CN113537683A - Production cycle analysis method and production cycle analysis system - Google Patents
Production cycle analysis method and production cycle analysis system Download PDFInfo
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- CN113537683A CN113537683A CN202010321226.7A CN202010321226A CN113537683A CN 113537683 A CN113537683 A CN 113537683A CN 202010321226 A CN202010321226 A CN 202010321226A CN 113537683 A CN113537683 A CN 113537683A
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Abstract
The invention provides a production cycle analysis method and a production cycle analysis system capable of rapidly positioning a problem point causing a production cycle extension. The production cycle analysis system includes: a work performance information collection unit that collects, for each product, work performance information of all the steps related thereto, the work performance information including a work start time and a work end time of the step; a process operation time calculation unit that calculates, for each process of each product, a process operation time, which is a time difference between a process start time and a process end time of the process, based on the work performance information; a process standard operation time acquisition unit for acquiring a corresponding process standard operation time for each process of a product; and a step delay time calculation unit that calculates, for each step of each product, a delay time of a step operation time of the step with respect to a corresponding step standard operation time as a step delay time of the step.
Description
Technical Field
The present invention relates to a production cycle analysis method and a production cycle analysis system for analyzing a production cycle of a product.
Background
In business activities, the demands of customers are diversified, and competition among enterprises is intensified, so that the production enterprise needs to meet the production cycle required by the customers. In the order stage, even if the price and quality of the goods are ideal, if a long time is generated until delivery, the order may be flowed to the competitor company. In order to shorten the production cycle, although the enterprise collects the current production cycle by using various IT technologies, the data is not sufficiently used, and for problem analysis and field improvement, human experience and knowledge are mainly used, so that the reliability and the universality are low.
Documents of the prior art
Patent document
Patent document 1: CN101727098A
Disclosure of Invention
Technical problem to be solved
However, mass production, production line production systems, and facilities such as semiconductor and IC manufacturers according to patent document 1 are only techniques suitable for a production line, and therefore have poor versatility. In addition, patent document 1 aims to shorten the production cycle by optimizing the production plan by accurately measuring the production cycle target, but since the production cycle itself is not analyzed, it is not known that a waiting state occurs in a stage inside the production cycle, and it is difficult to improve the production site in a targeted manner to shorten the production cycle.
Technical means for solving the technical problem
The present invention has been made to solve the above-mentioned problems, and provides a production cycle analysis method for analyzing a production cycle of one or more products, the products being formed by processing one or more semi-finished products through one or more processes, the semi-finished products being formed by processing one or more processes, the production cycle analysis method comprising: a work performance information collection step of collecting, for each of the products, work performance information of all the processes related thereto, the work performance information including a work start time and a work end time of the process; a step of calculating a step operation time, which is a time difference between an operation start time and an operation end time of each step of the product, for each step of the product based on the operation performance information; a step of acquiring process standard operation time, wherein corresponding process standard operation time is acquired for each process of the product; and a step delay time calculation step of calculating, for each step of each product, a delay time of the step operation time of the step with respect to the corresponding step standard operation time as a step delay time of the step.
The production cycle analysis method may be configured to: the method further includes a step of calculating a process dead time of each of the semi-finished products for each of the processes, which is a time difference between a work end time of the process and a work start time of a next process of the process, for each of the processes except for a latest process among the processes for the machining and forming of the semi-finished product and a latest process among the products.
The production cycle analysis method may be configured to: further comprising: an abnormality determination step of determining a process in which the process delay time exceeds a preset process delay threshold as an abnormal delay process, and determining a process in which the process stagnation time exceeds a preset process stagnation threshold as an abnormal stagnation process; and a display step of displaying at least one of the process operation time of each process, the process standard operation time of each process, and process abnormality information including at least one of the process delay time of each process, the process stagnation time of each process, the abnormal delay rate of a process, the abnormal stagnation rate of a process, identification information of the abnormally delayed process, and identification information of the abnormally stopped process.
Thus, when there is a demand for shortening the production cycle of a product, it is possible to intelligently, visually, and quickly locate a problem process that causes an extension of the production cycle, and take measures to avoid unnecessary waiting time in a targeted manner, thereby shortening the production cycle of the product.
The production cycle analysis method may be configured to: further comprising: a product production cycle calculation step of calculating, for each of the products, a product production cycle from the work performance information, the product production cycle being a time difference between a work start time of an earliest process and a work end time of a latest process among all the processes collected in the work performance information collection step; a product standard production cycle acquisition step of acquiring a product standard production cycle corresponding to the product; and a product delay time calculation step of calculating, for each of the products, a delay time of the product production cycle of the product relative to the product standard production cycle as a product delay time of the product, wherein in the abnormality determination step, a product whose product delay time exceeds a preset product delay threshold is determined to be an abnormally delayed product, and in the display step, at least one of the product production cycle, the product standard production cycle, and product abnormality information of each product is displayed, the product abnormality information including at least one of the product delay time of each product, an abnormal delay rate of the product, an average delay time, and identification information of the abnormally delayed product.
Thus, when there is a demand for shortening the production cycle of a product, a problem product that causes an extension of the production cycle can be intelligently, visually, and quickly positioned, and measures can be taken in a targeted manner to avoid unnecessary waiting time and to shorten the production cycle of the product.
