JP2003044115A - Method and device for designing manufacture line, and process designing method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To design a manufacture line with high productivity in a short period by uniting the information that respective processes o the manufacture line handle. SOLUTION: Information is transferred among process design, layout design, and production capacity design through a product and manufacture database 7 to generate a process flow according to the shape and component constitution information of a product. Manufacture resources are laid out according to the process flow, manufacture resource information consisting of at least facilities and workers for manufacturing the product and specific restricting conditions for manufacturing the product. A manufacture line virtual model is generated according to the layout design result and the manufacture resource information, and the movement of the manufacture line is reproduced by using the manufacture line virtual model to find the production capacity of the manufacture line.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a manufacturing line designing method for designing a manufacturing line by allocating equipment or workers for manufacturing products, an apparatus therefor, and a process designing method.

[0002]

2. Description of the Related Art In the process of designing a manufacturing line, first, a process flow is decided while making a prototype of a product based on a design drawing of the product, and then manufacturing resources for realizing this process, such as equipment and workers. , Allocation of jigs and tools, transportation means, etc. and calculation of required amount, then allocation of manufacturing resources,
Next, the procedure for evaluating the production capacity of the manufacturing process is performed.

[0003]

However, in the above-mentioned manufacturing line design, each process is designed by being distributed to each expert in each department, and each information handled in each process is different from each other. Has become.

From the above, the above process is determined by the know-how of each expert in each department and the information possessed by each individual of these experts, so that there is a discrepancy between the information handled by each process. Occurs.

For this reason, the process is backtracked, which causes the design period to be lengthened. Moreover, the designed manufacturing line specifications do not always maximize the capacity of the manufacturing resources. After installing the manufacturing line designed from such a thing, much effort is spent on the activity for improving this manufacturing line.

Therefore, the present invention provides a manufacturing line designing method, an apparatus and a process designing method which can design a manufacturing line having high productivity in a short period of time by unifying information handled between the processes of the manufacturing line. To aim.

[0007]

A first aspect of the present invention is a process design process for creating a process flow for manufacturing the product based on the shape of the product and the component configuration information of the product,
An allocation step of allocating manufacturing resource information consisting of equipment, workers, etc. for manufacturing the product to each step of the process flow, and a manufacturing line virtual model created by going through the process design step and the allocation step Is used to simulate the movement of the manufacturing line, and the manufacturing line is evaluated to evaluate the manufacturing line.

A second aspect of the present invention is a process design process for creating a process flow for manufacturing the product based on the shape of the product and the component configuration information of the product, and the product for each process of the process flow. An allocation step of allocating information on manufacturing resources including facilities for manufacturing, workers, etc., a layout design step of arranging the manufacturing resources in a layout based on a predetermined condition, the process design step, the allocation step and the layout design The manufacturing line design method is characterized by further comprising an evaluation step of simulating the movement of the manufacturing line using a virtual model of the manufacturing line created by going through the steps, and evaluating the manufacturing line.

A third aspect of the present invention is a process designing method for creating a process flow for manufacturing a product based on component configuration information of a product, in which a parent-child relationship of assembling each component forming the component configuration information is set. Based on this, the process designing method is characterized in that the order is determined so that the child parts are assembled into the parent parts.

According to a fourth aspect of the present invention, in the process designing method according to the third aspect of the present invention, the assembling man-hour is calculated by evaluating the assembling ability from the shape and the assembling direction of the parts based on the parent-child relationship of the assembling. Is characterized by.

A fifth aspect of the present invention is the method for designing a manufacturing line according to the first or second aspect of the present invention, in which a processed portion is recognized from the shape of the product, and an estimation criterion for estimating the processing man-hour is searched for and processed. It is characterized by calculating the man-hours.

According to a sixth aspect of the present invention, in the manufacturing line designing method according to the first or second aspect of the present invention, the required amount of manufacturing resources is calculated from the number of products produced for each product and the number of assembling / processing steps of the manufacturing resources. Is characterized by.

A seventh aspect of the present invention is the production line designing method according to the first or second aspect of the present invention, in which the production resource required amount calculated from the number of productions of each product and the number of assembling / processing steps of the production resource is The manufacturing cost per product is calculated from the material cost of the parts configuration and the labor cost.

An eighth aspect of the present invention is the manufacturing line designing method according to the second aspect of the present invention, wherein the layout designing step comprises:
A product / quantity analysis step of determining the relationship between the number of products for the product and the cumulative number and determining the product occupying a predetermined ratio as the product for layout, and the process of the product determined in this step. A flow analysis process for calculating the transport distance and the number of transports between processes based on the flow and the quantity of the product, and a correlation between the processes are analyzed by weighting the proximity relation of the distance between the processes of the product manufacturing. The relative positional relationship of each step of the product manufacturing is laid out based on the area correlation step, the transportation distance and the number of times of transportation calculated by the flow analysis step, and the weighting analyzed by the area correlation step. A layout creating step, and using the layout created by the layout creating step, carrying out the process based on the process flow and the quantity of the products. And having a flow line analysis step of representing the path by the flow line.

A ninth aspect of the present invention is the production line designing method according to the first or second aspect of the present invention, wherein the evaluation step reproduces the movement of the production line using the virtual production line model to achieve at least throughput. , Lead time, work-in-progress, operating rate.

According to a tenth aspect of the present invention, a process design process for creating a process flow for manufacturing the product based on the shape of the product and the component configuration information of the product, and at least the process flow information and each process. The process design information consisting of list information of manufacturing resources consisting of assignable devices and workers and list information of workers assignable to each manufacturing resource, and at least product name, start date, delivery date While inputting the production information, the manufacturing resource information and the respective allocation algorithms of the workers are designated, and the movement of the manufacturing line is simulated using the manufacturing line virtual model generated based on the production information and the algorithm. And an evaluation step of evaluating the production line.

