JP2003058228A - Product progress management method and device - Google Patents

Abstract

PROBLEM TO BE SOLVED: To shorten manufacture lead time and to manufacture production objects matched with delivery time. SOLUTION: At the time of manufacturing the production objects along the flow of a plurality of processes indicated in (a), in order to manufacture them in a just-in-time manner so as to be just in time for the delivery time, not only feed time is controlled but also a delivery margin after feed is controlled. When only the feed time is controlled, as indicated in (b), feed is performed with a time margin so as not to generate objects which do not make the delivery time and stock in process equivalent to the time margin is generated when production is smoothly completed. As indicated in (c), when progress management based on a delivery margin is performed among the respective processes, the manufacture lead time is shortened while keeping an appropriate delivery margin.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention is intended for overall production progress management in a production factory in which production input control is performed based on a "kanban delivery system contract" or the like according to a production instruction that does not depend on a production schedule. The present invention relates to a production progress management method and device.

[0002]

2. Description of the Related Art Conventionally, in order to realize the concept of Just In Time, a production management method called "Kanban system""produces what is needed, when it is needed and in the required amount". It has been installed in various production plants. The prior art relating to the signboard system is disclosed in, for example, Japanese Patent Laid-Open No. 3-142.
It is disclosed in Japanese Patent No. 666. This prior art has an ordering form in which the parts used in the assembly factory are not necessarily immediately ordered to the parts factory when the demand for the parts assembled in the assembly factory fluctuates between the parts factory and the assembly factory. As is the case, the idea of modifying the just-in-time concept is presented. If it takes time to use the parts used in the assembly plant next time, if you order the used parts immediately, the completed parts will be delivered and you will be able to use them for the next assembly. This is because it is necessary to keep it, which violates the just-in-time concept of not storing work-in-process.

In order to substantially practice the just-in-time concept in a production factory, it is necessary to respond to various fluctuating production plans in detail and strictly adhere to the delivery date for efficient production. It's gone. Prior art relating to creating a realistic production plan in consideration of delivery date is disclosed in, for example, Japanese Patent Laid-Open No. 2000-254838. In this prior art, a passing process is allocated between a scheduled input time and a delivery date for each order that is a product production request, and the waiting time in the passing process is adjusted according to the margin of the scheduled input time with respect to the delivery date for each order. I am trying to do it.

[0004]

In a production factory, a product to be produced is generally produced through a plurality of steps. When there are many types of small-lot production products, the production unit becomes relatively small, the time required for production preparation such as setup change becomes long, and the production efficiency decreases. Furthermore, there is a high possibility that production will be hindered. Even if failures occur in individual processes, etc., in order to be able to keep the delivery date as a whole, input into the production process with a certain number of days for the delivery date, keeping a margin, The current situation is to ensure delivery time by expecting the skills of the production site. Therefore, the current just-in-time production is limited to the control of the input time to start the production of the product, and there is more room to keep the delivery time, and the manufacturing lead time from the input time to the delivery time becomes longer, The manufacturing lead time has fluctuated due to adjustments at the production site.

An object of the present invention is to provide a production progress management method and apparatus capable of shortening the manufacturing lead time and manufacturing an object product to be produced in accordance with a delivery date.

[0006]

SUMMARY OF THE INVENTION The present invention is a factory that sequentially manufactures a plurality of processes, and in a production progress management method for satisfying a required production deadline, advance or delay in each process is required. The production progress management method is characterized in that it is evaluated as an absolute delivery margin with respect to the production delivery deadline, and the optimal input timing of the product to be produced and the production priority in each process are adjusted based on the delivery deadline. .

According to the present invention, in a plurality of processes for sequentially producing, the advance or delay is evaluated for each process as an absolute delivery time margin with respect to the required delivery time, and based on the delivery time margin. Since the optimum input timing of the product to be produced and the production priority in each process are adjusted, it is possible to perform production in each process with an appropriate margin, and there is room to protect the delivery date by adjusting between processes and products to be produced. In addition, it is possible to avoid a situation where the manufacturing lead time is extended and work in progress is increased with an excessive margin.

In the present invention, the delivery allowance is recalculated at each predetermined time, and the production priority in each process is
It is characterized in that the correction is performed so as to improve the accuracy based on the recalculated delivery time allowance.

According to the present invention, even after the product to be produced is put into production, the delivery allowance is recalculated at regular intervals such as a predetermined time and the number of products to be produced, and based on the recalculated delivery allowance. The accuracy of the production priority in each process is improved.
As a result, the production is performed based on the delivery margin in each process according to the actual situation of production, and even when a plurality of products to be produced are sequentially produced, the production progress is managed to keep the delivery date as a whole. be able to.

Further, the present invention is characterized in that the delivery allowance is determined from both sides of the leading degree and the delay degree, and is adjusted to an appropriate predetermined range.

According to the present invention, the delivery time margin becomes too large on the leading side and the manufacturing lead time becomes long, and the delivery time margin becomes too small on the delay side, making it impossible to keep the delivery time. You can avoid the situation by adjusting the delivery margin to an appropriate range.

Further, in the present invention, the delivery time margin is obtained by subtracting the production line stop time including the non-working time and the planned line stop time from the holding time up to the time designated as the manufacturing delivery time for each of the processes. In addition to the required man-hours, the required production time including the production line efficiency estimated from the remaining man-hours as the remaining required production time required for the production after the process, and the production preparation time including the setup change, and the production completion It is characterized in that it is calculated by dividing the spare man-hours obtained by subtracting a certain spare time required from the point of time until the supply to the customer.

