JP2002297216A - Planning simulation system and method for controlling the same and its program - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a planning simulation system capable of realizing the optimal plan in the case of making a planning plan necessary for executing each work process in a production line based on a production plan. SOLUTION: This planning simulation system for generating and distributing information for making a planning plan to terminals connected to an information communication network is provided with a storage means for storing first index data constituted of information related with a production plan and second index data constituted of information related with the capability of a production line, a simulation means for deciding an optimal order for optimally arranging operators to be assigned in the order of the work processes in the case of arranging the operators in the line, a fighting power analyzing means for analyzing the capability of the line based on at least the second index data, and a load calculating means for calculating the load plans of all actual operation dates in the line to be supplied from the production plan data of the line and the second index data.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION The present invention relates to a method for realizing an optimal plan in real time from an arbitrary place in order to formulate a replacement plan necessary for performing each standardized work process in a production line based on a production plan. BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an installation simulation system for realizing an installation, a control method thereof, and a program for implementing the control.

[0002]

2. Description of the Related Art With the diversification of customer demands, multivariate production has become mainstream in factories in order to quickly respond to customer demands. In addition, in order to realize multivariate production, a production plan is executed on an assembly line side of a factory by preparing a replacement plan (also referred to as a production line input plan) for executing production.

[0003] Fig. 25 shows an example in which a replacement plan is prepared. In Fig. 25 (a), for example, an assembly line is composed of three processes, and it is necessary to arrange workers in each process. In FIG. 6B, in the load management board for performing load management, it is assumed that the input sequence of the workers is such that the worker A is arranged in the step 1, the worker B is arranged in the step 2, and the worker C is arranged in the step 3. . In FIG. 9 (c), the set-up time of the line in the worker input order at this time is a total time coefficient indicating the work skill in each process assigned to each worker, for example, the sum of the work executable time coefficients. 3.2H (hour).

The actual required time based on the replacement plan is given by the following equation. H = A × α × B In the above equation, H: indicates an actual required time. A: Refers to the standard working time per unit production. α: Efficiency that varies depending on the composition of the worker and the skill level of the worker. B: Refers to the production volume. For example, in today's plan, the assembly man-hour is 0.5
The actual required time when the required man-hour for producing 20 units of time is planned to be 10 hours is given by the following equation. 0.5 × (3.2 / 3) × 20 ≒ 10.7 In the above equation, the numeral 0.5 indicates the number of assembling steps per vehicle. The expression 3.2 / 3 indicates the average time coefficient of each step. Numeral 20 indicates the number of units produced. The number 10.7
Indicates the actual required time. In this way, it is delayed by 0.7 hours from the scheduled time of 10 hours.

[0005] In preparing a replacement plan, a person in charge of preparing the replacement plan or a manager can use the daily production plan information, the input number information, and the line operation start time information to prepare the replacement plan. And where and where to place them was determined by past experience. However, in this case, if the planned number of products cannot be realized, shipping delays and excess product inventories will occur.

FIG. 26 shows a configuration diagram of the prior art. In the figure, the installation system includes a Web terminal 180a arranged for each production line, a Web terminal 180b arranged for a person in charge of drafting an installation plan, or a Web terminal 180c arranged for a manager. For example, it is connected to the delivery server 110 via an information communication network 170 such as an intranet.

The sending server 110 includes a control unit 111
And a setting unit 150 and a storage unit 160, which generate information for setting a setting plan and connect to the information communication network 170. A Web arranged for a person in charge of setting the setting plan. The content is distributed to the terminal 180b or the Web terminal 180c arranged for the administrator.

[0008] The storage unit 160 stores information on a production plan such as daily production plan information, input number information, and line operation start time information. FIG. 27 shows the daily production plan information, and FIG. 27 shows, for example, daily production plan numbers for each model in February. FIG. 28 shows the input number information, and FIG. 28 shows, for example, the daily input number of workers for each production line in February. Further, FIG. 29 shows line operation start time information, and FIG. 29 shows, for example, a daily line operation start time for each production line in February.

The control unit 111 reads each information from the storage unit 160 based on, for example, an instruction from the Web terminal 180b arranged for the person in charge of drafting the above-mentioned settlement plan, and the settlement unit 150 Is generated, and a series of processes for distributing the information to the Web terminal 180b are executed.

[0010]

As described above, the prior art has the following problems.

[0011] 1) When arranging the workers in the order of the work process, they have been drafted according to the rules of thumb of the person in charge of the replacement.

2) For this reason, if the predicted number of products cannot be realized, shipping delays and excess product inventories will occur.

3) That is, a method of optimally arranging the workers in the order of the work process has not been established in the preparation of the replacement plan.

An object of the present invention is to construct a setting simulation system that can plan an optimum setting in real time from an arbitrary place.

[0015] Another object of the present invention is to determine the optimum order of workers to be input based on skill information of each worker when arranging the workers.

