JP2003067452A - Information collecting and analyzing device for g-abm operation improvement act - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a device which enables analysis of business improving operational standards in manufacturing industry and the like. SOLUTION: When the analysis of business improving operational standards is performed in the manufacturing industry or the like, series of operations which takes on manufacturing system operation are organized as a current business process, the business is categorized in fine detail, and how long a worker actually takes time for each activity and how many times they are carried out are measured. An activity cost per activity unit can be calculated by multiplying the measured value (time period and the number of times) by worker's cost (standard time unit price) and aggregating them. The data of the activity cost are of enormous amount, but the data are efficiently aggregated and analyzed in a short period of time, and information on virtual modification, approximation of the effect, and improvement information output are output.

Description

Detailed Description of the Invention

[0001]

[Industrial application field] The present invention relates to a method of using a computer and resources related to it when conducting a business improvement type activity standard analysis in a manufacturing industry or the like.

[0002]

2. Description of the Related Art Conventionally, when performing work improvement type activity standard analysis in a manufacturing industry or the like, improvement measures have been intuitively presented based on the judgment of experience and intuition of workers in the workplace. The improvement plan has very little numerical information, and it was difficult for the company manager to measure the effect of the investment on the improvement plan.

[0003] Further, although it has been attempted to investigate the activity time of workers in the workplace, since there is no system capable of easily handling a huge amount of data as in today's day, the activity time data collected can be effectively analyzed. In many cases, it was not possible to make full use of it.

[0004]

[Problems to be Solved by the Invention] As a method of improving work in the manufacturing industry or the like, by investigating and analyzing the activity time of the worker, and focusing on the activity time or the activity costing a lot of activity, the improvement is made. There is a business improvement type activity standard analysis that derives measures. In order to carry out work improvement in a short period of time using the work improvement type activity standard analysis method, it is necessary to establish a sufficient method for utilizing the computer and related resources to process the enormous amount of data investigated. , Is a challenge. FIG. 3 is a basic configuration diagram of this device. 5. Input interface unit 6. ABC database unit 7. Output interface section

[0005]

[Means for Solving the Problem] A more specific solution is described as the first phase of FIG. 1 in which a series of operations for manufacturing system operation are carried out when a business improvement type activity standard analysis is performed in the manufacturing industry or the like. The work of is interviewed and investigated as the current business process. If you do not decide how to call the work or activity in advance, you should avoid expressing the same work or activity in different words and not being counted as the same activity later in the ABC database. In order to carry out this phase.

At this time, the manufacturing process is systematized by classifying it into several hierarchical levels of 2 or more and less than 10. Less than,
Here, assuming a case where the manufacturing process is divided into four layers from level 0 to level 3, a series of working processes are classified into four layers (levels) as shown in FIG. 2 and systematized.

When a single factory handles a plurality of items, each item is set to level 0. In the example, "city milk" and "fresh cream" are level 0.

Generally, in a factory, the process for manufacturing the item is divided into a plurality of workplaces and operated. The process is divided into several parts in this workplace. The process divided into some of these is classified as a process and is set to level 1. For example, "Material warehouse_reception" and "Quality control quality_
Process inspection ”and“ 1st control_preparation / dissolution ”are level 1. In other words, it is convenient in this case to use the name of the workplace plus the name of the process.

Level 2 is the work in the workplace. Work is one step at a time, for example "lifting" or "melting"
Is expressed in words such as.

A work is a series of motions actually involved by a person and is a collection of activities which are individual units. For example, in the case of "lift transportation" described above, "loading goods on the lift",
3 to "carry by lift" and "to remove things from the lift"
The two activities are combined. This activity is set as Level 3 and is included in the minimum unit activity time survey.

A list of the works and activities classified above is provided, and an ID number (hereinafter referred to as an ID) is assigned to each level.
Are allocated and put together in a table with a layout called "activity list" (example: Fig. 4). This table will be the master during the activity time survey. The registration items are IDs and item names for each level. At this time, the activity level ID is unique
Try to be.