An eleventh aspect of the present invention is a process design means for creating a process flow for manufacturing the product based on the shape of the product and the component configuration information of the product, and the product for each process of the process flow. The movement of the manufacturing line is simulated by using the allocating means for allocating the manufacturing resource information including the facilities for manufacturing, workers, etc., and the manufacturing line virtual model created by the process designing means and the allocating means, A manufacturing line designing device, comprising: an evaluation unit for evaluating a line.

A twelfth aspect of the present invention is a process design means for creating a process flow for manufacturing the product based on the shape of the product and the component configuration information of the product, and the product for each process of the process flow. Allocation means for allocating information on manufacturing resources, such as equipment for manufacturing, workers, etc., layout design means for arranging the manufacturing resources in a layout based on predetermined conditions, the process design means, the allocation means and the layout design means. A manufacturing line design apparatus, comprising: an evaluation means for simulating the movement of the manufacturing line by using a virtual model of the manufacturing line created by

A thirteenth aspect of the present invention is to provide a process design means for creating a process flow for manufacturing the product based on the shape of the product and the component configuration information of the product, and at least the process flow information and each process. The process design information consisting of list information of manufacturing resources consisting of assignable devices and workers and list information of workers assignable to each manufacturing resource, and at least product name, start date, delivery date While inputting the production information, the manufacturing resource information and the respective allocation algorithms of the workers are designated, and the movement of the manufacturing line is simulated using the manufacturing line virtual model generated based on the production information and the algorithm. In addition, the manufacturing line designing apparatus is provided with an evaluation means for evaluating the manufacturing line.

A fourteenth aspect of the present invention is a production line designing apparatus having a database for storing various information used when designing a production line for a product, wherein at least the shape of the product and the product stored in the database are provided. Process design means for creating a process flow based on the component configuration information of the product and storing the process flow in the database, the process flow stored in the database, and at least equipment and work for manufacturing the product. A layout design means for arranging the layout of the manufacturing resources based on the manufacturing resource information of a person and a constraint condition of a place where the product is manufactured, and storing the layout design result in the database; Based on the design result and the manufacturing resource information, the manufacturing line virtual model is Generates, it reproduces the movement of the production line with the production line virtual model, a manufacturing line design device being characterized in that; and a production capacity design means for obtaining a capacity of the production line.

The fifteenth aspect of the present invention is the production line designing apparatus of the fourteenth aspect of the present invention, wherein the process design means becomes a child based on a parent-child relationship of assembling each part forming the part configuration information. It is characterized by having a function of automatically generating the process flow by deciding the process order of assembling the parts into the parent parts and the work contents of each process.

The sixteenth aspect of the present invention is, in the manufacturing line designing apparatus of the fourteenth aspect of the present invention, based on a parent-child relationship of assembling of each component forming the component configuration information, from the shape and the assembling direction of the component, the assembling property is obtained. And an assembly man-hour estimating means for calculating the assembly man-hour.

In a seventeenth aspect of the present invention, in the manufacturing line designing apparatus of the fourteenth aspect of the present invention, a machining portion is recognized from the shape of the product, an estimation criterion for estimating the machining man-hour is retrieved, and the machining man-hour is calculated. It is characterized in that it is provided with a processing man-hour estimation means for performing.

The eighteenth aspect of the present invention is, in the production line designing apparatus of the fourteenth aspect of the present invention, a resource requirement calculation for calculating a resource requirement from the number of products produced and the number of assembly / processing steps of the resource. It is characterized by having means.

The nineteenth aspect of the present invention is, in the production line designing apparatus of the fourteenth aspect of the present invention, the required amount of manufacturing resources calculated from the number of productions of each product and the number of assembling / processing steps of the manufacturing resources, and the parts. It is characterized in that a manufacturing cost calculating means for calculating the manufacturing cost per product is provided from the material cost of the constitution and the labor cost.

The twentieth aspect of the present invention is the manufacturing line design apparatus according to the fourteenth aspect of the present invention, wherein the layout design means obtains the relationship between the number of products and the cumulative number of products,
Based on this relationship, the product / number analysis means for determining the product occupying a predetermined ratio as the layout product, and the process flow of the product and the quantity of the product determined by the product / number analysis means. Flow analysis means for calculating the transportation distance between the steps and the number of times of transportation, area correlation means for analyzing the correlation between the steps by weighting the proximity relationship of the distance between the steps of the product manufacturing, and the flow analysis means. A layout creating means for laying out the relative positional relationship of each step of the product manufacturing based on the carrying distance and the number of carrying times calculated by the above, and the weighting analyzed by the area correlating means, and the layout creating means. A flow line segment that expresses a transport path by a flow line based on the process flow and the quantity of the product using the layout created by Characterized by comprising a means.

The twenty-first aspect of the present invention is the production line designing apparatus of the fourteenth aspect of the present invention, wherein the production capacity designing means includes at least the process flow, the assignment of the device to the process, and the operator of the device. Input means for inputting process design information defining allocation, production information defining at least product type, start date, number of lots, delivery date, selecting means for selecting an algorithm suitable for work / allocation, and the input means It is characterized by further comprising: model generation means for generating the manufacturing line virtual model based on the input production information and the algorithm selected by the selection means.

A twenty-second aspect of the present invention is the production line designing apparatus of the fourteenth aspect of the present invention, wherein the production capacity designing means reproduces the movement of the production line by using the production line virtual model, thereby achieving at least throughput. It is characterized by having a function to obtain lead time, work in progress, and operating rate.