The production cycle analysis method may be configured to: further comprising: a semi-finished product production cycle calculation step of calculating a semi-finished product production cycle for each semi-finished product of each product according to the operation actual result information, wherein the semi-finished product production cycle is a time difference between an operation start time of an earliest process and an operation end time of a latest process in the processes for processing and forming of the semi-finished product; a semi-finished product standard production cycle acquisition step, wherein a corresponding semi-finished product standard production cycle is acquired for each semi-finished product of the product; calculating a semi-finished product delay time, namely calculating the delay time of the semi-finished product production cycle of each semi-finished product relative to the corresponding semi-finished product standard production cycle of each semi-finished product as the semi-finished product delay time of the semi-finished product; and a semi-finished product stagnation time calculation step of calculating a semi-finished product stagnation time of each of a plurality of semi-finished products for mutual assembly, the semi-finished product stagnation time being a time difference between a work end time of a latest one of the processes for the machining and forming of the semi-finished product and a work start time of an earliest one of the processes involved in the mutual assembly, the abnormality determination step further determining a semi-finished product in which the semi-finished product delay time exceeds a preset semi-finished product delay threshold as an abnormally delayed semi-finished product, and determining a semi-finished product in which the semi-finished product stagnation time exceeds a preset semi-finished product stagnation threshold as an abnormally stagnant semi-finished product, the display step further displaying at least one of the semi-finished product production cycle of each semi-finished product, the semi-finished product standard production cycle of each semi-finished product, and semi-finished product abnormality information, the semi-finished product abnormal information at least comprises one of the semi-finished product delay time of each semi-finished product, the semi-finished product dead time of each semi-finished product, the abnormal delay rate of the semi-finished product, the abnormal dead rate of the semi-finished product, the identification information of the abnormally delayed semi-finished product and the identification information of the abnormally stopped semi-finished product.
Thus, when there is a demand for shortening the production cycle of a product, a defective semi-finished product that causes an extension of the production cycle can be intelligently, visually, and quickly positioned, and measures can be taken in a targeted manner to avoid unnecessary waiting time and to shorten the production cycle of the product.
The production cycle analysis method may be configured to: in the step of acquiring the process standard operating time, the process standard operating time is calculated by removing an abnormal value from the process operating time of the process of each product for each process of the product.
Thus, the process standard operation time can be acquired more accurately.
The present invention also provides a production cycle analysis system for analyzing a production cycle of one or more products, the products being formed by processing one or more semi-finished products through one or more processes, the semi-finished products being formed by processing through one or more processes, the production cycle analysis system comprising: a work performance information collection unit that collects, for each of the products, work performance information of all the steps related thereto, the work performance information including a work start time and a work end time of the step; a step operation time calculation unit that calculates, for each step of each product, a step operation time, which is a time difference between a step start time and a step end time of the step, based on the operation performance information; a process standard operation time acquisition unit for acquiring a corresponding process standard operation time for each process of the product; and a step delay time calculation unit that calculates, for each step of each product, a delay time of the step operation time of the step with respect to the corresponding step standard operation time as a step delay time of the step.
The production cycle analysis system may be configured to: the work-stop time calculation unit calculates, for each of the products, a work-stop time of the step, which is a time difference between a work-end time of the step and a work-start time of a step next to the step, excluding a latest step among the steps for the machining and forming of each of the semi-finished products and the latest step in the product.
The production cycle analysis system may be configured to: further comprising: an abnormality determination unit that determines a process in which the process delay time exceeds a preset process delay threshold as an abnormal delay process, and determines a process in which the process stagnation time exceeds a preset process stagnation threshold as an abnormal stagnation process; and a display unit that displays at least one of the process operation time of each process, the process standard operation time of each process, and process abnormality information including at least one of the process delay time of each process, the process stagnation time of each process, an abnormal delay rate of a process, an abnormal stagnation rate of a process, identification information of the abnormally delayed process, and identification information of the abnormally stopped process.
Thus, when there is a demand for shortening the production cycle of a product, it is possible to intelligently, visually, and quickly locate a problem process that causes an extension of the production cycle, and take measures to avoid unnecessary waiting time in a targeted manner, thereby shortening the production cycle of the product.
The production cycle analysis system may be configured to: further comprising: a product production cycle calculation unit that calculates, for each of the products, a product production cycle that is a time difference between a work start time of an earliest step and a work end time of a latest step among all the steps collected by the work performance information collection unit, based on the work performance information; a product standard production cycle acquisition unit that acquires a product standard production cycle corresponding to the product; and a product delay time calculation unit that calculates, for each of the products, a delay time of the product production cycle of the product relative to the product standard production cycle as a product delay time of the product, the abnormality determination unit further determines a product in which the product delay time exceeds a preset product delay threshold as an abnormally delayed product, and the display unit further displays at least one of the product production cycle, the product standard production cycle, and product abnormality information of each product, the product abnormality information including at least one of the product delay time, an abnormal delay rate of the product, an average delay time, and identification information of the abnormally delayed product of each product.
Thus, when there is a demand for shortening the production cycle of a product, a problem product that causes an extension of the production cycle can be intelligently, visually, and quickly positioned, and measures can be taken in a targeted manner to avoid unnecessary waiting time and to shorten the production cycle of the product.
The production cycle analysis system may be configured to: further comprising: a semi-finished product production cycle calculation unit that calculates a semi-finished product production cycle, which is a time difference between a work start time of an earliest step and a work end time of a latest step among the steps for the machining of the semi-finished product, for each semi-finished product of each product, based on the work performance information; a semi-finished product standard production cycle acquisition section that acquires a corresponding semi-finished product standard production cycle for each type of semi-finished product of the product; a semi-finished product delay time calculation unit that calculates, for each semi-finished product of each of the products, a delay time of the semi-finished product production cycle of the semi-finished product relative to a corresponding semi-finished product standard production cycle as a semi-finished product delay time of the semi-finished product; and a semi-finished product stagnation time calculation unit that calculates a semi-finished product stagnation time of each of a plurality of semi-finished products to be assembled with each other, the semi-finished product stagnation time being a time difference between a work end time of a latest one of the processes for the machining and forming of the semi-finished product and a work start time of an earliest one of the processes related to the mutual assembly, the abnormality determination unit further determining a semi-finished product in which the semi-finished product delay time exceeds a preset semi-finished product delay threshold as an abnormally delayed semi-finished product and determining a semi-finished product in which the semi-finished product stagnation time exceeds a preset semi-finished product stagnation threshold as an abnormally stagnant semi-finished product, the display unit further displaying at least one of the semi-finished product production cycle of each semi-finished product, the semi-finished product standard production cycle of each type of semi-finished product, and semi-finished product abnormality information, the semi-finished product abnormal information at least comprises one of the semi-finished product delay time of each semi-finished product, the semi-finished product dead time of each semi-finished product, the abnormal delay rate of the semi-finished product, the abnormal dead rate of the semi-finished product, the identification information of the abnormally delayed semi-finished product and the identification information of the abnormally stopped semi-finished product.
