JP2004195615A - Work indication system - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a work indication system for timely indicating work in tact production in multiproduct mixed production by coping with a production fluctuation. <P>SOLUTION: This work indication system has: a part code DB 11 for storing encoded information in relation to a part name by making a product type of an apparatus product by encoding a part used by the apparatus product; an each part STDB 12 for storing work standard time to a using part of the apparatus product; a skilled degree DB 13 for storing a skilled degree of a worker to the using part of the apparatus product; and a simulation PC 30 and a procedure manual making PC 40 for making work instruction data by indexing an optimal process rate, work order and personnel arrangement by performing simulation on the basis of inputted information and information stored in a commodity code DB 11, the each part STDB 12 and the skilled degree DB 13 when inputting the product style of a production expected apparatus product and its quantity. <P>COPYRIGHT: (C)2004,JPO&NCIPI

Description

[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a work instruction system for instructing assembly, disassembly, and inspection work on an equipment product assembly line, and more particularly to a technique which is effective when applied to a technique for performing the work instruction in a timely manner.
[0002]
[Prior art]
In recent years, various types of equipment products have been developed, and when mixed production is performed on an assembly line, there is a problem in that the working time differs depending on the model, and the line efficiency is greatly reduced. Conventionally, as a countermeasure, files such as work contents, workers, standard flow order, product configuration, equipment jigs and tools are stored in a storage unit in advance, and a production instruction is received from a production management system to minimize tact. There has been a method of executing a work distribution calculation and outputting a work instruction to each line (for example, see Patent Document 1).
[0003]
In addition, for each type of product to be assembled, the arrangement of each worker, the number of staff, the procedure of element work performed by each worker and the standard element time are integrated, a work analysis table is created in advance, and a work analysis table is created in advance. In addition to creating a weighted average distribution table that multiplies the type of products to be mixed, the ratio of the number of production units, and the process time, the weighted average data is used to determine the weighted average cycle time of each process corresponding to each product type, There has been a system for distributing work so that the total of the time is within a set cycle time (for example, see Patent Document 2).
[0004]
Another problem of multi-product production is that the type of work differs depending on the type of machine, so that multi-skilled work is required, work efficiency varies depending on the skill level of the operator, and there is a problem of deterioration in quality. As a countermeasure, there has been known a method of improving the form of a work instruction sheet, such as a method of giving a work instruction to a predetermined place for each process using image data or audio data (for example, see Patent Document 3). A method of giving a work instruction using solid data or animation using three-dimensional CAD (for example, see Patent Document 4) is known.
[0005]
[Patent Document 1]
JP-A-6-168006 [0006]
[Patent Document 2]
JP 2002-215860 A
[Patent Document 3]
JP-A-9-262745
[Patent Document 4]
JP, 2002-56406, A
[Problems to be solved by the invention]
However, in the above-mentioned Patent Documents 1 and 2, since a database such as work contents and the arrangement of workers is created in advance for each product, tact production using a conveyor or the like in multi-product mixed production is performed. If the product changes, it is necessary to recreate the database, it is not possible to determine the optimal process allocation and worker allocation in a timely manner, and even if it takes time, it is necessary to give work instructions for each model and each process unit However, there was a problem that it could not be instructed in a timely manner.
[0010]
In the above-mentioned Patent Documents 3 and 4, the form of the work instruction is improved by using image data, audio data, solid data, animation, and the like. As in the above-mentioned Patent Documents 1 and 2, there is a problem that an optimal process allocation and an operator arrangement cannot be determined in a timely manner.
[0011]
The present invention has been made in order to solve such problems, and a work instruction system capable of responding to production fluctuations and performing a work instruction in tact production in multi-mix production in a timely manner. The purpose is to provide.