A twenty-third aspect of the present invention is a manufacturing line designing apparatus having a database for storing various information used when designing a manufacturing line for a product, wherein at least the shape of the product and the product stored in the database are stored. Based on the parent-child relationship of the assembly of each component forming the component configuration information, the process sequence of assembling from the child component to the parent component is determined and the work content of each process is automatically generated. Then, the process design means for storing the process flow in the database, the process flow stored in the database, the manufacturing resource information including at least equipment and workers for manufacturing the product, and the product. The manufacturing resources are laid out based on the constraints of the manufacturing place, and the layout design result is set to the data. A layout design means stored in the database, a production line virtual model is generated based on the design result and the production resource information stored in the database, and the movement of the production line is reproduced using the production line virtual model. The production capacity of the manufacturing line is at least the throughput, the lead time,
Assembly for calculating the assembly man-hours by evaluating the assembly ability from the shape and assembly direction of the parts based on the parent-child relationship of assembly of each part forming the part configuration information and the production capacity designing means for obtaining work-in-progress and operating rate. A man-hour estimating means, a processing man-hour estimating means for recognizing a processing part from the shape of the product, searching for an estimation standard for estimating the processing man-hour, and calculating a processing man-hour, a manufacturing number of each product and the manufacturing resource Resource requirement calculation means for calculating manufacturing resource requirement from assembly / processing man-hour, manufacturing resource requirement calculated from production number of each product and assembly / processing man-hour of the manufacturing resource, and material cost of the component structure And a manufacturing cost calculating means for calculating the manufacturing cost per product from the labor cost, and the layout design means obtains the relationship between the number of products for the product and the cumulative number, Products for determining the product from the relationship a predetermined ratio as the product for performing layout
A quantity analysis means, a flow analysis means for calculating a transportation distance and a number of times of transportation between steps based on the process flow of the product and the number of the products determined by the product / quantity analysis means, and Area correlation means for analyzing the correlation between the steps by weighting the proximity relation of the distances between the steps, the transport distance and the number of transports calculated by the flow analysis means, and analyzed by the area correlation means Based on the process flow and the quantity of the product using a layout creating means for laying out the relative positional relationship of each step of the product manufacturing based on weighting, and the layout created by the layout creating means. A flow line analysis unit that expresses a transport path by a flow line, and the production capacity designing unit includes at least the process flow and an apparatus for the process. Allocation, a process design information defining the allocation of personnel to the apparatus, at least breed,
Input means for inputting production information defining start date, number of lots, delivery date, selecting means for selecting an algorithm suitable for work / assignment, and production information input by the input means and selection by the selecting means And a model generation means for generating the manufacturing line virtual model based on the generated algorithm.

[0030]

BEST MODE FOR CARRYING OUT THE INVENTION An embodiment of the present invention will be described below with reference to the drawings.

FIG. 1 is a block diagram of a manufacturing line designing apparatus. A keyboard 3 and a mouse 4 are connected via an input unit 2 to a main control unit 1 including a CPU (central processing unit), and a display 6 composed of a CRT (cathode ray tube) or liquid crystal via an output unit 5. Are connected.

A database (hereinafter referred to as a product / manufacturing database) 7 for unifying and storing information and a program memory 8 are connected to the main control unit 1. Of these, the product / manufacturing database 7 includes a parts database area 7a for storing the shape of the product when designing the manufacturing line, the parts configuration information of the product, and the like.
A process database area 7b for storing process flow information and the like, a resource database area 7c for storing manufacturing resource information including at least equipment and workers for manufacturing products, and layout layout of the manufacturing resources. An arrangement database area 7d for storing the layout information etc. is formed.

The main controller 1 has the following functions by executing the manufacturing line design program stored in the program memory 8.

The process design means 10 receives the operation input from the keyboard 3 or the mouse 4 by the operator, and reads out the shape of the product and the part configuration information of the product stored in the part database area 7a of the product / manufacturing database 7. Is displayed on the display 6 to create a process flow in accordance with the operator's operation input based on the product shape and product part configuration information, and has the function of storing this process flow in the process database area 7b of the product / manufacturing database 7. is doing.

The process designing means 10 also reads the shape of the product and the component configuration information of the product stored in the component database area 7a of the product / manufacturing database 7.
It has a function to automatically generate a process flow by deciding the process sequence of assembling from child parts to parent parts and the work content of each process based on the parent-child relationship of the assembly of each part forming the part configuration information. ing.

That is, in the part database area 7a of the product / manufacturing database 7, the product shape Q ₁ and the part shape Q ₂ as shown in FIG. 2 are stored. Part shape Q
Reference numeral ₂ is a component of the product and is composed of, for example, parts a to h.

These parts a to h have a parent-child relationship to form the product shape Q ₁ . For example, each part d, e, f is attached to the part a, and each part g, e is attached to the part b.
h is attached. Here, the part a is each part d,
It becomes a parent of e and f, and on the contrary, each of the parts d, e and f becomes a child of the part a. In this way, the components a to h have a hierarchical structure.

Therefore, it is possible to determine the order of steps for assembling the child parts into the parent parts based on the parent-child relationship of assembling each of the parts a to h, and to determine the work contents of these steps, for example, assembling or processing.

The process flow F is determined in this way.
The process order, equipment, operator, assembly or processing time, etc. are assigned to the respective processes "1" to "6" of the process flow F.

The layout design means 11 receives an operation input from the keyboard 3 or the mouse 4 by the operator, and stores it in the process flow F stored in the process database area 7b of the product / manufacturing database 7 and the resource database area 7c. The manufacturing resource information consisting of at least the equipment and the worker for manufacturing the existing product, and receiving the operation input of the operator under the constraint condition of the place (space) for manufacturing the product, according to the process flow F. It has a function of laying out manufacturing resource information such as equipment and workers in a space and storing the layout design result in the layout database area 7d of the product / manufacturing database 7.

FIG. 3 shows an example of the result of layout arrangement of manufacturing resource information. Here, a plurality of equipments A _{1 to} A ₁ are installed.
₁₆ are arranged.

Further, the layout design means 11 needs to handle not only the time axis but also the space axis and the proximity as an evaluation index in order to optimize the layout. For this reason, the layout design means 11 has the following functions.

