there is an input, the operator ID is recorded in the sewing work time data D (step S6).

Then, in step S7, it is judged whether a new process ID is input due to the change of the process, and if not inputted, proceeds to the processing of step S9, and under the situation of having the input, the process ID is recorded to the sewing operation time data D ( Step S8).

In step S9, it is judged whether there is input of the counter switch 23, and when there is no input, it returns to the process of step S5. Moreover, when there is an input, after recording the sewing work time in the sewing work time data D (step S10), it returns to the process of step S5.

The above processing continues until the main power supply of the production control sewing machine 10 is turned off, thereby recording the sewing operation time data D in the EEPROM 35 of the production control sewing machine 10.

(job analysis device)

Operators of a plurality of sewing machines respectively use the above-mentioned production management sewing machine 10 to simultaneously carry out the sewing operations of their shared operation steps to produce a product, and the operation analysis device 101 collects the operation record data related to the production of the product. , the analysis is performed, and the "work required time" and "actual work time" are displayed on the display 103 as the analysis results. This job analyzing device 101 has: a keyboard 102, which performs various inputs described later; a display 103 as a display unit, which performs predetermined screen display; a ROM 104, which stores basic programs and initial data; and a CPU 105, which executes various Program RAM106, it stores each data related to the processing of CPU 105 in the work area; HD (hard disk) device 108 as a storage unit, it stores the program for carrying out each processing described later, and receives from each production management sewing machine 10 The sewing operation moment data D; As the flash memory card 36 of data acquisition unit and read-write device 109 thereof, this flash memory card 36 is used for obtaining the sewing operation moment data D from the production management sewing machine 10; And mouse 110, its The operation of moving the cursor displayed on the display 103 and the input of determination are performed. In addition, since the input operation for selecting and determining a display screen with the mouse 110 described below is well known, its principle and detailed description will be omitted.

(Home screen)

In the work analysis device 101, when the sewing operation time data D is acquired from each production control sewing machine 10, the main screen M1 is displayed on the display 103 by a predetermined processing program. In FIG. 5 , the main screen M1 is a display in the form of a list, which shows that among the sewing operation time data D acquired from each production management sewing machine 10, which belongs to a certain identification information (operator ID and process ID) and is in a certain position. Whether data for the period (datetime) exists. On the main screen M1, the identification information of the operator ID and the process ID are displayed in a list on the vertical axis, and they serve as ID selection switches, and the periods are displayed in time series on the horizontal axis, and they serve as the period selection switches. In addition, the display color of the cells at the positions where the cells arranged in a horizontal row from an arbitrary ID intersect with the cells arranged in a vertical row from an arbitrary period indicates that for an arbitrary ID, an arbitrary period Whether data exists in .

In addition, by operating the selector switch M11 with the mouse, it is possible to select which of the operator ID and the process ID is displayed on the vertical axis, and by operating the display period specifying switch M12 with the mouse, the period display range can be manipulated.

Furthermore, the main screen M1 functions as a "selection means" that selects either identification information or a data recording period (date and time) in order to select data to be displayed as recorded content or to be displayed in a form. That is, as described above, display a checkered pattern in which the vertical axis represents the ID and the horizontal axis represents the date. Since each cell of the grid serves as a selection switch, they are selected by mouse operation, and for the selected ID, Specifies and extracts the data acquired at the selected date and time.

Based on FIG. 6, the processing performed by the CPU 105 on the above-mentioned main screen M1 will be described. Here, a case where an operator ID is selected on the vertical axis will be described as an example.

First, when the main screen M1 is displayed, the process of color-coding and displaying the presence or absence of data of each ID and each period will be described.

This process, at first, sewing operation time data D is read in from the forefront of the data arrangement (step S21), judges whether the record of the first operator ID exists (step S22), when finding the record of the operator ID In this case, the latest sewing operation time information located behind the operator ID is searched (step S23), and the date and time of the data record is read from the sewing operation time information (step S24). By performing this operation (step S25) over the entire range of each sewing operation time data D, all recorded dates and times of the first operator ID can be obtained. By performing the same process for subsequent operator IDs, it is possible to specify whether or not there is job log data for each operator ID and each date and time, thereby performing color-coded display control for each cell.

