JP2003256619A - Quality control system - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To stabilize the quality of product by making uniform the skill of each team for performing the work related to the units of the same category. <P>SOLUTION: Each team 3 performs the work unit by unit in a cell 5. The actual result value of work conducted by one of teams and the standard value are compared to evaluate the work of the team. The evaluation value is equally given to the respective members of the team. Subsequently, some of members of the team having a high evaluation value are added to the members of a team having a low evaluation values. Thus, the members are reshuffled so that the evaluation value is uniform in the respective teams. <P>COPYRIGHT: (C)2003,JPO

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a production system in which a predetermined unit is produced in team units, the productivity of each team is evaluated, and an appropriate rotation plan for the members of the team is automatically created. The present invention relates to a quality control system and a quality control program used for leveling the variation in productivity for each product.

[0002]

2. Description of the Related Art As a general industrial production system, a line production system and a cell production system are known. The line production system is a system in which a worker and working equipment are arranged in the order of processes and the product assembling work is carried out while the product is transported along the line. In the cell production system, work equipment is concentrated in a predetermined space called a cell, and several members collectively perform product assembly work from the state of parts to the finished product. , It is a method of self-contained work. A unit house is an assembly of units such as a bath unit, a kitchen unit, and a front door unit. A cell production system is used to produce these units. In housing production, in order to receive detailed customer orders, the parts, materials, and equipment layout of the same kitchen unit may differ slightly. Therefore, it becomes necessary to make full use of various assembly techniques. By the cell production method, the assembly technique of such complicated units is complemented by the skill of each member to improve the productivity.

[0003]

By the way, the above conventional techniques have the following problems to be solved. The cell production method is suitable for the production of large-scale products including tasks that are difficult to automate, but there is a problem that the productivity varies depending on the proficiency level of the members. In addition, it is difficult to evaluate the amount of work and the work content, and if the production pace is set incorrectly, there is a problem in that harsh work is forced or idle time is increased. Furthermore, it is difficult to train highly-skilled members unless standards are established to properly evaluate the individual capabilities of each member of the team.

The present invention has been made by paying attention to the above points, and the production capacity that constantly changes due to the improvement of the proficiency level of the members and the improvement of the work content is grasped as accurately as possible, and the production is performed at an appropriate timing. The purpose is to provide a quality control system that can provide feedback to the plan. Furthermore, the present invention evaluates productivity in team units, automatically creates an appropriate rotation plan for team members, and levels out productivity variations among teams. The purpose is to provide a management program.

[0005]

The present invention solves the above problems by the following configurations. <Structure 1> One team is composed of a plurality of members, and each of the plurality of teams inputs a performance value required to execute a work for one unit belonging to the same category, and the same means as described above. The means for holding the standard value of the working time for one unit belonging to the category is compared with the actual value and the standard value of each team, and the evaluation value of each team is obtained from the relationship between the actual value and the standard value. And a means for reflecting the evaluation value equally on the evaluation values of the members of each team.

<Structure 2> In the quality control system according to Structure 1, there is provided means for accumulating evaluation values of a plurality of teams for a plurality of units belonging to the same category and executing a standard value optimization process. Quality control system characterized by.

<Structure 3> In the quality control system according to Structure 1, the evaluation values of a plurality of teams that have performed the work for one unit belonging to the same category are compared, and the members of the team with a high evaluation value are compared. A quality control system comprising means for generating new team formation data so that a part of the members of a team having a low evaluation value is replaced with a part of the members selected.

<Structure 4> In the quality control system according to Structure 1, some members of a team having a low evaluation value are replaced by some members of a team having a low evaluation value, and A quality control system comprising means for adding a predetermined bonus point to the newly added evaluation value of a member when the evaluation value of a team having a low evaluation value is improved.

<Structure 5> In the quality control system according to Structure 1, new team formation data is created so that the evaluation values of each team, which is the sum of the evaluation values of the members of the team, are almost equal at a predetermined timing. A quality control system comprising means for generating.

<Structure 6> A process in which one team is composed of a plurality of members, and each of the plurality of teams inputs the actual value required to execute the work for one unit belonging to the same category, The process of holding the standard value of the working time for one unit belonging to the same category is compared with the actual value of each team and the standard value, and the team of each of the teams is determined from the relationship between the actual value and the standard value. A quality control program that causes a computer to execute a process of calculating an evaluation value of 1. and a process of reflecting the evaluation value equally to the evaluation values of the members of each team.