Product / quantity analysis (product PQ analysis) means 12
Has a function of obtaining the relationship between the number of products and the cumulative number of products, and determining the product occupying a predetermined ratio as the product to be laid out from this relationship.

That is, if the layout arrangement is decided for all products, there is a high possibility that the solution cannot be found. Therefore, the target products are narrowed down by the following procedure.

First, as shown in FIG. 4, the product P (Pr
oduction) and the vertical axis represents the number of vehicles Q (Quantity). The left vertical axis shows the number of vehicles, and the left vertical axis shows the cumulative number of vehicles.

Next, the target products are arranged on the horizontal axis in descending order of the number of units, and the number of units is represented by a bar graph and the cumulative number of units is represented by a broken line.

Next, for example, a product whose cumulative number of vehicles is 0 to 70% is A rank, a number of vehicles showing 70 to 90% is B rank, and a product of which 90 to 100% is C rank.

A product of rank A among ranks A, B and C is a target product for layout arrangement.
As a result, in the case shown in FIG. 4, only 20% of all products need to be targeted.

The flow analysis unit 13 has a function of calculating the transport distance between processes and the number of transports based on the process flow F and the number of products for the products determined by the product / number analysis unit 12.

That is, paying attention to the layout layout problem only in the transportation time, the transportation distance and the number of transportations between each process are calculated from the process flow F and the number of products for the products narrowed down by the product / number analysis means 12. In Figure 5, the vertical axis is Fro
The process of “To” is matrixed on m and the horizontal axis, and shown in FIG.
As shown in the enlarged view of the -To chart, the transport distance is indicated from the inter-process position information, and the number of times of conveyance is indicated from the product quantity.

The area correlating means 14 has a function of analyzing the correlation between the processes by weighting the proximity relation of the distance between the respective processes of the product manufacturing.

That is, the problem of the layout arrangement cannot be evaluated only by the transportation time. In addition to the position information, the proximity of each facility is determined by the cleanliness, atmosphere, noise, etc. FIG. 7 analyzes the correlation between processes by weighting the proximity relationship between processes by, for example, distance close and distance.

The layout creating means 15 lays out the relative positional relationship of each step of product manufacturing based on the carrying distance and the number of carrying times calculated by the flow analyzing means 13 and the weighting analyzed by the area correlating means 14. It has a function to do.

That is, the relative positional relationship between the processes is represented by the diagram shown in FIG. 8 based on the transport distance and the transport frequency by the flow analysis of the flow analysis means 13 and the weighting by the area correlation means 14.

In the figure, the process B written near the process G,
It is shown that arranging the three processes of D and H is the optimum arrangement. 2 specified based on this relative positional relationship
The equipment shape corresponding to the process is arranged in the dimensional space, and the layout arrangement is determined.

The flow line analyzing means 16 uses the layout created by the layout creating means 15 in the process flow F.
Based on the number of products and the quantity of products, it has a function of expressing a transport route by a flow line as shown in FIG. The thicker the flow line, the higher the transportation frequency. As a result, it is possible to visually confirm the movement of the object and the transport state on the layout.

The production capacity designing means 17 generates a manufacturing line virtual model based on the design result and manufacturing resource information stored in the product / manufacturing database 7, and uses this manufacturing line virtual model to move the manufacturing line. Reproduce, that is, manufacturing resources (equipment, workers, jigs, transportation means, etc.)
As shown in FIG. 10, at least throughput, lead time, work in progress, operation rate, Gantt chart, cumulative number of completed arrivals, flow line analysis, bottleneck analysis, etc. It has the function of seeking the production capacity of.

This production capacity designing means 17 has respective functions of an inputting means 18, a selecting means 19 and a model generating means 20 for automatically generating a production line virtual model (simulation model).

As shown in FIG. 11, the input means 18 includes a process flow F defining a process sequence, processes and man-hours for each product name,
Ability to assign manufacturing resources by assigning equipment (devices) to processes Table 2
1 and process information D1 including a worker assignable table 22 that defines the assignment of workers to equipment (device), and production instruction information D2 that defines at least product type, start date, lot size, lot number, and delivery date. It has a function to input and.

The selection means 19 has a plurality of allocation algorithms (a plurality of rules) registered in advance as a library.
It has a function of selecting an allocation algorithm suitable for work / allocation among M.

Here, the assignment algorithm M is a worker assignment algorithm when a plurality of workers can be assigned, for example, a rule giving priority to a vacant worker and a rule giving priority to a worker with a low operating rate. The macro is registered in the library in advance.

Further, as an execution algorithm, when it can be assigned to a plurality of equipments, for example, there is a rule of selecting equipments in the order of vacant equipments, a rule of ordering equipments with a lower operation rate, and a plurality of work lots. In this case, for example, a macro for a rule for selecting a work in the order of first-in first-out (FIFO) and a macro for a rule for selecting a work with priority on delivery date are registered in the library in advance.

The model generation means 20 has a function of automatically generating a virtual model (simulation model) based on the production instruction information D2 input by the input means 18 and the allocation algorithm selected by the selection means 19. .

That is, the model generating means 20 automatically generates a process model D1, production instruction information D2, and a line model according to the definitions of a plurality of allocation algorithms M and outputs a production line virtual model (execution line model). To do.

FIG. 12 is a schematic diagram showing an example of a virtual model of a production line. The installation order of a plurality of equipments (devices) M _{1 to} M ₁₄ and the product flow are indicated by arrows (→).
This production line virtual model is, for example, an order table,
It is a macro program for controlling the process flow table, manufacturing resource allocation, and flow.

As shown in FIG. 13, the assembly man-hour estimating means 23 determines that the assembly work will be performed at the node where the child parts are aggregated based on the parent-child relationship of the assembly of each part forming the part configuration information. It has a function of scoring the ease of assembling from the shape and the assembling direction, and evaluating the assembling ability based on the difficulty level to calculate the assembling man-hours.