Next, the resource information is organized. Here, the resource represents a worker. Resources are classified by resource type. This is a grouping of people with the same hourly unit price as the same resource type. Enter these in the "Resource type list" (example: Fig. 5). In general, employees have a high hourly price, and outsourcing and part-timers have a low hourly price. Originally, the hourly unit price varies from person to person, but in this analysis, the same resource type has the same hourly unit price.
The hourly rate is not the hourly wage itself, but the standard hourly rate that takes into account welfare costs, etc. is used. FIG. 5 shows an example of resource types, and this table is used as a resource type master.

The second phase of FIG. 1 is an activity survey.
Select one standard production day of the factory for one day and investigate.
Ask each worker to write down the activities they have performed in chronological order.

The summarized results are input to the ABC database from the table filled in by each worker in the third phase of FIG. The layout of the ABC database is shown in Figure 6.
It looks like. 8. Sequence No. 9. Level 1_ID 10. Level 1 item name 11. Level 2_ID 12. Level 2 item name 13. Level 3_ID 14. Level 3 item name 15. Various analysis flags 16. Resource: worker name 17. Resource type 18. Total activity time (minutes) 19. “While working” correction time (min) 20. Number of activities (times) 21. Resource unit price (yen) 22. Unit time / total activity time after correction / number of activities (minutes / times) 23. Total time (min) after amendment 24. Activity cost (yen)

As an input interface of the ABC database, the following three points are taken into consideration to simplify the input.

1. If only the 13: level 3_ID of FIG. 6 is input, the 14: level 3 activity name of FIG. 6, the 12: level 2 work name of FIG. 6 on which the activity depends, 11 of FIG. 6: level 2_ID, 10 of FIG. 6: The division name of the level 1 process, 5 items of 9: level 1_ID of FIG. 6 is acquired from the master, and the trouble of inputting is omitted. this is

[Level 3] This is realized by making the ID unique. As a result, when a change in the work to which the level 3 activity is subordinate occurs, it is possible to reflect the change in only the master in the entire ABC database.

2. 16 in FIG. 6: resource name (worker name)
In 17: Resource type input of FIG. 6, the standard time unit price of the resource can be acquired from the resource type master by inputting the resource type. As a result, when the standard time unit price of a certain resource type is changed, it is possible to reflect it in the entire ABC database by changing only the master.

3. When the total activity time 18 in FIG. 6 and the total activity time 20 in FIG. 6 are entered, the activity cost (24 in FIG. 6) of the activity is automatically calculated from the standard time unit price.
Further, the activity cost per activity is automatically calculated and reflected as a unit time (22 in FIG. 6).

The following three items are prepared on the ABC database so that they can be used in the analysis phase.

1. When multiple activities are performed in parallel at the same time, the activity is defined as "while doing", the overlapping time is prorated, the pure time of each activity is calculated, and the corrected total is calculated. It is reflected as time (23 in FIG. 6). The activity time analysis is mainly performed using this corrected total time.

2. The line for inputting each activity (level 3) has an area (15 in FIG. 6) for inputting various flags for classifying the activity. In the analysis phase, this flag allows the activity time to be aggregated. The characteristics for classification are: Operation, B.
Utility, C.I. Waiting, D. Trouble, E. There are five types of product switching work.

A. Operations are activities related to manufacturing, and most activities in the manufacturing process are classified into these. For example, assembling parts, receiving materials, and inspecting. B. Utilities are activities other than manufacturing activities. For example, meals, breaks, gymnastics, etc. All activities are classified as either A or B. Further overlapping, they are also classified into C, D, and E. C. Waiting-related activities are activities related to manufacturing, and are activities that are waiting for other activities or work in process, materials, and the like.
Including waiting for machine steps. For example, waiting for melting, waiting for a truck, etc. D. Trouble is an activity related to manufacturing and is an activity when a trouble occurs. For example, repairs at the time of machine failure, elimination of abnormal products on the line, etc. E. Product type switching work is an activity for switching the product type that flows on the line in the manufacturing related activities. For example, tank switching, packing material replacement, etc.

In the manufacturing industry, it is particularly important to reduce trouble time and product type switching time. Therefore, it is possible to classify and aggregate activities by these flags to grasp how much trouble time and product type switching time are spent. This is the first step for improvement.

