JP2006040160A - Device and method for creating operation procedure manual - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a creation device of an operation procedure manual and its method by which the operation procedure manual indicating the best operational procedures is always created, small improvement at an individual level is also reflected on other workers, and spread to large improvement of the whole workers, and the best operational procedures are surely matched to the procedures of the operational procedure manual. <P>SOLUTION: Reference data including "operation procedures" and "standard time" is selected from a reference database and whether or not measured "actual operation time" is shorter than the "standard time" is decided. When the "actual operation time" is shorter and "actual operational procedures" are changed from the "operation procedures" of the reference data, the one after change is created as new reference data and the reference data of the reference database is updated. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a work procedure manual creation apparatus and a work procedure manual creation method which are created to instruct a work procedure at a manufacturing site or the like. In particular, the present invention relates to a measure for reflecting the best work procedure of the worker on the manufacturing site in the work procedure manual. The “work procedure manual” in the present specification is not limited to the printed matter printed on the paper, but the information itself when the information on the work procedure is displayed on the screen. .

  In each work process at the manufacturing site, for example, as disclosed in Patent Document 1 below, based on a work instruction given by a designer (engineer), assembly and production of a target product is performed. It is common to create a work procedure manual showing necessary parts, necessary work, the order of those work, and other necessary items, and assemble and manufacture products according to the work procedure manual. In some cases, the work instruction document given by the designer is used as it is as the work procedure manual at the manufacturing site, and the work procedure manual is not created.

Conventionally, the production procedure manuals at the manufacturing site have been created by the person in charge at the initial stage of production, using a word processor, personal computer, etc. Had created it. In addition, each time the work procedure manual needs to be changed due to a design change or the like, the person in charge of the preparation has made corrections and changes to all the work procedure manuals one by one.
JP 2003-67449 A

  As described above, it takes time and effort to create a work procedure manual. In addition, the daily production activity load is large at the production site, so when there is a change in the work procedure due to a new problem, it is not possible to create a new work procedure document that adds the changes. In some cases, the worker's best work procedure does not match the contents of the work procedure manual presented. As a result, when a person who is not engaged in the workplace, such as a factory manager or a process investigator, confirms the work procedure, the worker's actual work and the contents of the work procedure document posted in the workplace are inconsistent. It was sometimes confusing.

  In addition, when one worker notices the best work procedure different from the content of the work procedure manual and personally improves the work procedure, the improvement measures are not reflected in the work procedure manual. It was. For this reason, other workers are working on the work procedure manual without noticing that (there is an improvement measure), and thus the loss that can be reduced cannot be improved. The “best work procedure” here refers to the shortest time (shorter than the work procedure in accordance with the work procedure manual) and no problem in product quality due to the change of the work procedure. A work procedure that can be performed.

  The present invention has been made in view of such points, and the object of the present invention is to always create a work procedure manual showing the best work procedure, and to make small improvements at the individual level to other workers. To provide an apparatus and method for creating a work procedure manual that can be reflected in a large improvement of the entire worker and that can reliably match the best work procedure with the procedure of the work procedure manual. is there.

-Summary of invention-
The solution means of the present invention taken to achieve the above object measures the time actually taken by the worker and evaluates the measured work time to create a work procedure manual. In the created work procedure manual, the work procedure that can be worked in the shortest time is defined (updated) as reference data, and the reference data is stored, so that the work procedure manual that always shows the best work is stored. Creation is possible.

-Solution-
Specifically, the present invention relates to storage means for storing information on a “work item” of a work, a “work procedure” of the work item, and a “standard time” required for the work, and a work in the “work item”. Recognizing the actual work procedure by the person as "actual work procedure", receiving the information from the measurement means for measuring the time required for the work as "actual work time", the storage means and the measurement means, Time comparison means for comparing “standard time” with the above “actual work time”, and an output from this time comparison means, and the time comparison means determines that “actual work time” is shorter than “standard time”. The work procedure comparing means for comparing the “work procedure” stored in the storage means with the “actual work procedure” recognized by the measuring means, and receiving the output from the work procedure comparing means, Procedure comparison means Therefore, when it is determined that the “work procedure” is different from the “actual work procedure”, the “actual work procedure” is updated as the “work procedure” stored in the storage means; Is provided.