According to the present invention, for each product to be produced,
The delivery man-hours are calculated by dividing the man-hours for each process by the man-hours owned. The number of man-hours held is the time obtained by subtracting the production line stop time including non-working time and planned line stop time from the holding time until the time specified as the manufacturing delivery date. Production line efficiency, which is assumed to be the remaining production time required for production at the factory, and production preparation time including production preparation time including setup changes, and a certain margin required from the completion of production to the supply to customers. It is the time minus the time. Since the delivery allowance is calculated as a ratio, an appropriate range can be evaluated as a ratio, and the allowance in each process can be evaluated regardless of the amount of time required for each process.

Further, the present invention is characterized in that the preset initial production unit is stepwise divided into minimum producible units to improve the delivery margin with respect to the production delivery date.

According to the present invention, the size of a lot, which is a preset initial production unit, is divided step by step into the minimum producible unit which is the minimum producible unit, so that the delivery date can be expedited. It becomes possible to control the production priority.

Further, according to the present invention, a production sequence sequence in which a plurality of production target products are sequentially produced in the plurality of steps is evaluated by the work factors necessary for setup change to determine the identity of the production target products before and after the production sequence sequence. The production priority is adjusted so that the production preparation time including the setup change time is minimized.

According to the present invention, a production sequence sequence in which sequential production is carried out in a plurality of steps is performed for a product to be produced before and after, and the identity of the product to be produced before and after is evaluated by a work factor required for setup change to produce the product. The priority is adjusted so as to minimize the production preparation time including the setup change time. Since the production priority is adjusted by evaluating the identity of the product to be produced, the production preparation time including the setup change time can be easily minimized.

Further, according to the present invention, the amount of in-process products in transition from a process having a long operating time zone to a process having a short operating time zone is maximized at the start of the operation of the process having a short operating time zone and minimized at the end of the operation. In addition, the in-process amount control is performed.

According to the present invention, the amount of work in progress when a process having a long operating time period shifts to a process having a short operating time period, such as a process operating from 16 hours a day to a process operating from 8 hours a day. The amount of work-in-process is controlled so that it is maximized at the start of the operation and minimized at the end of the operation, so even if there are processes with long operating hours mixed in order to recover the investment of expensive equipment, It is possible to maintain the proper production.

Furthermore, the present invention is an apparatus used for controlling the production progress in order to meet the required production deadline in a factory which sequentially manufactures in a plurality of processes, and the advance or delay in each process By adjusting the delivery time margin evaluation means that evaluates as an absolute delivery time margin against the required manufacturing delivery time and the optimal input time of the product to be produced and the production priority in each process based on the delivery time margin, A progress predicting means for predicting progress and one axis on the display screen as an elapsed time axis,
Set the reference point that represents the current time on the elapsed time axis with the other axis as the process forward direction, display the progress record on the past side of the reference point on the time axis, and display the progress on the time axis. The production progress management device is characterized in that it includes a progress display unit for displaying a progress prediction predicted by the progress prediction unit on the future side of the point based on the progress measurement up to the present time.

According to the present invention, the production progress management device used for performing the production progress management for satisfying the required production delivery time in a factory that sequentially produces in a plurality of processes is a delivery time allowance evaluating means. , A progress predicting means and a progress displaying means. The delivery time allowance evaluation means evaluates the lead or delay in each process as an absolute delivery time allowance with respect to the requested production delivery time. The progress prediction means adjusts the optimum input timing of the product to be produced and the production priority in each process based on the delivery margin, and performs the progress prediction. The progress display means sets one axis on the display screen as the elapsed time axis and the other axis as the process forward direction, and sets a reference point representing the current time on the elapsed time axis, and sets the reference point from the reference point on the time axis. Also displays the progress record on the past side, and displays the progress prediction predicted by the progress prediction unit on the time axis on the future side of the reference point based on the progress measurement up to the current time. On the display screen of the progress predicting means, the past progress on the time axis is displayed on the basis of the current time, and the progress progress is displayed on the future side on the time axis.
An easy-to-understand display for managing the progress can be displayed. It is possible to improve the management accuracy in the direction of shortening the manufacturing lead time by making a comprehensive judgment on the delivery margin while looking at the display.

Further, the present invention is directed to the plurality of steps,
A time calculating means for calculating the required production preparation time and the required production time for a plurality of production target products for which a production delivery date is designated, and based on the progress prediction predicted by the progress prediction means for the plurality of production target products. A time calculation means for calculating the expected production start time and the estimated production end time, a required production preparation time and a required production time calculated by the time calculation means, and an estimated production start time and an estimated production end time calculated by the time calculation means And a production instruction means for displaying a detailed value including the current state of the delivery time margin evaluated by the delivery time margin evaluation means together with the production order of the products to be produced, and giving a production instruction. And

According to the present invention, the production instructing means provides the required production preparation time and the required production time for a plurality of processes,
The estimated production start time and estimated production end time, and detailed values including the current state of the delivery allowance are displayed together with the production order of the products to be produced, and the production instruction is given. It is possible to easily carry out the management in accordance with.

Further, according to the present invention, the production instructing means may preliminarily check, based on the delivery time allowance evaluated by the delivery time allowance evaluating means, for a product to be produced whose delivery time allowance is smaller than an appropriate value. It is characterized in that necessary preparatory work is extracted, and a work instruction is given as an interrupt work during an instruction sequence for a production target product to which a preceding production instruction is given.

According to the present invention, since preparatory work is performed in advance for a product to be produced having a small delivery allowance, production can be performed without delay in delivery.

Further, in the invention, it is preferable that the progress display means displays the delivery allowance in a predetermined size of a graphic for each of the steps.

According to the present invention, the delivery allowance is displayed in the shape predetermined for each process, for example, the size of a circle or a square, so that the delivery allowance can be easily read from the progress display means.

In the present invention, the progress display means associates the stage of the delivery time allowance with the color change in advance, and the delivery time allowance evaluated by the delivery time allowance evaluating means is set for each of the steps. It is characterized by displaying in the color.