The processing man-hour estimating means 24 judges that the child component itself in the component structure is not an assembly but a processing, that is, cutting, sheet metal, molding, etc., recognizes the processed portion from the shape of the product, and estimates the processing man-hour. It has the function of searching the estimation standard and calculating the processing man-hours.

FIG. 14 is a diagram showing the estimation of processing man-hours.
This processing man-hour estimation employs the following four general-purpose man-hour estimating methods that have characteristics.

The first is to obtain an estimation element. For example, from three-dimensional CAD (Computer Aided Design), an estimation element such as processing information and attribute information necessary for estimation and part configuration information are obtained. To do.

Secondly, in the man-hour estimation, based on the acquired information, affirmative setting → man-hour estimation → cost calculation is performed by searching the estimation reference database.

Thirdly, in the cost analysis, the calculated cost and man-hours are visualized and expressed as the cost by drawing number or the man-hour by process to analyze the sensitivity to the cost and reduce the cost to the designer. Point out the point of view.

Fourthly, in the source generator, there are a process setting standard, a quotation element, a basic unit table, a quotation calculation formula, a constant table, etc. as a quotation standard, but these need to be reviewed when the processing method or equipment changes. . Therefore, we have these as an external database and have a method to automatically generate a source program for estimation based on this.

As shown in FIG. 15, the resource requirement amount calculating means 25 has a function of calculating the production resource requirement amount by calculating the following equation from the number of products produced for each product and the number of manufacturing resource assembling / processing steps. . That is, the required amount of manufacturing resources = the number of productions / the number of man-hours (pieces / unit) (1) The manufacturing cost calculating means 26 is calculated from the number of productions of each product and the number of assembling / processing of manufacturing resources as shown in FIG. It has a function of calculating the manufacturing cost per product by calculating the following formula from the required amount of manufacturing resources, the material cost of the parts composition, and the labor cost.

Manufacturing cost = material cost + (equipment number × equipment cost + labor cost × labor cost) ÷ production quantity (2) The manufacturing cost calculated here and the sensitivity to the design parameter can be analyzed, and the design specifications can be calculated. The food back can be realized, which can contribute to the cost reduction of the product.

The manufacturing resource allocating means 27, for the process flow F for each product shown in FIG.
"6" has a function of allocating manufacturing resources such as equipment, workers, jigs and tools. In this case, workers are assigned to the assembly and facilities are assigned to the processing.

The manufacturing resource arranging means 28 arranges the facilities, workers, jigs and tools, which are the manufacturing resources, in a two-dimensional space based on the constraint conditions in the building, such as columns, aisles, and crane positions. It has a function to do. In this case, the shape of the manufacturing resource is made into a library in advance.

With such a configuration, in the product / manufacturing database 7, as shown in FIG. 16, the product shape Q ₁ and its part shape Q ₂ , these parts a to h, and these parts a are stored in the parts database area 7a. The hierarchical structure indicating the parent-child relationship of ~ h is stored.

In the process database area 7b, each part a is
Process flow F consisting of a process sequence determined based on the parent-child relationship of assembling, assembly or processing that is the work content of these processes, the order assigned to these processes, equipment, workers, assembly or processing time, etc. Is memorized.

The resource database area 7c stores manufacturing resource information including at least equipment and workers for manufacturing products. Further, in the resource database area 7c, the order S, for example, the production plan, the starting order, the lot size, etc. are stored in a linked structure with respect to the product having the component structure.

The layout result obtained by the layout creating means 15 is stored in the layout database area 7d.

Next, the operation of the apparatus configured as described above will be described.

First, a case where a manufacturing line is designed by an operator's operation will be described.

In response to an operation input from the keyboard 3 or the mouse 4 by the operator, the process design means 10 reads out the shape of the product and the component configuration information of the product stored in the component database area 7a of the product / manufacturing database 7. Is displayed on the display 6 and the process flow F shown in FIG. 2 is created according to the operation input of the operator based on the shape of the product and the component configuration information of the product.

At this time, for example, each part a constituting the product
The symbols h to h have a hierarchical structure by establishing a parent-child relationship with each other. Therefore, the operator can determine the order of steps for assembling the child parts to the parent parts based on the parent-child relationship of assembling each of the parts a to h, and the work contents of these steps, for example, assembling or processing. .

However, the operator creates the process flow F by operating and inputting the order of these assembling steps and the work contents in each step, for example, assembling or processing from the keyboard 3 or the mouse 4.

This process flow F is stored in the process database area 7b of the product / manufacturing database 7 according to an operator's instruction.

Next, in response to an operation input from the keyboard 3 or the mouse 4 by the operator, the layout design means 11 causes the process flow F stored in the process database area 7b of the product / manufacturing database 7 and the resource database area. The manufacturing resource information including at least equipment and workers for manufacturing the product stored in 7c is read out.

Next, in response to the operation input from the keyboard 3 or the mouse 4 by the operator, the layout design means 11 performs the equipment and work according to the process flow F under the constraint condition of the place (space) for manufacturing the product. manufacturing resource information such as who, for example, a plurality of equipment as shown in Figure 3 a ₁ ~
A ₁₆ is laid out in a space.

Next, in response to the operation input from the keyboard 3 or the mouse 4 by the operator, the layout design means 11 stores the layout design result in the layout database area 7d of the product / manufacturing database 7.

Next, the production capacity designing means 17 creates a manufacturing line virtual model as shown in FIG. 12 based on the layout design result and the manufacturing resource information stored in the arrangement database area 7d of the product / manufacturing database 7. To generate.

