JP2006079287A - Device and method for organizing production process - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To attain efficient organization by making the best of the features of a coexisting line under the consideration of the fluctuation of an operation time accompanied with the allocation contents of a process. <P>SOLUTION: This production process organizing method comprises steps (step S306 to step S309) for calculating a product type categorized operation time per product in each of a plurality of processes allocated to each operator by adding a fluctuating time required for an operation which fluctuates according to the allocation contents of a process and a fixed time required for an operation which does not fluctuate according to the allocation contents, a step(step S310) for calculating a weighted time by weighting and averaging the product type categorized operation time according to the rate of the product type and a step for permitting a tact time to be acquired by subtracting the prescribed number of request production by an operating time to be exceeded by at least one of the product type categorized operation time, and for allocating the process so that the tact time cannot exceed the weighted time. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a production process organization apparatus and method, and more particularly, to a production process organization apparatus and method for assigning a plurality of processes to a plurality of workers on a production line in which a plurality of types of products flow.

  The allocation (organization) of processes to a plurality of workers is executed based on the assembly order (process order) of products and the restrictions of equipment installed in the production line. However, a production line for precision machines such as engines includes many processes. As a result, the combinations of allocation of these processes are diverse and complicated, and there is a limit to manual allocation work. Therefore, conventionally, a production process organization apparatus for assigning processes to a plurality of workers has been proposed.

  On the other hand, production lines (hereinafter referred to as “mixed lines”) in which a plurality of types of products flow in a mixed manner are now common. The mixed line is characterized in that a plurality of types of products are produced, and the work time required for each product differs for each product type.

  Therefore, for one type of product, even if the work time in the process assigned to a certain worker exceeds the target tact time, the work time for the other type of product is not included in the tact time. If there is a margin, the more efficient knitting becomes possible by offsetting the excess by the unreached portion. However, in order to enable such efficient knitting, it is required to calculate the reference work time with high accuracy.

  In recent years, a production process knitting apparatus that can be applied to a mixed line has been proposed (Patent Document 1). The work organization system disclosed in Patent Document 1 can be said to be a production process organization device configured to calculate an average work time per product in each work process unit based on the production ratio of each vehicle type. .

However, since the time factor such as the worker's walking time changes when the process assignment changes, the work time may also vary. The work organization system disclosed in Patent Document 1 cannot calculate the work time with high accuracy because it does not take into account the change in work time associated with such a change in the content of the process assignment. Therefore, the work knitting system disclosed in Patent Document 1 has a difficulty in realizing efficient knitting using the characteristics of the mixed line as described above.
Japanese Unexamined Patent Publication No. 2000-218475 (paragraph numbers “0022” to “0025”, FIG. 7, FIG. 9, etc.)

  The present invention has been made to solve the above problems. An object of the present invention is to provide a production process knitting apparatus and a production process knitting method capable of efficient knitting taking advantage of the characteristics of the mixed line in consideration of fluctuations in work time according to process allocation contents. is there.

  In order to solve the above problems, the present invention has the following configuration.

  (1) The production process organization apparatus of the present invention is a production process organization apparatus that assigns a plurality of processes to a plurality of workers in a production line in which a plurality of types of products flow in a mixed manner, and the processes assigned to each worker. First, calculating a work time for each product type per product in the process by adding a change time required for work that varies depending on the content of the process and a fixed time required for work that does not vary depending on the content of the assignment A calculation means, a second calculation means for calculating an average weighted time by weighting the work time for each product type according to the ratio of the product type, and dividing a predetermined required production number by the operating time. The tact time obtained in this way is allowed to exceed at least one of the work times for each product type, while the weighted time is not exceeded. Characterized in that it has a allocation means for allocating step.

  (2) The production process organization method of the present invention is a production process organization method for allocating a plurality of processes to a plurality of workers on a production line in which a plurality of types of products flow in a mixed manner. Adding a variation time required for work that varies depending on the content of the process allocation and a fixed time required for work that does not vary depending on the content of the allocation, and calculating a work time for each product type per product in the process; A step of calculating a weighted time obtained by weighting the working time for each product type according to a ratio of the product type and taking an average, and a tact time obtained by dividing a predetermined required production number by an operating time. A step of assigning a process so that at least one of the work times for each product type is allowed to be exceeded, but the tact time is not exceeded. And having a, the.

  According to the production process knitting apparatus and method of the present invention, a production process knitting apparatus capable of efficient knitting utilizing the characteristics of the mixed line while taking into consideration that the working time varies depending on the contents of the process allocation, and A production process organization method can be provided.