Since it is necessary to register the input activities in one database on the database, two types of input interfaces are prepared as shown by 5 in FIG. A. Direct input from the screen (including via WEB) B. It is imported from the spreadsheet entered in the spreadsheet software.

A. The input interface of direct input from the screen is also used for maintenance of the ABC database. By inputting via the WEB, it is possible to input from a remote place. B. When importing from a spreadsheet entered using spreadsheet software, the format for inputting is exported in advance in the form of spreadsheet file of spreadsheet software and passed to the data input person. You will be asked to enter the necessary data into the table file and register it in the ABC database by the method of importing the returned table file. By this method, it is possible to acquire data from a place where the line is not connected and input work in parallel processing at the same time.

The activity data collected in the fourth phase of FIG. 1 is totaled, and the activity data collected in the fifth phase of FIG. 1 is analyzed. When the activity data is input to the ABC database, a total of 12 types of the following 6 analysis results can be generated for each work (level 1) for each work (level 2) and each activity (level 3). All examples are for level 2. 1. Summary data table (Fig. 7) 2. Aggregated data cost ranking table (Fig. 8) 3. Analysis by activity time (pie chart) (Fig. 9) 4. Analysis by activity cost (pie chart) (Fig. 10) 5. Activity time / cost analysis (line graph) (Fig. 11) 6. Activity time analysis table by resource (Fig. 12)

1. The total data table of FIG. 7 is a table in which the activities input for each resource (individual) are summarized by the activity time and activity cost of the same activity by activity ID. It is a table which is a basis of each analysis of 2 to 6.

2. The aggregated data cost ranking table of FIG. 8 is obtained by rearranging the activities written in the aggregated data table in descending order of activity cost, and calculating the cumulative activity cost and the activity cost ratio. Generally, the top 2 activities with the highest activity costs
There is a tendency that the “two-to-eight rule” applies to the fact that the cumulative total activity costs account for about 80% of the total activity costs for the workplace (level 1). Top 2 from this
Considering the improvement measures for the issues that the activities that occupy a large part of the work will lead to the improvement measures that are effective for the whole.

3. The hourly analysis (pie chart) in FIG. 9 is a pie chart showing the ratio of a certain activity time to the activity time of the entire workplace. You can see the ratio of activity time with a large range to total activity time.

4. The cost-based analysis (pie chart) of FIG. 10 is a pie chart showing the ratio of a certain activity cost to the activity cost of the entire workplace. We can see the ratio of activity costs with a large range to the total activity costs.

5. In the time / cost analysis (line chart) of FIG. 11, the activity name is arranged on the horizontal axis and the activity time and activity cost are graphed respectively. By considering improvement measures by focusing on activities with high peaks in this line graph, it is possible to derive improvement measures that are highly cost effective in terms of time.

6. The time analysis by resource in FIG. 12 is a matrix in which the horizontal axis represents the resource (worker) and the vertical axis represents the activity, and it is possible to see the correlation between the activity and the person and the overlapping degree of the activity.

Since the output interface 7 in FIG. 3 enables export to spreadsheet software,
It also supports various other analyses.

In the work improvement type activity standard analysis, the sixth item in FIG.
In the phase, improvement measures will be examined based on the analysis results.
Conduct in a session format, and sort out "problems,""solutions," and "effects."

According to the work improvement type activity standard analysis, the seventh item in FIG.
In the phase, simulate the improvement effect. The effect has a quantitative effect and a qualitative effect, but the quantitative effect can be expressed by performing a simulation using an ABC database. ABC as a simulation method
Copy the database for simulation,
Review the activity itself, change the resource of the activity to a resource with a different unit price, issue various analysis data again, and compare the values before simulation to calculate the effect.

In the work improvement type activity standard analysis, the eighth item in FIG.
The execution plan is formulated in the phase. The person in charge will be appointed for each of the improvement measures formulated in the fourth phase, and the improvement measures will be specified by specifying specific actions and the implementation time. It is this phase that prepares the plan.

What is to be concretely done monthly to realize the improvement measures is specified and used for progress management. If possible, if the progress result is linked to the performance evaluation of the person in charge, the motivation of the person in charge will be improved. If you explain the created improvement plan and execution plan to the company management and get approval, you can move to the implementation phase.