Next, the production capacity designing means 17 reproduces the movement of the manufacturing line by using the virtual model of the manufacturing line, that is, the movement of the manufacturing resources (equipment, workers, jigs and tools, transportation means, etc.) and the movement of the goods in time. Simulate while changing,
As shown in FIG. 10, at least the throughput, the lead time, the work in progress, the operating rate, the Gantt chart, the cumulative number of completed arrivals, the flow line analysis, the bottleneck analysis, and other production line production capacities are obtained.

If the production capacity of this production line is highly evaluated, the production line is determined. However, if the evaluation of the production capacity of the production line is lower than a predetermined evaluation value, the production line virtual model is created again by changing the equipment of the production line, the arrangement of workers, the capacity of the equipment, etc. To execute.

Next, a case of automatically designing a manufacturing line will be described.

The process design means 10 reads out the shape of the product and the component configuration information of the product stored in the component database area 7a of the product / manufacturing database 7, and establishes the parent-child relationship of the assembly of each component forming the component configuration information. Based on the process flow F shown in FIG. 2, the process order of assembling the child parts into the parent parts and the work content of each process are determined based on the above.
Is automatically generated. Each process “1” of this process flow F
The order of processes, equipment, workers, assembly or processing time, and the like are assigned to “6”.

Next, the layout design means 11 determines the product / product.
The process flow F stored in the process database area 7b of the manufacturing database 7 and the resource database area 7c
In accordance with the process flow F, under the constraint condition of the place (space) for manufacturing the product, the manufacturing resource information including at least the facility and the worker for manufacturing the product stored in The manufacturing resource information of 1 is laid out in a space, and the result of the layout arrangement in which the plurality of facilities A _{1 to} A ₁₆ are arranged as shown in FIG. 3 is obtained.

The layout design means 11 optimizes the layout according to the optimization flowchart shown in FIG.

The product / quantity analysis (product PQ analysis) means 12 of the layout design means 11 determines in step # 1.
The relationship between the number of products and the cumulative number of products is obtained, and products occupying a predetermined ratio are determined as products to be laid out from this relationship.

That is, first, as shown in FIG. 4, a graph in which the horizontal axis represents the product P (Production) and the vertical axis represents the number Q (Quantity) is created.

Next, the target products are arranged on the horizontal axis in descending order of the number of units, and the number of units is represented by a bar graph and the cumulative number of units is represented by a broken line.

Next, for example, a product whose cumulative number of vehicles is 0-70% is ranked A, a number of vehicles showing 70-90% is ranked B, and a product whose number is 90-100% is ranked C.

A product of rank A among ranks A, B and C is a target product for layout arrangement.

Next, the flow analysis means 13 determines in step # 2.
6, based on the process flow F and the number of products for the product determined by the product / number analysis means 12, as shown in the enlarged view of the From-To chart shown in FIG. Calculate the number of transfers from the quantity of products.

Next, the area correlating means 14 performs step #
In FIG. 3, the proximity relationship between processes is weighted by, for example, distance close or distance, as shown in FIG. 7, depending on the degree of cleanliness, atmosphere, noise, etc., and the correlation between processes is analyzed.

Next, the layout creating means 15 in step # 4, based on the carrying distance and the number of carrying times calculated by the flow analyzing means 13, and the weighting analyzed by the area correlating means 14, the diagram shown in FIG. As described above, the relative positional relationship of each process of product manufacturing is laid out.

Next, the flow line analyzing means 16 uses the layout created by the layout creating means 15 to express the transport route by a flow line as shown in FIG. 9 based on the process flow F and the number of products. . In this case, the thicker the flow line, the higher the frequency of transportation, and the movement of the object and the transportation state can be visually confirmed on the layout.

Next, the layout design means 11 evaluates the created layout in step # 5, and returns to step # 1 according to the evaluation result to decide again the product to be laid out, or step Returning to step # 4, the layout of the relative positional relationship of each process of product manufacturing is performed again.

If the created layout is evaluated well, the layout is selected.

Next, the input means 1 of the production capacity design means 17
As shown in FIG. 11, 8 is a process flow F in which a process sequence, a process, and a man-hour are defined for each product name, a manufacturing resource assignable table 21 in which facilities (devices) are allocated to processes, and a facility (device) Process information D1 including a worker assignable table 22 that defines worker assignments, and production instruction information D that defines at least product type, start date, lot size, lot number, and delivery date.
Enter 2 and.

Next, the selecting means 19 selects an allocation algorithm suitable for work / allocation from among a plurality of allocation algorithms (a plurality of rules) M registered in advance as a library.

Next, the model generating means 20 has the input means 1
A production line virtual model as shown in FIG. 12 is automatically generated on the basis of the production instruction information D2 input by 8 and the allocation algorithm selected by the selection means 19.

Then, the production capacity designing means 17 reproduces the movement of the manufacturing line using the generated virtual model of the manufacturing line, that is, the movement of the manufacturing resources (equipment, workers, jigs and tools, etc.) and the movement of the object in time. While changing, the simulation is performed to obtain at least the throughput, the lead time, the work in progress, the operating rate, the Gantt chart, the cumulative number of completed arrivals, the flow line analysis, the bottleneck analysis, and other production capacity of the manufacturing line.

On the other hand, the assembly man-hour estimating means 23 is shown in FIG.
Based on the parent-child relationship of the assembly of each part that forms the part configuration information as shown in Fig. 3, the ease of assembly is scored from the shape of the part and the assembly direction, assuming that the assembly work occurs at the node where the child parts are aggregated. Then, the assembling man-hour is calculated by evaluating the assembling property according to the degree of difficulty.

The processing man-hour estimating means 24 judges that the child component itself in the component structure is not an assembly but a processing, that is, cutting, sheet metal, molding, etc., recognizes a processed portion from the shape of the product, and estimates the processing man-hour. The estimation standard is searched and the processing man-hour is calculated.

As shown in FIG. 15, the resource requirement amount calculation means 25 calculates the above-mentioned formula (1) from the number of products produced for each product and the number of assembling / processing steps of the production resource to calculate the production resource requirement amount.