Another object of the present invention is to clarify the current problem by analyzing the capacity of a production line based on information on the capacity of a production line when drafting a replacement plan.

Further, when preparing the replacement plan, from the production plan data of the line and the information on the capacity of the production line, from a long-term perspective, all future actual working days in the line to be put in based on the current strength are considered. Is to calculate a load plan.

[0018]

In order to solve the above problems, the present invention employs the following means.

In a placement simulation system for generating information for preparing a placement plan and distributing the information to terminals connected to an information communication network, the system has information on a production plan and information on the capacity of a production line, and works on a line. Means for executing a simulation for optimally arranging the workers to be arranged on the line based on at least the skill information of each worker when arranging the workers, and at least information on the capacity of the production line when drafting the replacement plan And a means for calculating a load plan of a line to be input from the production plan data of the line and information on the capacity of the production line.

Further, when arranging the workers on the line, a process of determining an optimum order for arranging the workers to be optimally arranged on the line based on at least skill information of each worker, and preparing a replacement plan. At the time, at least the step of analyzing the capacity of the line based on the information on the capacity of the production line, and the step of calculating the load plan of the line to be input from the production plan data of the line and information on the capacity of the production line, Provided is a control method of a placement simulation system that generates information for drafting a placement plan and distributes the information to a terminal connected to an information communication network.

Further, a program for realizing the control of the insertion simulation system is provided.

By using the above means, information for drafting a replacement plan is generated based on the information on the production plan and the information on the capacity of the production line, and distributed to a terminal connected to the information communication network. In order to make an optimal replacement plan in real time from any location. Also,
When arranging the workers, the optimum rank of the workers to be input is determined based on the skill information of each worker. In addition, when formulating a replacement plan, the current problems are clarified by analyzing the capacity of the line based on information on the capacity of the production line. Also, when preparing the replacement plan, from the production plan data of the line and information on the capacity of the production line, from a long-term perspective, the load plan for all future production days on the line to be input based on the current strength Is calculated.

[0023]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention has the following embodiments.

As shown in the block diagram of the present invention in FIG. 1, the replacement simulation system drafts a replacement plan necessary for performing each standardized work process in a production line based on a production plan. 8a, 8b, 8c for generating information for connection to the information communication network 7
Storage means 6 for storing the first index data consisting of information relating to the production plan and the second index data consisting of information relating to the capacity of the production line in the placing apparatus 1; Means for arranging the workers, at least based on at least the skill information of each worker included in the second index data, a simulation means 2 for deciding an optimum order for arranging the workers to be input in the order of the work process optimally; At the time of planning, at least force analysis means 3 for analyzing the capacity of the line based on the second index data, and load planning for all actual working days in the line to be input from the production plan data of the line and the second index data Load calculating means 4 for calculating.

[0025] By adopting the above-described form, information for drafting a replacement plan is generated based on the information on the production plan and the information on the capacity of the production line, and is distributed to a terminal connected to the information communication network. In order to formulate an optimal offer in real time from any location. Further, when arranging the lines of the workers, the optimum rank of the workers to be input is determined based on the skill information of each worker. Furthermore, when formulating the refill plan, the current problems are clarified by analyzing the capacity of the line based on information on the capacity of the production line. Also, when preparing the replacement plan, from the production plan data of the line and information on the capacity of the production line, from a long-term perspective, the load plan for all future production days on the line to be input based on the current strength Automatically calculate and provide information.

Further, the storage means 6 includes daily production plan information, input number information, and line operation start time information in the first index data, and information on the schedule of worker arrival / departure in the second index data. The information includes work technology skill information of each worker based on the work history of each worker and line facility capability information.

By adopting the above-described form, when making a replenishment plan, information taking into account the worker's going-in / out schedule, the work skill of each worker based on the work history of each worker, and the line facility capability is taken into account. provide.

Further, the above-mentioned force analysis means 3 is capable of promptly increasing the level of the worker when planning an optimal replacement based on the work skill information of each worker included in the second index data. To identify.

By adopting the above-mentioned form, if it is not possible to allocate a highly skilled worker in each step, a worker who can be upgraded with the minimum education is specified, and it is assumed that the worker will be upgraded. Determine the optimal ranking of the workers to be input.

Further, the force analysis means 3 specifies a line to be used when making a replacement plan based on the equipment capacity information of each line included in the second index data.

By adopting the above-mentioned form, information for determining an optimal input line when drafting a replacement plan is provided.

Further, the load calculating means 4 calculates the loads on all the actual working days in the line to be put in on the assumption that the worker who needs the urgent level increase specified by the force analyzing means 3 performs the level up. Calculate the plan.

By taking the above-described form, when calculating the load plans for all the actual working days in the line to be put in, information for comparing the load plan at the present strength with the load plan at the time of level up is provided. I do.