  The production process knitting apparatus according to the embodiment of the present invention is an apparatus that executes work process knitting. Specifically, a plurality of processes are transferred to a plurality of workers in a production line in which a plurality of types of products flow. It is an allocating device. In particular, the production process organizing apparatus obtains the work time in consideration of the fluctuation of the work time associated with the process allocation contents. Even if the working time for one type of product exceeds the target tact time (reference time), the working time for another type of product has not reached the tact time, and there is a margin. If there is, the process is allocated as it is by offsetting the excess by the unreached portion. Hereinafter, the production process organization apparatus of the present embodiment will be described with reference to the drawings.

  FIG. 1 is a diagram illustrating an example of a schematic configuration of a production process organization apparatus according to the present embodiment. The production process organizing apparatus 1 is configured by a computer such as a personal computer or an engineering workstation, for example. As shown in FIG. 1, the production process organization device 1 includes a processor 11, a display unit 12, a memory 13, an operation unit 14, and a hard disk 15.

  The display unit 12 is, for example, a display device such as a liquid crystal display or a CRT, and displays intermediate results and final results of the production process organization process.

  The memory 13 includes a RAM and a ROM, stores various data and parameters, and provides a working area in which processing is executed.

  The operation unit 14 is a pointing device such as a keyboard, a mouse, and a touch panel, and is used when a user inputs and gives various information.

  The hard disk 15 is a storage unit that stores a program executed by the processor 11. The hard disk 15 stores various data necessary for executing the production process organization process in advance. These necessary data include, for example, a process list, an element work list, a required production number, an operating time, line arrangement data, walking speed data, a product type ratio, a product input schedule, and facility specifications.

  The process list is a list of processes executed on the production line. It can be said that the production process organization device 1 assigns a plurality of processes included in the process list to a plurality of workers. On the other hand, the element work list is a list of works included in each process. The element work list is used to calculate the work time for each product type per product in each process. The process list may be provided together with the element work list in one piece of data.

  The required production number is the production number of products required on the production line. The required production number is determined in advance based on the production plan. The operating time is the time for operating the production line. The required production number and the operation time are used for calculating a target tact time.

  The line arrangement data is CAD data including layout information such as equipment arrangement, shelf position, and buffer area arrangement for temporarily storing products. Specifically, it is desirable to store a plurality of types of line arrangement data according to the combination of each process that can be arranged. The line arrangement data is used not only in the process flow simulation but also in considering the change in walking time according to the process assignment, which is one of the feature points of the present embodiment. The walking speed data is a worker's walking speed and is set in advance. Walking speed data is also used to calculate walking time.

  The product type ratio is the ratio of product types flowing through the mixed line. The ratio of the product type is used to calculate a weighted time (average work time) obtained by weighting the work time for each product type according to the ratio of the product type and taking an average.

  The product introduction schedule is the order in which products are introduced into the mixed line. Equipment specifications include cycle time and availability. The product input schedule and facility specifications are mainly used by process flow simulation.

  In addition, the necessary data includes organization rules. The organization rules include process order, which is information relating to the order of processes, restrictions by processes (hereinafter referred to as “process restrictions”), and restrictions by equipment (hereinafter referred to as “equipment restrictions”). Process constraints and equipment constraints are information on processes that must be continuously executed by the same worker (hereinafter referred to as “same worker execution constraints”), and information on processes that cannot be executed continuously by the same worker. (Hereinafter referred to as “non-holdable restrictions”).

  A recording medium other than the hard disk 15 can also be used as a storage unit for storing these necessary data. In addition, necessary data can be acquired from another device via a network (not shown).

  Next, the processor 11 will be described. The processor 11 is a so-called CPU (Central Processing Unit), and plays various roles such as a calculation unit, an allocation unit, a simulation unit, and a correction unit by executing a program stored in the hard disk 15 or the like.

  A calculation part is divided roughly and contains a 1st calculation part and a 2nd calculation part. A 1st calculation part is a 1st calculation means which calculates the working time according to the product type per product in a process about a plurality of processes allocated to each worker. Here, as shown in FIG. 2, the work time includes a change time required for work that varies depending on the content of the process assignment, and a fixed time required for work that does not vary depending on the content of the assignment. Therefore, the first calculation unit calculates the work time for each product type per product in the process by adding the variation time and the fixed time. Here, the variation time is, for example, the worker's walking time that varies depending on the content of the process assignment. In addition, the variation time may include a time required for the operator's reflection operation (reflection time) depending on the contents of the process.