As shown in FIG. 15, the manufacturing cost calculating means 26 uses the manufacturing resource requirement amount calculated from the number of products produced for each product and the assembly / processing man-hours of manufacturing resources, the material cost of the component structure, and the personnel cost. The manufacturing cost per product is calculated by calculating the above formula (2).

The manufacturing resource allocating means 27, for the process flow F for each product shown in FIG.
The equipments, workers, jigs and tools, which are manufacturing resources, are assigned to “6”.

The manufacturing resource arranging means 28 arranges the equipments, workers, jigs and tools, which are the manufacturing resources, in a two-dimensional space based on the constraint conditions in the building, such as pillars, passages and crane positions. To do.

As described above, in the above-mentioned one embodiment,
Each piece of information is shared between the process design, the layout design, and the production capacity design through the product / manufacturing database 7, and these pieces of information are passed, and the process flow is based on at least the product shape and the product component configuration information. Create and layout the manufacturing resources based on this process flow, manufacturing resource information consisting of at least equipment and workers for manufacturing the product, and constraint conditions of the place where the product is manufactured. A production line virtual model is generated based on the production resource information, and the movement of the production line is reproduced by using this production line virtual model so that the production capacity of the production line is obtained.
Each piece of information handled in each step of layout design and production capacity design can be unified and stored in the product / manufacturing database 7, and there is no discrepancy between the pieces of information handled in each process.

This prevents the process from turning back,
The design period for a highly productive manufacturing line can be shortened. or,
The capacity of the manufacturing resource in the designed manufacturing line can be maximized, and the work for improving the manufacturing line after installing the designed manufacturing line can be reduced.

Further, the process design means 10 for automatically generating the process flow F, the layout design means 11, and the input means 18
A production line virtual model is automatically generated by the selection means 19 and the production capacity designing means 17 having the functions of the model generation means 20, and the movement of the production line is reproduced by using this production line virtual model, and the production line is reproduced. You can ask for production capacity.

In this case, the layout design means 11 is provided with the product / quantity analysis (product PQ analysis) means 12, the flow analysis means 13, the area correlation means 14, the layout creation means 15, and the flow line analysis means 16, Target products can be narrowed down to achieve layout optimization.

Further, in order to automatically design the production line, the assembly man-hour estimating means 23 scores the easiness of assembly from the shape and the assembly direction of the parts, and the assembly man-hour is evaluated by the difficulty level to evaluate the assembly man-hour. Can be calculated.

The processing man-hour estimating means 24 can retrieve the estimation standard for estimating the processing man-hour and calculate the processing man-hour.

The resource requirement calculation means 25 can calculate the manufacturing resource requirement quantity, and the manufacturing cost calculation means 26 can calculate the manufacturing cost per product.

The present invention is not limited to the above-mentioned one embodiment, and can be variously modified at the stage of implementation without departing from the spirit of the invention.

Furthermore, the above embodiments include inventions at various stages, and various inventions can be extracted by appropriately combining a plurality of disclosed constituent elements. For example, even if some constituent elements are deleted from all the constituent elements shown in the embodiment, the problem described in the section of the problem to be solved by the invention can be solved, and it is described in the section of the effect of the invention. When the effect of being obtained is obtained, a configuration in which this constituent element is deleted can be extracted as an invention.

[0127]

As described above in detail, according to the present invention, a manufacturing line designing method and an apparatus therefor capable of designing a highly productive manufacturing line in a short period of time by unifying information handled between the processes of the manufacturing line. Also, a process design method can be provided.

[Brief description of drawings]

FIG. 1 is a configuration diagram showing an embodiment of a production line design apparatus according to the present invention.

FIG. 2 is a diagram showing an operation of a process design means in one embodiment of the manufacturing line design apparatus according to the present invention.

FIG. 3 is a diagram showing a result of layout arrangement of manufacturing resource information in the embodiment of the manufacturing line designing apparatus according to the present invention.

FIG. 4 is a diagram showing a graph used by a product / quantity analysis (product PQ analysis) means in an embodiment of the production line design apparatus according to the present invention.

FIG. 5 is a From-To chart used by the flow analysis means in the embodiment of the manufacturing line designing apparatus according to the present invention.

FIG. 6 is an enlarged view of a From-To chart used by the flow analysis means in the embodiment of the manufacturing line designing apparatus according to the present invention.

FIG. 7 is a diagram showing the operation of the area correlation means in the embodiment of the manufacturing line design apparatus according to the present invention.

FIG. 8 is a diagram showing a relative positional relationship between processes by the layout creating means in the embodiment of the manufacturing line designing apparatus according to the present invention.

FIG. 9 is a diagram showing a flow line of a conveyance path by a flow line analysis means in an embodiment of the manufacturing line designing apparatus according to the present invention.

FIG. 10 is a diagram showing the evaluation output of the production capacity designing means in the embodiment of the manufacturing line designing apparatus according to the present invention.

FIG. 11 is a diagram showing generation of a production line virtual model by the production capacity designing means in the embodiment of the production line designing apparatus according to the present invention.

FIG. 12 is a schematic diagram showing an example of a production line virtual model in one embodiment of the production line design apparatus according to the present invention.

FIG. 13 is a diagram for explaining the operation of the assembly man-hour estimating means in the embodiment of the manufacturing line designing apparatus according to the present invention.

FIG. 14 is a diagram for explaining the operation of the processing man-hour estimating means in the embodiment of the manufacturing line designing apparatus according to the present invention.

FIG. 15 is a diagram showing the calculation result of the manufacturing cost calculation means in the embodiment of the manufacturing line designing apparatus according to the present invention.

FIG. 16 is a schematic diagram of a product / manufacturing database in an embodiment of the manufacturing line designing apparatus according to the present invention.