Moreover, when process ID is selected on the vertical axis by the changeover switch M11, it is judged whether process ID exists in the process of said step S22.

Next, the processing performed by the CPU 105 when the main screen M1 functions as a selection unit will be described based on FIG. 7 . Here, a case where an operator ID is selected on the vertical axis will be described as an example.

In the display state of the main picture M1, CPU 105 judges whether a certain operator ID on the vertical axis is selected (step S31), and then judges whether a certain period on the horizontal axis is selected (step S32). Then, it is judged whether both the operator ID and the period are selected (step S33).

As a result, when both are selected, the CPU 105 extracts data belonging to the selected operator ID for the sewing operation time data D (step S34). The extraction method is to read the data from the front row of the sewing operation time data D, and search for the operator ID. If an operator ID is detected, it is judged whether the operator ID is a selected operator ID, and only in the case of the selected operator ID, data up to the next operator ID is extracted and recorded. Detection, determination, and data extraction of the operator ID are performed over the entire range of the rotational speed data D1, and all the extracted data are stored in the RAM 106 as temporarily extracted data.

Then, if the temporarily extracted data is extracted, the CPU 105 extracts the extracted data belonging to the selection period with respect to the temporarily extracted data (step S35).

The method of extraction is to read the data of each sewing operation time from the forefront of the temporarily extracted data, judge whether the time represented by each data is within the selected period, extract only if it is within the period, and record In RAM 106, this operation is performed for the entire range of temporarily fetched data. Thereby, with respect to the sewing work time data D, the extracted data corresponding to the selected operator ID and the selection period are extracted.

In addition, when the process ID is selected on the vertical axis by the selector switch M11, the CPU 105 judges whether or not a process ID is selected in the process of the above-mentioned step S31, and extracts temporarily extracted data belonging to the selected process ID in the process of step S34.

Also, it is of course possible to select a plurality of operator IDs or process IDs and periods. In addition, in this case, the temporary extraction data and the extraction of the extraction data are performed separately for each selection ID and each period.

(Process list[1])

Each display screen has tab switches M13 to M16 for switching the display type, and by operating the mouse on these, the display type can be switched. In addition, here, the operation status monitor displayed on M14 related to this invention is demonstrated below. When the display type is switched to the operation status monitor by the above-mentioned tab switch M14 , the process list screen M2 shown in FIG. 8 can be displayed on the display 103 .

The process list screen M2 is based on the process ID. The process ID is displayed in the leftmost column, the operator ID is displayed in the adjacent right column of the process ID, and the operator ID is displayed in the adjacent right column of the operator ID. The average tact time (1) of the required time, and the average tact time (2) which is the time required for the job is displayed in the right column adjacent to the average tact time (1). In addition, in the process list screen M2, the items are displayed in a row in a horizontal row, that is, the ID of the operator who performs the operation process indicated by the process ID is displayed in the adjacent right column of each process ID. On the right side of the operator ID, the average tact time (1) when the operator performs the work process is displayed, and the average tact time based on the average tact time (1) is displayed on the right side of the average tact time (1) (2).

Here, the so-called average takt time (1) is the average value of the takt time (time required for work) of each operator producing one sewn product in each sewing process in seconds [s]. . This average tact time (1) is calculated from the time difference between the sewing operation timings before and after within the range of the extracted data of the sewing operation timing data D described above.

That is, the CPU 105 of the job analysis device 101 functions as a "work required time calculation unit" by performing calculation of the average tact time (1) by the method described above.

And, as in the case where the same operator sews a plurality of pieces of the same operation process, in the case where there are a plurality of sewing operation times with the same operator and operation process in the extracted data, by combining all these sewing operations The total time is divided by the number of times of sewing, averaged by adding and averaging, and the average takt time (1) is calculated.

The average tact time (2) is calculated based on the average tact time (1), and is used for calculation of the actual work time described later.

The average tact time (2) is also expressed in seconds [s], and it is determined whether or not a plurality of operators are used for one operation process by the division of work determination process performed by the CPU 105 within the range of the extracted data. When the operation is performed, if the judgment is negative, that is, if it is judged that one operation procedure is performed by only one operator, the calculation is carried out according to the average takt time (1) = the average takt time (2), and if the judgment is positive, that is, it is judged When one operation process is divided into operations by a plurality of operators, the average tact time (1) of each operator is averaged by harmonic averaging and calculated.