  If the work time is shortened by changing the work procedure with small improvements at the individual level of the worker due to this specific matter, this information can be reflected in the work procedure manual, and other workers can also It becomes possible to perform work in accordance with the updated highly efficient work procedure manual. In this way, the work procedure manual is updated sequentially each time improvements are made by each worker, so it is possible to automatically update and create a work procedure manual that summarizes all the improvements of each worker. , Work can be improved efficiently.

  Specific examples of the measuring means include the following. That is, it has a wireless tag in which identification information is recorded and the identification information can be transmitted wirelessly, and a detection range in which the identification information transmitted by the wireless tag can be detected, and when the wireless tag enters the detectable range. The measuring means includes at least one antenna capable of measuring the time and the time when the sensor is out of the perceivable range, and a data receiver that receives each time measured by the antenna as data.

  With this specific matter, for example, if a wireless tag is attached to the operator's hand and an antenna is provided on the action table or parts shelf, the operator's work status can be grasped from the measurement information from the antenna. Can do. This makes it possible to easily recognize the actual work procedure (actual work procedure) and actual work time by the worker. Also, the worker does not need to perform special work to measure the work time (work time can be measured just by performing normal manufacturing work), so that the worker's original work is affected. It is possible to measure the working time.

  As the work procedure manual creation method executed in the work procedure manual creation apparatus according to the above-described solution, the following methods are listed. A step of selecting reference data including the “work procedure” and “standard time” from a reference database storing “work procedure” of a work item and “standard time” information required for the work; A step of measuring the “actual work time” of the worker, a step of determining whether or not the measured “actual work time” is shorter than the “standard time” of the reference data; ”Whether or not the“ actual work procedure ”in the specification is changed from the“ work procedure ”of the reference data, and the above“ actual work procedure ”. A step of replacing the work procedure when the “work procedure” has been changed from the above “work procedure”, a step of creating new reference data based on the replacement operation of the work procedure, and A method for creating a work procedure manual comprising the steps of updating the reference data to new reference data, storing the new reference data as reference data in a reference database, and outputting the updated new reference data. .

  Also in this creation method, when the work time is shortened by changing the work procedure with a small improvement at the individual level of the worker, this information can be reflected in the work procedure manual. As a result, a work procedure manual summarizing all improvements of each worker can be automatically updated and created, and work can be improved efficiently.

  In the present invention, by making a work procedure manual that always shows the best work procedure based on the measurement result, a small improvement at the individual level is reflected in other workers, and the entire worker is greatly improved. In addition, it is possible to create a work procedure manual that can make the best work procedure consistent with the procedure shown in the work procedure manual.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings.

  FIG. 1 is a diagram showing a schematic configuration of a work procedure manual creation apparatus according to the present embodiment, FIG. 2 is a plan view schematically showing a work place to which this work procedure manual creation device is applied, and FIG. FIG. 4 is a diagram showing a reception timing chart, and FIG. 4 is a flowchart showing an operation procedure manual update operation.

−Configuration of work procedure manual creation device−
First, the configuration of the work procedure manual creation apparatus will be described with reference to FIG. The work procedure manual creation apparatus includes a measurement data input device 301 and a calculation device 302.

  The measurement data input device 301 includes a wireless tag 311 in which identification information is recorded and the identification information can be transmitted to the antenna 312 (wireless transmission), and a time when the wireless tag 311 enters a detectable range. And one or more antennas 312 (four as will be described later in this embodiment) that can measure the time when the sensor goes out of the detectable range, and the time measured by the antenna 312 (the wireless tag 311 can detect the time) And a data receiver 313 capable of receiving as data the time when it entered and the time when it went out of the perceivable range.

  On the other hand, the arithmetic unit 302 stores a storage unit 321 that stores the input data of the measurement data input unit 301 as electronic data that can be used for arithmetic processing, and calculates a work time from the electronic data stored in the storage unit 321. Unit 322, and a work procedure manual creation unit 323 as work procedure update means for evaluating the work time calculated by the work time calculation unit 322 and creating (updating) a work procedure manual.