  On the other hand, the second calculation unit is a second calculation unit that calculates a weighted time obtained by weighting the work time for each product type calculated by the first calculation unit according to the ratio of the product type and taking an average. is there.

  The allocation unit is an allocation unit that allocates a plurality of processes to a plurality of workers. Specifically, the process is assigned such that at least one of the work times for each product type exceeds the target tact time and the weight time does not exceed the tact time. In particular, the allocation unit allocates processes according to the above-described knitting rules. Here, the tact time is obtained by dividing a predetermined required number of production by the operation time.

  The simulation unit is a process flow simulation unit that executes a dynamic process flow simulation. The simulation unit simulates the flow of products in the production line and predicts the number of products produced on the production line.

  The correction unit is a correction unit that automatically corrects the process allocation content by the allocation unit so that the predicted production quantity on the production line reaches the required production quantity in response to the result of the dynamic process flow simulation.

  The production process knitting apparatus 1 configured as described above executes the production process knitting process as follows. Below, the processing content of the production process organization apparatus 1 of this Embodiment, in other words, the production process organization method of this Embodiment is demonstrated. In the following description, a plurality of processes are performed on a plurality of workers A, B, and C in a production line in which a plurality of types of products a, b, and c flow. The case of assignment will be described as an example.

  FIG. 3 is a flowchart showing a processing procedure performed by the production process organization device 1 according to the present embodiment. The processing contents shown in the flowchart are stored as a computer program in a storage unit such as the hard disk 15, and this computer program is executed by the processor 11.

  First, various necessary data are acquired (step S101). Specifically, the process list, the element work list, the required production number, the operating time, the line arrangement data (CAD data), the walking speed data, and the product type ratio are acquired.

  FIG. 4 shows a process order (part assembly order). Specifically, the relationship between each part and process is shown. Based on the product drawing (not shown), the necessary components are selected. Then, using FIG. 4, a process corresponding to a necessary component is selected. As a result, a process list that is a list of processes necessary for the production line is acquired.

  5 and 6 show element work lists included in each process. As shown in FIG. 5, for example, a plurality of element operations (head dowel removing, hammer removing, dowel setting, feeding, hitting, hammer placing, and next process walking) included in step I (cylinder head dowel assembly) are shown. It is. Hereinafter, similarly, for the steps II to IV, the element work included in each step is shown. Based on such an element work list, the time required for each element work (fixed time and variable time) is calculated, and for each process (work group), the time required for all the element work is added. The working time for each process is calculated. As shown in FIGS. 5 and 6, the fixed time is set in advance for each element work. On the other hand, the change time required for the work that varies depending on the contents of the process assignment, such as work number 7 “next step walking” of process I, is appropriately calculated according to the contents of the process assignment.

  Next, a composition rule is acquired (step S102 in FIG. 3). In addition to the order of steps as shown in FIG. 4 described above, the organization rules include the same worker execution restrictions and the non-holdable restrictions described above (not shown). The organization rules are stored in advance.

Next, the first work organization process is executed (step S103). Here, the first work organization process is the following process.
(First work organization process)
7 and 8 are flowcharts showing an example of the first work organization process. 7 and 8 correspond to the subroutine of step S103.

  First, an operator is selected (step S201). For example, first, worker A (first worker) is selected. Next, a process is selected according to the process order shown in FIG. 4 (step S202). Next, it is determined whether or not the selected process violates the holding restriction (step S203). In the case of conflicting with the non-holding restriction (step S203: YES), the same worker A cannot execute the selected process, so the process proceeds to step S212 in FIG. 2 workers) is selected. Then, a process is assigned to the selected next worker B (step S211). On the other hand, if there is no conflict with the non-holdable restriction (step S203: NO), the process proceeds directly to step S204.

  In step S204, it is determined whether or not the next process of the selected process needs to be executed by the same worker. That is, it is determined whether or not there is a same worker execution constraint related to the selected process. If it is necessary for the same worker to execute the next process (step S204: YES), the next process is also selected at the same time (step S205). On the other hand, when it is not necessary for the same worker to execute the next process (step S204: NO), the process of step S205 is skipped and the process proceeds to step S206.

  Next, a fixed time when a process is assigned to the selected worker A is calculated for each product type (step S206). Specifically, based on the element work list shown in FIG. 5 and FIG. 6, among the element works included in the selected process, the total time required for each element work that does not vary depending on the process assignment content is obtained. Is used to calculate the fixed time.

  Next, in step S207 and step S208, the variation time required for the element work that varies depending on the content of the process assignment among the element works included in the selected process is calculated. Specifically, the variation time is the worker's walking time that varies depending on the content of the process assignment.