Specifically, the process (45) in the process list screen M2 is divided into tasks by operators (1067), (1105), and (1106). In this case, the average takt time (1) of each person is 85[s], 103[s], and 69[s] are averaged according to the concept of harmonic mean, and the average value is calculated as

Since this value is just equivalent to the required time 1/((1/85)+(1/103)+( 1/69))[s] three times, so this value can be called the operation time required for the operator with the average ability of the operator (1067), (1105), (1106) to perform the operation process.

That is, the CPU 105 of the job analysis device 101 functions as a "work required time calculation unit" of the job analysis device 101 by calculating the average tact time (2) by the method described above.

In FIG. 9, the CPU 105 reads the extracted data extracted from the sewing operation time data D for each selected operator ID and each selected period from the front row (step S41).

And, in the process of reading in from the forefront of the extracted data, the detection of the process ID and the operator ID is carried out, and according to the time difference before and after the sewing operation time data associated with it, the time required for sewing is sequentially calculated, that is, takt time (step S42).

Then, a process of removing an outlier value from the sequentially calculated tact time is performed (step S43).

Here, an example of processing performed by the CPU 105 to remove the above-mentioned outliers and calculate the average will be described in detail.

First, within the range of the extracted data, the standard deviation S is calculated for each set of a plurality of tact times having the same operator ID and process ID. The standard deviation S is calculated based on the following formulas (1) to (3). That is, for each of the above-mentioned ranges, the average value of the tact time is calculated. Here, the symbol x represents each takt time in the target range, and the overlined x represents the average value thereof. In addition, the symbol n is the number of samples of the takt time which becomes the target range.

Then, based on the following formula (2), the square deviation s ² is calculated from the obtained average value, and based on the following formula (3), the standard deviation s is calculated from the square root thereof.

[number 1]

$\stackrel{<span\; class="notranslate">\; \&OverBar;</span>}{\mathrm{<span\; class="notranslate">\; x</span>}}<span\; class="notranslate">\; =</span>\frac{\mathrm{<span\; class="notranslate">\; \&Sigma;x</span>}}{\mathrm{<span\; class="notranslate">\; no</span>}}<span\; class="notranslate">\; \&Center\; Dot;</span><span\; class="notranslate">\; \&Center\; Dot;</span><span\; class="notranslate">\; \&Center\; Dot;</span><span\; class="notranslate">\; (</span>\mathrm{<span\; class="notranslate">\; 1</span>}<span\; class="notranslate">\; )</span>$

${\mathrm{<span\; class="notranslate">\; the\; <figure-callout\; id="2"\; label="s"\; filenames="A2009101721100035H1.png,A2009101721100043H1.png"\; state="\{\{state\}\}">s</figure-callout></span>}}^{\mathrm{<span\; class="notranslate">\; 2</span>}}<span\; class="notranslate">\; =</span>\frac{\mathrm{<span\; class="notranslate">\; \&Sigma;</span>}{<span\; class="notranslate">\; (</span>\mathrm{<span\; class="notranslate">\; x</span>}<span\; class="notranslate">\; -</span>\stackrel{<span\; class="notranslate">\; \&OverBar;</span>}{\mathrm{<span\; class="notranslate">\; x</span>}}<span\; class="notranslate">\; )</span>}^{\mathrm{<span\; class="notranslate">\; 2</span>}}}{\mathrm{<span\; class="notranslate">\; no</span>}<span\; class="notranslate">\; -</span>\mathrm{<span\; class="notranslate">\; 1</span>}}<span\; class="notranslate">\; \&Center\; Dot;</span><span\; class="notranslate">\; \&Center\; Dot;</span><span\; class="notranslate">\; \&Center\; Dot;</span><span\; class="notranslate">\; (</span>\mathrm{<span\; class="notranslate">\; 2</span>}<span\; class="notranslate">\; )</span>$