  Further, the work procedure manual creating apparatus determines a work procedure that can be worked in the shortest time among the work procedure manuals created by the arithmetic unit 302 as reference data, and serves as a reference as a storage means for storing the reference data. A data D / B (database) 303, an operation instruction / character input device (such as a keyboard) 304, a display device (such as a display device) 305, and an output device (such as a printer) 306 are provided.

-Work area configuration and work time measurement method-
Next, a method for measuring the working time will be described with reference to FIGS.

  As shown in FIG. 2, the work place 401 is provided with a work table 402 and a plurality of (three in this embodiment) parts shelves 4021, 4022, and 4023 according to the number of work. That is, in this embodiment, a unit assembly operation in which one worker 405 wearing the wireless tag 311 (for example, wearing on a wrist) attaches three parts on the work table 402 to complete the product 403 is taken as an example. explain.

  The work table 402 is provided with one antenna 3124 (hereinafter referred to as a main antenna). Sub-antenna) is installed.

  The main antenna 3124 has a reception area 4044 for measuring the work time of the worker. While the wireless tag 311 is in the reception area 4044, a transmission signal from the wireless tag 311 can be received. ing. Each sub-antenna 3121, 3122, 3123 has receiving areas 4041, 4042, 4043 for reliably grasping the change of work, and when the wireless tag 311 enters the receiving areas 4041, 4042, 4043, wireless A transmission signal from the tag 311 can be received. The reception areas 4044, 4041, 4042, and 4043 of the antennas 3124, 3121, 3122, and 3123 are set to areas that do not interfere with each other.

  Hereinafter, the reception timing of the transmission signal of the wireless tag 311 by the antennas 3124, 3121, 3122, 3123 will be described in parallel with FIG. First, when the worker 405 reaches the parts shelf A 4021, the sub-antenna 3121 installed in the parts shelf A 4021 senses the transmission signal of the wireless tag 311. As a result, the sub-antenna 3121 transmits a sensing signal to the data receiver 313. Then, the arithmetic unit 302 stores this reception timing through the data receiver 313. In this manner, it is detected that the part A stocked in the parts shelf A 4021 has been taken out at the reception timing 501 of the sub antenna 3121 shown in FIG.

  Next, when the worker 405 brings the part A taken out from the parts shelf A 4021 onto the work table 402, the main antenna 3124 on the work table 402 senses the transmission signal of the wireless tag 311. As a result, the main antenna 3124 transmits a sensing signal to the data receiver 313. The main antenna 3124 continues to transmit a signal while receiving the transmission signal of the wireless tag 311. When the main antenna 3124 is sensed, the transmission signal is cut off. In this way, the arithmetic unit 302 stores the reception timings 502 and 503 shown in FIG. 3 through the data receiver 313. The arithmetic unit 302 determines that the transmission time 504 (the time from the reception timing 502 to 503) of the main antenna is the time required for the mounting work of the part A, thereby reducing the work time on the work table 402. calculate. In addition, by measuring the time from timing 501 to timing 503, it is possible to calculate the work time from the operation of taking out the component A from the component shelf A 4021 to the operation of completing the mounting of the component A.

  Similarly, for the parts shelves B and C, each operation time is repeated by repeating the transmission signal sensing operation of the wireless tag 311 and the sensing signal transmission operation to the data receiver 313 by the sub antennas 3122 and 3123 and the main antenna 3124. And the total work time is calculated from the total of each work time. Since the work time is obtained in this way, the measurement data input device 301 and the work time calculation unit 322 constitute the measurement means referred to in the present invention.

  Thus, by using the measurement data input device 301 including the wireless tag 311, the receiving antennas 3124, 3121, 3122, and 3123, and the data receiver 313, the worker can measure the working time. Since it is not necessary to perform a special work, the work time can be measured without affecting the original work of the worker.

-Operation procedure update operation-
Next, the work procedure manual update operation will be described with reference to FIG.