Further, the setting simulation system sets the setting device 1 to set a setting plan for each of the input lines based on the load plans of all the actual working days calculated for each input line by the load calculating means 4. Erecting means 5 is provided.

By adopting the above-described embodiment, a long-term replacement plan is prepared based on the load plans of all the actual working days in the line to be put in.

Further, the simulation means 2 comprises:
Based on the line production plan information on a daily basis for each line prepared by the placing means 5, the daily work load information for the standard capacity of the line is presented.

By adopting the above-described embodiment, information for preparing an optimal replacement plan while simulating the replacement of each line based on the current strength or the strength when the level is increased is provided.

In addition, the control method of the replacement simulation system uses the information relating to the production plan to generate information necessary for performing a standardized work process in the production line based on the production plan. And a method of controlling an insertion simulation system that generates and distributes the information to a terminal connected to an information communication network based on information related to the capacity of the production line. A first step of deciding an optimal order for optimally arranging the workers to be input in the order of the work process based on the skill information of each worker included in the information on The second step of analyzing the capacity of the line based on the information, the production plan data of the line and the capacity of the production line And a third step of calculating the production date all load planning in line fed through the information about.

By adopting the above-described form, when drafting a replacement plan, the optimum order of the workers to be input is determined based on the skill information of each worker, and the line is determined based on the information on the capacity of the production line. Analysis to determine the current problems, calculate the load plan for all future production days on the line to be put in from a long-term perspective, and provide information to formulate a replacement plan. Is distributed to a terminal connected to the information communication network, and an optimal placement plan is drafted in real time from an arbitrary place.

Further, the program for realizing the control of the replacement simulation system produces information for drafting a replacement plan necessary for performing each standardized work process in the production line based on the production plan. A program for controlling an insertion simulation system that is generated based on information on a plan and information on a capability of a production line and distributed to a terminal connected to an information communication network. A first step of deciding an optimal order for optimally arranging the workers to be input in the order of the work process based on at least the skill information of each worker included in the information on the performance of the production line, and setting up a replacement plan. Analyzing the capacity of the production line based on at least information on the capacity of the production line. Degree and to execute a third step of calculating the production date all load planning in line to introduce the information about the capability of the production plan data the production line of the line.

By adopting the above-described mode, the setting simulation system is caused to execute a procedure for preparing an optimum setting plan in real time from an arbitrary place.

[0042]

DESCRIPTION OF THE PREFERRED EMBODIMENTS A representative embodiment according to the present invention will be described with reference to FIGS. In the following, the same portions are denoted by the same reference numerals, and detailed description may be omitted.

FIG. 2 is a block diagram showing an embodiment of the present invention.

In the same figure, the insertion simulation system includes a Web terminal 80 arranged for each production line.
a and We to place for the person in charge of drafting the replacement plan
b terminal 80b or a Web terminal 80c arranged for an administrator is connected to an information communication network 7 such as an intranet.
0 and the server 10.

The setting simulation system can set each menu of the worker input order, the force analysis, the load calculation, and the setting on the main menu screen shown in FIG.

The placement server 10 includes a control unit 11, a simulation unit 20, a strength analysis processing unit 30, a load calculation processing unit 40, a placement processing unit 50, and a storage unit 60.
And the control unit 11 reads a necessary program,
Generates information for drafting a replacement plan and distributes it to a Web terminal 80b arranged for a person in charge of drafting the replacement plan to be connected to the information communication network 70 or a Web terminal 80c arranged for an administrator. Things.

Next, an example of data stored in the storage unit 60 will be described.

The storage section 60 stores first index data composed of information relating to the production plan and second index data composed of information relating to the capacity of the production line. As shown in FIGS. 27 to 29, the first index data stores the daily production plan information, the input number information, and the line operation start time information. The first index data is referred to when producing the production process data and the input worker data.

The second index data includes information on the schedule of the worker's going-in / out, work skill information, and work history (experience).
Information and line facility capacity information are stored. Note that FIG.
Indicates the worker's attendance schedule information.
For example, it shows the clock-in time and the clock-out schedule information for each worker indicating the clock-out time and the clock-out time and the working time for each day, which have been declared in advance by each worker in February. The work attendance schedule information is referred to when input worker data is generated.

FIG. 4 shows the worker's work skill information. FIG. 4 shows the work skill of each worker from I to V corresponding to each process in each model.
It is shown divided into stages. The work skill divided into five stages can be indicated by, for example, a work executable time coefficient in each process. For example, the skill V with the highest level is 0.8, and the skill I with the lowest level is 1.2. In addition, the worker's work technology skill information is used to generate input worker data, to determine the optimal order to optimally arrange the workers to be input in the work process order, to analyze the ability of the line, Used when calculating the load.