Thus, when there is a demand for shortening the production cycle of a product, a defective semi-finished product that causes an extension of the production cycle can be intelligently, visually, and quickly positioned, and measures can be taken in a targeted manner to avoid unnecessary waiting time and to shorten the production cycle of the product.
The production cycle analysis system may be configured to: the step standard work time acquisition unit calculates the step standard work time by removing an abnormal value from the step work time of the step for each product, for each step of the product.
Thus, the process standard operation time can be acquired more accurately.
Effects of the invention
According to the present invention, when there is a demand for shortening the production cycle of a product, it is possible to intelligently, visually, and quickly locate a problem point that causes an extension of the production cycle, and take a targeted measure to avoid unnecessary waiting time and shorten the production cycle of the product.
Drawings
Fig. 1 is a block diagram showing the configuration of a production cycle analysis system 100 according to a first embodiment.
Fig. 2 (a) shows an example of the work performance information collected by the work performance information collection unit 101, (b) shows a schematic diagram of partial semi-finished products SM00001 to SM00004 for product assembly, one serial number P0000001 of the product PRD01, with respect to time, and (c) shows a schematic diagram of four steps for machining and forming, one serial number BD9AD01 of the semi-finished product SM00002, with respect to time.
Fig. 3 is a graph showing the analysis result of the process analysis unit 103 displayed on the display unit 105 in the first embodiment.
Fig. 4 is a block diagram showing the configuration of a production cycle analysis system 200 of the second embodiment.
Fig. 5 is a graph showing the analysis result of the product analysis unit 201 displayed on the display unit 105 in the second embodiment.
Fig. 6 is a block diagram showing the configuration of a production cycle analysis system 300 of the third embodiment.
Fig. 7 is a graph illustrating the production cycle condition of four semi-finished products of the third embodiment.
Fig. 8 is a graph showing the analysis result of the semi-finished product analysis unit 301 displayed on the display unit 105 in the third embodiment.
Fig. 9 is a flowchart showing a production cycle analysis method of the fourth embodiment.
Fig. 10 is a graph for explaining the principle of the occurrence of dead time between two adjacent processes.
Fig. 11 is a graph for explaining the principle of the generation of dead time between respective semifinished products in the relation of mutual assembly.
Fig. 12 is a graph for explaining a comparison between an actual operation time of a process and a standard operation time of the process.
Detailed Description
In manufacturing fields including both manual and mechanical manufacturing, the time spent by a product from order to delivery typically includes processing operation time, handling time, and dead time. Of these, the time at which the ratio is highest and the reduction is most achieved is the dead time. There are two main reasons for the occurrence of stagnation, the first being that there is no seamless connection between the processes that are executed in sequence. For example, as shown in fig. 10, when the horizontal direction of the paper is taken as a time axis, if there is a time difference between the job end time of the preceding step and the job start time of the subsequent step in two sequentially executed steps, an unnecessary dead time is generated.
The second is that the individual semi-finished products, which are in mutual assembly relationship, are not produced simultaneously. For example, as shown in fig. 11, assuming that a certain product needs to be formed by assembling three semi-finished products with the horizontal direction of the paper as a time axis, and the assembly process is performed once all the three semi-finished products are completed, the three semi-finished products are not manufactured at the same time, and therefore, unnecessary dead time is generated for the semi-finished products 1 and 2.
In order to eliminate the dead time as much as possible, it is necessary to specify the location where the dead occurs, i.e., which process or which semi-finished product, and to improve the manufacturing process in a targeted manner, so as to shorten the production cycle of the entire product.
On the other hand, reduction of the machining operation time and the conveyance time is considered. In a process mainly based on human work, since the standardization of work is often insufficient, even if the same process is performed or the same product or semi-finished product is produced, the time required for the process varies. In contrast, targeted improvement of the process operation, the product production, and the semi-finished product production can be achieved by establishing the standard operation. For example, as shown in fig. 12, a process standard operation time is set for a certain process, and a time difference between an actual operation time of the process and the process standard operation time is compared as a process delay time, so that a process having a long process delay time is identified as a process requiring improvement (for example, it can be determined by setting a process delay threshold). Thus, the production cycle of the entire product can be shortened more reliably.
Based on the technical ideas, the invention provides a production cycle analysis method and a production cycle analysis system for analyzing the production cycle of one or more products by using process operation actual result information collected on site in order to shorten the production cycle of the products in the manufacturing industry.
The following describes a method and a system for analyzing a production cycle according to the present invention, taking a specific embodiment as an example.
[ first embodiment ]
The production cycle analysis system of the present embodiment analyzes the production cycle of a certain product PRD01, each of which is formed by processing a plurality of types of semi-finished products through a plurality of types of processes, and each of which is formed by processing a plurality of types of semi-finished products through a plurality of types of processes.
The production cycle analysis system 100 is shown in fig. 1 and includes a work performance information collection unit 101, a storage unit 102, a process analysis unit 103, an abnormality determination unit 104, and a display unit 105.
The work performance information collection unit 101 collects work performance information of all the processes related to each product PRD 01. The work performance information includes, for example, as shown in fig. 2 (a), the work start time and the work end time of each step, and the data source may be collected in real time at the manufacturing site or may be imported from another database. Each of the products PRD01 is assembled and processed from semi-finished products SM00001 to SM00010, and each semi-finished product is processed through a plurality of processes, for example, semi-finished product SM00002 is processed through four processes with process code L3-DDL-01 to L3-DDL-04. As an example, fig. 2 (b) shows a schematic diagram of partial semi-finished products SM00001 to SM00004 for product assembly of one serial number P0000001 of the product PRD01 with respect to time, and fig. 2 (c) shows a schematic diagram of four processes for machining and forming a semi-finished product of one serial number BD9AD01 of the semi-finished product SM00002 with respect to time.
The storage unit 102 stores the work performance information collected by the work performance information collection unit 101, and the storage format of the work performance information in the storage unit 102 is not limited to the format (a) of fig. 2, and may be another format.
The process analysis unit 103 analyzes the operation time of each process, and includes a process operation time calculation unit 106, a process standard operation time acquisition unit 107, a process delay time calculation unit 108, and a process dead time calculation unit 109.