$\mathrm{<span\; class="notranslate">\; the\; s</span>}<span\; class="notranslate">\; =</span>\sqrt{\frac{\mathrm{<span\; class="notranslate">\; \&Sigma;</span>}{<span\; class="notranslate">\; (</span>\mathrm{<span\; class="notranslate">\; x</span>}<span\; class="notranslate">\; -</span>\stackrel{<span\; class="notranslate">\; \&OverBar;</span>}{\mathrm{<span\; class="notranslate">\; x</span>}}<span\; class="notranslate">\; )</span>}^{\mathrm{<span\; class="notranslate">\; 2</span>}}}{\mathrm{<span\; class="notranslate">\; no</span>}<span\; class="notranslate">\; -</span>\mathrm{<span\; class="notranslate">\; 1</span>}}}<span\; class="notranslate">\; \&Center\; Dot;</span><span\; class="notranslate">\; \&Center\; Dot;</span><span\; class="notranslate">\; \&Center\; Dot;</span><span\; class="notranslate">\; (</span>\mathrm{<span\; class="notranslate">\; 3</span>}<span\; class="notranslate">\; )</span>$

Then, the average value of the 3σ range is calculated from the standard deviation s.

That is, +3σ=(average value of x)+(s×3) and -3σ=(average value of x)-(s×3) are obtained, and only ±3σ range (greater than or equal to -3σ and less than or Equal to the takt time within +3σ), remove the deviation value.

Then, the average tact time (1) is calculated for each range by averaging the tact times in each range after the deviation is removed by adding and averaging (step S44).

Then, the process of calculating the average tact time (2) is performed (step S45).

In this averaging process, as shown in the flowchart of FIG. 10 , first, it is judged whether or not a plurality of operators perform divisional work for a certain work process (divided work determination process) (step S451 ).

That is, the extracted data is classified into each process, and it is determined whether or not there are a plurality of operators belonging to each process. When there is only one operator for one process, the value of the average tact time (1) belonging to the process becomes the average tact time (2) as it is (step S452).

Also, when there are a plurality of operators for one process, the values of the average tact time (1) of each operator belonging to the process are averaged by harmonic averaging to calculate the average tact time (2) ( Step S453).

If the average tact time (2) is found for all the processes from which data is extracted, the CPU 105 calculates the summed average of the average tact times (2) in all the processes. Then, an upper limit value (=average value÷0.85) and a lower limit value (=average value×2−upper limit value) are calculated by multiplying the overall average value by a predetermined ratio (step S46).

Then, the process list screen M2 is displayed, or the graphic display screen M3 is displayed (step S47). In the case of displaying the graphic display screen M3, as shown in Fig. 11, the values of the average takt time (2) of each process are plotted to display a broken line graphic, and at the same time, the comprehensive average is displayed in the graphic display area. The average value line M31 of the value, the upper limit value line M32 of the upper limit value, and the lower limit value line M33 of the lower limit value. Thus, when displaying the graph of the average takt time (2), by displaying the lines M31 and M32 of the upper limit and the lower limit at the same time, the manager of the sewing operation can make the respective lines of the upper limit and the lower limit The lines M31 and M32 are used as standards, and the degree of fluctuation of the average takt time (2) of each process can be easily judged.

Switching between tables and graphs is performed by operating the mouse on the graph display switch M22 in the screen.

(Process list[2])

The process list screen M2 is a screen based on the process ID as described above, and the changeover switch M21 for switching from the process ID to the operator ID is provided. That is, when the changeover switch M21 is operated with the mouse, the display is switched to the process list screen M4 based on the operator ID as shown in FIG. 12 .

In this process list screen M4, the operator ID is displayed in the leftmost column, the process ID is displayed in the right adjacent column of the operator ID, and the production quantity is displayed in the right adjacent column of the process ID. The column adjacent to the right of the shows the average takt time (2), and the column adjacent to the right of the average takt time (2) shows the actual job time. In addition, on the process list screen M4, the items are displayed in a horizontal row in association with each other, that is, on the right side of each operator ID, the process ID of the work process performed by the operator is displayed. On the right side, the production quantity of the operation process performed by the operator is displayed. On the right side of the production quantity, the average production takt time (2) when the operator performs the operation process is displayed. In the average production takt time (2) On the right side of , the actual operating time based on the average takt time (2) is displayed.