FIG. 5 shows the work history (experience) of the worker.
This figure shows the information, and each of the performance indices indicating the speed, reliability, and experience of each worker's work skill is shown as I for each process in each model.
5 are divided into five stages. In the ability index divided into five levels, for example, the highest level of the work skill V is 0.8, and the lowest level of the work skill I is 1.2. The work history (experience)
The information can be used as the source of the work skill information shown in FIG.

When the work skill level of each worker shown in FIG. 4 is determined, the work history (experience) information of the worker is determined by a single item such as speed, reliability, and experience. Alternatively, the determination may be made in consideration of a plurality of items from among speed, certainty, and experience.

Further, FIG. 6 shows, as one of the line facility capacity information, the line capacity based on the processing time evaluated in the benchmark test of the test machine in each line, divided into five stages from I to V. . In the line capability index divided into five stages, for example, the line capability V having the highest level is set to 0.8, and the line capability I having the lowest level is set to 1.2. The line facility capacity information is used when generating production process data including a production line, when analyzing the capacity of a line, when calculating a load, or when performing a replacement simulation.

Further, FIG. 7 shows, as one of the line facility capability information, a mixed product matrix in a matrix form showing each line and a model that can be produced in each line. The mixed product matrix is used when generating production process data including a production line.

Next, the simulation section 20 will be described.

When arranging the workers on the line, the simulation unit 20 determines the optimum order for arranging the workers to be input in the order of the work process based on at least the skill information of each worker included in the second index data. decide. That is, the worker who arranges the line is specified from the worker's attendance schedule screen for each day shown in FIG.

In this case, as shown in FIG. 10, for example, the assembly line is composed of three processes, and the skill information of each worker corresponding to each process is based on the worker's work skill data shown in FIG. Take control of Further, as shown in FIG. 11, each pattern in the worker input order at this time is developed,
The total time coefficient of the set time coefficients of the line in each of the developed patterns is calculated. Further, the optimum order is presented in the order of the smallest total time coefficient in each pattern. In the figure, the worker input order shown by pattern 2 is determined as the optimal arrangement.

In this example, it is determined that the input order of the workers is to arrange the worker A in the step 1, the worker C in the step 2, and the worker B in the step 3, respectively. In the order in which the lines are set, the total time coefficient obtained by summing up, for example, the work executable time coefficients indicating the work skills in each process assigned to each worker is 2.6.

For example, in today's plan, the actual required time when the required man-hour for producing 20 units each having 0.5 hours of assembly per unit is 10 hours is calculated by the following equation. 0.5 × (2.6 / 3) × 20 ≒ 8.7 In the above equation, the numeral 0.5 indicates the number of assembling steps per vehicle. 2.6 / 3 in the equation indicates the average time coefficient of each step. Numeral 20 indicates the number of units produced. The number 8.7
Indicates the actual required time. Thus, the scheduled time 10
It will be 1.3 hours faster than time.

Further, the simulation unit 20 presents daily work load information with respect to the standard capacity of the line based on the daily line production plan information for each line, which is set up by the replacement processing unit 50, which will be described later. Alternatively, based on the strength at the time of level-up, information is provided for creating an optimal replacement plan while simulating the replacement of each line. The details will be described later.

Next, the strength analysis processing section 30 will be described.

The force analysis processing section 30 analyzes the performance of the line based on at least the second index data shown in FIGS. 4 to 7 when making a replacement plan. Analyzing the capacity of the line based on the information on the clarification of the current problems.

That is, in the above-described worker arrangement showing the optimum order shown in FIG. 11, when the arrangement is performed based on the current work skill, the worker A arranged in the process 1 has the skill
III indicates that no highly skilled workers can be assigned to each process.

The force analysis processing section 30 constitutes an operator analysis section 31 and a line analysis section 32. As shown in FIG. 12, as shown in FIG. When planning an optimal replacement based on the information, by specifying a worker who needs an immediate level-up, an optimum rank of the worker is determined on the premise of the rank-up of the worker.

In this case, as an example of specifying a worker who needs an immediate level-up, a worker who has the skill V or the skill closest to the skill V alone in each process is preferentially arranged. Next, a worker whose level is to be upgraded is extracted so that the number of workers to be upgraded is the smallest. Further, the worker closest to the skill V is specified from the extracted workers. In this example, FIG.
As shown in (a), it is best to educate the worker A who has the skill III to be assigned to the process 1 so as to become the skill IV.

Further, as shown in FIG. 13, in a pattern in which the skill level is raised by one rank in all the processes, a total sum of, for example, work executable time coefficients indicating the work skills in each process assigned to each worker. A pattern is extracted in which the time coefficient is the smallest and the number of people who need level-up is the smallest.

As a result, the strength analysis processing unit 30
As shown in FIG. 2 (b), the worker A who educates the input sequence of the workers to the skill IV in the process 1, the worker C having the skill V in the process 2, and the skill V in the process 3 are provided. It is determined that the workers B are to be arranged. At this time, the set-up time coefficient of the line in the order of input of the workers is, for example, the sum of the work-permissible time coefficients indicating the work skills in each process assigned to each worker. The total time coefficient thus obtained is 2.5.