The process operation time calculation unit 106 calculates, for each process of each product PRD01, a process operation time, which is a time difference between the operation start time and the operation end time of the process, that is, a time length for completing the process, based on the operation performance information shown in fig. 2 (a), and stores the process operation time in the storage unit 102. Thus, the process operation time is stored for each process of the product PRD 01.
The process standard operating time acquiring unit 107 acquires a corresponding process standard operating time for each process of the product PRD01 and stores the acquired time in the storage unit 102. The concept of process standard hours herein is illustrated in FIG. 12, described above, for comparison with the process hours of the process for each product PRD01 to determine the corresponding process delay time. Considering a method of acquiring the process standard operation time, for example, for the process standard operation time of the process with the process code L1-ASM-01, the operation performance information stored in the storage unit 102 may be obtained by removing an abnormal value from the process standard operation time of the process L1-ASM-01 for each product PRD01 by the giblas method and averaging the remaining data, and the average value may be used as the process standard operation time of the process L1-ASM-01. Thus, the process standard operation time is stored for each process of the product PRD 01.
The process delay time calculation unit 108 calculates a delay time of the process operation time of each product PRD01 with respect to the corresponding process standard operation time, and stores the delay time in the storage unit 102 as the process delay time of the corresponding process. Thus, the process delay time is stored for each process of each product PRD 01.
The process dead time calculation unit 109 calculates the process dead time of each process other than the latest process among the processes for forming each product PRD01 and each of the semi-finished products SM00001 to SM00010, and stores the process dead time in the storage unit 102. That is, the process stagnation time calculation unit 109 calculates the process stagnation time of each of the processes for each of the semi-finished products except the latest process among the processes for machining and forming of each of the semi-finished products and the latest process among the entire products for each of the processes PRD01, and stores the process stagnation time in the storage unit 102, the process stagnation time being the time difference between the operation end time of the process and the operation start time of the next process of the process.
First, since the latest process itself in the product is the last process, its process dead time is not calculated. On the other hand, the "step for forming a semifinished product" refers to each step for forming the semifinished product, and for example, if the semifinished product is assembled from a plurality of other semifinished products, the "latest step in the step for forming a semifinished product" refers to an assembling step for assembling the other semifinished products (the latest assembling step if there are a plurality of assembling steps); if the semi-finished product is assembled by a plurality of other semi-finished products and then is processed through a plurality of working procedures, or is not assembled by a plurality of other semi-finished products, the 'latest working procedure in the working procedures for processing and forming' of the semi-finished product refers to the last working procedure in the plurality of working procedures for producing the semi-finished product. Thus, the process dead time is stored for each process except the latest process for forming the semi-finished product and the latest process in the product PRD 01.
The abnormality determination unit 104 determines the process delay time and the process dead time of each process by using a preset threshold value stored in the storage unit 102. Specifically, the abnormality determination unit 104 determines, as an abnormal delay process, a process in which the process delay time exceeds a preset process delay threshold among the processes of each product PRD01, and determines, as an abnormal stagnation process, a process in which the process stagnation time exceeds a preset process stagnation threshold among the processes of each product PRD 01.
The display unit 105 displays the analysis result of the process analysis unit 103 of the production cycle analysis system 100 according to the present embodiment to the outside. As shown in fig. 3, the abnormal delay rate and the abnormal stagnation rate of each process in the plurality of products PRD01 produced over a certain period of time can be displayed in the form of a graph. The abnormal delay rate and the abnormal stagnation rate of each process are stored in the storage unit 102 as one type of process abnormality information calculated by a calculation unit, not shown, based on the above-mentioned data, and the user may click on different parts of the graph on a computer display interface to acquire a process standard operation time for each process, a process operation time for a certain process, and other process abnormality information, such as a process delay time for each process, a process stagnation time for each process, a process code and other identification information determined as an abnormally delayed process, a process code and other identification information determined as an abnormally stopped process, and the like. The analysis result of the process analysis unit 103 is illustrated in fig. 3 by way of example only, and the illustrated form is not limited thereto.
Thus, according to the present embodiment, when there is a demand for shortening the production cycle of a product, it is possible to intelligently, visually, and quickly locate the position of a problematic process that causes an extension in the production cycle, and take measures to avoid unnecessary waiting time in a targeted manner, thereby shortening the production cycle of the product.
[ second embodiment ]
The production cycle analysis system 200 of the present embodiment is shown in fig. 4, and includes a product analysis unit 201 for analyzing the production cycle of each product, including a product production cycle calculation unit 202, a product standard production cycle acquisition unit 203, and a product delay time calculation unit 204, in addition to the same configuration as the production cycle analysis system 100 of the first embodiment.
The product production cycle calculation unit 202 calculates, for each of the products PRD01 (i.e., products having the same product number and different product serial numbers), a product production cycle, which is a time difference between the work start time of the earliest step and the work end time of the latest step among all the steps collected by the work performance information collection unit 101 and stored in the storage unit 102, that is, a time length for producing the product, based on the work performance information, and stores the product production cycle in the storage unit 102. Thus, each of the products PRD01 correspondingly stores a product production cycle.
The product standard production cycle acquiring unit 203 acquires a product standard production cycle corresponding to the product PRD01 and stores the product standard production cycle in the storage unit 102. The product standard production cycle is defined herein similarly to the process standard operating time previously described for comparison with the product production cycle of each product PRD01 to determine the corresponding product delay time. The method of acquiring the product standard production cycle is similar to the aforementioned process standard operation time, and for example, the abnormal value is removed by the guerray method and the remaining data is averaged in each product production cycle stored in the storage unit 102, and the average value can be used as the product standard production cycle of the product PRD 01. Thus, the storage unit 102 stores the product standard production cycle for the product PRD 01.
The product delay time calculation unit calculates a delay time of the product production cycle of the product relative to the product standard production cycle for each of the products PRD01, and stores the delay time as the product delay time of the product in the storage unit 102. Thus, each of the products PRD01 stores a corresponding product delay time.