  First, in step S207, a work flow line that is a worker's walking route is acquired based on line arrangement data (CAD data). Then, the walking distance of the worker is calculated from the acquired work flow line. In step S208, the variation time when the process is assigned to the selected worker, specifically, the walking time is calculated for each product type. The walking time is calculated by reading the walking speed data set in advance and multiplying the walking speed by the walking distance.

  Next, by adding the fixed time calculated in step S206 and the walking time calculated in step S207 and step S208 for a plurality of processes assigned to each worker, the product type per product in these processes Another working time is calculated (step S209).

  FIG. 9 is a diagram schematically illustrating an example of calculating the working time in consideration of the walking time that varies depending on the content of the process assignment. FIG. 9A shows a case where steps 1 to 3 are assigned to the worker A and steps 4 and 5 are assigned to the worker B. On the other hand, FIG. 9B shows a case where Step 1 and Step 2 are assigned to the worker A, and Steps 3 to 5 are assigned to the worker B.

  First, in the organization shown in FIG. 9A, the work time for each product type in the steps 1 to 3 assigned to the worker A, and the products in the steps 4 and 5 assigned to the worker B. The working time for each product type is as shown in Table 1 below.

  Considering each process, it is as follows. The fixed time in the working time of step 1 is 0.16. The walking time to the next step is walking distance 1.5 m × walking speed 0.015 minutes / m = 0.0225 minutes. The walking time to the next process becomes a variation time in the work time of the process 1. Therefore, the total operation time of step 1 is 0.16 minutes + 0.0225 minutes = 0.1825 minutes.

  Similarly, in step 2, the fixed time is 0.21 minutes and the walking time is 2 m × 0.015 minutes / m = 0.03 minutes, so the work time in step 2 is 0.21 + 0.03 = 0.24 minutes. In Step 3, since the fixed time is 0.13 minutes and the walking time is (3 + 3.2) m × 0.015 minutes / m = 0.0945 minutes, the working time in Step 3 is 0. .13 + 0.0945 minutes = 0.2245 minutes.

  Therefore, when the processes 1 to 3 are assigned to the worker A, the work time of the processes 1 to 3 is 0.1825 + 0.24 + 0.2245≈0.65 minutes.

  Similarly, when the process 4 and the process 5 are assigned to the worker B, the work time of the process 4 and the process 5 is a fixed time of 0.18 + 0.14 minutes, and the walking time which is a variable time is 0. .11 minutes, so 0.43 minutes.

  On the other hand, in the organization shown in FIG. 9B, the work time for each product type in the process 1 and the process 2 assigned to the worker A, and the products in the processes 3 to 5 assigned to the worker B The work time for each product type is as shown in Table 2 below.

  Next, when the process up to step S209 is completed and the working time of the process is calculated in consideration of not only the fixed time but also the fluctuation time such as the walking time, the process proceeds to step S210. The work time is calculated for each product a, b, c.

  In step S210, when the process selected in step 202 (or step S202 and step S204) is assigned to the currently selected worker (for example, worker A), the work time is tact time. It is determined whether there is a product that does not fit inside. The tact time is a reference time that is a target for satisfying the required production quantity, and is obtained, for example, by dividing a predetermined required production quantity by the operation time. If the work time for all products falls within the tact time (reference time) (step S210: NO), the process is assigned to the selected worker (step S211). On the other hand, if there is a product whose working time does not fall within the tact time (step S210: YES), the process proceeds to step S212, and the next worker (for example, worker B) is newly selected and selected. A process is assigned to the worker (step S211).

  FIG. 10 schematically shows a state where the next worker B is selected and the process 7 is assigned to the worker B when the work time does not fall within the tact time. In the example shown in FIG. 10, when the process 7 is assigned to the worker A, the work time for the product a in the worker A exceeds the tact time. Therefore, a new worker B is selected and process 7 is assigned to this worker B.

  Next, it is determined whether or not all the processes have been assigned (step S213). If there is a process that has not been assigned yet (step S213: NO), the process returns to step S202 of FIG. 7 until all the processes are assigned (step S213: YES), step S201. -The process of step S213 is repeated. When the assignment of all the processes is completed, it is assumed that the first work organization process is completed, and the process returns to the main routine shown in FIG.

  FIG. 11 shows an allocation state of each process in a state where the first work organization process is completed. As in the conventional process, the first work organization process can be said to be a process of assigning processes so that the work time for all products is within the tact time.

  When the first work organization process is completed and the process returns to the main routine shown in FIG. 3, the process of step S104 is then executed. In step S104, an average considering the ratio of product types is calculated for the work time for each product type. Specifically, a weighted time (average work time) is calculated by weighting the work time for each product type according to the ratio of the product type and taking an average.