For example, in today's plan, the actual required time when the required man-hour for producing 20 units each having 0.5 hours of assembly per unit is planned to be 10 hours is as follows. 0.5 × (2.5 / 3) × 20 ≒ 8.3 In the above equation, the numeral 0.5 indicates the number of assembling steps per vehicle. 2.5 / 3 in the formula indicates the average time coefficient of each step. Numeral 20 indicates the number of units produced. Number 8.3
Indicates the actual required time. Thus, the scheduled time 10
1.7 hours faster than time.

Further, the line analysis unit 32 determines an optimal input line when drafting a refilling plan based on the line facility capacity information shown in FIG. 6 and the mixed product matrix information in a matrix form shown in FIG. Provide information to decide.

Next, the load calculation processing section 40 will be described.

The load calculation processing section 40 calculates the load plans of all the actual working days in the line to be put in from the production plan data of the line and the second index data, and makes a long-term From the viewpoint, present the load plan information of all future working days on the line to be put in based on the current strength.

That is, as shown in FIG. 14A, the current month plan, the actual working day, the current strength (arranged in the pattern 2 shown in FIG. 11, line ability III), and the daily working hours are set. In this case, the load calculation details are calculated and presented.

An example of a procedure in the load calculation is to calculate the number of vehicles that can be produced in the set operating time by setting the planned number of vehicles,
Distribute on each working day. Next, the number of units that can be made including the overtime hours is calculated while considering the remaining units as the upper limit for overtime work. The days when overtime work is performed are set sequentially from the back of the working day.

For example, in the setting shown in FIG. 14A, 1) the production time per unit is 0.5 × (2.6 / 3) ×
1.0 ≒ 0.43 The number of units produced per day is 8 ÷ 0.43 = 18. In the above equation, the numeral 0.5 indicates the number of assembly steps per unit. 2.6 / 3 in the equation indicates the average time coefficient of each step. The numeral 1.0 indicates a line ability index. The number 8 indicates the working hours of the day. 2) The number of units produced per day during 2 hours overtime is 10 ÷
0.43 = 23 In the above equation, the numeral 10 indicates the working hours of one day including overtime hours.

When presenting the load plan information, for example,
As shown in FIG. 14B, the number of production units, the number of input persons, the operation time, and the remaining number of units are displayed as prorated data on all operation days. Further, as alarm information, with the set working hours of 8 hours a day, 1
Indicates that 0 cars remain. It also indicates that the fourth and fifth days require 10 hours of work per day to execute the plan.

Further, the load calculation processing section 40 is provided for all the actual working days in the line to be put in on the assumption that the worker who needs the urgent level up specified by the force analyzing means 3 will level up. Calculate the load plan and present the load plan information for all future working days.

That is, as shown in FIG. 15A, the current month plan, the actual working day, the current strength (arranged in the pattern 7 shown in FIG. 12B, line capability III), the daily working hours, Is set, the load calculation details are calculated and presented.

For example, in the setting shown in FIG. 15A, 1) the production time per unit is 0.5 × (2.5 / 3) ×
1.0 ≒ 0.41 The number of vehicles produced per day is 8 ÷ 0.41 = 19. In the above equation, the numeral 0.5 indicates the number of assembly steps per vehicle. 2.5 / 3 in the formula indicates the average time coefficient of each step. The numeral 1.0 indicates a line ability index. The number 8 indicates the working hours of the day. 2) The number of units produced per day during 2 hours overtime is 10 ÷
0.41 = 24 In the above equation, the numeral 10 indicates the working hours of one day including overtime hours.

When presenting the load plan information, for example,
As shown in FIG. 15B, the number of production units, the number of input persons, the operation time, and the remaining number of units are displayed as prorated data on all operation days. Further, as the alarm information, the set working hours of 8 hours a day is 5
Show that you are left behind. It also indicates that the fifth day requires 10 hours of work per day to execute the plan.

Thus, when calculating the load plans for all the actual working days in the line to be inserted, it is possible to compare the load plan at the present strength with the load plan at the time of level up.

Next, the insertion processing section 50 will be described.

The replacement processing unit 50 can also formulate a long-term replacement plan for each line based on the load plans for all the actual working days for each input line calculated by the load calculation processing unit 40. is there.

When a long-term replacement plan is drawn up, the above-mentioned simulation unit 20 increases the current strength or the level based on the daily line production plan information for each line prepared by the replacement unit 50. The daily work load information for the standard ability of each line is presented based on the strength at the time. Thus, the placement processing unit 50 formulates an optimal placement plan while simulating the placement of each line based on the current strength or the strength when the level is increased.