[0012]
[Means for Solving the Problems]
A work instruction system according to a first aspect of the present invention is a work instruction system for assembling, disassembling, and inspecting an equipment product on an assembly line, wherein a product model of the equipment product is coded by coding parts used by the equipment product. A component code database that creates and stores the coded information in relation to the component name, a component-specific standard time database that stores the standard working time for components used in equipment products, and an operator for components used in equipment products Once the skill level database that stores the skill level and the product model and the quantity of the equipment product to be produced are input, the input information and the part code database, the standard time database for each part and the skill level database are stored. A simulation is performed based on the information to determine the optimal process schedule, work sequence, and staffing, and Those comprising a processor for creating data.
[0013]
Further, the work instruction system according to the second invention is the work instruction system according to the first invention, further comprising an image database for storing image data of used parts, and the processing device further stores the information calculated by the simulation and the image database. Based on the received information, work instruction data using images is created and distributed to a plurality of display units provided for each worker on the assembly line.
[0014]
Further, the work instruction system according to the third invention is the work instruction system according to the second invention, wherein the work instruction system is provided for each worker of the assembly line, and includes a sensor for recognizing passage of the device product. When the work quantity of each worker reaches the planned quantity based on the information, the next work instruction data is distributed to the display unit of the worker.
[0015]
BEST MODE FOR CARRYING OUT THE INVENTION
Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings.
[0016]
With reference to FIG. 1, an example of a configuration of a work instruction system according to an embodiment of the present invention will be described. FIG. 1 shows a configuration diagram of the work instruction system.
[0017]
1, the work instruction system includes a main server 10, an image data server 20, a simulation PC 30, a procedure manual PC 40, an input control PC 50, a distribution server 60, an output PC 70, and an input passage sensor 80. The processing device is composed of the procedure document creation PC 40, the input control PC 50, and the distribution server 60.
[0018]
The main server 10 includes a component code database (component code DB) 11, a component-specific standard time database (component-specific STDB) 12, a skill level database (skill level DB) 13, and a group model database (group model DB) 14. The image data server 20 includes a component image database (component image DB) 21, a comment database (comment DB) 22, a group model basic image database (group model basic image DB) 23, and a procedure format database ( It is composed of a procedure manual format DB) 24.
[0019]
The simulation PC 30 has a general database (general DB) 31 in which basic information for performing a simulation is stored, and the distribution server 60 stores a procedure manual database (procedure) in which information of a procedure manual to be distributed is stored. DB) 61.
[0020]
The output PC 70 is installed for each worker on the production line, and displays on its monitor an electronic work procedure manual for giving work instructions to each worker.
[0021]
The input passage sensor 80 is provided for each worker on the work line, and counts the number of products that have been completed by each worker.
[0022]
Next, the operation of the work instruction system according to the present embodiment will be described with reference to FIGS. FIG. 2 is a flowchart showing the operation of the work instruction system, FIG. 3 is a diagram showing an example of a production instruction form indicating the product type and the quantity required for production indicated by the higher-level production planning system, and FIG. 4 is a part code DB11. FIG. 5 is a diagram showing an example of group information described in the product model stored in the product model and information that is listed so that parts used by the group model can be categorized. FIG. FIG. 6 is a diagram showing an example of information listing standard times in each process for each part name. FIG. 6 shows the rating for each worker stored in the skill level DB 13 and the skill level for each worker-work classification. FIG. 9 is a diagram illustrating an example of information in a list.
[0023]
First, for example, the input control PC 50 fetches the product type and the quantity of the product of the production instruction, as shown in FIG. 3, output from the higher-level production planning system or the like (S100).
[0024]
Then, the information of the work instruction taken in S100 is sent to the simulation PC 30, and the simulation PC 30 determines the part name from the product model of the work instruction taken in S100 (S101).
[0025]
Here, the determination of the component name in S101 will be described.
[0026]
First, as shown in FIG. 3, the product type indicated in the production instruction is the first three digits of the product type expressed in alphanumeric characters, and represents the group type classified according to the shape and configuration of the product. More specifically, the group models are divided into basic process components such as work processes, housings and covers, and the information is stored in the group model DB 14.