Here, as the actual work time, in principle, all the work processes represented by the process IDs within the extracted data range of the sewing work time data D are allocated to each operator, and the time belonging to each operator is allocated to each operator. The average takt time (2) of the work process is summed up and calculated.

However, when there is a work process in which a plurality of operators divide the work, as shown in area B, for the operator who performs the divided work, the value of the average tact time (2) is multiplied by the operator's Based on the ratio of the number of pieces produced to the total number of pieces produced in this work process, it is summed up with the average takt time (2) of each other work process to calculate the actual work time.

As mentioned above, the process (45) is divided into tasks by the operators (1067), (1105), and (1106). If the operator (1105) is used as an example for illustration, the operator (1105) will The average production takt time (2) in is about 83 [s] (referring to Fig. 8), but the total production quantity of operation (45) is 5+15+10=30, wherein, due to the production quantity of operator (1105) is 5, so multiply 5/30 by 83[s] to become

Thus, the actual work time of the operator (1105) is calculated as 88+194+72+14=368 [s] by summing up the above-mentioned value and the average tact time (2) of other work processes.

That is, the CPU 105 of the work analysis device 101 functions as an "actual work time calculation unit" by performing the calculation of the actual work time by the above-mentioned method.

In Fig. 13, the CPU 105, for each selected operator ID and selected period, reads the extracted data extracted from the sewing operation time data D from the front row (step S51).

Then, in the process of reading in from the forefront of the extracted data, the process ID and operator ID are detected, and the time required for sewing is calculated sequentially based on the time difference between the sewing operation time data associated with it, that is, Takt time. And the number of pieces of sewing operation time data whose process and operator match is counted, and the production quantity is calculated (step S52).

Then, a process of removing an outlier value from the sequentially calculated tact time is performed (step S53). The method of removing the deviation value is the same as that of step S43.

Then, on the basis of removing the deviation value, the takt time of each range in which the operator and the process are consistent is averaged again by adding the average, and the average takt time (1) is calculated for each range (step S54 ).

Then, calculation processing of the average tact time (2) and the actual work time is performed (step S55).

In this process, as shown in the flowchart of FIG. 14 , it is judged whether or not a plurality of operators are divided into a certain process (divided work determination process) as in step S451 (step S551 ).

And, when the division of work is not performed, the value of the average tact time (1) belonging to the process is taken as the average tact time (2) as it is (step S552).

In addition, in the case of division of work, the average tact time (1) of each operator belonging to the process is averaged by harmonic averaging to calculate the average tact time (2) (step S553).

And, for each operator who performs the division of work, the value of the calculated average takt time (2) is multiplied by the production quantity ratio of each operator (the production quantity of the individual operator/the production quantity of the entire process) ( Step S554).

And, for each operator, the average tact time (2) of the process performed by each operator is calculated in total. At this time, the average tact time (2) of the process in which the divided work is performed is summed up by multiplying the value obtained by the production quantity ratio as described above (step S555 ). Through this process, the actual work time of each operator is calculated.

When the actual work time is obtained for all the operators whose data was extracted, the CPU 105 calculates the summed average of the actual work time of all the operators. Then, an upper limit value (=average value÷0.85) and a lower limit value (=average value×2−upper limit value) are calculated by multiplying the overall average value by a predetermined ratio (step S56).

Then, the process list screen M4 is displayed, or the graph display screen M5 is displayed (step S57). In the case of displaying the graph display screen M5, as shown in FIG. 15 , the values of the actual working time of each operator are plotted to display a broken line graph, and at the same time, an average line of a comprehensive average value is displayed in the graph display area. M51, the upper limit line M52 of the upper limit, and the lower limit line M53 of the lower limit. As described above, by displaying the lines M51 and M52 of the upper limit and the lower limit at the time of the graphic display of the actual working time, the manager of the sewing operation can use the lines M51 and M52 of the upper limit and the lower limit M52 is the standard, and the degree of fluctuation in actual work time can be easily judged.

In this case, switching between the table and the graph may be performed by operating the mouse on the graph display switch M22 on the screen.