FIG. 17 shows a display example of the daily work load information with respect to the standard capacity of each line based on the daily line production plan composed of the model and the number shown in FIG. FIG. 19 shows a display example of daily work load information with respect to the standard capacity of each line based on the daily line production plan including the model and the number shown in FIG.

Next, the control of the insertion simulation system will be described.

FIG. 20 is an example showing an outline of a series of processing executed by the insertion simulation system.

In step S 01, the simulation section 20 reads the first index data and the second index from the storage section 60.

In step S02, the information of the production line, the production process, and the worker to be arranged, which is input from the Web terminal 80b arranged for the person in charge of drafting the replacement plan, is read.

In step S03, the simulation section 20 presents an optimal order for optimally arranging the workers to be input in the order of the work process based on at least the skill information of each worker included in the second index data.

In step S04, if there is an instruction of OK in the presented optimum order, the process proceeds to step S05. O
If it is not K, the process returns to step S02.

In step S05, the strength analysis processing section 30 analyzes the performance of the line based on the second index data. For example, if it is not possible to assign highly skilled workers to each process, identify the workers who need immediate level up and analyze the line capabilities to clarify the current problems. I do.

In step S06, information necessary for load calculation input from the Web terminal 80b arranged for the person in charge of drafting the replacement plan is read.

In step S07, the load calculation processing section 40 calculates the load plans of all the actual working days in the line to be inserted from the first index data and the second index data, and obtains the load plan information of all the actual working days. Is presented.

In step S08, if there is an instruction of OK in the presented load plan information, the process proceeds to step S09. If not, the process returns to step S06.

In step S09, the daily line production plan information (replacement plan) input from the Web terminal 80b arranged for the person in charge of preparing the replacement plan is read.

In step S10, the simulation section 20 presents daily work load information for the standard capacity of each line based on the taken daily line production plan information (replacement plan).

In step S11, if there is an instruction of OK in the presented daily work load information, step S1
Proceed to 2. If not, the process returns to step S09.

[0098] In step S12, the placement processing section 50 drafts and determines a long-term placement plan for each line based on the load plans for all the actual working days for each input line. Then, the process ends.

Next, an example of the processing procedure of the optimal worker input order simulation will be described.

FIG. 21 shows a flowchart of the embodiment.

In step S21, menus are set in the order of operator input.

In step S22, the simulation section 20 reads the second index data including the work skill data.

In step S23, the production process data for designating the production line and the production process input in consideration of the line facility capacity information is read from the Web terminal 80b arranged for the person in charge of drafting the replacement plan. .

In step S24, the information is arranged in correspondence with the production process data input from the Web terminal 80b, which is arranged for the person in charge of drafting the replacement plan, in consideration of the information on the schedule of the worker's attendance / exit and work skill information. To read the input worker data to perform.

In step S25, the skill information of each worker corresponding to each process is grasped based on the worker's work skill data, and the respective patterns in the worker input order at this time are developed. Calculate the total time coefficient of the line setting time.

In step S26, the optimum ranking is presented in the order of the smallest total time coefficient in each pattern.
The worker input order having the smallest optimum order is determined as the optimum arrangement.

In step S27, the actual required time is calculated and presented based on the determined worker input order.

In step S28, if there is an instruction to end the process, the process is ended. If not, the process returns to step S23.

In this manner, an optimum input pattern based on the current production capacity is derived in consideration of the attendance of the worker.

Next, an example of the strength analysis processing procedure will be described.

FIG. 22 is a flowchart of the embodiment.

In step S41, the menu is set to strength analysis.

At step S42, the worker analyzing unit 3
1 reads second index data including work skill data.

In step S43, the production process data for designating the production line and the production process inputted from the Web terminal 80b arranged for the person in charge of drafting the replacement plan is read.

In step S44, input worker data to be arranged corresponding to the production process data input from the Web terminal 80b arranged for the person in charge of drafting the replacement plan is read.

In step S45, each pattern in the worker input order is developed, and steps having no skill V are extracted.

In step S46, if there is a process without skill V, the process proceeds to step S47. When each process has the skill V, the process proceeds to step S50.

In step S47, a pattern in which the skill level is raised by one rank in all steps is developed based on the developed patterns in the order of input of the workers.

In step S48, a pattern is extracted in which the total time coefficient obtained by summing up the work operable time coefficients of the respective developed patterns is the smallest, and the number of persons who need further level-up is the smallest.

In step S49, a worker who needs education for raising the skill level by one rank in the extracted pattern is specified and presented.

In step S50, if there is an instruction to end the process, the process is ended. If not, the process returns to step S43.

In this way, when it is not possible to arrange a highly skilled worker in each process, a worker who can rank up with a minimum amount of education is derived.

Next, an example of a load calculation processing procedure will be described.

FIG. 23 shows a flowchart of the embodiment.

In step S81, the menu is set to load calculation.