In the present embodiment, the abnormality determination unit 104 also performs determination using a preset threshold value stored in the storage unit 102 for each product delay time of the PRD 01. Specifically, the abnormality determination unit 104 determines that a product, for which the product delay time exceeds a preset product delay threshold value, in each of the products PRD01 is an abnormally delayed product.
The display unit 105 displays the analysis result of the product analysis unit 201 of the production cycle analysis system 200 according to the present embodiment to the outside. When the plurality of products PRD01 to PRD10 produced within a certain period are analyzed by using the production cycle analysis system 200 of the present embodiment, the abnormal delay rate and the average delay days for each product can be displayed in the form of a graph as shown in fig. 5. The abnormal delay rate and the average delay time of the product are stored in the storage unit 102 as one type of product abnormality information calculated by the calculation unit, not shown, based on the above-mentioned data, and the user may click on different parts of the graph on the computer display interface to obtain the product standard production cycle of each product, the product production cycle of a certain product, and other product abnormality information, such as the product delay time of each product, and the product number and serial number of the product determined to be abnormally delayed. The analysis result of the product analysis unit 201 is illustrated in fig. 5 by way of example only, and the illustrated form is not limited thereto.
Thus, according to the present embodiment, when there is a demand for shortening the production cycle of a product, it is possible to intelligently, visually, and quickly locate a problem product that causes an extension in the production cycle, and take measures to avoid unnecessary waiting time in a targeted manner, thereby shortening the production cycle of the product.
[ third embodiment ]
The production cycle analysis system 300 of the present embodiment is shown in fig. 6, and includes a semi-finished product analysis unit 301 for analyzing the production cycle of each semi-finished product, including a semi-finished product production cycle calculation unit 302, a semi-finished product standard production cycle acquisition unit 303, a semi-finished product delay time calculation unit 304, and a semi-finished product dead time calculation unit 305, in addition to the same configuration as the production cycle analysis system 100 of the first embodiment.
The semi-finished product production cycle calculation unit 302 calculates a semi-finished product production cycle, which is a time difference between the work start time of the earliest step and the work end time of the latest step in the steps for forming the semi-finished product stored in the storage unit 102, that is, a time length for forming the semi-finished product, for each semi-finished product of each product PRD01, based on the work performance information described above, and stores the calculated semi-finished product production cycle in the storage unit 102. Thus, each semi-finished product is correspondingly stored with a semi-finished product production period.
The semi-finished product standard production cycle acquiring unit 303 acquires a corresponding semi-finished product standard production cycle for each type of semi-finished product of the product PRD01 and stores the corresponding semi-finished product standard production cycle in the storage unit 102. The semi-finished product standard production cycle is defined herein similarly to the aforementioned process standard operating time for comparison with the semi-finished product production cycle of the semi-finished product of each product PRD01 to determine the corresponding semi-finished product delay time. The method of acquiring the semi-finished product standard production cycle is similar to the aforementioned process standard operation time, and for example, in the semi-finished product production cycle of each product PRD01 stored in the storage unit 102, the abnormal value is removed by the guerras method and the remaining data is averaged, and the average value is used as the semi-finished product standard production cycle of the semi-finished product of the product PRD 01. Thus, the half-finished product standard production cycle is stored in the storage unit 102 for the product PRD 01.
The semi-finished product delay time calculation unit 304 calculates, for each semi-finished product of each product PRD01, a delay time of a semi-finished product production cycle of the semi-finished product with respect to a corresponding semi-finished product standard production cycle, as a semi-finished product delay time of the semi-finished product, and stores the delay time in the storage unit 102. Thus, each of the semi-finished products of the product PRD01 has a corresponding semi-finished product delay time stored therein.
The semi-finished product stagnation time calculation unit 305 calculates a semi-finished product stagnation time of each of a plurality of semi-finished products to be assembled with each other, where the semi-finished product stagnation time is a time difference between a work completion time of a latest step among steps for forming the semi-finished product and a work start time of an earliest step among the steps involved in the assembling with each other.
With respect to the "mutual assembly" herein, for example, the semi-finished product C is formed by assembling the semi-finished product a and the semi-finished product B and then processing them, and the final product is formed by assembling the semi-finished product C and the semi-finished product D. Semi-finished product a and semi-finished product B are "two semi-finished products for mutual assembly", and semi-finished product C and semi-finished product D are "two semi-finished products for mutual assembly".
For the sake of simplicity of explanation, the production cycle of the above four semi-finished products is shown in fig. 7, semi-finished product a is produced from time t0 until time t1 is completed, and semi-finished product B is produced until time t2 is completed. During the time t2 to t3, both blanks A and B stagnate. t3 to t4 represent assembling steps of semi-finished product a and semi-finished product B, that is, "a step involving mutual assembly of semi-finished product a and semi-finished product B", and may be a single step or a combination of a plurality of steps, and the assembling step is completed at time t4, and the assembly is completed. After a certain period of processing (time t4 to time t6), the production of semifinished product C is completed at time t 6. At time t5, production of intermediate product D is complete, and during time t6 to t7, intermediate products C and D are stagnant. t7 to t8 represent an assembly process of the semi-finished product C and the semi-finished product D, that is, "a process involving mutual assembly of the semi-finished product C and the semi-finished product D", and the assembly process is completed at time t8, and the assembly is completed to obtain a product. In this example, as defined above, the half-finished product retention time of half-finished product A is (t3-t1), the half-finished product retention time of half-finished product B is (t3-t2), the half-finished product retention time of half-finished product C is (t7-t6), and the half-finished product retention time of half-finished product D is (t7-t 5).
Thus, each semi-finished product in each product PRD01 has a corresponding semi-finished product dead time stored therein.
In the present embodiment, the abnormality determination unit 104 also performs determination using a threshold value set in advance stored in the storage unit 102 for each semi-finished product delay time for each product PRD 01. Specifically, the abnormality determination unit 104 determines that a semi-finished product whose semi-finished product delay time exceeds a pre-set semi-finished product delay threshold value in each product PRD01 is an abnormally delayed semi-finished product, and determines that a semi-finished product whose semi-finished product stagnation time exceeds a pre-set semi-finished product stagnation threshold value in each product PRD01 is an abnormally stagnant semi-finished product.