According to the present invention, the delivery allowance is stepwise,
Since it is displayed with a predetermined color change, the delivery margin can be easily read from the progress display means.

Further, in the present invention, the progress display means is provided with a delivery time margin for a process in which the delivery time margin evaluated by the delivery time margin evaluation means is exhausted and the required manufacturing delivery time is not satisfied. The feature is that the degree is displayed in a predetermined color.

According to the present invention, when the delivery time allowance is displayed in a predetermined color, the delivery time allowance is exhausted, and it is displayed in an easy-to-understand manner as a process in which it is predicted that the required production delivery time will not be met. It can be a warning to recognize the necessity of measures.

Further, according to the present invention, the progress display means is provided with a delivery time margin for a process in which the delivery time margin evaluated by the delivery time margin evaluation means is exhausted and the required manufacturing delivery time is not satisfied. The feature is that the degree is displayed in a form that changes with time.

According to the present invention, when the delivery margin is displayed in a form that changes with time, such as blinking, it is predicted that the delivery margin will be exhausted and the required manufacturing delivery deadline will not be met. It can be displayed in an easy-to-understand manner and can be used as a warning to recognize the necessity of measures.

Further, in the present invention, the progress display means, for each product to be produced, the progress predicted by the progress prediction means at the time of introducing the product into the first step of the plurality of steps, and a predetermined constant time. It is characterized in that it has a function of displaying a difference from the actual value summed up for each as a transitional state for each fixed time.

According to the present invention, for each product to be produced,
Since the difference between the predicted value of production completion at the time of input and the actual value that is aggregated at fixed time intervals is displayed as the transition status at fixed time intervals, it is possible to browse the transition status of the process progress in an easy-to-understand manner. become.

Further, according to the present invention, the progress display means is provided with a function of displaying past performance data by shifting the reference point to the past side on the time axis.

According to the present invention, it is possible to browse past performance data by the progress display means and easily grasp the progress performance.

Further, in the present invention, the progress display means is provided with a function of displaying a future supply schedule and a production simulation result by shifting the reference point to the future side on the time axis. .

According to the present invention, it is possible to browse future supply schedules and production simulation results by the progress display means, and it is possible to easily grasp the progress prediction.

[0040]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS FIG. 1 shows a basic concept of a production progress management method according to an embodiment of the present invention. Figure 1
As shown in (a), when it is necessary to produce the product to be produced in sequence through a plurality of processes in time to meet the delivery time, in order to avoid the situation which is not in time, the situation shown in FIG.
As shown in (b), a certain number of days is expected for the delivery date, and the input is made. For this reason, for example, even if the product to be produced has a lead time of 2 days, which is completed in 2 days, the lead time is set to 3 days in anticipation of an extra day. If production goes smoothly, production will be completed one day earlier than the delivery date and inventory will be left for one day. It should be noted that although the production of the electronic device is described as an example in the present embodiment, the idea of the present invention can be applied to any product to be produced.

In the present embodiment, as shown in FIG. 1 (c), an ideal process with an appropriate allowance is set and a product to be produced is introduced, and in the middle of the process, the delivery margin after the next process is predicted. Evaluate and perform feedback control so that it approaches the ideal time. The delivery allowance becomes larger if it goes beyond the ideal process and becomes smaller if it goes behind. When the delivery allowance becomes smaller, the priority of the other production target products having a larger delivery allowance is given to the process, and the progress is corrected. When the delivery allowance becomes large, other products to be produced, which have a small delivery allowance, are preferentially put into the process, and adjustments are made so that the plurality of products to be produced satisfy the delivery as a whole.

The delivery allowance is evaluated in, for example, five levels. Feedback control is performed so that the stage that is most delayed is "1" and the stage that is most advanced is "5" so as to stay in the intermediate stage "3". If the delivery margin becomes "2" or less on the way, it is judged that the progress is starting to be delayed,
Priority is given to the next process to accelerate the progress. When the delivery allowance becomes "4" or more in the middle, it is determined that the progress is starting to progress, and it is possible to delay the progress by prioritizing the introduction of other products to be produced in the next process.

FIG. 2 shows an example of the form in which the products to be produced flow in the production factory. FIG. 2A shows a form of a dedicated process such as an assembling process. In the assembly process and the like, a plurality of processes form a line, and the order of input matches the order of completion. In such a dedicated process, just returning the "Kanban" corresponding to the finished product in the final process to the first process enables just-in-time production. FIG. 2B shows a form of a cell production system such as a machine process. In a machine process using various automated production devices, particularly in the case of performing a variety of small-volume production, a plurality of types of production target products are mixed and produced in order to increase the operation rate of each process. Therefore, the input order and the completion order do not always match. In the current “Kanban” method, the cell production method is simply instructed to put back the “Kanban” in the first step after the completion of production in the final step and start manufacturing. Since the present invention can adjust the progress between processes, it is not only applicable to the dedicated process as shown in FIG. 2 (a) but also to the cell production system as shown in FIG. 2 (b). Can be applied. Figure 2
Even in (b), considering a specific product to be produced,
This is because it can be considered that the products are sequentially manufactured in the series of steps shown in (a).

In the production instruction unit such as "Kanban", the production completion delivery date is described in units of day and time. Starting from this delivery time, the delivery allowance in the current state of intermediate production is re-evaluated at regular time intervals based on the remaining production required time, the process production allowance, etc., or every time the production results change. Production priority, production unit, optimal work-in-progress amount, etc. are detected, the progress is corrected, and production control is performed while maintaining a certain delivery margin during the production process up to the delivery time. In addition, for products to be produced that have been finalized and have been put into the first process of the monitored process group, the final production completion scene is predicted, and the estimated production start time and the delivery margin at each point A monitor screen for managing the progress control state is provided. This delivery time margin is used as the starting point of production control, as an absolute evaluation scale of advance / delay that does not depend on the production plan. As a result, it is possible to manage the entire production progress even in a production factory mainly based on the post-replenishment system based on the “Kanban delivery system contract” for which no production schedule plan exists.