In the work improvement type activity standard analysis, the ninth item in FIG.
Actual improvement is implemented according to the action plan in the phase.

In the work improvement type activity standard analysis, the first item in FIG.
Verification of improvement results in Phase 0. The activity data is collected again by limiting the scope of the activities that have been improved. Input this data into a new ABC database and create analytical data again. By comparing this material with past materials, it is possible to grasp the effect. In this way, it becomes possible to cycle through the "plan", "implement" and "verify" cycles.

[0040]

EXAMPLE FIG. 13 is an outline of a method when this method is carried out in one factory of a food manufacturer. This factory is in charge of the production of milk products for general consumers and the production of fresh cream for commercial and general consumers at the main factory in Kansai of this food manufacturer. The factory has about 120 employees and the annual output is about 21 billion yen. In the example, the workplaces to be surveyed were 7 workplaces related to manufacturing.

The production of milk products and fresh cream products is in the equipment industry. Raw materials (raw milk, butter, juice, etc.) carried by the carrier are received in the receiving tank, passed through the blending process with additives etc. and the sterilization process, and then passed from the receiving tank to the product tank.
Finally, the process of filling the package or bottle and placing it in the refrigerator for shipping to the market was targeted. There are other manufacturing processes such as inspection processes and maintenance processes, and these processes were also targeted.

[0042]

[Effects of the Invention] Prior to applying the improvement to the actual site, the actual improvement effect is expected to be clarified in advance, and the actual improvement effect is simulated by the amount and time. It will be possible to select improvement measures with low load on the work site and high success rate, and apply them to the work site. In this example, as shown in FIG. 13, it took 3 months for the investigation, analysis, and preparation of materials. By this method,
A total of 163 improvement problems, large and small, were extracted from each workplace, and as a result of organizing and examining them, we narrowed down to 24 problems for which a significant improvement effect can be expected. The implementation plan for realizing the improvement of the 24 issues has reached 72 items including the review of the factory layout and the review of the equipment. After the improvement measures were implemented, the improvement effect was estimated to be about 200 million yen per year, which is equivalent to about 1% of the annual sales of about 21 billion yen. However, this does not include capital investment. Here, since the average food manufacturing industry sales to operating profit ratio is about 4% in general, it can be said that the improvement by this method has improved the operating profit by about 25%.

[Brief description of drawings]

FIG. 1 is a basic configuration diagram of a work improvement type activity standard analysis method.

[Figure 2] Concept of activity level of this procedure.

FIG. 3 is a basic configuration diagram of a work improvement type activity standard analysis device.

FIG. 4 is a list of activity items of the embodiment.

FIG. 5 is a list of resource types according to the embodiment.

FIG. 6 is an example ABC database layout.

FIG. 7 is a summary data table of an example.

FIG. 8 is an analysis output result form 1 of the ABC database of the embodiment (activity data cost ranking table).

FIG. 9 is an analysis output result form 2 (activity time analysis graph) of the ABC database of the embodiment.

FIG. 10 is an analysis output result form 3 of the ABC database of the embodiment (activity cost analysis graph).

FIG. 11 is an analysis output result form 4 of the ABC database of the embodiment (activity time / cost analysis graph).

FIG. 12 is an analysis output result form 5 of the ABC database of the embodiment (time analysis table by resource).

FIG. 13 is a method development procedure of the embodiment.

[Explanation of symbols]

1. Level 3 (Activity) 2. Level 2 (work) 3. Level 1 (process division) 4. Level 0 (item) 5. Input interface unit 6. ABC database unit 7. Output interface unit 8. Sequence No. 9. Level 1_ID 10. Level 1 item name 11. Level 2_ID 12. Level 2 item name 13. Level 3_ID 14. Level 3 item name 15. Various analysis flags 16. Resource: worker name 17. Resource type 18. Total activity time (minutes) 19. “While working” correction time (min) 20. Number of activities (times) 21. Resource unit price (yen) 22. Unit time: Total activity time after correction / number of activities (minutes / times) 23. Total time (min) after amendment 24. Activity cost (yen)

Continued front page    (72) Inventor Tsuyoshi Shirahata             2-3 2-3 Uchisaiwaicho, Chiyoda-ku, Tokyo Date             Hiya International Building 18th Floor GA Co., Ltd.             In Bus Consulting F term (reference) 5B075 ND34 NS02 NS03 PQ72