[0027]
The alphanumeric characters after the hyphen of the product model are codes representing the components to be incorporated, and are defined by the component code DB11 shown in FIG. In the case of the product type AAA-AFIJ designated as 1, the first three digits of AAA represent the group type, and the AFIJ after the hyphen is the first digit of the alphanumeric character "A", and the parts shown in FIG. “A” in the first column on the horizontal axis of the table of the code DB 11 is the component name X100. Also, since the second line is "F", similarly, Y030, the third and fourth digits are the same, and since "I" and "J" are Z003 and α001, the component name incorporated from the product model. Is determined.
[0028]
In the part code DB 11, the parts are classified according to similar shapes and work contents, and classification codes are set. In this embodiment, the part names X100, X200, and X300 are classified as “A”, Y010, Y020, Y030 is classified as “b”, Z001, Z002, and Z003 are classified as “c”, and α001, α002, and α003 are classified as “d”.
[0029]
When the determination of the component name is completed in S101, the standard time for serving, assembling, inspecting, etc. is determined from the component name determined in S101 based on the information stored in the component-specific STDB 12 shown in FIG. 5 (S102). . For example, the component name "X100" is a standard time of serving 0.5, assembly 3.0, inspection 0, packing 0.5, and other 0, and the standard time for each component is similarly determined.
[0030]
Then, the information on the standard time for each component determined in S102, the work process for each group type stored in the group type DB 14, the information on the standard time for each component, and the information for the standard time stored for each worker stored in the skill level DB 13 A simulation is performed based on the information on the rating and the skill level, and the product input sequence and input amount, personnel arrangement, and process division are determined (S103).
[0031]
Then, the product input sequence and the input amount, the staffing, and the process division determined in S103 are sent to the input control PC 50 and the procedure manual PC 40.
[0032]
Here, information stored in the skill level DB 13 will be described.
[0033]
As shown in FIG. 6, the information stored in the skill level DB 13 stores the rating for each worker and the skill level for the classification for each worker. And the percentage of all the work that can be done by the worker.
[0034]
For example, in the case of the worker I, the rating is 0.8, which indicates that only 80% of the entire work can be performed.
[0035]
In addition, the information on the skill level for each class indicates the skill level of each worker for the parts of each class, and indicates the ratio of how skilled the worker is for the work of the parts of a certain category. Is shown.
[0036]
For example, in the case of the worker I, the class A is 1, the class B is 1, the class C is 0.8, and the class D is 0.5. Since the degree is 100%, the worker has the ability to work in the rating of the worker. For parts of Class C, the skill level is 80%. This indicates that only 50% of the rating of the worker can be performed with respect to the rating of the worker because the skill level is 50%.
[0037]
Then, the procedure manual PC 40 stores the information determined in S103, the information stored in the component image DB 21, the information stored in the group model basic image DB 23, the information stored in the procedure manual format DB 24, and the comment DB 22. A procedure manual is created based on the obtained information (S104), divided for a plurality of output PCs 70, and stored in the procedure manual DB 61 for each group type (S105).
[0038]
Then, an input instruction is given via the input control PC 50 based on the input order result determined by the simulation in S103, and when the work instruction control is performed (S106), the distribution server 60 sends the instruction based on the information stored in the procedure manual DB 61. The divided electronic work procedure manual is distributed to the plurality of output PCs 70, and the electronic work procedure manual for each worker is displayed on the monitor of the output PC 70 (S107).
[0039]
Here, an example of data stored in the group type basic image DB 23, the component image DB 21, the procedure manual format DB 24, and the comment DB 22 and an electronic work procedure manual will be described with reference to FIGS.
[0040]
FIG. 7 is a view showing an example of an electronic work procedure manual for displaying work procedures on the monitor of the output PC 70. FIG. 8 is a view showing work procedures on the monitor of the output PC 70 when process division is required after simulation. It is a figure showing an example of an electronic work procedure manual.
[0041]
First, the group type basic image DB 23 stores group type basic image data representing the shapes of the basic component parts of the group type, and the part image DB 21 stores component image data representing the shapes of the components for each group type. The procedure manual format DB 24 stores procedure manual format data, which is a format of a work procedure manual including data and character arrangement, and the comment DB 22 stores comment data in which specific work contents required for each part are stored. Is stored.