  From the reference data D / B 303, the reference data for the work whose work time is to be measured is selected (step S21). Then, the work time (actual work time) of the worker is measured by the above-described operation by the measurement data input device 301 using the wireless tag 311, the antenna 312, and the data receiver 313 shown in FIG. 1 (step S 22). .

  This measurement time (actual work time) is compared with the total value (standard time) of the reference data, and it is determined whether or not the measurement time is shorter than the reference data (work is fast) (step S23: time referred to in the present invention). Comparison operation of comparison means). If the measurement time is longer than the reference data (the work is slow) NO, this operation is terminated without updating the work procedure manual. On the other hand, if the measurement time is shorter than the reference data (work is faster), the process proceeds to step S24. Here, it is determined whether or not the work procedure is performed as prescribed (step S24). If NO is not performed as specified, this operation is terminated. If YES is being performed as specified, the process proceeds to step S25. Here, it is determined whether or not there is a change in the work procedure within the regulation (comparison operation of the work procedure comparison means in the present invention). Here, if NO is unchanged, the process proceeds to step S27. If YES is present, the work procedure is switched (step S26), and then the process proceeds to step S27. In step S27, new reference data is created based on the measurement result.

  Thereafter, in step S28, the reference data is updated to the new reference data and stored in the reference data D / B 303 (update operation of the work procedure update means referred to in the present invention), and the updated new reference data is output and the process ends. (Step S29). At this time, in step S29, the new reference data 1101 shown in FIG. 10 is output and displayed on the display device 305 or output from the output device 306 as a printed matter.

  In the flowchart of FIG. 4 described above, the “procedure changing method when the work procedure is changed within the rules” processed in steps S24, S25, and S26 will be described in detail below.

  Here, in the example of unit assembling work for attaching the three parts described with reference to FIG.

・ Regular work procedure (1) Install part A → priority number 1
(2) Perform part B installation work-> priority number 2
(3) Installation of part C is performed → priority number 2
Here, the same priority numbers for the parts B and C indicate that the work may be performed from either of them.

  After defining the above-mentioned rules, it is expressed as a priority number 812 in the reference data 801 shown in FIG. The priority number 812 is described separately from the work procedure 811, and a young number is assigned from the work to be performed first, and the same number is assigned to a work zone in which the procedure can be changed. In the example shown in FIG. 7, “part B attachment work” and “part C attachment work” are permitted to be interchanged, and are assigned the same number “2”. Even if the number of operations exceeds three, it is possible to confirm which operations can be changed in procedure by using the same procedure.

  From here, the method of exchanging work procedures will be described with reference to FIGS.

  First, the creation operation of the priority number confirmation table 1003 as shown in FIG. 9 will be described according to the processing flow diagram of FIG.

  A loop counter i is prepared and “1” is set as an initial value (S62). The maximum value “2” is searched from the priority number 812 of the reference data 801 (FIG. 7), and stored as a loop end value designation variable Max (S63). The header part 1011 of the priority number confirmation table 1001 is prepared, the table part 1021 is obtained, and creation of the priority number confirmation table 1001 (uppermost table creation in FIG. 9) is started (S64).

  Next, “1” is written in the priority number of the first row 1012 of the table first row 1012 as the value of the i-th row priority number of the table portion 1021 of the priority number confirmation table 1001, and i in the priority number 821 of the reference data 801 is Since the antenna ID of the row having the matching value, that is, “1” is searched to obtain the antenna ID “A” of the first row, “A” is written as the value of the element 1 in the first row 1012 of the table, and the table The total number of elements “1” is written in the number of elements in the first row 1012 to obtain the priority number confirmation table 1002 (the middle table in FIG. 9) (S65).

  Thereafter, it is determined whether i is equal to or greater than Max (S66). Since i = 1 and Max = 2, NO is determined and the process proceeds to step S67. The loop counter i = i + 1 is executed, i = 2 is set (S67), and the process returns to step S65.