Next, the second work organization process is executed (step S105). Here, the second work organization process is the following process.
(Second work organization process)
12 and 13 are flowcharts showing an example of the second work organization process. 12 and 13 correspond to the subroutine of step S105.

  First, an operator is selected (step S301). First, the worker A located at the most upstream is selected. Next, a process assigned to a downstream worker (for example, worker B) is selected (step S302). A process is selected along the process order mentioned above. Next, it is determined whether or not the selected process violates the holding restriction (step S303). That is, when the selected process is transferred to the worker A, if the conflicting restriction is violated (step S303: YES), the selected process cannot be transferred to the worker A. In S313, it is determined whether or not there is a next worker. If there is a next worker (step S313: YES), the next worker is selected (step S314), and step S302 is performed. The following processing is executed. On the other hand, if there is no conflict with the non-holdable restriction (step S303: NO), the process proceeds directly to step S304.

  In step S304, it is determined whether or not the next process of the selected process needs to be executed by the same operator. That is, it is determined whether or not there is a same worker execution constraint related to the selected process. If it is necessary for the same worker to execute the next process (step S304: YES), the next process is also selected (step S305). On the other hand, when it is not necessary for the same worker to execute the next process (step S304: NO), the process of step S305 is skipped and the process proceeds to step S306.

  Next, a fixed time when the selected process is moved to the worker A is calculated for each product type (step S306). Further, a new walking distance is calculated when the worker A moves the selected process to the worker A (step S307). Next, the fluctuation time when the selected process is moved to the worker A, specifically, the walking time is calculated for each product type (step S308). Next, in a state in which the process is moved to the worker A, the fixed character time calculated in step S306 and the walking time calculated in steps S307 and S308 for the plurality of processes assigned to the worker A are obtained. In addition, the work time for each product type per product in these processes is calculated (step S309). In addition, the process of step S306 thru | or step S309 in this 2nd work organization process is a process which calculates the work time and weighting time when a process is moved to each worker. This is substantially the same as the processing from step S206 to step S209 in the one-work organization process.

  Next, in the second work organization process, the weighted time is calculated by weighting the work time for each product type calculated in step S309 according to the product ratio and taking the average (step S310). When the weighting time is calculated, the process proceeds to step S311 and subsequent steps.

  In step S311, when the process selected in step S302 (or step S302 and step S304) is assigned to the currently selected worker (for example, worker A), the weighting time is tact time. It is determined whether or not it falls within. If the weighting time is within the tact time (step S311: YES), the process is moved to the selected worker and the process is assigned (step S312). On the other hand, when the weighted time does not fall within the tact time (step S311: NO), the process cannot be moved to the selected worker, so the process is stopped and the process proceeds to step S313. In step S313, it is determined whether or not a further downstream worker exists. If there is a further downstream worker (step S313: YES), the next worker is selected (step S314). Return to step S302. And the process of step S302-S313 is repeatedly performed about the operator newly selected by step S314, and a process is allocated.

  If there is no downstream worker (step S313: NO), it returns to the main routine shown in FIG. 3 assuming that all the second work organization processes have been completed.

  14 and 15 are diagrams schematically showing the contents of the second work organization process. FIG. 14 shows the relationship between the weighting time and the tact time when the process is moved between workers by the second work organization process. On the other hand, FIG. 15 shows the relationship between the work time and the tact time for each product type in the state corresponding to FIG. As shown in FIG. 14 and FIG. 15, according to the second work organization process, the tact time is allowed to exceed at least one of the product types and the weight time is exceeded. Processes are assigned so that they do not.

  In the above-described second work organization process, the processes in steps S306 to S309 are performed for a plurality of processes assigned to each worker to a work that does not vary depending on the variation time required for the work that varies depending on the content of the process and the content of the allocation. It corresponds to the first calculation means for calculating the work time for each product type per product in the above process in addition to the required fixed time. Further, the process of step S310 corresponds to a second calculation unit that calculates a weighted time obtained by weighting the work time for each product type according to the ratio of the product type and taking an average. In addition, the processes in steps S311 and S312 allow the tact time obtained by dividing the predetermined required production number by the operation time to be exceeded by at least one of the work times for each product type. Corresponds to an assigning means for assigning processes so that the weighting time does not exceed.

  Returning to the main routine of FIG. 3, the process of step S106 is executed. In step S106, various data such as a product input schedule and facility specifications necessary for the process flow simulation are acquired.