[0042]
Then, the procedure manual format data stored in the procedure manual format DB 24, the group model basic image data stored in the group model basic image DB 23, the component image data stored in the component image DB 21, The comment data stored in the comment DB 22 is combined, divided, and stored in the procedure manual DB 61 for each group type.
[0043]
The electronic work procedure manual displayed on the monitor of the output PC 70 based on the information stored in the procedure manual DB 61 is, for example, as shown in FIG. 7, and in the example of FIG. Based on the result, a screen display 90 of the assembly work name is displayed at the upper left of the screen, an image display 91 based on the group type basic image data stored in the group type basic image DB 23, and an image display 92 based on the part image data stored in the part image DB 21. , An image display 93 based on the comment data stored in the comment DB 22, a screen display 94 of the work procedure determined by the simulation, and a screen display 95 such as a title.
[0044]
Further, in the example shown in FIG. 7, the work of the four processes is displayed on one monitor, but if it is more efficient to divide the work based on the result of the simulation, as shown in FIG. One electronic work procedure manual is divided into three divided screens and distributed.
[0045]
Next, the switching operation of the electronic work procedure manual displayed on the monitor of the output PC 70 will be described.
[0046]
FIG. 9 is an explanatory diagram for explaining a switching operation of the electronic work procedure manual displayed on the monitor.
[0047]
In FIG. 9, the product 101 transferred by the transfer cart 100 is transferred onto the pallet 102 placed on the roller conveyor 103 of the production line, and is arbitrarily in accordance with the procedure described on the monitor screen 104 of the output PC 70. After assembly and completion, the product 101 is transferred to the carrier 100 and moved to the next step such as inspection.
[0048]
The electronic work procedure manual displayed on the monitor screen 104 can be changed at any time according to the optimum input order and the input quantity obtained in advance by simulation. In this embodiment, the burden on the worker is small, It performs an operation that can be varied in a leeway.
[0049]
First, a sensor 80 capable of detecting the presence / absence of the pallet 102 moving on the roller conveyor 103 is installed between each process on the roller conveyor 103 of the assembly line, and the movement of the pallet 102 is counted.
[0050]
In the electronic work procedure manual displayed on the monitor screen 104, the type of work to be performed and its quantity are registered for each process, and are subtracted each time the pallet passes. Is distributed to each monitor screen 104.
[0051]
Therefore, as shown in FIG. 9, an electronic work procedure manual called AAB is displayed on the monitor screen 104 of the leftmost worker, and an electronic work manual called AAA is displayed on the monitor screens 104 of the remaining workers. Display such as display can be performed in real time.
[0052]
Further, it is also possible to distribute all comments to each monitor according to the quantity.
[0053]
By adopting the display method on the monitor screen 104, the operator does not need to operate the screen one by one, and can obtain an electronic work procedure manual of the next model, thereby improving work efficiency.
[0054]
In this embodiment, the configuration of the work instruction system is configured by the main server 10, the image data server 20, the simulation PC 30, the procedure manual PC 40, the input control PC 50, the distribution server 60, the output PC 70, and the input passage sensor 80. However, the main server 10 and the image data server 20 can be configured as storage devices, and the simulation PC 30, the procedure manual PC 40, the input control PC 50, and the distribution server 60 can be configured as processing devices.
[0055]
Also, in this embodiment, the product type is represented by alphanumeric characters, but the product type is not limited to this, and if the product type can specify a product group or a built-in part, Any coding system may be used.
[0056]
Also, as in this embodiment, the product model numbers used in PDM (Product Data Management: Production Data Management) and SCM (Supply Chain Management) are grouped and incorporated from the product model number. If it is possible to specify the parts that have been set, it is also possible to perform a simulation and give a production instruction based on information from the PDM or SCM.
[0057]
Further, in this embodiment, the example of the production line has been described. However, the present invention is not limited to the production instruction. For example, by using a code that can specify the size, shape, weight, and restrictions of the product in the product model number It is also possible to simulate the type and number of trucks at the time of loading the goods on the trucks in real time.