  In the second loop, “2” is written to the priority number in the second row 1013 of the table as the value of the i-th row priority number in the priority number confirmation table 1002, and also matches i in the priority number 812 of the reference data 801. Value, that is, the antenna ID of the row having “2” is retrieved, and the antenna ID “B” of the second row and the antenna ID “C” of the third row are obtained. As the value of element 1, “C” is written as the value of element 2, and the total number of elements “2” is written in the number of elements in the second row 1013 of the table, and the priority number confirmation table 1003 (the bottom table in FIG. 9). ) Is obtained (S65). Then, it is determined whether i is equal to or greater than Max (S66). Since i = 2 and Max = 2, the determination is YES and the process ends.

  Next, a method for determining the work procedure will be described with reference to the processing flowchart of FIG.

  A priority number counter i is prepared and “1” is set as an initial value (S71). Also, a work procedure counter j is prepared and “1” is set as an initial value (S72). 8 is searched from the work procedure 911 of the measurement result 901 shown in FIG. 8, and “3” is stored in the loop end value designation variable Max (S73). A table element counter t is prepared and “1” is set as an initial value (S74). The element number “1” in the first row 1012 of the priority number confirmation table 1003 created by the flowchart of FIG. 5 is extracted, and “1” is stored in the element number designation variable f (S75). The antenna ID of the j-th row, that is, the antenna ID “A” of the first row is extracted from the measurement result 901 and stored in the ID variable x (S76). It is determined whether or not “A”, which is the same as the ID variable x, exists in the elements 1 to n in the first row 1012 of the priority number confirmation table 1003 (S77). If there is no same, it is determined that the procedure is wrong, and the determination result is stored as NG (S83). If there is the same “A”, the table element counter t = t + 1 is performed (S78). Since “A” exists now, t = 2. It is determined whether or not the table element counter t is larger than the element designation variable f (S79). Now, since t = 2 and f = 1, the determination is YES, and the process proceeds to step S84. The priority number counter i = i + 1 (S84) and the work procedure counter j = j + 1 (S85) are performed, and i = 2 and j = 2. It is determined whether the work procedure counter j is larger than the loop end value designation variable Max (S86). Now, since j = 2 and Max = 3, the determination is NO and the processing returns to step S74.

  In the second loop, first, the table element counter t is returned to the initial value “1” (S74). The number of elements “2” in the second row 1013 of the priority number confirmation table 1003 is extracted, and “2” is stored in the element number designation variable f (S75). The antenna ID of the j-th row, that is, the antenna ID “C” of the second row is extracted from the work procedure 911 of the measurement result 901, and “C” is stored in the ID variable x (S76). It is determined whether or not “C” that is the same as the ID variable x exists in the elements 1 to n in the second row 1013 of the priority number confirmation table 1003 (S77). If there is no same, it is determined that the procedure is wrong, and the determination result is stored as NG (S83). If there is the same “C”, the table element counter t = t + 1 is performed (S78). Now, since there is the same “C”, t = 2. It is determined whether or not the table element counter t is larger than the element designation variable f (S79). Since t = 2 and f = 2 at this time, the determination is NO and the process proceeds to step S80. The work procedure counter j = j + 1 is performed (S80), and j = 3. It is determined whether or not the work procedure counter j is larger than the loop end value designation variable Max (S81). Now, since j = 3 and Max = 3, the determination is NO and the processing returns to step S76.

  In the third loop, the antenna ID “B” in the third row is extracted from the work procedure 911 of the measurement result 901, and “B” is stored in the ID variable x (S76). It is determined whether or not “B”, which is the same as the ID variable x, exists in the elements 1 to n in the second row 1013 of the priority number confirmation table 1003 (S77). If there is no same, it is determined that the procedure is wrong, and the determination result is stored as NG (S83). If there is the same “B”, the table element counter t = t + 1 is performed (S78). Now, since there is the same “B”, t = 3. It is determined whether or not the table element counter t is larger than the element designation variable f (S79). Now, since t = 3 and f = 2, the determination is YES, and the process proceeds to step S84. The priority number counter i = i + 1 (S84) and the work procedure counter j = j + 1 (S85) are performed, and i = 3 and j = 4. It is determined whether the work procedure counter j is larger than the loop end value designation variable Max (S86). Now, since j = 4 and Max = 3, the determination is YES, the determination result is stored as OK, and the process ends.