<Structure 7> In the quality control program according to Structure 6, the evaluation values of a plurality of teams are aggregated for a plurality of units belonging to the same category, and the computer is caused to execute the standard value optimization process. A characteristic quality control program.

<Structure 8> In the quality control program according to Structure 6, the evaluation values of a plurality of teams that have executed one unit of work belonging to the same category are compared, and the members of the team with a high evaluation value are compared. Select some, and replace the members with some of the members of the team with a low evaluation value,
A quality control program characterized by causing a computer to execute processing for generating new team formation data.

<Structure 9> In the quality control program according to Structure 6, some members of a team with a high evaluation value are replaced by some members of a team with a low evaluation value, and A quality control program characterized by causing a computer to execute processing of adding predetermined bonus points to the evaluation value of the newly added member when the evaluation value of the team having a low evaluation value is improved. .

<Structure 10> In the quality control program according to Structure 6, new team formation data is created so that the evaluation values of each team, which is the sum of the evaluation values of the members of the team, are almost equal at a predetermined timing. A quality control program characterized by causing a computer to execute the processing to be generated.

[0015]

BEST MODE FOR CARRYING OUT THE INVENTION Embodiments of the present invention will be described below with reference to specific examples. FIG. 1 is a block diagram showing a specific example of the quality control system of the present invention. The team 3 is composed of, for example, three members 4. Each team 3 assembles a unit in a work space called a cell. In the case of a unit house, this unit is a unit product such as a bus unit or an entrance unit. When each team 3 finishes the work of one unit, the work time (actual value) 6 is measured. The computer 1 manages and controls the entire quality control system.
The working time (actual value) 6 is input to the computer 1. The input means of the work time (actual value) 6 may be a keyboard or the like, or various data input devices connected to a network (not shown).

The computer 1 includes a team-based evaluation value calculation means 11, a member-based evaluation value calculation means 12, a category determination means 13, a standard value optimization processing means 14, a team formation data generation means 15 and bonus points. The adding means 16 is provided. Further, the storage device 20 and the storage device 21 are provided. A standard value 22 is stored in the storage device 20. The storage device 21 stores team formation data 23, a team-based evaluation value list 24, and a member-based evaluation value list 25. The storage devices 20 and 21 may be built in the computer 1 or externally attached.

When the working time (actual value) 6 is input to the computer 1, the team-by-team evaluation value calculating means 11 reads the standard value 22 stored in the storage device 20 and performs a predetermined calculation process described later. And has a function of calculating an evaluation value for each team. The member-by-member evaluation value calculation means 12 has a function of calculating the member-by-member evaluation value from the team-by-team evaluation value. The category determination means 13 has a function of determining the category of the unit produced by each team 3. According to this category, the standard value 22 prepared for each category is read.

The standard value optimizing processing means 14 receives a predetermined number of working hours (actual values) 6 and calculates the respective evaluation values. After that, the difference between the standard value 22 and the working time (actual values) 6 is calculated. It has a function of determining whether the standard value 22 is equal to or more than the threshold value, and if the threshold value is exceeded, the standard value 22 is optimized so that the standard value 22 approaches the average value of the calculated evaluation values. The team formation data generation means 15 is the working time (actual value) 6 of several teams that have produced units belonging to the same category.
When there is a variation in the number of team members, it has a function of generating team formation data for rotation of the member 4 by a predetermined calculation process described later. The bonus point addition means 16 has a function of executing a calculation for giving a predetermined member the result obtained by the new team formation as a bonus point.

The team formation data 23 is data managed by the team formation data generation means 15 and displaying the members of each team 3. Evaluation value list by team 24
Are generated by the team-by-team evaluation value calculation means 11, and the member-by-member evaluation value calculation means 12 and the standard value optimization processing means 14 are generated.
Is a data group referred to by. The member-by-member evaluation value list 25 is data generated by the member-by-member evaluation value calculation means 12 and updated by the bonus point addition means 16 at a predetermined timing. Note that each of the above means is composed of a computer program that causes the computer 1 to execute a predetermined process.

In addition, the computer 1 is provided with man-machine interface hardware such as a display, a keyboard, a mouse, and a printer.
The display is a display output device of any configuration for outputting the result of processing by the computer. A keyboard and a mouse are devices for inputting instructions to a computer. Known hardware can be used for all of these man-machine interface hardware, and therefore, illustration and specific description of each function are omitted.