  Next, a process flow simulation is executed. The process flow simulation is a dynamic simulation that predicts the number of products produced on the production line by simulating the product flow in the production line.

  The dynamic simulation is a simulation considering a time flow, and is particularly effective when the process includes a frequency work. Here, the frequency work is an element work that occurs at a constant frequency or irregularly per a plurality of products (per plurality of cycles). The work that occurs at a certain frequency for a plurality of products includes various work such as parts supply work, and the work that occurs irregularly includes work related to quality and equipment defects.

  FIG. 16 is a diagram schematically illustrating a calculation example of work time when a process includes frequency work. The example shown in FIG. 16 shows the case where the receiving work of the supply parts necessary for the frequency of once per 6 products in the process 3 is added to the example shown in FIG. 9A. Yes. In this case, as shown in Table 3 below, the frequency work can be reflected statically in the work time.

  Here, since the walking distance is 5 m (one-way 2.5 m) in the frequency work, the walking time is 5 m × 0.15. Moreover, the fixed time in the frequency work is 0.12 minutes. By multiplying (5 m × 0.15 + 0.12) plus the frequency (1/6), the frequency work can be statically reflected in the work time.

  However, from the dynamic viewpoint, since the execution of the process A cannot be started when the worker A is performing the frequency work, the process is delayed. Therefore, when a dynamic process flow simulation is actually executed, the required production number may not be achieved. Therefore, in order to consider such points, a process flow simulation is executed in step S107.

  Next, in step S108 of FIG. 3, it is determined whether or not the required production number can be achieved based on the result of the process flow simulation. If the required production number can be achieved (step S107: YES), it is not necessary to modify the content of the process assignment in the second work organization process in step S105, and the process is completed. On the other hand, when the required production number cannot be achieved (step S107: NO), the process proceeds to step S109, and the knitting correction process is executed. Here, the knitting correction process is as follows.

  FIG. 17 is a flowchart illustrating an example of the composition correction process. FIG. 17 corresponds to the subroutine of step S109.

  First, an operator is selected (step S401). Then, in accordance with the process order, the process is selected (step S402), and the next process is also selected as necessary while taking into consideration the non-holding restriction (step S403) and the same worker execution restriction (step S404). Next, as shown in FIG. 18, the selected process is moved to a downstream operator, and the content of the process allocation is corrected (step S406). Note that the process order may be changeable. For example, in the case shown in the process order of FIG. 4, the process order cannot be changed from process I to process VI, while for process VII to process X, the process order is within the range shown in the figure. Can change. In step S406, the process can be moved to another worker in consideration of such a range in which the process order can be changed.

  In the process of step S406, the above-described frequency work can be dynamically reflected in the process assignment. Specifically, the content of the process assignment can be automatically corrected so that it differs depending on whether the frequency work is occurring or not.

  FIG. 19 is a diagram schematically showing a state in which the process assignment contents are automatically corrected so that the frequency work is different from the state where it is not generated. As shown in FIG. 19, in a state where no frequency work has occurred, Steps 1 to 3 are assigned to the worker A, and Steps 4 and 5 are assigned to the worker B. On the other hand, in a state where the frequency work is occurring, the process 1 and the process 2 are allocated to the worker A, and the processes 3 to 5 are allocated to the worker B. According to such dynamic process assignment, when the worker A is performing the frequency work associated with the component supply, the worker B is also in charge of the process 3 that the worker A originally takes charge of. Will be temporarily in charge.

  When the process movement process is completed for all workers and there is no downstream worker (step S407: NO), it returns to the main routine shown in FIG. 3 assuming that the knitting correction process is completed. .

  Returning to the main routine of FIG. 3, the process flow simulation is executed again (step S110), and it is determined whether or not the required production quantity has been achieved (step S111). As shown in the third organization of FIG. 20, if the required production number has been achieved (step S111: YES), the processing is completed at that time. On the other hand, when the required number of production is not achieved (step S111: NO), the composition correction process (step S110) is performed until all possible combinations of processes are tried with respect to the movement of processes between workers. Is repeated.

  In addition, regarding the movement of processes between workers, when all the possible combinations of processes have been tried and the required number of production cannot be achieved (step S112: YES), the process proceeds to step S113 and subsequent steps. . In the processing after step S113, after the product input schedule is changed (step S113), a process flow simulation is executed (step S114), and it is determined whether or not the required production quantity has been achieved (step S115). If the required production quantity is achieved by changing the product input schedule (step S115: YES), the process is completed at that time. If the required number of production cannot be achieved even if the product input schedule is changed, other processes such as increasing the number of workers are executed (step S116), and the process is completed.