FIG. 17 is an optimization flowchart in one embodiment of the manufacturing line design apparatus according to the present invention.

[Explanation of symbols]

1: Main control unit 2: Input section 3: Keyboard 4: Mouse 5: Output section 6: Display 7: Product / manufacturing database 7a: Parts database area 7b: Process database area 7c: Resource database area 7d: placement database area 8: Program memory 10: Process design means 11: Layout design means 12: Product / unit analysis (product PQ analysis) means 13: Flow analysis means 14: Area correlation means 15: Layout creating means 16: Flow line analysis means 17: Production capacity design means 18: Input means 19: Selection means 20: Model generating means 21: Device allocation table 23: Assembly man-hour estimation means 24: Processing man-hour estimation means 25: Resource requirement calculation means 26: Manufacturing cost calculation means 27: Manufacturing resource allocation means 28: Manufacturing resource allocation means

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Claims (13)

[Claims] 1. A process designing process for creating a process flow for manufacturing the product based on the shape of the product and component configuration information of the product, and equipment for manufacturing the product in each process of the process flow. , An allocation step of allocating manufacturing resource information made up of workers, etc., and a movement of the manufacturing line is simulated using a manufacturing line virtual model created by going through the process design step and the allocation step, A manufacturing line design method, comprising: an evaluation step of performing evaluation. 2. A process design process for creating a process flow for manufacturing the product based on the shape of the product and component configuration information of the product, and equipment for manufacturing the product in each process of the process flow. , An allocation step of allocating information of manufacturing resources including workers, a layout designing step of laying out the manufacturing resources based on a predetermined condition, the process designing step, the allocating step and the layout designing step. Simulate the movement of the manufacturing line using the manufacturing line virtual model created by
A manufacturing line designing method, comprising: an evaluation step of evaluating the manufacturing line. 3. A process design method for creating a process flow for manufacturing the product based on component configuration information of a product, comprising: a child based on a parent-child relationship of assembly of each component forming the component configuration information. A process designing method, characterized in that the order is determined so that the parts are assembled into the parent parts. 4. The process designing method according to claim 3, wherein the assembling man-hour is calculated by evaluating the assembling property from the shape and the assembling direction of the parts based on the parent-child relationship of the assembling. 5. A processed portion is recognized from the shape of the product,
The manufacturing line designing method according to claim 1 or 2, wherein an estimation criterion for estimating the processing man-hour is searched and the processing man-hour is calculated. 6. The manufacturing line designing method according to claim 1, wherein the manufacturing resource requirement is calculated from the number of products produced for each product and the number of assembling / processing steps of the manufacturing resource. 7. The manufacturing cost per product is calculated from the manufacturing resource requirement calculated from the number of productions of each product and the assembly / processing man-hours of the manufacturing resource, the material cost of the component composition, and the labor cost. The manufacturing line designing method according to claim 1, wherein the manufacturing line designing method is a calculation. 8. A product / number analysis step of determining the relationship between the number of products for the product and the cumulative number of products, and determining the product occupying a predetermined ratio as the product to be laid out in the layout designing process, A flow analysis step of calculating the transport distance and the number of transports between steps based on the process flow of the product and the number of the products determined in this step, and the proximity relationship of the distance between the steps of manufacturing the product. Area correlation step of analyzing the correlation between the steps by weighting, the transportation distance and the number of times of transportation calculated by the flow analysis step, of the product manufacturing based on the weight analyzed by the area correlation step A layout creating process for laying out the relative positional relationship of each process and the layout created by the layout creating process Production line design method according to claim 2, characterized in that it comprises a flow-line analysis step of the conveying path is represented by a flow line based on the process flow and the quantity of the product, the. 9. The evaluation step obtains at least the throughput, the lead time, the work in progress, and the operation rate by reproducing the movement of the production line using the production line virtual model. The manufacturing line design method described. 10. A process design process for creating a process flow for manufacturing the product based on a product shape and component configuration information of the product, and at least the process flow information, and an apparatus assignable to each process. Process design information consisting of list information of manufacturing resources consisting of workers and workers, and list information of workers who can be assigned to each manufacturing resource, and at least product name, start date, production information instructing delivery date At the same time, the manufacturing resource information and each allocation algorithm of the worker are specified, and the movement of the manufacturing line is simulated by using the manufacturing line virtual model generated based on the production information and the algorithm. A manufacturing line design method, comprising: 11. A process design means for creating a process flow for manufacturing the product based on the shape of the product and component configuration information of the product, and equipment for manufacturing the product in each process of the process flow. , Allocating means for allocating manufacturing resource information including workers and the like, and simulating movements of the manufacturing line using the manufacturing line virtual model created by the process designing means and the allocating means, and evaluating the manufacturing line. A manufacturing line design apparatus comprising: an evaluation unit. 12. A process design means for creating a process flow for manufacturing the product based on the shape of the product and component configuration information of the product, and equipment for manufacturing the product in each process of the process flow. Created by the allocating means for allocating information on manufacturing resources, such as workers, a layout designing means for laying out the manufacturing resources based on a predetermined condition, the process designing means, the allocating means and the layout designing means. A manufacturing line design apparatus, comprising: an evaluation unit that simulates the movement of the manufacturing line using a virtual model of the manufacturing line and evaluates the manufacturing line. 13. A process design means for creating a process flow for manufacturing the product based on the shape of the product and the component configuration information of the product, and at least the process flow information, and an apparatus assignable to each process. Process design information consisting of list information of manufacturing resources consisting of workers and workers, and list information of workers who can be assigned to each manufacturing resource, and at least product name, start date, production information instructing delivery date At the same time, the manufacturing resource information and each allocation algorithm of the worker are specified, and the movement of the manufacturing line is simulated by using the manufacturing line virtual model generated based on the production information and the algorithm. A manufacturing line design apparatus, comprising: an evaluation unit that evaluates.