That is, in the present embodiment, the advance or delay is evaluated as the absolute delivery time margin with respect to the required production delivery time for each process in a plurality of production steps, and based on the delivery time allowance. By adjusting the optimal input timing of production target products and the production priority in each process, it is possible to carry out production in each process with an appropriate margin, and the delivery date is protected by adjustment between processes and production target products. It is possible to avoid the situation where the manufacturing lead time is extended and the number of work in process is increased with a room and an excessive margin.

Further, in this embodiment, the delivery allowance is recalculated at each predetermined time, and the production priority in each process is corrected so as to improve the accuracy based on the recalculated delivery allowance. . Therefore, even after the product to be produced has been put into production, the delivery time allowance is recalculated at regular intervals such as the predetermined time and the number of productions, and the production priority in each process is prioritized based on the recalculated delivery time allowance. The degree of precision is improved. As a result, the production is performed based on the delivery margin in each process according to the actual situation of production, and even when a plurality of products to be produced are sequentially produced, the production progress is managed to keep the delivery date as a whole. be able to.

The delivery allowance is determined from both sides of the leading degree and the delay degree, and adjusted within a predetermined appropriate range. Due to this, the delivery margin becomes too large on the leading side, the manufacturing lead time becomes long, and the inventory increases, and the delivery margin becomes too small on the delay side, making it impossible to keep the delivery date. It is possible to avoid the situation that happens.

FIG. 3 shows an example of a device configuration necessary for executing the production progress management method of the embodiment shown in FIG. Process side terminal devices 1, 2, 3, 4, ... Are respectively installed in a plurality of processes, receive a production instruction from the management side terminal device 10 and proceed with the production of the product to be produced, and the results are sequentially managed by the management side terminal. Report to device 10. Process side terminal devices 1, 2, 3, 4, ...
The management side terminal device 10 and the management side terminal device 10 are computer devices, respectively, and perform processing for production progress management according to a preset program.

The management-side terminal device 10 executes the program operation to determine the due date margin evaluation means 11, the progress prediction means 12,
Progress indicator 13, time calculator 14, time calculator 1
5 and the production instruction means 16. The process side terminal devices 1, 2, 3, 4, ... And the management side terminal device 10 are connected via a LAN (Local Area Network) 20 so that information communication is possible. The production instruction means 16 of the management side terminal device 10 gives a production instruction to each process side terminal device 1, 2, 3, 4, ... Via the LAN 20. The production performance data from each process side terminal device 1, 2, 3, 4, ...
It is collected in the management side terminal device 10 via N10.

The time calculating means 14 calculates the required production preparation time and the required production time for a plurality of production target products for which the manufacturing deadlines are designated, for a plurality of processes. The time calculation means 15 calculates the predicted production start time and the predicted production end time for the plurality of production target products based on the progress prediction predicted by the progress prediction means 12. The production instructing means 16 produces the detailed values including the required production preparation time and the required production time, the estimated production start time and the estimated production end time, and the present state of the delivery schedule margin for the plurality of processes, in order to produce the production target product. Since it is displayed together with the order and the production instruction is given, it is possible to easily carry out the management of putting a plurality of products to be produced in time for each delivery date.

In the production progress management of the present embodiment, not only the production target products that produce a relatively stable production amount every day as originally assumed in the "Kanban system" but also
The goal is to effectively manage the products that are subject to large fluctuations in production. In recent years, high-mix, low-volume production has progressed,
This is because the fluctuation of the production amount is increasing, and it is a subject to effectively manage the production progress in response to such fluctuation. Further, even for a product to be produced for which mass production is performed stably, the fluctuation of the production amount becomes large in the trial production before the mass production or the production when the mass production is finished and the production is converged.

FIG. 4 shows an example of the result of measuring the current manufacturing lead time for the daily production product that is stably mass-produced every day and the intermittent production product in which the production amount varies greatly. With intermittent products, the manufacturing lead time is distributed over a wide range, so
It can be seen that it suffices to improve so that the part on the long side shifts to the short side.

FIG. 5 shows the influence of the difference in work style on the fluctuation of the in-process inventory quantity. Generally, in a machine process or the like in which an automatic machine or the like is installed, in order to recover a large amount of capital investment, the operating time of the facility may be lengthened and the work form may differ from other processes. That is, the workers take turns to operate the equipment by changing a plurality of work shifts to shorten the non-working time per day. Depending on the equipment, it may be operated continuously for 24 hours. In the present embodiment, for example, in a machine process that works in two shifts, which is two shifts per day, production is performed even during a non-working time in a board process or an assembly process that works in one shift. Management is performed such that the in-process inventory amount becomes the maximum Max at the start of production and the in-process inventory amount becomes the minimum Min at the end of the production immediately after. Such management cannot be appropriately performed by the conventional method of managing the distribution amount of “Kanban”. It is necessary to constantly monitor and control the current work in progress.

For example, the amount of work in progress when a process having a long operating time shifts from a process having a long operating time to a process having a short operating time, such as a process of two shifts working 16 hours a day to a process of one shift working eight hours Maximum at the start of operation in a short process,
By controlling the amount of work in progress so that it becomes the minimum at the end of operation, even if there are processes with long operating hours mixed in order to recover the investment of high-priced equipment etc. It can be performed.