  As described above, the processing content in each step has been described, but the process by the process flow simulation in step S107 described above predicts the number of products produced in the production line by simulating the product flow in the production line. This corresponds to the process flow simulation means. Further, the processing of step S109 (that is, step S401 to step S407 in FIG. 17) is a correction that automatically corrects the process allocation content by the allocation means so that the predicted production quantity on the production line reaches the required production quantity. Corresponds to the means.

(Modification)
In the above example, the case where the process assignment is executed in two stages of the first work composition process and the second work composition process is shown. However, the process assignment can be executed in two stages. .

  FIG. 21 is a flowchart illustrating a processing procedure performed by the production process knitting apparatus according to the modification. Steps S501 and S502 in FIG. 21 are the same as steps S101 and S102 in FIG. Therefore, repeated description is omitted.

In this modification, in step S503, work organization processing is performed in consideration of the product type ratio. Here, the work organization process in consideration of the product type ratio is as follows.
(Work organization process considering the ratio of product types)
FIG. 22 and FIG. 23 are flowcharts showing an example of the work organization process in consideration of the product type ratio. 22 and FIG. 23 correspond to the subroutine of step S503 in FIG.

  First, the processing of step S601 to step S609 is the same as the processing of step S201 to step S209 shown in FIG. That is, for the process assigned to the selected worker, the working time for each product type is calculated by adding the variable time and the fixed time.

  Next, the weighting time is calculated by weighting the work time for each product type calculated in step S609 according to the product ratio and taking the average (step S610).

  In step S611, when the process selected in step S602 (or step S602 and step S604) is assigned to the currently selected worker (for example, worker A), the weighting time is set. It is determined whether or not the time is within the tact time. If the weighting time is within the tact time (step S611: YES), the process is assigned to the selected worker (step S612). On the other hand, when the weighted time does not fall within the tact time (step S611: NO), the process proceeds to step S213, the next worker (for example, worker B) is newly selected, and the process is performed on the selected worker. Are allocated (step S612).

  Next, it is determined whether or not all the processes have been assigned (step S614). l If there is a process that has not been assigned yet (step S614: NO), the process returns to step S602 in FIG. 22 until all the processes are assigned (step S614: YES). The processing from S601 to step S614 is repeated. When the allocation of all the processes is completed, it returns to the main routine shown in FIG. 21 assuming that the work organization process considering the ratio of product types is completed.

  Returning to the main routine of FIG. 21, the processing from step S504 onward is executed. The processing after step S504 is the same as the processing from step S106 to step S116 in FIG. Therefore, repeated description is omitted.

  Also according to this modification, it is possible to perform efficient knitting that takes advantage of the characteristics of the mixed line in consideration of the variation of the working time according to the process allocation content.

  As described above, the production process organization apparatus and method according to the present embodiment have been described. However, according to the production process organization apparatus and method according to the present embodiment, the following effects can be achieved.

  Working time for each product type per product in the process is calculated by adding the variable time and fixed time, and the work time for each product type is weighted according to the ratio of the product type and averaged. The weighting time is calculated and the tact time is allowed to be exceeded by at least one of the product types, and the process is assigned so that the tact time does not exceed the weighting time. It is possible to provide a production process knitting apparatus and a production process knitting method capable of efficient knitting taking advantage of the characteristics of the mixed line while considering that the working time fluctuates. In particular, it is possible to take into account the walking time of the worker, which varies depending on the content of the assignment to the process, so the work time that is the premise of the assignment of the process can be calculated with high accuracy, and high-accuracy process assignment is possible. .

  Storing in advance a knitting rule including information relating to the order of the steps, information on a process that must be continuously executed by the same worker, and information on a process that cannot be executed continuously by the same worker; Accordingly, since the process is allocated, it is possible to prevent the process allocation that cannot be performed from being performed in advance.

  Process flow simulation is performed to predict the number of products on the production line by simulating the product flow in the production line, so it is not possible to grasp static work time as in the case where the process includes frequency work. Events that are not sufficient can be reflected in the process allocation. In particular, since the process assignments can be automatically corrected so that the frequency work is different from the non-occurrence state, efficient assignment without increasing the number of workers more than necessary. Is possible.

  As described above, the production process organization apparatus and method of the present embodiment have been described. However, the present invention is not limited to these cases, and various omissions, additions, and modifications can be made by those skilled in the art. It is clear.

  The present invention determines the work time that changes depending on the content of the process assignment in consideration of the fluctuation time such as walking time, and assigns the process so that the tact time does not exceed the weighted time. The various data formats described above and the processing order shown in the flowcharts can be changed as appropriate.