In the above system, each team 3
Each unit of work is executed in the area called cell 5. A unit is a unit of a batch of work that is executed collectively, and a cell 5 is a work area for executing the work of the corresponding unit. How many hours each unit can work is empirically obtained in advance for each unit, or calculated according to a predetermined standard. This value is called the standard value of the working time for one unit. On the other hand, the time actually spent by one of the teams is called the actual value. Obtain the standard value and the actual value, compare them, and evaluate the work of the team. Comparative evaluation is easy if the units have exactly the same work content. However, there are many times when there are no units with the same content. Therefore, each unit classifies the level of work and the difficulty level, and
Determine the category of each unit.

Units belonging to the same category can be compared and evaluated using the same standard value. When there is a difference between the standard value and the actual value, a predetermined evaluation value is given to the team that has performed the work of the unit. For example, if the standard value H / actual value T is 1.2, the evaluation value is plus 20 points. If the standard value H / actual value T is 0.9, the evaluation value is minus 10. The team-by-team evaluation value calculation means 11 performs this processing. This evaluation value may be any value as long as it is a numerical value indicating the degree of improvement in productivity. This rating is given equally to each member of the team. When one team is composed of 6 members, each member is given an evaluation value of 20 points, for example. The evaluation value can be reflected freely, but in principle it is reflected equally to each member of the team. The member-by-member evaluation value calculation means 12 performs this processing.

FIG. 2A is an explanatory view of a unit category according to the work amount, FIG. 2B is an explanatory view of the actual value of the working time of each team, and FIG. 2C is an explanatory view of the team formation. . (A) of the figure is a graph in which the vertical axis represents the amount of work and the horizontal axis represents the unit number of each unit to be assembled. As shown in the figure, the difficulty level and man-hours of the work are calculated in advance for the various units to be produced,
Find the amount of work. It is considered that this work amount is almost proportional to the work time. In this way, the work amounts of the respective units are compared with each other, and units having similar configurations and having similar work amounts are determined as units belonging to the same category.
The category determination means 13 performs this processing. Based on this work amount, the standard value 22 of the work time is calculated, and the storage device 2
Store at 0.

(B) is a graph in which the vertical axis represents the working time and the horizontal axis represents the team number of the team that has worked to produce the units of the same category. The standard value 22 is prepared in advance based on predetermined performance data, and the working time (performance value) 6 of each team 3 is actually acquired. This figure compares the results for each team. The level indicated by the broken line is a standard value. As described above, when there is a variation in the work time actually obtained for each team, the work ability of each team is leveled and the teams are reorganized in order to improve the work ability as a whole.

First, the evaluation values of all teams are compared. In the comparison of the evaluation values of the team, the total evaluation value of all the members of the team is compared. If all 6 members have an evaluation value of 20, the team has an evaluation value of 120. Then, a part of the members of the team having a high evaluation value is moved to the members of the team having a low evaluation value to replace the members. The team formation data generation means 15 performs this processing. (C) of the figure shows the formation of the old and new teams.

The team of NO5 shown in the figure has a short working time and a high evaluation value. On the other hand, the team of NO6 has a long working time and a low evaluation value. In this case, NO
Swap the two members of the No. 5 team with the two members of the No. 6 team. For example, two people in a team whose evaluation values are all 5 points are replaced with two people in a team whose evaluation values are all 20 points. In this way, some of the members of the team with a high evaluation value are added to the members of the team with a low evaluation value to improve their skills. If a new member of a team with a high evaluation value joins a team with a low evaluation value and the evaluation value of the team after that improves, a certain bonus point will be given to the new member who contributed to the improvement of the evaluation value. Given. For example, when a new member joins a team with an evaluation value of 5 and the evaluation value improves to 15 points,
The evaluation value of each of the two new members is increased by 5 points. The bonus point adding means 16 performs this processing.

When such processing is repeated, it becomes clear that the higher the evaluation value, the higher the skill. In addition, by replacing the mabers so that the evaluation value of each team is almost the same for each team, the skills of each team performing the work related to the unit of the same category are equalized, and the product quality can be stabilized. Like Note that setting the standard value is important for calculating the evaluation value. If the skill of each team improves, the standard value will need to be corrected. Therefore, it is advisable to correct the standard value for the work of a large number of units in the same category at an appropriate timing with the evaluation value of each team. The standard value optimization processing means 14 performs this processing.

