JP2005085067A - Process charge assignment system for production line - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a process charge assignment system for a production line that enables efficient production of multiple models requiring different workloads on the same production line. <P>SOLUTION: The process charge assignment system, which creates a time schedule of workers on a production line comprising a main line for assembling parts to manufacture products and sub lines for supplying parts to the main line, comprises process information setting means 21 for inputting and setting workers for each process on the main line and inputting and setting information about products in each process on the main line, and work assigning means 22 for grasping a work assignment status of each worker on the main line from the information input and set by the process information setting means 21 and assigning work on the sub lines to idle working times of each worker on the main line to create a time schedule of each worker. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  The present invention relates to a production line process assignment system for creating a time schedule of workers in a production line comprising a main line for assembling parts to produce a product and a sub-line for supplying parts to the main line.

A method for constructing a production line that can produce multiple types of vehicle bodies on a single main line, wherein a main sub-classification process that extracts parts common to each model as main parts and the remaining parts as sub-parts, and sub Synchronous asynchronous classification process that extracts sub-parts that can be assembled in the sub-line in synchronization with the main line, and extracts the remaining sub-parts as asynchronous sub-parts. There is known a method having an asynchronous sub-part assignment step for assigning at least one of a man-hour deviation between main parts different for each model in the main line and a man-hour deviation between synchronous sub-parts different for each model in the sub-line (for example, , See Patent Document 1).
JP 2002-103186 A

  However, the invention described in Japanese Patent Laid-Open No. 2002-103186 does not disclose specific means, and it is necessary to create a work plan by hand.

  The present invention has been made in view of such problems of the prior art, and the object of the present invention is to efficiently produce multiple models with different work loads on the same production line. It is intended to provide a process line assignment system for production lines.

  In order to solve the above-mentioned problem, the invention according to claim 1 is a process for creating a worker's time schedule in a production line comprising a main line for assembling parts and manufacturing a product, and a sub-line for supplying parts to the main line. The assigned assignment system, which inputs and sets the workers of each process on the main line, inputs and sets information on products flowing through each process on the main line, and is input and set by the process information setting means. Work assignment means for grasping the work assignment status of each worker on the main line based on the obtained information and assigning the sub-line work to the work free time of each worker on the main line to create a time schedule is provided.

  According to a second aspect of the present invention, in the production line process assignment system according to the first aspect, the time schedule of the subline created by the work assignment means is displayed, and editing means for freely editing the time schedule is provided. It was.

  The invention according to claim 3 is the production line process assignment system according to claim 1 or 2, further comprising: a time schedule output means for outputting a time schedule of each worker based on the data assigned by the work assignment means. Provided.

  As described above, according to the first aspect of the present invention, based on the process organization of the main line, the work free time of each worker caused by the difference in the work amount of each model flowing through the main line is assigned to the work of the subline. Thus, an efficient work plan can be created.

  According to the second aspect of the present invention, an efficient work plan can be created by reorganizing the timeline of the subline created by the work assignment means so as to satisfy another condition.

  According to the invention according to claim 3, it is possible to create an efficient work plan by reorganizing the time schedule of each worker's subline created by the work assignment means so as to satisfy another condition. it can.

  Embodiments of the present invention will be described below with reference to the accompanying drawings. Here, FIG. 1 is a simplified process organization diagram to which the production line process assignment system according to the present invention is applied, FIG. 2 is a flowchart showing the work procedure, FIG. 3 is a subline work editing screen, and FIG. FIG. 5 is a diagram showing a line staff subline work management table, FIGS. 6 to 8 are flow charts for automatic lot assignment, and FIGS. 9 and 10 are flow charts for worker assignment.

  As shown in FIG. 1, a production line to which the production line process assignment system according to the present invention is applied is an assembly line for a motorcycle.

  The assembly line of the motorcycle includes a main line 1 that assembles components to a vehicle body frame to complete a vehicle, a synchronous subline 2 that assembles components in synchronization with a vehicle body that flows through the main line 1, and a vehicle body that flows through the main line 1. The assembly is composed of asynchronous sub-lines 4 which are assembled in advance and assembled and stored in the stock area 3 before the components are supplied to the main line 1.