FIG. 6 shows the concept of managing the production progress between processes by using "kanban" in this embodiment. In each process, the size of the solid on the left side shows the production capacity, and the size of the solid on the right side shows the required in-process inventory amount. However, the “Kanban” in this embodiment is the process-side terminal devices 1, 2, 3, from the production instruction means 16 of FIG.
It is an electronic command given to 4, .... Figure 6 (a)
Shows the case where the production is performed at the same process cycle time in each process and the ideal post-replenishment method is applied. It is sufficient to return the "Kanban" to the preceding process by the amount of production completed in each process and receive the product to be produced for the next production. FIG. 6B shows the case where there is a difference in the process cycle time, and the following 3 steps of the process with a long cycle time of 8 minutes are performed.
In the minute step, it is necessary to keep a large amount of in-process inventory. FIG. 6C shows a case where there is a difference in operating time, and it is necessary to increase the in-process inventory in the first shift process after the second shift process. FIG. 6D shows the case where there is a difference in the production lot, and it is necessary to increase the in-process inventory in the process in which the production lot is small.

7 and 8 show the progress indicator 1 of FIG.
3 shows an example of the progress management monitor screen displayed in 3. The horizontal X-axis is used as a time axis, and a reference point corresponding to the current time is set near the center on the time axis. Progress data is displayed on the past side of the reference point, and progress prediction is displayed on the future side. The vertical Y axis shows the flow of the process, and in each process,
The allocation of time for each product to be produced is displayed as a strip of time. FIG. 7 shows a state in which a production progress curve obtained by connecting the time divisions of a specific production target product with a curve is displayed.

That is, the progress display means 13 represents the present time on the elapsed time axis with the X axis, which is one axis on the display screen, as the elapsed time axis and the other axis, the Y axis, as the process forward direction. Set a reference point, display the progress record on the time axis in the past of the reference point, and display the progress record on the time axis in the future of the reference point, based on the progress measurement up to the current time. The progress prediction predicted by the prediction means is displayed. On the display screen of the progress predicting means, the actual progress is displayed on the past side of the time axis and the predicted progress is displayed on the future side of the time axis based on the current time, which is easy to understand for managing the progress. The display can be done. It is possible to improve the management accuracy in the direction of shortening the manufacturing lead time by making a comprehensive judgment on the delivery margin while looking at the display.

FIG. 8 shows the production progress curve and the ideal curve of FIG. 7, and also shows the delivery margin for the production progress curve. The ideal curve is a curve predicted when the product to be produced is put into the first step, and the production progress curve is obtained by combining the actual results and the prediction based on the actual results.

In the progress display means 13, for each product to be produced, the progress predicted by the progress prediction means at the time of inputting into the first step of the plurality of steps, and the record of totaling at a predetermined fixed time. It is provided with a function of displaying a difference from the value as a transitional state for each fixed time. For each production target product, the difference between the predicted production completion value at the time of input and the actual value that is aggregated at fixed time intervals is displayed as a transitional status at fixed time intervals, so the progress status of the process can be known. It becomes possible to browse easily.

Further, the progress display means has a function of displaying past performance data by shifting the reference point to the past side on the time axis. It is possible to browse past performance data on the progress display means 13 and easily grasp the progress performance.

Further, the progress display means 13 has a function of displaying the future supply schedule and production simulation result by shifting the reference point to the future side on the time axis. The progress display means 13 makes it possible to browse future injection schedules and production simulation results, and it is possible to easily grasp the progress prediction.

The "R process" indicates a mounting process by soldering the surface mounting component to the back surface side of the electronic device on the back side by reflow soldering. “F process” indicates a mounting process on the front surface side of the double-sided wiring board. "P process"
Shows a bond chip process. “Vertical” indicates a process of attaching a vertical component in which a connecting lead is provided on one side. "Horizontal" is
The process of attaching a horizontal component with connection leads on both sides is shown.

FIG. 9 shows the procedure of progress management using the monitor screens shown in FIGS. 7 and 8. Step s0
The procedure is started from, and the delivery time is determined in step s1. At step s2, an input instruction plan for each process is made in time for the delivery time. In step s3, the delivery allowance in each process is evaluated. At step s4, it is judged whether or not a shortage of goods which is not in time for delivery occurs, and when it is judged that there is a shortage, a warning by an alarm is given at step s5. When the closing instruction plan is corrected in step s6 according to the alarm, the process returns to step s3.

If it is determined in step s4 that there is no shortage, it is determined in step s7 whether the in-process inventory can be reduced. When it is determined that the lead time is long and the lead time can be reduced, the closing instruction plan is corrected in step s8, and the process returns to step s3. When it is determined in step s7 that it is not possible to reduce the in-process inventory, in step s9, an input instruction according to the input instruction plan is given to each process. This input instruction is
It corresponds to the above-mentioned ideal curve.

When the product to be produced is input, step s1
At 0, the production performance is monitored. In step s11, it is determined whether or not the production target product that has been input is completed in all the processes. When it is determined that the process is not completed, in step s12, based on the production results,
The margin is evaluated in the remaining steps. In step s13, it is determined whether or not it is necessary to correct the plan input instruction based on the margin. When it is determined that the correction is necessary, the progress correction for adjusting the margin to an appropriate value is performed in step s14, and the process returns to step s10. When it is determined in step s13 that the correction of the closing instruction is unnecessary, the correction is not performed and the process returns to step s10. Step s
When it is determined in 11 that the production of the entire process is completed, the procedure ends in step s15.

In the procedure of FIG. 9, in the first stage from step s1 to step s6, the present value is grasped and analyzed by the delivery date determination and the margin evaluation, and the monitoring mode in which the situation that the delivery date cannot be met is avoided. We are in control. In the second stage of step s7 and step s8, a correction control mode for correcting the excessive increase in the in-process inventory due to the excessive margin is performed. In the third stage from step s9 to step s13, a closing control mode is performed in which the lead time is shortened in the optimum closing state.