FIG. 3 is a flow chart specifically showing the overall processing procedure of the computer 1. Steps S1 to S3 are processing procedures based on the function of the category determination unit 13. From step S5 to step S7,
It is a processing procedure based on the function of the evaluation value calculation means 11 for each team. Steps S8 to S9 are processing procedures based on the function of the member-by-member evaluation value calculation means 12. When one of the teams 3 finishes the processing of the cell 5, the working time (actual value) 6 is input to the computer 1. Step S
In 1, the unit name is input. In step S2, the team name is input. In step S3, the actual working time is input. In step S4, the category determination means 13 determines the category of the unit.

In step S5, the team-by-team evaluation value calculation means 11 acquires the standard value 22. Thus, step S
At 6, the evaluation value is calculated. In step S7, the team-based evaluation value list 24 is updated. Next, in step S8, the evaluation value is equally distributed to the members of the team, and the evaluation value for each member is calculated. Based on the result, the member-by-member evaluation value list 25 is updated in step S9. In step S10, it is determined whether processing for another team is necessary. If processing is required for another team, step S
Returning to step 1, the processing from step S1 to step S9 is repeated. By the above processing, when each team completes the assembly of the unit, a list of evaluation values is created for each team member.

FIG. 4 is a flow chart specifically showing the processing procedure of the team formation data generating means 15 of the computer 1. Next, based on the list of accumulated evaluation values, team formation is performed to replace the members of the team with a high evaluation value and the team with a low evaluation value. First, in step S21, the work times of the teams of the units in the same category are compared. Then, in step S22, the difference between the maximum value and the minimum value of the team evaluation values is obtained. Step S23
Then, it is determined whether or not the difference is equal to or larger than a preset threshold value. If the difference between the maximum value and the minimum value is small, the skills of each team are leveled as a whole, and there is no need to reorganize the team. If the difference exceeds the threshold value, step S23.
To step S24. In step S24, the team formation data 2 in which the two members of the team having the maximum evaluation value and the two members of the team having the minimum evaluation value are exchanged
3 is generated. Then, the team formation data 23 in the storage device 21 is updated. In the 26th, it is determined whether or not there is a combination for extracting another one team from the group of units in the same category. Then, with respect to the remaining teams other than the team having updated the team formation data, the maximum value and the minimum value of the evaluation values are compared again, and it is determined whether the team reorganization is necessary. As described above, new team formation data is generated. Team formation data 2
3 is taken out at a predetermined timing and is actually used for reorganization of each team.

FIG. 5 is a flow chart specifically showing the standard value optimization processing of the computer 1 and the evaluation processing procedure of the members of the team. Steps S30 to S35 of (a) are processing procedures based on the function of the standard value optimization processing means 14. Steps S41 to S45 of (b) are a processing procedure based on the function of the bonus point adding means 16. First, the work time list for each team is acquired from the result shown in FIG. 2B, and the maximum value of the work time is detected in step S30. And
Exclude its maximum value. In step S31, the minimum value of the working time is detected and excluded. Step S30
And step S31 is a process for excluding singular points. In step S32, the average value of the working time is calculated. In step S33, the difference between the average value and the standard value is calculated. In step S34, the difference is compared with the threshold value. If the difference is greater than or equal to the threshold, the process proceeds to step S35. In step S35, a correction process is performed to bring the standard value closer to the average value. Specifically, for example, the standard value is replaced with the average value. After that, the process ends. If it is determined that the value is equal to or less than the threshold value in step S34, the process is performed as it is. In this way, the standard value is brought close to the average value at an appropriate timing to optimize the evaluation value calculation process.

In step (b), in step S41, the evaluation value of the team is divided by the number of members of the team. This answer is P
And In step S42, P is added to the evaluation value of each member. In step S43, it is determined whether the evaluation value of the team has improved from the previous time. If the evaluation value of the team has improved, bonus points are calculated in step S44. Finally, in step S45, bonus points are added to the members who newly joined the team and contributed to improving the evaluation value. In this way, the member-by-member evaluation value list 25 is updated. As described above, the team is formed according to the achievement, the ability of the team is leveled, the standard value for evaluation is optimized, and the evaluation value according to the contribution degree is given to each member. As a result, product quality improvement and an efficient production system can be realized.