  The main line 1 includes an overhead region 5 for assembling components on a body frame that is transported overhead, a frame engine coupling region 6 that is located downstream of the overhead region 5 and that assembles an engine assembly to the vehicle body, and a downstream of the frame engine coupling region 6. A rear coupling area 7 for assembling the rear suspension components to the vehicle body, a front coupling area 8 for positioning the front suspension assembly to the vehicle body downstream of the rear coupling area 7, and a vehicle body positioned downstream of the front coupling area 8 It comprises an exterior / transmission area 9 for assembling an exterior part and a transmission part.

  The synchronization subline 2 is arranged in the vicinity of the rear frame line 10 for assembling a rear frame located in the vicinity of the overhead region 5, the power train inline 11 for assembling a power train located in the vicinity of the frame engine coupling region 6, and the front coupling region 8. It consists of a front suspension line 12 for assembling the front suspension located.

  The asynchronous sub-line 4 includes a dedicated assembly process 13, a large assembly process 14, a medium assembly process 15, a small assembly process 16, and a dedicated assembly process 17, a large assembly process 18, a medium assembly process 19, and a small assembly process 20. ing.

As shown in FIG. 2, the production line process assignment system according to the present invention includes process information setting means 21, work assignment means 22, time schedule editing means 23, and time schedule output means 24. To output the work plan (production line process assignment table). This system is configured by a computer.
The process information setting means 21 inputs and sets the workers of each process of the main line 1, and information on products flowing through each process of the main line 1 is stored in each of the parameter file, main line production plan, process organization, and small assembly parts. Make input settings on the input screen.
In the parameter file input screen, the parameters of the sublines 2 and 4 (subline names, subline attributes, subline positions, etc.), part names, transport times from the sublines 2 and 4 of the parts to the main line 1, sublines 2 and 4 Enter and set operating hours.

  On the main line production plan input screen, the model and the number of productions to be sent to the main line 1 for each lot are input and set. On the process organization input screen, the name of the worker in charge of the work is input and set at the corresponding location. On the small part input screen, enter the item of parts required for the small part process, the actual man-hours that indicate the man-hours required to manufacture one part, the tracking method (part item or asynchronous in the case of synchronization), etc. Set.

  The work assignment means 22 grasps the work assignment status of each worker on the main line 1 based on the information input and set by the process information setting means 21, and sublines 2 4 is assigned, and a time schedule is created for each process (equipment) in sublines 2 and 4.

  When this time schedule is completed, in the subline work editing screen shown in FIG. 3, the work allocation status of each process (equipment) in sublines 2 and 4 including the main line 1 indicates the assembly model in blocks for each work time. expressed. The block is movable.

  Further, the work assignment means 22 creates a time schedule for each worker based on the time schedule of each process (equipment) in the sublines 2 and 4. When the assignment is completed according to this time schedule, the work assignment status of each process (equipment) in sub-lines 2 and 4 including the main line 1 on the personnel assignment plan editing screen shown in FIG. In addition to being represented, the individual personnel assignment status is represented by indicating the process (main line, handle, inner box, etc.) in blocks for each work time. Blocks cannot be moved.

  The time schedule editing means 23 displays the time schedule of the sublines 2 and 4 created by the work assignment means 22 and freely edits this time schedule.

  In the time schedule editing means 23, a line graph (short broken line) representing the number of workers required in the sublines 2 and 4 for each work time in the subline work personnel operating status on the subline work edit screen shown in FIG. The work allocation means 22 compares the line graphs (solid lines) representing the number of workers that become free work time in the main line 1 at every work time, and the work assigning means 22 reduces the number of work free time workers as much as possible. Re-edit the time schedule of the created sublines 2 and 4.

  This re-editing is performed by adjusting the assembly time of parts in the sublines 2 and 4. In addition, like the time slot | zone T shown in FIG. 3, when personnel are insufficient, it eliminates by work assignment correction, or responds with a supporter.

  The time schedule output means 24 outputs the time schedule of each worker created based on the data assigned by the work assignment means 22. For example, a form (item sub leader work management table, line staff sub line work management table, worker work) that describes items, start time, end time, work location, production quantity, personnel name, number of personnel, work time, etc. (Instruction table) is displayed on the screen or printed.

  FIG. 5 shows an example of a sub-line work management table for line staff, describing the start and end time, model, item, number of production, number of personnel, personnel name, etc. in a certain process (equipment name: 1 C / V). It is useful for staff work management.

  The operation of the production line process assignment system according to the present invention configured as described above will be described.