FIG. 10 shows an example in which the three-stage procedure shown in FIG. 9 is applied to control an appropriate delivery margin. First, the delivery time is determined, and the closing instruction is created in the monitoring mode. After executing the correction control mode that shortens the work in process from 1 day to 0 days, excluding the case where out-of-stock items that are not in time for delivery occur
A lead time of 1.5 days can be realized by executing the closing control mode.

The progress display means 13 can display the delivery allowance for each process in a predetermined graphic size, for example, a size of a circle or a square. As a result, the delivery allowance can be easily read from the progress display unit 13.

In the progress display means 13, the stage of the delivery time allowance is associated with the color change in advance, and the delivery time allowance evaluated by the delivery time allowance evaluating means 11 is set for each process.
It can also be displayed by changing the color. If the delivery allowance is displayed stepwise with a predetermined color change, the delivery allowance can be easily read from the progress display unit 13.

Further, the progress display means 13 is a color for predetermining a delivery time allowance for a process in which the delivery time allowance evaluated by the delivery time allowance evaluating means 11 is exhausted and the required manufacturing delivery time is not satisfied. It can also be displayed in red, for example. When the delivery time allowance is displayed in a predetermined color, the delivery time allowance is exhausted, and it is displayed in an easy-to-understand manner as a process in which it is predicted that the required manufacturing delivery time will not be met, and a warning is displayed to recognize the necessity of countermeasures. can do.

Further, the progress display means 13 temporally sets the delivery time allowance for the process in which the delivery time allowance evaluated by the delivery time allowance evaluating means 11 is exhausted and the required manufacturing delivery time is not satisfied. It can also be displayed in the form of changing blinking. When the delivery allowance is displayed in a form that changes with time, for example, by blinking, the delivery allowance disappears, and it is easy to understand that this is a process in which it is predicted that the required manufacturing delivery cannot be met.

FIG. 11 shows the concept of allocating the production of emergency products for a specific process. The production target product having a small delivery allowance has an LV value of 1, which is a priority level, and is interrupted and injected in the instructing order. As a result, with the progress prediction as shown in FIG. 10, it is possible to perform the correction for the process in which the margin becomes small and to give the production instruction for recovering to the proper margin.

Based on the delivery allowance evaluated by the delivery allowance evaluation means 11, such a production instruction is required in advance for a product to be produced with a delivery allowance smaller than an appropriate value. It is done as an interrupt into the ordering sequence for the product to be produced that extracts the work and gives the preceding production instruction. Since preparation work is performed in advance for a product to be produced that has a small delivery allowance, it is possible to perform production without delay in delivery.

FIG. 12 shows algorithm components for controlling the delivery allowance as shown in FIG. The main components of the algorithm are evaluated as follows.
First, in the scheduling of the input instruction, it is necessary to clarify the previous process completion record or forecast of the relevant kanban that is the starting point. The estimated time of completion of the previous process can be calculated by the following equation (1). Expected time to complete the previous process = Expected time to start the previous process + Required production time for the previous process (1)

For example, when the cycle time of the pre-process is 3 minutes and the number of productions is 24, 3 × 24 = 72 (minutes) is the necessary production time of the pre-process.

Next, the urgency of the delivery date, Kanban,
Alternatively, the delivery allowance, which is quantitatively expressed per the number of magazines accommodated, is calculated according to the following equation (2). Delivery time margin = (Man-hours held by delivery time-Required production time until final process-Preparatory time by delivery time-Nonworking time) ÷ (Man-hours held by delivery time-Unworking time) (2)

For example, it is assumed that the delivery date is set to the departure time of a truck for shipping, the number of man-hours held by the shipping time is 20 hours, the pre-shipment spare time is 2 hours, and the non-working time is 5 hours. When the required cycle time is 4 minutes, 24 units are produced, and the standard operation rate is 80%, the required production time is 4 × 24 ÷ 0.8 = 120 (minutes) = 2 (hours). Therefore, the delivery margin is (20-9) ÷ (20
-5) = 0.73 = 73 (%).

In other words, the delivery time allowance is calculated by holding man-hours obtained by subtracting the production line stop time including the non-working time and the planned line stop time from the holding time up to the time designated as the manufacturing delivery time for each process. Production line efficiency that is assumed as the remaining production time required for production after that process from the number of man-hours held, and production preparation time including production preparation time including setup change, and supply to customers from the time production is completed It is calculated by dividing the man-hours that are obtained by subtracting a certain margin time required up to. Since the delivery allowance is calculated as a ratio, the allowance in each process can be evaluated regardless of the size of the required time for each process.

The delivery date allowance can be converted into, for example, five levels of urgency, as shown by the urgency conversion table in percentage display. This urgency level is equivalent to the five levels of delivery allowance as shown in FIGS. Further, as shown in FIG. 11, it corresponds to the level LV that is an evaluation scale when interrupting as an emergency item.

Next, as the degree of adjustment with respect to the operating time zone of the next process, the adjustment allowance per kanban or the number of magazines accommodated is calculated according to the following equation (3). The adjustment allowance quantitatively represents the degree of adjustability in order adjustment and lot formation. Adjustment allowance = (margin man-hours until next process production available time-non-working time) / required production time at item bottom (3)

When the adjustment allowance is large, the size of a lot, which is a preset initial production unit, is divided into the minimum producible unit, which is the minimum producible unit, in stages, so that the delivery date is expedited. Moreover, it becomes possible to control the production priority.

Next, in order to improve the accuracy of the production load time,
The standard setup change time is calculated according to the following equation (4). Setup change time = Parts exchange time + Substrate width adjustment time + Metal mask exchange time + Program switching time + Initial product confirmation time-External setup time (4)

The production sequence sequence in which the production target products before and after are sequentially produced in a plurality of processes is evaluated by the work factor necessary for the setup change to determine the identity of the production target products before and after, and the production priority is adjusted by The production preparation time including the setup change time should be minimized. Since the production priority is adjusted by evaluating the identity of the product to be produced, the production preparation time including the setup change time can be easily minimized.