Claims (11)

[Claims] 1. In a factory or the like for a manufacturing industry or the like, a simulation device accompanied by input by a user interface: analysis 1, analysis 2, time cost evaluation, virtual change, estimation of effect, and improvement information are used. Improve device for output, sharing and execution. 2. A user interface for investigating and inputting an activity data and preventing a mistake input or a missing page at the time of performing a business improvement type activity standard analysis in a factory or the like for a manufacturing industry. An improvement device for execution according to claim 1, characterized in that it also uses a layout of forms. 3. An activity standard database for analyzing activity data when performing a business improvement type activity standard analysis in a factory or the like for a manufacturing industry, etc., characterized by using a layout of an ABC database group. An improvement device for carrying out according to claim 1 or claim 2. 4. When registering activity data to be used in a business improvement type activity standard analysis in a factory or the like for a manufacturing industry, etc., at several levels from 0 to less than 10 The improvement device for execution according to claim 3, characterized in that the items are divided into layers, each level item is input with a level ID, and is input to be useful in the analysis phase. 5. A group of output result forms for analyzing the activity data of the ABC database when performing the work improvement type activity standard analysis in a factory or the like for the manufacturing industry: 1. Summary data table (Fig. 7) 2. Aggregated data cost ranking table (Fig. 8) 3. Analysis by activity time (pie chart) (Fig. 9) 4. Analysis by activity cost (pie chart) (Fig. 10) 5. Activity time / cost analysis (line graph) (Fig. 11) 6. The improvement device for execution according to claim 3, characterized in that a resource-specific activity time analysis table (FIG. 12) layout is used. 6. In a factory or the like for a manufacturing industry, etc., when performing work improvement type activity standard analysis, if data is input to an ABC database for analyzing activity data, 1. Summary data table (Fig. 7) 2. Aggregated data cost ranking table (Fig. 8) 3. Analysis by activity time (pie chart) (Fig. 9) 4. Analysis by activity cost (pie chart) (Fig. 10) 5. Activity time / cost analysis (line graph) (Fig. 11) 6. It is characterized in that the analysis output result of the resource-specific activity time analysis table (FIG. 12) is created to save labor, and the claim 1 or claim 2 or claim 3 or claim 4 is characterized.
Or an improvement device for the implementation according to claim 5. 7. In a factory or the like for a manufacturing industry, etc., when conducting a work improvement type activity standard analysis, in order to analyze the activity time, by rearranging the investigated activity time, It is possible to determine whether or not the cost is required, and it is possible to confirm that the “2 to 8 law” tends to hold, 8. A pie chart of activity time is created to analyze activity time in a factory or the like for a manufacturing industry, etc., in order to analyze activity time when performing work improvement type activity standard analysis. It is characterized in that it is defined as an improvement target. Claim 1 or claim 2 or claim 3 or claim 4 or claim 5
An improvement device for the implementation according to claim 6 or claim 7. 9. A pie chart of activity costs is prepared in order to analyze activity costs when conducting a work improvement type activity standard analysis in a factory or the like for the manufacturing industry, etc. It is characterized in that it is defined as an improvement target. Claim 1 or claim 2 or claim 3 or claim 4 or claim 5 or claim 6 or claim 7 or claim 8 Improvement device for implementation as described in. 10. In a factory or the like for a manufacturing industry or the like, when performing work improvement type activity standard analysis, as a means of activity time analysis and activity cost analysis, the horizontal axis represents time and the vertical axis represents activity cost. Create a line graph that draws a line, and define activities with a relatively steep vertical slope as activities with too high an activity cost, and activities with a relatively long distance between one point and the next take too much time. An improvement device for execution, which is characterized by being defined as an activity and being the point of improvement. 11. In the form of a matrix in which workers are taken as resources on the horizontal axis and activities are taken on the vertical axis when performing work improvement type activity standard analysis in a factory or the like for the manufacturing industry. An improvement device for execution, which has a feature that can be used to make a table summarizing activity time, determine the degree of duplication of activities and work and the impact after improvement, and can be used to consider improvement measures.