In step S82, the load calculation processing section 40 reads the second index data including the work technology skill information and the line facility capacity information.

In step S83, data necessary for load calculation input from the Web terminal 80b arranged for the person in charge of drafting the replacement plan is read.

In step S84, the number of vehicles that can be produced in the set number of operating hours is calculated and distributed to each operating day.

In step S85, the remaining number of the planned number is calculated.

In step S86, it is determined whether there is a remaining number. If there is a remaining number, the flow advances to step S87. If there is no remaining number, the process proceeds to step S89.

In step S87, the number of units that can be manufactured including the overtime hours is calculated while considering the overtime upper limit.

In step S88, it is determined whether or not the planned number of units can be made on the set actual operation day including overtime hours.
If it can be made, the process proceeds to step S89. If not, the process returns to step S87.

In step S89, the number of production units, the number of input persons, the operation time, and the remaining number of units are displayed as daily data on all actual operation days. The days when overtime work is performed are set sequentially from the back of the working day.

In step S90, if there is an instruction to end the process, the process is ended, and if not, the process returns to step S83.

As a result, the load of each line is calculated, and the load information is totaled.

Next, a description will be given of the insertion simulation.

FIG. 24 shows an example of the embodiment.

In step S101, a menu is set for the offer.

In step S102, the simulation section 20 reads the second index data including the line facility capacity information.

In step S103, the daily line production plan information for each line inputted from the Web terminal 80b arranged for the person in charge of drafting the replacement plan is read.

In step S104, the standard capacity of each line is compared with the daily production plan information based on the current strength or the strength when the level is increased.

In step S105, daily work load information is presented.

In step S106, it is determined whether or not there is an instruction of OK from the person in charge of drafting the replacement plan.
Proceeds to step S108. If there is no OK instruction, the process proceeds to step S107.

At step S107, the person in charge of drafting the replacement plan changes the daily line production plan information for each line. Then, the process returns to step S103.

In step S108, if there is an instruction to end the process, the process is ended. If not, the process returns to step S103.

As a result, an optimal replacement plan is derived from the load balance of each line based on the daily work load information.

[0147]

According to the present invention, the following effects can be expected.

The replacement simulation system generates information for preparing a replacement plan based on the information on the production plan and the information on the capacity of the production line, and distributes the generated information to a terminal connected to the information communication network. It is possible to plan an optimal offer in real time from any place. Further, when arranging the lines of the workers, it is possible to determine the optimum order of the workers to be input based on the skill information of each worker. Further, when drafting a replacement plan, the current problem can be clarified by analyzing the capacity of the line based on information on the capacity of the production line. Also, when preparing the replacement plan, from the production plan data of the line and information on the capacity of the production line, from a long-term perspective, the load plan for all future production days on the line to be input based on the current strength Information can be automatically calculated and provided.

Further, when making a replacement plan, it is possible to provide information in consideration of the worker's going-in / out schedule, the work skill of each worker based on the work history of each worker, and the line facility capacity.

Further, when it is not possible to assign a highly skilled worker to each process by the force analysis means, it is possible to specify a worker who can be upgraded with a minimum amount of education, and to improve the rank of the worker. Can be determined based on the premise of the input.

Further, the force analysis means can provide information for determining an optimal input line when making a replacement plan.

Further, when the load calculation means calculates the load plans for all the actual working days in the line to be put in, information for comparing the load plan at the present strength with the load plan at the time of level up is provided. Can be.

Further, in the setting simulation system, the setting means can formulate a long-term setting plan based on the load plans of all the actual working days in the line to be inserted.

Further, the simulation means can provide information for making an optimal replacement plan while simulating the replacement of each line based on the current strength or the strength when the level is increased.

Further, in the control method of the compensation simulation system, when drafting a compensation plan, the optimum order of the workers to be input is determined based on the skill information of each worker, and the information on the production line capacity is determined. Analyze the capacity of the line based on this to clarify the current problems, calculate the load plan for all future working days of the line to be put in from a long-term perspective, and make a replacement plan By distributing such information to terminals connected to the information communication network, it is possible to draft an optimal placement plan in real time from any location.

Further, a program for realizing the control of the insertion simulation system can cause the insertion simulation system to execute a procedure for drafting an optimum installation plan in real time from an arbitrary place.

[Brief description of the drawings]

FIG. 1 is a configuration diagram of the present invention.

FIG. 2 is a configuration diagram of an embodiment of the present invention.

FIG. 3 is a diagram of an embodiment of the present invention.

FIG. 4 is a diagram of an embodiment of the present invention.

FIG. 5 is a diagram of an embodiment of the present invention.

FIG. 6 is a diagram of an embodiment of the present invention.

FIG. 7 is a diagram of an embodiment of the present invention.

FIG. 8 is a diagram of an embodiment of the present invention.

FIG. 9 is a diagram of an embodiment of the present invention.