Further, in the invention, it is preferable that the progress display means displays the delivery allowance with a predetermined size of a figure for each of the steps.

13 and 14 show examples of calculation results of the delivery margin and the adjustment margin, respectively. Using these calculation results, it is possible to dynamically recalculate the production start time.

[0086]

As described above, according to the present invention, in a plurality of processes in which production is sequentially performed, the optimum input time of the product to be produced and each process are determined based on the absolute delivery time margin with respect to the required production delivery time. Since the production priority is adjusted, the production in each process can be performed with an appropriate margin, and the manufacturing lead time can be shortened overall.

Further, according to the present invention, even after the product to be produced is put into production, the delivery allowance is recalculated at regular intervals such as a predetermined time and the number of productions, and each process is adjusted according to the actual situation of production. Even if the production is performed based on the delivery time margin in the case of multiple production target products in sequence, the production progress is managed so that the delivery time can be kept as a whole and the manufacturing lead time can be shortened. be able to.

Further, according to the present invention, it is possible to adjust the delivery time allowance within an appropriate range and shorten the manufacturing lead time within the range where the delivery time is satisfied.

Further, according to the present invention, for each product to be produced, the spare man-hour for each process is divided by the possessed man-hour to calculate the delivery time allowance as a ratio, and it is necessary to determine whether it is within an appropriate range for each process. It can be evaluated regardless of the amount of time.

Further, according to the present invention, the size of a lot, which is an initial production unit, is divided into the minimum producible unit which is the minimum producible unit step by step, and the production priority is set so that the delivery date is accelerated. Can be controlled.

Further, according to the present invention, the identity of the products to be produced before and after is evaluated by the work factor necessary for the setup change,
Since the production priority is adjusted by evaluating the identity of the product to be produced, the production preparation time including the setup change time can be easily minimized.

Further, according to the present invention, the amount of in-process products in transition from a process having a long operating time zone to a process having a short operating time zone is maximized at the start of operation of the process having a short operation time zone and minimized at the end of operation. As described above, since the amount of work-in-progress is controlled, even if there are processes with long operating hours, production can be performed with an appropriate delivery margin.

Further, according to the present invention, on the display screen of the progress predicting means, the progress progress is displayed on the past side of the time axis and the predicted progress is displayed on the future side of the time axis with reference to the present time. , It is possible to improve the management accuracy in the direction of shortening the manufacturing lead time by making a comprehensive judgment on the delivery margin while looking at the display.

Further, according to the present invention, for a plurality of steps,
The required production preparation time and required production time, the estimated production start time and estimated production end time, and the detailed value including the current state of the delivery allowance are displayed together with the production order of the products to be produced, and the production instruction is given. It is possible to easily perform management to put a plurality of products to be produced in time for each delivery date.

Further, according to the present invention, it is possible to perform a preparatory work in advance for a product to be produced with a small delivery allowance so that production can be performed without delay in delivery.

Further, according to the present invention, the delivery allowance can be displayed for each process in a predetermined figure, for example, the size of a circle or a square, so that the delivery allowance can be easily read.

Further, according to the present invention, since the delivery allowance is displayed stepwise by the change in the predetermined color, the delivery allowance can be easily read from the progress display means.

Further, according to the present invention, it is possible to display a process in which a margin of delivery date is exhausted and a required production delivery date is not satisfied in a predetermined color, and to warn the user to recognize the necessity of countermeasure. it can.

Further, according to the present invention, it is possible to display a process, which is predicted to be out of the delivery time allowance and the required manufacturing delivery time is not satisfied, by blinking or the like to warn the user to recognize the necessity of the countermeasure. it can.

Further, according to the present invention, the progress predicting means, for each product to be produced, the predicted production completion value at the time of introduction,
It is possible to display the difference from the actual value that is aggregated at regular intervals as a transitional state at regular intervals so that the transitional state of the progress of the process can be easily viewed.

Further, according to the present invention, the past performance data can be browsed by the progress display means.

Further, according to the present invention, it is possible to view the future production schedule and production simulation result by the progress display means.

[Brief description of drawings]

FIG. 1 is a graph showing a schematic concept of a production progress management method according to an embodiment of the present invention.

FIG. 2 is a diagram showing a form of a process targeted for production progress management in the present invention.

FIG. 3 is a block diagram showing a configuration of an apparatus for executing the production progress management method of FIG.

FIG. 4 is a graph showing targets for which the manufacturing lead time should be improved in the daily production product and the intermittent production product according to the present invention.

FIG. 5 is a diagram showing a concept of reflecting a difference in work style in a change in work-in-process inventory according to the present invention.

FIG. 6 is a diagram showing an example of a process form for performing progress management of the present invention.

7 is a diagram showing an example of a display screen displaying a production progress curve on a progress display means 13 of FIG.

8 is a diagram showing an example of a display screen displaying a production progress curve, an ideal curve, and a delivery deadline on the progress display means 13 of FIG.

FIG. 9 is a flowchart showing a schematic procedure for performing progress management in the present invention.

10 is a diagram showing an example of progress management according to the procedure of FIG.

FIG. 11 is a diagram showing interruption of a process for an emergency item in the progress management of the present invention.

FIG. 12 is a diagram showing algorithm components for performing progress management in the present invention.

FIG. 13 is a graph showing an example of a result of calculating a delivery allowance using the algorithm components of FIG.

FIG. 14 is a graph showing an example of a result of calculating an adjustment allowance using the algorithm components of FIG.