(Effect of embodiment of invention)

In the sewing machine job analysis system 100, based on a plurality of sewing operation time data D acquired from a plurality of production management sewing machines 10, the job analysis device 101 uses the operator ID and process ID included in the sewing operation time data D And sewing operation time information, which operator performs which operation process, and how much takt time the operation process requires. Then, in the extracted data extracted from the aggregated plurality of sewing operation time data D, if there is a work process in which a plurality of operators perform a division operation, the operator for each division operation is identified by The values of the average tact time (1) obtained by adding and averaging are again averaged by harmonic averaging to calculate the average tact time (2). Thus, it is possible to obtain the tact time required for an operator having the average ability of the operators of the division of work to perform the work process, and to obtain the actual work time by reflecting the work ability of each operator.

As a result, when adjustments are made so that the actual work time of each operator corresponds to the work ability as much as possible, the actual work time can be calculated more appropriately, and the work analysis device 101 can be used to accurately adjust the operation time. The process allocation of the operator can realize the improvement of production efficiency.

In addition, in the sewing machine job analysis system 100, when there are work steps in which a plurality of operators perform division work, the work analysis device 101 calculates the actual work time of each operator, for the division work. Multiply the average takt time (2) of the operation process by the production quantity ratio of each operator, and on this basis, add up the average takt time (2) of other operation processes to calculate the actual operation time. As a result, the actual working time can be obtained, which more reliably reflects the time ratio shared by the operator in the total time required for the overall working process performed jointly, and the operator's time can be adjusted accurately. Process allocation, to achieve the improvement of production efficiency.

In addition, the task analysis device of the present invention is not limited to the above-mentioned embodiment, and various modifications can be made. For example, in the above-mentioned embodiment, when there are work processes in which a plurality of operators perform divisional work, the actual work time is always calculated using the average tact time obtained from the harmonic mean, but it may be used in conjunction with Irrespective of the operation process without division of work by multiple operators, a switching option unit is provided that can be switched to calculate the actual operation time using the average takt time obtained by summing the average for all operators, and the operation time One of them is selected according to the situation on the spot.

In addition, in the above-mentioned embodiment, the work analyzing device of the present invention displays only the "required time for work" and "actual work time" which are the analysis results of summarizing and analyzing the sewing work time data D on the work analyzing device. On the display of the main body, an unillustrated interface capable of communicating with an external printer, storage device, etc. may be provided on the job analysis device, and the analysis result may be output to an external printer, storage device, etc.

In addition, in the above-mentioned embodiment, the case where the sewing operation is analyzed by the sewing machine has been described as an example of the work analysis device of the present invention, but the work analysis device of the present invention is not limited to the above-mentioned embodiment, as long as it is It is only necessary for a plurality of operators to simultaneously perform the work of their shared work steps to produce products, and it is of course applicable to the production of various products.

Claims (2)

1. An operation analysis device, which is to summarize the operation record data related to the production of the following products, analyze them on this basis, and display or output the analysis results to the outside. Those produced by performing the operations of the respective operating procedures at the same time, It is characterized in that it has: a data acquisition unit that acquires work record data including information specific to an operator who undertakes each of the work steps, information specific to the work process, and information specific to the time required for each work process; a work time calculation unit that calculates the work time for each operator for each work process within the range of all or part of the work record data; and an actual working time calculation unit that, for each of the workers, totals the time required for the work of the work process performed by the worker to calculate the actual working time, The actual work time calculation unit, when there is time-required work identification information in the case where one work process is divided into tasks by a plurality of workers in each of the work record data, calculates the work steps of these workers The time required for work is averaged using the harmonic mean, and the actual work time for each of the workers is calculated based on the time required for work obtained by the averaging. 2. The job analysis device according to claim 1, wherein: Each of the work record data includes information on the production quantity of each operator in each work process, The actual work time calculation unit, when there is work time specific information in the case where one work process is divided into work by a plurality of workers in each of the work record data, On the basis of multiplying the required work time calculated by averaging the harmonic mean by the ratio of the production quantity of each operator to the production quantity of the entire operation process of the division of work, , and the time required for the work of other work processes is summed up to calculate the actual work time of each operator.

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