The display unit 105 displays the analysis result of the semi-finished product analysis unit 301 of the production cycle analysis system 300 according to the present embodiment to the outside. As shown in fig. 8, the abnormal delay rate and the abnormal stagnation rate of each of the plurality of semi-finished products PRD01 produced over a certain period of time may be displayed in the form of a graph. The abnormal delay rate and the abnormal stagnation rate of the semi-finished products are respectively used as a type of abnormal information of the semi-finished products, and are calculated and stored in the storage unit 102 by the calculation unit not shown according to the above data, and the user can also respectively obtain the standard production cycle of the semi-finished product of each type of semi-finished product, the production cycle of the semi-finished product of a certain semi-finished product and other abnormal information of the semi-finished products by clicking different parts of the chart on the computer display interface, such as the delay time of the semi-finished products of each type of semi-finished product, the stagnation time of the semi-finished products of each type of semi-finished product, the number and the serial number of the semi-finished products judged to be abnormally delayed semi-finished products, the number and the serial number of the semi-finished products judged to be abnormally stopped, and the like. The analysis result of the semi-finished product analysis unit 301 is illustrated in fig. 8 by way of example only, and the illustrated form is not limited thereto.
Thus, according to the present embodiment, when there is a demand for shortening the production cycle of a product, it is possible to intelligently, visually, and quickly locate a defective semi-finished product that causes an extension in the production cycle, and take measures to avoid unnecessary waiting time in a targeted manner to shorten the production cycle of the product.
[ fourth embodiment ]
The present embodiment relates to a production cycle analysis method, and a flowchart of the production cycle analysis method is shown in fig. 9.
The production cycle analysis method analyzes the production cycle of a certain product PRD01, each of the products PRD01 is formed by processing a plurality of semi-finished products through a plurality of processes, and each semi-finished product is formed through a plurality of processes.
First, in step S901, job performance information of all the processes related to each product PRD01 is collected, the job performance information including the job start time and the job end time of the process, and the specific form thereof coincides with the first embodiment, and the description thereof is omitted here.
Next, in step S902, a process operation time, which is a time difference between the operation start time and the operation end time of the corresponding process, is calculated for each process of the product PRD01 based on the operation performance information.
Next, in step S903, for each process of the product PRD01, a corresponding process standard work time is acquired. The definition of the process standard operation time is the same as that of the first embodiment, and the description thereof is omitted here.
Next, in step S904, for each process of each product PRD01, a delay time of the process operation time of the process with respect to the corresponding process standard operation time is calculated as a process delay time of the process. The specific definition of the process delay time is the same as that of the first embodiment, and the description thereof is omitted here.
Next, in step S905, for each of the steps of the product PRD01 excluding the latest step of the steps for machining and forming of each semi-finished product and the latest step of the product, a step stagnation time of the step is calculated, where the step stagnation time is a time difference between the operation end time of the step and the operation start time of the step next to the step. The specific definition of the process dead time is the same as that of the first embodiment, and the description thereof is omitted here.
Next, in step S906, for each product PRD01, a product production cycle is calculated from the aforementioned work performance information, the product production cycle being a time difference between the work start time of the earliest step and the work end time of the latest step among all the steps collected in the work performance information collection step.
Next, in step S907, a product standard production cycle corresponding to the product PRD01 is acquired, and the definition of the product standard production cycle is the same as that of the second embodiment, and the description thereof is omitted here.
Next, in step S908, for each product PRD01, a delay time of the product production cycle of the product relative to the product standard production cycle is calculated as the product delay time of the product. The specific definition of the product delay time is the same as that of the second embodiment, and the description thereof is omitted here.
Next, in step S909, a semi-finished product production cycle is calculated for each semi-finished product of each product PRD01 based on the work performance information, and the semi-finished product production cycle is a time difference between the work start time of the earliest step and the work end time of the latest step among the steps for forming the semi-finished product. The "step for forming" is the same as in the first embodiment, and the description thereof is omitted here.
Next, in step S910, for each semi-finished product of the product PRD01, a corresponding semi-finished product standard production cycle is acquired. The definition of the standard production cycle of the semi-finished product is the same as that of the third embodiment, and the description thereof is omitted here.
Next, in step S911, for each semi-finished product of each product PRD01, a delay time of the semi-finished product production cycle of the semi-finished product relative to the corresponding semi-finished product standard production cycle is calculated as a semi-finished product delay time of the semi-finished product. The specific definition of the half-finished product delay time is the same as that of the third embodiment, and the description thereof is omitted here.
Next, in step S912, for each of a plurality of semi-finished products to be assembled with each other, a semi-finished product stagnation time of the semi-finished product is calculated, the semi-finished product stagnation time being a time difference between a work end time of the latest step among the steps for machining and forming the semi-finished product and a work start time of the earliest step among the steps involved in the mutual assembly. The specific definition of the dead time of the semifinished product is the same as that of the third embodiment, and the description thereof is omitted here.
Next, in step S913, an abnormality determination is made, specifically, a process in which the process delay time exceeds a preset process delay threshold is determined as an abnormal delay process, and a process in which the process stagnation time exceeds a preset process stagnation threshold is determined as an abnormal stagnation process; judging the product with the product delay time exceeding a preset product delay threshold value as an abnormal delay product; and judging the semi-finished product with the semi-finished product delay time exceeding a preset semi-finished product delay threshold as an abnormal delay semi-finished product, and judging the semi-finished product with the semi-finished product stagnation time exceeding a preset semi-finished product stagnation threshold as an abnormal stagnation semi-finished product.
Next, in step S914, display is performed. Specifically, the analysis results relating to the process, the analysis results relating to the product, and the analysis results relating to the semi-finished product are displayed. The specific display contents are the same as those of the first to third embodiments, and the description thereof is omitted here. The process ends.
Thus, according to the present embodiment, when there is a demand for shortening the production cycle of a product, it is possible to intelligently, visually, and quickly locate a problem point that causes an extension of the production cycle, and take measures to avoid unnecessary waiting time in a targeted manner, thereby shortening the production cycle of the product.