[Explanation of symbols]

1, 2, 3, 4, ... Process side terminal device 10 Management side terminal device 11 Delivery time margin evaluation means 12 Progress prediction means 13 Progress display means 14 hours calculation means 15 Time calculation means 16 Production instruction means 20 LAN

   ─────────────────────────────────────────────────── ─── Continued front page    (72) Inventor Kazuhiro Kobayashi             1-228 Goshodori, Hyogo-ku, Kobe-shi, Hyogo               Within Fujitsu Ten Limited F term (reference) 3C100 AA03 AA05 AA18 AA23 AA24                       AA29 AA32 BB04 BB14 BB15                       BB31 CC02 DD15

Claims (17)

[Claims] 1. In a production progress management method for satisfying a required production delivery date in a factory that sequentially manufactures in a plurality of processes, the lead or delay in each process is an absolute delivery date with respect to the required production delivery date. A production progress management method characterized by evaluating the margin as a margin, and adjusting the optimum input timing of production target products and the production priority in each process based on the delivery margin. 2. The delivery margin is recalculated at each predetermined time, and the production priority in each process is corrected so as to improve accuracy based on the recalculated delivery margin. The production progress management method according to claim 1, which is characterized in that. 3. The production progress management method according to claim 1, wherein the delivery allowance is judged from both sides of the advancement and the delay and adjusted within a predetermined appropriate range. 4. The delivery time allowance is the number of man-hours held for each of the processes, which is obtained by subtracting the production line stop time including non-working time and planned line stop time from the holding time until the time specified as the manufacturing delivery time. Then, from the man-hours held, the production line efficiency estimated as the remaining production time required for the production after the process, and the production required time including the production preparation time including the setup change, The production progress management method according to any one of claims 1 to 3, wherein the man-hours obtained by subtracting a certain allowance time required for supplying to the product are calculated by division. 5. The preset initial production unit is divided step by step to a minimum producible unit to improve the delivery margin with respect to the production delivery date. The production progress management method described in. 6. The production priority sequence in which a plurality of production target products are sequentially produced in the plurality of processes is evaluated by the work factor required for setup change to determine the identity of the preceding and following production target products, and the production priority is set. 2. The adjustment is performed so as to minimize the production preparation time including the setup change time.
5. The production progress management method according to any one of 5 to 5. 7. The work-in-process is set so that the amount of in-process products during the transition from a process having a long operating time zone to a process having a short operating time zone is maximized at the start of operation of the process having a short operation time zone and minimized at the end of operation. The amount control is performed, and the amount control is performed.
The production progress management method described in any one of. 8. A device used to control the production progress to meet a required production deadline in a factory that sequentially manufactures in a plurality of processes, and is required to lead or delay each process. The delivery time margin evaluation means that evaluates the delivery time as an absolute delivery time margin, and based on the delivery time margin, the optimal input time of the product to be produced and the production priority in each process are adjusted to predict the progress. The progress predicting means to be performed and one axis on the display screen as the elapsed time axis, the other axis as the process forward direction, and a reference point representing the current time is set on the elapsed time axis, and the reference point is set on the time axis. The progress display that displays the progress record on the past side and displays the progress prediction predicted by the progress prediction unit on the time axis on the future side of the reference point based on the progress measurement up to the current time. Production progress tube characterized by including means Processing equipment. 9. A time calculating means for calculating a required production preparation time and a required production time for a plurality of production target products whose production delivery dates are designated for the plurality of processes, and a plurality of production target products, A time calculation means for calculating an expected production start time and an estimated production end time based on the progress prediction predicted by the progress prediction means, and a necessary production preparation time and a required production time, time calculation means calculated by the time calculation means. The estimated production start time and the estimated production end time calculated by the above, and detailed values including the current state of the delivery schedule margin evaluated by the delivery schedule margin evaluation means are displayed together with the production order of the product to be produced, 9. The production progress management device according to claim 8, further comprising production instruction means for giving an instruction. 10. The production instructing means, on the basis of the delivery time allowance evaluated by the delivery time allowance evaluating means, for the production target product having the delivery time allowance smaller than an appropriate value,
10. The production progress management apparatus according to claim 9, wherein a necessary preparatory work is extracted in advance, and a work instruction is given as an interrupt work during an instruction sequence for a product to be produced which gives a preceding production instruction. 11. The production progress management device according to claim 8, wherein the progress display means displays the delivery allowance in each of the steps in a size of a predetermined graphic. . 12. The progress display means associates the stage of the delivery time allowance with a change in color in advance, and the delivery time allowance evaluated by the delivery time allowance evaluating means is indicated by the color for each step. It displays, The production progress management apparatus in any one of Claims 8-11. 13. The progress display means preliminarily sets a delivery time allowance for a process in which the delivery time allowance evaluated by the delivery time allowance evaluating means is exhausted and the required manufacturing delivery time is not satisfied. 13. The production progress management device according to claim 11 or 12, wherein the production progress management device is displayed in a defined color. 14. The progress display means sets a delivery time allowance as a time for a process in which the delivery time allowance evaluated by the delivery time allowance evaluation means is exhausted and the required manufacturing delivery time is not satisfied. 14. The production progress management apparatus according to claim 11, wherein the production progress management apparatus displays the production progress management apparatus. 15. The progress display means collects, for each product to be produced, the progress predicted by the progress prediction means at the time when the product is put into the first step of the plurality of steps and a predetermined time interval. 15. The production progress management device according to claim 8, further comprising a function of displaying a difference from the actual result value as a transitional state for each fixed time. 16. The progress display means has a function of displaying past performance data by shifting the reference point to the past side on the time axis. The production progress management device described in Crab. 17. The progress display means has a function of displaying a future supply schedule and a production simulation result by shifting the reference point to the future side on the time axis. The production progress management device according to any one of 1 to 16.