[0058]
【The invention's effect】
As described above, according to the present invention, a product type of an equipment product is created by coding parts used by the equipment product, and the coded information is associated with the part name in the part code database. The standard time database for parts used in equipment products is stored in the standard time database for each part, and the skill level of workers used for parts used in equipment products is stored in the skill level database. When the product type and quantity of equipment products are input, simulation is performed based on the input information and the information stored in the part code database, the standard time database for each part, and the skill level database, and the optimal process , Work sequence and staffing, and work order data is created. It can be determined in Imuri, also because it is a reliable work instructions in a timely manner, it is possible to respond to changes in the production fluctuation and personnel.
[Brief description of the drawings]
FIG. 1 is a configuration diagram of a work instruction system according to an embodiment of the present invention.
FIG. 2 is a flowchart showing an operation of the work instruction system according to one embodiment of the present invention.
FIG. 3 is a diagram illustrating an example of a production instruction sheet indicating a product type and a quantity required for production instructed by a higher-level production planning system in the work instruction system according to the embodiment of the present invention.
FIG. 4 is a view showing a group type and a part used in each product type stored in the part code DB in the work instruction system according to the embodiment of the present invention. FIG. 6 is a diagram showing an example of information obtained.
FIG. 5 is a diagram showing an example of information listing standard times in each process in a part name unit for each group type stored in the parts STDB in the work instruction system according to one embodiment of the present invention; .
FIG. 6 is a diagram showing an example of information that lists a rating for each worker and a skill level for each worker and for each work category stored in the skill level DB in the work instruction system according to the embodiment of the present invention; It is.
FIG. 7 is a diagram showing an example of an electronic work procedure manual for displaying a work procedure on a monitor of an output PC in the work instruction system according to one embodiment of the present invention.
FIG. 8 is a diagram showing an example of an electronic work procedure manual for displaying a work procedure on a monitor of an output PC when a process division is required after a simulation in the work instruction system according to one embodiment of the present invention.
FIG. 9 is an explanatory diagram for explaining a switching operation of an electronic work procedure manual displayed on a monitor in the work instruction system according to one embodiment of the present invention.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 10 ... Main server, 11 ... Part code database, 12 ... Part-specific standard time database, 13 ... Skill level database, 14 ... Group type database, 20 ... Image data server, 21 ... Parts image database, 22 ... Comment database, 23 ... Group model basic image database, 24 ... Procedure manual format database, 30 ... Simulation PC, 31 ... General database, 40 ... Procedure manual creation PC, 50 ... Input control PC, 60 ... Distribution server, 61 ... Procedure manual database, 70 ... Output PC, 80: Input passage sensor, 90: Screen display of assembly work name, 91: Image display by loop type basic image data, 92: Image display by component image data, 93: Image display by comment data, 94: Work procedure Screen chart , The screen display such as 95 ... title, 100 ... transporting carriage, 101 ... Products, 102 ... pallet, 103 ... roller conveyor 104 ... monitor screen.

Claims (3)

In a work instruction system that performs work instructions for assembly, disassembly, and inspection on the assembly line of equipment products,
A product code of the device product, a component code database for creating by coding the components used by the device product, and storing the coded information in relation to the component name,
A standard time database for each part that stores a standard working time for the used parts of the device product,
A skill level database storing the skill level of the worker for the used parts of the equipment product,
When the product type and the quantity of the equipment product to be produced are input, a simulation is performed based on the input information and the information stored in the component code database, the component-specific standard time database and the skill level database. And a processing device for determining an optimal process schedule, work sequence, and staffing, and creating work instruction data. The work instruction system according to claim 1,
An image database that stores image data of the used parts,
The processing device further creates work instruction data using an image based on the information calculated by the simulation and the information stored in the image database, and is provided for each worker on the assembly line. A work instruction system for distributing to a plurality of display units. The work instruction system according to claim 2,
A sensor that is installed for each worker of the assembly line and recognizes passage of the device product,
The processing device further comprising: when the work quantity of each worker reaches a planned quantity, based on information from the sensor, delivering the next work instruction data to a display unit of the worker. system.

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