[ modified embodiment ]
Although the present invention has been shown and described with reference to certain preferred embodiments thereof, it will be apparent to those skilled in the art that the present invention is not necessarily limited to the embodiments having all the configurations described above, and that the configurations of other embodiments may be added to the configuration of a certain embodiment, and that other configurations may be added, deleted, and replaced to a part of the configurations of the respective embodiments, within a range not departing from the technical spirit of the present invention.
For example, the production cycle analysis system may include both the product analysis unit 201 according to the second embodiment and the semi-finished product analysis unit 301 according to the third embodiment, or may include only the product analysis unit 201 according to the second embodiment or the semi-finished product analysis unit 301 according to the third embodiment without including the process analysis unit 103 according to the first embodiment.
In addition, the process analysis unit 103 according to the first embodiment may calculate only the process delay time without including the process dead time calculation unit 109, and similarly, the work piece analysis unit 301 according to the third embodiment may calculate only the work piece delay time without including the work piece dead time calculation unit 305.
Although the above embodiment has been described with respect to the analysis of a plurality of types of semi-finished products PRD01, the product may be processed from only one type of semi-finished product, and in this case, since there is no mutual assembly between the semi-finished products, the "latest step in the process for forming the semi-finished product" is the latest step in the entire product. Each of the semi-finished products may be formed by a single process, or may be analyzed for only a single product.
In the above embodiment, the process standard operation time of a certain process is calculated by averaging a plurality of process operation times of the process for each product, except for abnormal values, by the guerbus method. The acquisition of the process standard operation time may be obtained by calculation based on existing data, or may be set in advance manually, and for example, an industry standard process operation time may be used. Regarding the product standard production cycle and the semi-finished product standard production cycle, it may be obtained by other calculation methods or set in advance, similarly.
The production cycle analysis method according to the fourth embodiment includes steps S902 to S905 relating to process analysis, steps S906 to S908 relating to product analysis, and steps S909 to S912 relating to semi-finished product analysis, but the execution order therebetween is not limited to this, and may be executed sequentially or simultaneously in another execution order. In addition, the production cycle analysis method may include only a step related to process analysis, only a step related to product analysis, or only a step related to semi-finished product analysis, and in such a case, only the corresponding object is determined and displayed in the abnormality determination step of step S913 and the display step of step S914.
Claims (12)
1. A production cycle analysis method for analyzing a production cycle of one or more products, the products being formed by processing one or more semi-finished products through one or more processes, the semi-finished products being formed by processing through one or more processes, the production cycle analysis method comprising the steps of:
a work performance information collection step of collecting, for each of the products, work performance information of all the processes related thereto, the work performance information including a work start time and a work end time of the process;
a step of calculating a step operation time, which is a time difference between an operation start time and an operation end time of each step of the product, for each step of the product based on the operation performance information;
a step of acquiring process standard operation time, wherein corresponding process standard operation time is acquired for each process of the product; and
and a step of calculating a process delay time, which is a delay time of the process operation time of each product with respect to the corresponding process standard operation time, for each process of the product.
2. The production cycle analysis method according to claim 1,
the method further includes a step of calculating a process dead time of each of the semi-finished products for each of the processes, which is a time difference between a work end time of the process and a work start time of a next process of the process, for each of the processes except for a latest process among the processes for the machining and forming of the semi-finished product and a latest process among the products.
3. The production cycle analysis method according to claim 2, further comprising:
an abnormality determination step of determining a process in which the process delay time exceeds a preset process delay threshold as an abnormal delay process, and determining a process in which the process stagnation time exceeds a preset process stagnation threshold as an abnormal stagnation process; and
and a display step of displaying at least one of the process operation time of each process, the process standard operation time of each process, and process abnormality information including at least one of the process delay time of each process, the process stagnation time of each process, an abnormal delay rate of a process, an abnormal stagnation rate of a process, identification information of the abnormally delayed process, and identification information of the abnormally stagnant process.
4. The production cycle analysis method according to claim 3, further comprising:
a product production cycle calculation step of calculating, for each of the products, a product production cycle from the work performance information, the product production cycle being a time difference between a work start time of an earliest process and a work end time of a latest process among all the processes collected in the work performance information collection step;
a product standard production cycle acquisition step of acquiring a product standard production cycle corresponding to the product; and
a product delay time calculation step of calculating, for each of the products, a delay time of the product production cycle of the product relative to the product standard production cycle as a product delay time of the product,
in the abnormality judgment step, a product of which the product delay time exceeds a preset product delay threshold is judged as an abnormal delay product,
in the displaying step, at least one of the product production cycle, the product standard production cycle, and product abnormality information of each product is also displayed, the product abnormality information including at least one of the product delay time, an abnormality delay rate of a product, an average delay time, and identification information of the abnormally delayed product of each product.
5. The production cycle analysis method according to claim 3, further comprising:
a semi-finished product production cycle calculation step of calculating a semi-finished product production cycle for each semi-finished product of each product according to the operation actual result information, wherein the semi-finished product production cycle is a time difference between an operation start time of an earliest process and an operation end time of a latest process in the processes for processing and forming of the semi-finished product;
a semi-finished product standard production cycle acquisition step, wherein a corresponding semi-finished product standard production cycle is acquired for each semi-finished product of the product;
calculating a semi-finished product delay time, namely calculating the delay time of the semi-finished product production cycle of each semi-finished product relative to the corresponding semi-finished product standard production cycle of each semi-finished product as the semi-finished product delay time of the semi-finished product; and
a semi-finished product stagnation time calculation step of calculating a semi-finished product stagnation time of each of a plurality of semi-finished products for mutual assembly, the semi-finished product stagnation time being a time difference between a work completion time of a latest one of the processes for machining and forming of the semi-finished product and a work start time of an earliest one of the processes involved in the mutual assembly,
in the abnormality determining step, a semi-finished product of which the semi-finished product delay time exceeds a preset semi-finished product delay threshold is determined as an abnormally delayed semi-finished product, a semi-finished product of which the semi-finished product stagnation time exceeds a preset semi-finished product stagnation threshold is determined as an abnormally stagnant semi-finished product,
in the displaying step, at least one of the semi-finished product production cycle of each semi-finished product, the semi-finished product standard production cycle of each semi-finished product, and semi-finished product abnormality information is further displayed, wherein the semi-finished product abnormality information at least includes one of the semi-finished product delay time of each semi-finished product, the semi-finished product stagnation time of each semi-finished product, an semi-finished product abnormality delay rate, a semi-finished product abnormality stagnation rate, identification information of the abnormally delayed semi-finished product, and identification information of the abnormally stagnated semi-finished product.