The computer program installed in the computer 1 may be configured by combining independent program modules, or may be configured by an integrated program. All or part of the processing controlled by the computer program may be configured by hardware having an equivalent function. Further, the above computer program may be incorporated into an existing application program for use. The computer program for implementing the present invention as described above can be recorded in a computer-readable recording medium such as a CD-ROM and installed in any information processing device for use. It can also be downloaded and used in the memory of any computer via a network.

[Brief description of drawings]

FIG. 1 is a block diagram showing a specific example of a quality control system of the present invention.

2A is an explanatory diagram of a category of a unit according to a work amount, FIG. 2B is an explanatory diagram of actual values of working hours of each team, and FIG. 2C is an explanatory diagram of team organization.

FIG. 3 is a flowchart specifically showing the overall processing procedure of the computer 1.

FIG. 4 is a team formation data generation means 1 of the computer 1.
It is a flow chart which shows the processing procedure of 5 concretely.

FIG. 5 is a flowchart specifically showing a standard value optimization process of the computer 1 and a team member evaluation process procedure.

[Explanation of symbols]

1 computer 3 teams 4 members 5 cells 6 working hours (actual value) 11 Team-based evaluation value calculation means 12 Evaluation value calculation means by member 13 Category determination means 14 Standard value optimization processing means 15 Team formation data generation means 16 Bonus point addition means 20 storage 21 storage device 22 standard value 23 Team formation data 24 List of evaluation values by team 25 Evaluation Value List by Member

Claims (10)

[Claims] 1. A team comprises a plurality of members,
Multiple teams each belong to the same category 1
A means for inputting a performance value required to execute a unit of work, a means for holding a standard value of work time for one unit belonging to the same category, a performance value of each team and the standard value And means for calculating the evaluation value of each team from the relationship between the actual value and the standard value, and means for reflecting the evaluation value equally to the evaluation value of the members of each team. A quality control system characterized by that. 2. The quality control system according to claim 1, further comprising means for collecting evaluation values of a plurality of teams for a plurality of units belonging to the same category and executing a standard value optimization process. Characteristic quality control system. 3. The quality control system according to claim 1, wherein the evaluation values of a plurality of teams that have executed one unit of work belonging to the same category are compared, and one of the members of the team with a high evaluation value is compared. A quality control system characterized by comprising means for generating new team organization data so as to replace a member with a member of a team having a low evaluation value by selecting a section. 4. The quality control system according to claim 1, wherein some members of a team having a low evaluation value are replaced and some members of a team having a high evaluation value are newly added. A quality management system comprising means for adding a predetermined bonus point to the newly added evaluation value of a member when the evaluation value of a team having a low evaluation value is improved. 5. The quality control system according to claim 1, wherein new team formation data is generated so that the evaluation values of each team, which is the total of the evaluation values of the members of the team, are almost equal at a predetermined timing. A quality control system comprising means for performing. 6. A team is composed of a plurality of members,
Multiple teams each belong to the same category 1
The process of inputting the actual value required to execute the work for a unit, the process of holding the standard value of the working time of one unit belonging to the same category, the actual value and the standard value of each team And a computer that calculates the evaluation value of each team from the relationship between the actual value and the standard value, and that reflects the evaluation value equally to the evaluation values of the members of each team. A quality control program characterized by being executed by. 7. The quality control program according to claim 6, wherein evaluation values of a plurality of teams are aggregated with respect to a plurality of units belonging to the same category, and a computer is made to perform a standard value optimization process. And quality control program. 8. The quality control program according to claim 6, wherein the evaluation values of a plurality of teams that have performed one unit of work belonging to the same category are compared, and one of the members of the team with a high evaluation value is compared. A quality control program characterized by causing a computer to execute a process of generating new team formation data so as to replace a member with a member of a team having a low evaluation value by selecting a section. 9. The quality control program according to claim 6, wherein a member of a team with a high evaluation value is replaced by a member of a member of a team with a low evaluation value. A quality control program for causing a computer to execute processing of adding a predetermined bonus point to the evaluation value of a newly added member when the evaluation value of a team having a low evaluation value is improved. 10. The quality control program according to claim 6, wherein new team formation data is generated so that the evaluation values of each team, which is the sum of the evaluation values of the members of the team, are almost equal at a predetermined timing. A quality control program characterized by causing a computer to execute the processing.