  First, as shown in FIG. 2, in step SP1, the process information setting means 21 inputs data relating to the production line using the parameter file, main line production plan, process organization, and small part input screens.

  In step SP2, a worker having a work free time is searched for in the main line 1, and a workable time is calculated in the sublines 2 and 4 of the worker.

  Next, in step SP3, the work assignment means 22 performs lot assignment processing for the sublines 2 and 4. The lot allocation processing of the sublines 2 and 4 is performed according to the flowcharts shown in FIGS.

  In step SP4, a work plan for the sublines 2 and 4 is created by the work assigning means 22 and the time schedule editing means 23. The personnel plans for sublines 2 and 4 are created according to the flowcharts shown in FIGS.

  Next, in step SP5, the time schedule output means 24 uses the sub-line work management table for small leaders and the sub-line work management table for line staff (item staff, start time, end time, work place, number of production, worker name, etc.) FIG. 5), an operator work instruction table work plan and the like are output.

  As shown in FIG. 6, the lot allocation process of sublines 2 and 4 in step SP3 initializes the internal memory in step SP10, and performs the initial allocation process in step SP11. In step SP12, it is determined whether or not the reallocation execution is set. If the reallocation execution is set, the reallocation processing is performed in step SP13. If the reallocation execution is not set, the process proceeds to step SP14 to store the allocation result as a database. And lot allocation processing is completed.

  As shown in FIG. 7, in the initial allocation process in step SP11, an allocation lot is selected in step SP20 on the basis of the item shape and the start reference time, and in step SP21, the standard work location of the lot is set as a search target work location. In the search target work place, search for an empty space on condition that it is as close as possible to the start reference time.

  In step SP23, it is determined whether or not an empty space is found. If an empty space is found, the empty space is stored in step SP24, and if not found, whether or not there is an unprocessed work place in step SP25. to decide. If there is an unprocessed work place, the process returns to step SP22 with the unprocessed work place as the search target work place in step SP26, and if there is no unprocessed work place, the free space stored in step SP27. The lot is assigned to the space ignoring the personnel, and the process proceeds to step SP30.

  Next, in step SP28, it is determined whether or not there are enough personnel. If there are enough personnel, a lot is allocated to the empty space in step SP29, and if there are not enough personnel, the process returns to step SP21. In step SP30, it is determined whether or not all the lots have been allocated. If all the lots have been allocated, the initial allocation process ends. If all the lots have not been allocated, the process returns to step SP20.

  In addition, as shown in FIG. 8, in the reassignment process in step SP13, a lot to be reassigned is selected in the initial assignment in step SP40 under the condition that the number of personnel is over, and in step SP41, the priority is multiplied to the manpower / work place / inventory. The evaluation value of the initial allocation lot is calculated on the condition calculated in the above.

  Next, in step SP42, the initial allocation lot is set as a candidate for reassignment, and in step SP43, an empty space is searched in all work places on condition that it is as close as possible to the start reference time. In step SP44, it is determined whether or not an empty space is found. If an empty space is found, an evaluation value of a reallocation candidate is calculated in step SP45. If no empty space is found, the reallocation candidate is assigned to the initial allocation lot in step SP46. Determine whether they are not equal.

  If it is determined in step SP46 that the reallocation candidate is not equal to the initial allocation lot, the initial allocation lot is deleted and the reallocation candidate is allocated in step SP47. If it is determined that the reallocation candidate is equal to the initial allocation lot, Proceed to step SP48.

  In step SP49, the evaluation value of the reallocation candidate is compared with the evaluation value of the current candidate. If the evaluation value of the reallocation candidate is larger than the evaluation value of the current candidate, the lot assigned to the free space in step SP50 is reallocated. The process returns to step SP43 as a candidate, and if the evaluation value of the reallocation candidate is smaller than the evaluation value of the current candidate, the process returns to step SP43.

  In step SP48, it is determined whether or not all the lots have been allocated. If all the lots have been allocated, the reallocation process ends. If all the lots have not been allocated, the process returns to step SP40.

  Next, as shown in FIG. 9, in the process of creating the subline personnel plan in step SP4, the work on the planned day is first listed for each subline in step SP60, and the availability of sublines 2 and 4 is high in step SP61. The allocation order of the sublines 2 and 4 is determined in order. Then, in step SP62, jobs are extracted from the list of sublines 2 and 4 in the order of allocation, and the job allocation priority on the same sublines 2 and 4 is set higher in the future than in the past.