  In the above description, the case where the processor executes various programs such as the calculation unit, the allocation unit, the simulation unit, and the correction unit by executing the computer program has been described. However, the present invention is limited to this case. Absent. A dedicated logic integrated circuit or the like can be used to play the role of each unit.

It is a figure which shows an example of schematic structure of the production process organization apparatus in embodiment of this invention. It is a figure which shows the fluctuation time and fixed time which are contained in work time. . It is a flowchart which shows the process sequence by the production process organization apparatus of FIG. It is a figure which shows process order. It is a figure which shows an element work list. FIG. 6 is a diagram subsequent to FIG. 5. It is a flowchart which shows an example of the 1st work organization process in step S103 of FIG. It is a flowchart following FIG. It is a figure which shows typically the example of calculation of the working time which considered the walking time which fluctuate | varies with the allocation content of a process. It is a figure which shows typically the state where the next worker B was selected and the process 7 was allocated to this worker B when work time does not fall within tact time. It is a figure which shows the allocation state of each process of the state which the 1st work organization process was completed. It is a flowchart which shows an example of the 2nd work organization process in step S105 of FIG. 13 is a flowchart subsequent to FIG. It is a figure which shows the relationship between the weighting time at the time of moving a process between workers by 2nd work organization process, and tact time. It is a figure which shows the relationship between the work time for every kind of goods at the time of moving a process between workers by 2nd work organization process, and tact time. It is a figure which shows typically the example of calculation of the working time in case a process includes frequency work. It is a flowchart which shows an example of the correction process of the formation in step S109 of FIG. It is a figure which shows the state which moves a process between workers by the correction process of organization. It is a figure which shows typically the state which corrected automatically the allocation content of the process so that it may differ with the state in which the frequency work has arisen, and the state which has not arisen. It is a figure which shows typically that the correction process of organization is made until the required production number is achieved. It is a flowchart which shows the process sequence by the production process organization apparatus of a modification. It is a flowchart which shows an example of the work organization process which considered the ratio of the product kind in step S503 of FIG. It is a flowchart following FIG.

Explanation of symbols

1 Production process organization device,
11 processor,
12 Display section,
13 memory,
14 operation unit,
15 Hard disk.

Claims (7)

A production process organization device that assigns multiple processes to multiple workers in a production line in which multiple types of products flow.
For the process assigned to each worker, add the change time required for the work that varies depending on the content of the process and the fixed time required for the work that does not vary depending on the content of the assignment, for each product type per product in the process. First calculating means for calculating a working time;
A second calculating means for calculating a weighted time obtained by weighting the work time for each product type according to a ratio of the product type and calculating an average;
The process is performed so that the tact time obtained by dividing the predetermined required production number by the operation time is allowed to exceed at least one of the work times for each product type, but the tact time is not exceeded. A production process knitting apparatus comprising: an allocating means for allocating.   The production process knitting apparatus according to claim 1, wherein the fluctuation time is a walking time of an operator that varies depending on a process allocation content. There is a storage means for preliminarily storing organization rules including information on the order of processes, information on processes that must be continuously executed by the same worker, and information on processes that cannot be executed continuously by the same worker. And
The production process knitting apparatus according to claim 1, wherein the allocating means assigns a process according to the knitting rule. Furthermore, a process flow simulation means for simulating the product flow in the production line and predicting the number of products produced in the production line;
2. The production according to claim 1, further comprising: a correction unit that automatically corrects a process allocation by the allocation unit so that a predicted production number on the production line reaches the required production number. Process organization device. The process includes a frequency operation that occurs at a certain frequency or irregularly per production of a plurality of products,
5. The production process organizing apparatus according to claim 4, wherein the pre-correction means automatically corrects the content of the process allocation so that the pre-correction means is different between a state where the frequency work is occurring and a state where the frequency work is not occurring. A production process organization method in which a plurality of processes are assigned to a plurality of workers in a production line in which a plurality of types of products flow.
In the process assigned to each worker, the change time required for the work that varies depending on the assignment contents of the process and the fixed time required for the work that does not vary depending on the assignment contents, Calculating the working time;
Calculating a weighted time averaged by weighting according to the ratio of the product type with respect to the work time for each product type;
The process is performed so that the tact time obtained by dividing the predetermined required production number by the operating time is allowed to exceed at least one of the work times for each product type, but the tact time is not exceeded. And a step of allocating the production process. The production process organization method according to claim 6, wherein the variation time is a walking time of an operator that varies depending on a process allocation content.

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