  By the method described above, it can be determined whether the work procedure of the measurement result is performed according to a predetermined rule. By updating the measurement result in which the determination result is stored as OK as new reference data that replaces the existing reference data (step S28 in FIG. 4), the best work procedure that can be performed at the fastest is the work procedure manual. Can be reflected. A small improvement at the individual level can be reflected to other workers and spread to a large improvement in the entire worker, leading to an improvement in the work efficiency of the entire worker.

-Other embodiments-
In the above embodiment, the work time is measured by the input method using the wireless tag 311, the reception antenna 312, and the data receiver 313. However, the work procedure and work time of the worker are performed by video processing analysis using a camera or the like. You may employ | adopt the method of measuring.

  In the above embodiment, the work procedure manual is sequentially updated, but a history of past work procedure manuals may be left. Thereby, when inconvenience arises in the latest work procedure manual, it becomes possible to easily return to the past work procedure manual.

  According to the work procedure manual creation apparatus and method according to the present invention, when a plurality of workers repeatedly perform a series of work in a factory production site or the like, variation due to individual differences among workers can be minimized. And the work procedure of the work can be optimized.

It is a figure which shows schematic structure of the work procedure manual preparation apparatus which concerns on embodiment. It is a top view which shows the outline of the workplace using a work procedure manual preparation apparatus. It is a figure which shows the reception timing chart of an antenna. It is a flowchart figure which shows work procedure manual preparation operation | movement. FIG. 10 is a flowchart for explaining a priority number confirmation table creation operation. It is a flowchart for demonstrating the determination method of a work procedure. It is a figure which shows the reference data of a unit assembly operation. It is a figure which shows the measurement result of working time. It is a figure for demonstrating the preparation order of a priority number confirmation table. It is a figure which shows the new reference | standard data of a unit assembly operation.

Explanation of symbols

301 Measurement Data Input Device 303 Reference Data D / B (Storage Unit)
311 Wireless tag 312 Antenna 313 Data receiver 322 Work time calculation unit 323 Work procedure manual creation unit (work procedure update means)

Claims (3)

A storage means for storing each information of the “work item” of the work, the “work procedure” of the work item, and the “standard time” required for the work;
Recognizing the actual work procedure by the worker in the above "work item" as "actual work procedure", and measuring means for measuring the time required for the work as "actual work time",
Time comparison means for receiving information from the storage means and the measurement means and comparing the "standard time" and the "actual work time";
When the output from the time comparison means is received and it is determined by this time comparison means that the “actual work time” is shorter than the “standard time”, the “work procedure” stored in the storage means and the measurement means Work procedure comparison means for comparing with the "actual work procedure" recognized by
When the output from the work procedure comparison means is received and the work procedure comparison means determines that the “work procedure” is different from the “actual work procedure”, the “actual work procedure” is stored in the storage means. A work procedure manual creation apparatus comprising: work procedure update means for updating as a stored "work procedure". In the work procedure manual preparation apparatus according to claim 1,
Measuring means
A wireless tag in which identification information is recorded and the identification information can be transmitted wirelessly;
At least one antenna having a sensing range capable of sensing identification information transmitted by the wireless tag and capable of measuring the time when the wireless tag enters the sensing range and the time when the wireless tag leaves the sensing range. When,
A work procedure manual creation apparatus, comprising: a data receiver configured to receive each time measured by the antenna as data. Selecting reference data including the “work procedure” and “standard time” from a reference database storing information on “work procedure” of a work item and “standard time” required for the work;
Measuring the "actual work time" of the worker in the above work items;
Determining whether the measured “actual work time” is shorter than the “standard time” of the reference data;
A step of determining whether or not the “actual work procedure” of the worker is as prescribed;
Determining whether the "actual work procedure" within the above rules has been changed from the "work procedure" of the reference data;
Replacing the work procedure when the “actual work procedure” has been changed from the “work procedure”;
A step of creating new reference data based on the above operation procedure replacement operation;
Updating the reference data to new reference data and storing the new reference data as reference data in a reference database;
Outputting the updated new reference data;
A method for creating a work procedure manual characterized by comprising:

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