6. The production cycle analysis method according to any one of claims 1 to 5,
in the step of acquiring the process standard operating time, the process standard operating time is calculated by removing an abnormal value from the process operating time of the process of each product for each process of the product.
7. A production cycle analysis system that analyzes a production cycle of one or more products, the products being formed from one or more semi-finished products that are processed through one or more processes, the semi-finished products being formed through one or more processes, the production cycle analysis system comprising:
a work performance information collection unit that collects, for each of the products, work performance information of all the steps related thereto, the work performance information including a work start time and a work end time of the step;
a step operation time calculation unit that calculates, for each step of each product, a step operation time, which is a time difference between a step start time and a step end time of the step, based on the operation performance information;
a process standard operation time acquisition unit for acquiring a corresponding process standard operation time for each process of the product; and
and a step delay time calculation unit that calculates, for each step of each of the products, a delay time of the step operation time of the step with respect to the corresponding step standard operation time as a step delay time of the step.
8. The production cycle analysis system according to claim 7,
the work-stop time calculation unit calculates, for each of the products, a work-stop time of the step, which is a time difference between a work-end time of the step and a work-start time of a step next to the step, excluding a latest step among the steps for the machining and forming of each of the semi-finished products and the latest step in the product.
9. The production cycle analysis system of claim 8, further comprising:
an abnormality determination unit that determines a process in which the process delay time exceeds a preset process delay threshold as an abnormal delay process, and determines a process in which the process stagnation time exceeds a preset process stagnation threshold as an abnormal stagnation process; and
and a display unit that displays at least one of the process operation time of each process, the process standard operation time of each process, and process abnormality information including at least one of the process delay time of each process, the process stagnation time of each process, an abnormal delay rate of a process, an abnormal stagnation rate of a process, identification information of the abnormally delayed process, and identification information of the abnormally stagnant process.
10. The production cycle analysis system of claim 9, further comprising:
a product production cycle calculation unit that calculates, for each of the products, a product production cycle that is a time difference between a work start time of an earliest step and a work end time of a latest step among all the steps collected by the work performance information collection unit, based on the work performance information;
a product standard production cycle acquisition unit that acquires a product standard production cycle corresponding to the product; and
a product delay time calculation unit that calculates, for each of the products, a delay time of the product production cycle of the product relative to the product standard production cycle as a product delay time of the product,
the abnormality determination section further determines a product whose product delay time exceeds a preset product delay threshold as an abnormally delayed product,
the display unit further displays at least one of the product production cycle, the product standard production cycle, and product abnormality information of each product, the product abnormality information including at least one of the product delay time, an abnormality delay rate of the product, an average delay time, and identification information of the abnormally delayed product of each product.
11. The production cycle analysis system of claim 9, further comprising:
a semi-finished product production cycle calculation unit that calculates a semi-finished product production cycle, which is a time difference between a work start time of an earliest step and a work end time of a latest step among the steps for the machining of the semi-finished product, for each semi-finished product of each product, based on the work performance information;
a semi-finished product standard production cycle acquisition section that acquires a corresponding semi-finished product standard production cycle for each type of semi-finished product of the product;
a semi-finished product delay time calculation unit that calculates, for each semi-finished product of each of the products, a delay time of the semi-finished product production cycle of the semi-finished product relative to a corresponding semi-finished product standard production cycle as a semi-finished product delay time of the semi-finished product; and
a work piece stagnation time calculation unit that calculates a work piece stagnation time of each of a plurality of work pieces to be assembled with each other, the work piece stagnation time being a time difference between a work completion time of a latest one of the work pieces to be used for the machining and forming and a work start time of an earliest one of the work pieces to be assembled with each other,
the abnormality judgment section also judges a semi-finished product of which the semi-finished product delay time exceeds a preset semi-finished product delay threshold as an abnormally delayed semi-finished product, and judges a semi-finished product of which the semi-finished product stagnation time exceeds a preset semi-finished product stagnation threshold as an abnormally stagnant semi-finished product,
the display part further displays at least one of the semi-finished product production cycle of each semi-finished product, the semi-finished product standard production cycle of each semi-finished product, and semi-finished product abnormality information, wherein the semi-finished product abnormality information at least includes one of the semi-finished product delay time of each semi-finished product, the semi-finished product dead time of each semi-finished product, an semi-finished product abnormality delay rate, a semi-finished product abnormality dead rate, the abnormality delayed semi-finished product identification information, and the abnormality stopped semi-finished product identification information.
12. The production cycle analysis system according to any one of claims 7 to 11,
the step standard work time acquisition unit calculates the step standard work time by removing an abnormal value from the step work time of the step for each product, for each step of the product.
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| CN116663868A (en) * | 2023-08-01 | 2023-08-29 | 深圳市特旺电子有限公司 | PCB assembly progress monitoring system |
| CN114637264B (en) * | 2022-03-15 | 2024-05-17 | 广州明珞装备股份有限公司 | Motion stability analysis method, system, device and storage medium |
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| JP3419216B2 (en) * | 1996-09-05 | 2003-06-23 | トヨタ自動車株式会社 | Production plan creation device |
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| CN114637264A (en) * | 2022-03-15 | 2022-06-17 | 广州明珞装备股份有限公司 | Motion stability analysis method, system, device and storage medium |
| CN114637264B (en) * | 2022-03-15 | 2024-05-17 | 广州明珞装备股份有限公司 | Motion stability analysis method, system, device and storage medium |
| CN116663868A (en) * | 2023-08-01 | 2023-08-29 | 深圳市特旺电子有限公司 | PCB assembly progress monitoring system |
| CN116663868B (en) * | 2023-08-01 | 2024-04-19 | 江门市科能电子有限公司 | PCB assembly progress monitoring system |
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