  Next, in step SP63, it is determined whether or not there is an unassigned work. If there is an unassigned work, a workable person is selected in step SP64, and the work staff assigned to the subline 2 or 4 with the work assigned immediately before is selected. Search for. If there is no unassigned job, the process proceeds to the next-ranked work list in step SP65 and returns to step SP63.

  In step SP66, it is determined whether or not there is a corresponding person, and if there is a corresponding person, it is determined whether or not it is completely assigned in step SP67. If there is no corresponding person, a search is made for a person who can afford the work in step SP68. In step SP69, it is determined whether or not there is an appropriate person. If there is an appropriate person, the process proceeds to step SP67, and if there is no appropriate person, the work is removed from the work list as unassignable in step SP70.

  In step SP67, it is determined whether or not the personnel are completely allocated. If the personnel is completely allocated, the job is removed from the work list in step SP71. If the personnel is not completely allocated, the task is not allocated in step SP72. Insert a new part into the list.

  Next, in step SP73, it is determined whether or not the check has been completed for all work. If the check has been completed for all work, the assignment is completed after performing the adjustment process in step SP74, and the check is completed for all work. If not, the process returns to step SP63.

  In the adjustment process in step SP74, as shown in FIG. 10, the work assigned to individual personnel in step SP80 is first checked from the beginning. Next, it is determined whether or not there is an unadjusted job for the personnel A in step SP81. If there is an unadjusted job in the personnel A, the job to be adjusted by the personnel A is set to T1 in step SP82. If there is no unadjusted work for personnel A, the process proceeds to the next personnel in step SP83 and returns to step SP81.

  Next, in step SP84, it is determined whether or not there is a person B who has a work T2 that is different from the work T1 and has the same assignment time. The process proceeds to SP85, and if there is no person B who has a work T2 that is different from the work T1 and has the same allocation time, the process proceeds to step SP87.

  In step SP85, it is determined whether any work before and after the worker A is the same as the job T2, and if any work before and after the worker A is the same as the job T2, the worker A in step SP86. The work T1 and the work T2 of the worker B are exchanged, and if any work before and after the worker A is not the same as the work T2, the process proceeds to step SP87.

  Next, in step SP87, it is determined whether or not all the adjustment processes are completed. If all the adjustment processes are completed, the adjustment process is completed. If all the adjustment processes are not completed, the process returns to step SP81. .

  Based on the process organization of the main line, an efficient work plan can be created by allocating the work idle time of each worker caused by the difference in work amount of each model flowing through the main line to the work of the subline. Further, an efficient work plan can be created by reorganizing the time schedule of the subline so as to satisfy another condition. Furthermore, an efficient work plan can be created by reorganizing the time schedule of each worker's subline so as to satisfy different conditions. Therefore, according to the present invention, it is possible to efficiently configure a production line for multi-model small-volume production.

Simplified process organization chart to which the production line process assignment system according to the present invention is applied The flowchart which shows the work procedure of the process charge assignment system of the production line which concerns on this invention Figure showing the subline work editing screen Figure showing the personnel assignment plan edit screen The figure which shows the subline work management table for line staff Flow chart for automatic lot assignment Flow chart for automatic lot assignment Flow chart for automatic lot assignment Flow chart of worker assignment Flow chart of worker assignment

Explanation of symbols

  DESCRIPTION OF SYMBOLS 1 ... Main line, 2 ... Synchronous subline, 3 ... Stock area, 4 ... Asynchronous subline, 21 ... Process information setting means, 22 ... Work allocation means, 23 ... Time schedule edit means, 24 ... Time schedule output means

Claims (3)

This is a process assignment system that creates time schedules for workers in a production line that consists of a main line that assembles parts and manufactures products, and a sub-line that supplies parts to the main line. Process information setting means for inputting and setting information on products flowing through each process on the main line, and work assignment on each worker's main line based on the information input and set by the process information setting means A production line process assignment system characterized by comprising a work assignment means for grasping the situation and assigning a work of a subline to a work free time of each worker on the main line to create a time schedule. 2. The production line process assignment system according to claim 1, further comprising an editing means for displaying the time schedule of the subline created by the work assignment means and freely editing the time schedule. 3. The production line process assignment system according to claim 1, further comprising time schedule output means for outputting a time schedule of each worker based on the data assigned by the work assignment means.