FIG. 10 is an explanatory diagram of an embodiment of the present invention.

FIG. 11 is an explanatory diagram of an embodiment of the present invention.

FIG. 12 is an explanatory diagram of an embodiment of the present invention.

FIG. 13 is a diagram of an embodiment of the present invention.

FIG. 14 is a diagram of an embodiment of the present invention.

FIG. 15 is a diagram of an embodiment of the present invention.

FIG. 16 is a diagram of an embodiment of the present invention.

FIG. 17 is a diagram of an embodiment of the present invention.

FIG. 18 is a diagram of an embodiment of the present invention.

FIG. 19 is a diagram of an embodiment of the present invention.

FIG. 20 is a schematic flowchart of an embodiment of the present invention.

FIG. 21 is a flowchart of an embodiment of the present invention.

FIG. 22 is a flowchart of an embodiment of the present invention.

FIG. 23 is a flowchart of the embodiment of the present invention.

FIG. 24 is a flowchart of an embodiment of the present invention.

FIG. 25 is an explanatory diagram of a conventional technique.

FIG. 26 is a configuration diagram of a conventional technique.

FIG. 27 is a diagram showing daily production plan information.

FIG. 28 is a diagram showing line input number information.

FIG. 29 is a diagram showing line operation start time information.

[Explanation of symbols]

 1: Setting device 2: Simulation means 3: Strength analysis means 4: Load calculation means 5: Setting means 6: Storage means 7: Information communication network 8a, 8b, 8c: Terminal

Continued on the front page (72) Inventor Keiichi Komatsu 98 Uno-ki-nu, Unoki-cho, Kawakita-gun, Ishikawa Prefecture F-Terminal Co., Ltd. F-term (reference) 3C100 AA02 AA05 AA43 BB13 BB17 CC02

Claims (9)

[Claims] An information processing system for generating a replacement plan necessary for performing each standardized work process in a production line based on a production plan is generated and distributed to terminals connected to an information communication network. A storage means (6) for storing first index data comprising information relating to a production plan and second index data comprising information relating to the capacity of a production line; A simulation means (2) for deciding an optimal order for optimally arranging the workers to be input in the work process sequence based on at least the skill information of each worker included in the second index data; A force analysis means (3) for analyzing the performance of the line based on the second index data; Load calculation means (4) for calculating a load plan for all actual working days in a line to be input from the reference data. 2. The storage means (6), wherein the first index data includes daily production plan information, input number information, and line operation start time information; 2. The insertion simulation system according to claim 1, further comprising: information, work technology skill information of each worker based on a work history of each worker, and line facility capability information. 3. 3. The work force analyzing means (3) is a work requiring an immediate level-up when planning an optimal replacement based on work skill skill information of each worker included in the second index data. The replacement simulation system according to claim 1, wherein a user is specified. 4. The power analysis means (3) specifies an input line for making a replacement plan based on equipment capacity information of each line included in the second index data. Item 4. The replacement simulation system according to Item 1. 5. The load calculating means (4) is operated in a line which is supplied on the assumption that a worker who needs an urgent level increase specified by the force analyzing means (3) will level up. The replacement simulation system according to claim 1, wherein a load plan is calculated for all days. 6. A setting means (5) for setting a setting plan for each line on the basis of a load plan for all the actual working days for each input line calculated by the load calculating means (4). 6. The method according to claim 1, further comprising the steps of:
The replacement simulation system described in the section. 7. The simulation means (2) presents daily workload information for a standard capacity of a line based on the daily line production plan information for each line prepared by the placing means (5). 7. The method according to claim 1, wherein:
The replacement simulation system described in the section. 8. Information for drafting a replacement plan necessary for performing each standardized work process in the production line based on the production plan is converted into information on the production plan and information on the capacity of the production line. A method of controlling an insertion simulation system that generates based on and distributes to a terminal connected to an information communication network, wherein at the time of arranging workers on a line, at least the skills of each worker included in information on the performance of the production line A first step of deciding an optimal order for optimally arranging workers to be input in a work process order based on the information; and analyzing a line capacity based on at least information on the capacity of the production line when drafting a replacement plan. The second process to be performed, and the actual operation date of the line to be input based on the production plan data of the line and information on the capacity of the production line. Third and a process control method of Sashitate simulation system and calculates the load plan Te. 9. Information for formulating a replacement plan necessary for performing each standardized work process in a production line based on a production plan is converted into information on the production plan and information on the capacity of the production line. A program that realizes the control of an insertion simulation system that is generated based on and distributed to terminals connected to an information communication network. A first step of deciding the optimal order for optimally arranging the workers to be input in the order of the work process based on the skill information of each worker, including: The second step of analyzing the capacity of the production line, from the production planning data of the production line and the information on the production line capacity And a third step of calculating the load plans of all the actual working days in the line to be input.