JP2006163810A - Work process simulation method and work process simulation device - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a work process simulation method and a work process simulation device which are effective in planning of a work process for performing production (or scrapping) of products in large quantities and efficiently on an assembly line. <P>SOLUTION: Based on a measured result or an estimated result of work hours at each workplace for each type of work to a plurality of kinds of works, processes at workplaces of a plurality of kinds of works are set at each work process on the assembly line by a work process setting section 6. Then, a time book showing work hours of respective work processes for each kind of work is created from the 1st time book creation section 1. Also, an input sequence of a plurality of kinds of works when inputted to the first process of the assembly line is set by an input sequence setting section 9. A simulation section 4 carries out simulation of each assembly line so that standby time of a plurality of operators may be minimized to the works inputted based on the time book created by the 1st time book creation section 1, and the input sequence set by the input sequence setting section 9. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a work process simulation method used for simulation of a work process for assembling or disassembling a product, and more particularly to a work process simulation method for an assembly line or a disassembly line in which products of different types and forms are randomly flowed.

  The specific household equipment re-commercialization law (Home Appliance Recycling Law) was enacted in 2001, and the re-commercialization (recycling) of various industrial products has become obligatory. From such a background, industrial products are designed in consideration of not only assembly but also product disassembly. At that time, in addition to the productivity of the product, a technique for obtaining the dismantling time has been proposed in order to examine the dismantling property when recycling the parts constituting the product (for example, JP 2000-37685 A). See Patent Document 1)). A technique for predicting the assembly work time of a product has also been proposed (see, for example, Japanese Patent Application Laid-Open No. 7-164267 (Patent Document 2)).

However, the above-mentioned conventional technology predicts and estimates the assembly work time and disassembly time of a single product at the product design stage, and predicts and estimates the product assembly work time and disassembly time at the production (or disassembly) site. In this case, it is effective only when the same product continues to flow. For this reason, it is not easy to reduce the waiting time by predicting and reconsidering each worker's work process, especially when a wide variety of products are randomly flowed to the production line and flow work is performed. There's a problem.
JP 2000-37685 A JP 7-164267 A

  An object of the present invention is to reduce the waiting time of each worker, and a work process simulation method effective for planning a work process for performing product production (or disassembly) in a large amount and efficiently in a flow work. And providing a work process simulation apparatus.

In order to achieve the above object, a work process simulation method of the present invention is a work process simulation method when a plurality of workers sequentially process a plurality of types of workpieces in a flow operation, and for the plurality of types of workpieces Based on the result of measuring or estimating the work time at each work part for each type of work, the work part setting process is set for each work process of the flow work by the work process setting means. A work process setting step to perform,
A work time table creating step for creating a work time table showing work time at each work site for each work type by the work time table creating means, and the plurality of types of work are sequentially input to the first step of the flow work. The loading sequence is set based on the loading sequence setting step for setting the loading sequence at the loading sequence setting unit, the work time table created by the working time table creating unit, and the loading sequence set by the loading sequence setting step. And a simulation step of simulating each work process of the flow work by a simulation means so as to minimize the waiting time of the plurality of workers for the work.

  According to the work process simulation method, based on the result of measuring or estimating the work time at each work site for each type of work for the plurality of types of work, the processing of the work sites of the plurality of types of work is performed. The work process setting means sets the work processes of the above-mentioned flow work. Next, a work time table indicating the work time at each work part for each work type is created by the work time table creating means. Further, the loading sequence setting means sets the loading sequence when the multiple types of workpieces are sequentially loaded into the first process of the flow work. The work waiting time of a plurality of workers is minimized with respect to a work that is input based on the work time table created by the work time table creating means and the input order set by the input order setting means. Each work process of the flow work is simulated by the simulation means. As a result, it is possible to reduce the waiting time of each worker and to plan a work process that can efficiently and efficiently produce (or dismantle) a product in a large amount by a flow work.

  In the work process simulation method according to an embodiment, for each work process of the flow work set by the work process setting unit, the work process that the plurality of workers are in charge of is set by the worker charge setting unit. It is characterized by that.

  According to the work process simulation method of the above-described embodiment, the work process assigned by the plurality of workers is set by the worker charge setting means for each work process of the flow work set by the work process setting means. For example, one worker is set to be in charge of one work process, and other work processes (for example, the previous and subsequent work processes) other than the work process (main work process) for each worker are also set. Or Thereby, it is possible to easily adjust the work balance according to the setting of the work process that the worker is in charge of.

  Also, the work process simulation method according to an embodiment includes at least one worker among the plurality of workers in a work process in which each of the plurality of workers set by the worker charge setting unit is in charge. In the case of taking charge of a plurality of work processes, a criterion for determining the work process in charge of each of the works by each of the workers in charge of the plurality of processes is set.

  According to the work process simulation method of the above-described embodiment, in the work process in which a plurality of workers set by the worker charge setting unit are respectively in charge, at least one worker among the plurality of workers is a plurality of workers. In the case of taking charge of the work process, a criterion for determining the work process in charge of each of the plurality of types of work by the worker in charge of the plurality of processes is set. Even by changing the setting of this judgment criterion, the simulation result fluctuates, and it is possible to plan a work process with less waiting time for each worker.

  Here, “judgment criteria” means that when an operator completes the processing of one work process of one work, the worker is responsible for the main process next, or is responsible for the previous process or the subsequent process. It is a standard for judging whether to do. Specifically, "Is there work in progress", "If there is no work in progress, can be in charge of the previous process and the subsequent process, and there is work inventory in the previous process and the subsequent process," This is a criterion such as “when the main process of the product is finished, whether the inventory of the subsequent process exceeds the reference number”.

  Further, the work process simulation method according to one embodiment is based on at least one of the processing plan for the plurality of types of workpieces for each type of the plurality of types of workpieces or the occurrence probability for each type of the plurality of types of workpieces. The order setting means sets the order of input when sequentially entering the first work process of the flow work.

  According to the work process simulation method of the above embodiment, based on at least one of the processing plan of the plurality of types of workpieces for each of the plurality of types of workpieces or the occurrence probability for each of the types of workpieces, the input order setting means To set the input order when sequentially entering the first work process of the flow work. By doing so, it is possible to determine the order of loading at the time of simulation so as to be closer to the order of loading of workpieces that are actually put into the first work process of the flow work.

  Further, the work process simulation method according to an embodiment is based on a result of measuring or estimating a work time at each work site for each type of work and an occurrence probability for each type of the plurality of types of work. Processing of the work parts of the plurality of types of workpieces is set in each work process by the work process setting means so that the work balance can cope with variations in the weighted average time of each work process within a predetermined range. It is characterized by.

  According to the work process simulation method of the above embodiment, each work process is based on the result of measuring or estimating the work time at each work site for each work type and the occurrence probability for each type of work. Process in each work process by setting the work part processing of multiple types of work in each work process by work process setting means so that the work balance can cope with variations in the weighted average time of Work efficiency can be improved by flattening the amount.

  In addition, when there is a difference in the ability of the worker in charge of each work process, the work process setting means sets the work site to be processed in each work process according to the difference in the ability of the worker. Simple work process. In other words, the work time of the work process in charge of the worker with high ability is made long, while the work time of the work process in charge of the worker with low ability is made short.

  Further, the work process simulation method of one embodiment, when the plurality of types of workpieces are processed by the plurality of workers, the result of measuring or estimating the work time in each work site for each type of the workpiece, The work time for each worker required for each work part is set based on the worker ability for each worker set by the worker ability setting means.

  According to the work process simulation method of the above embodiment, when a plurality of types of workpieces are processed by a plurality of workers, the work time table set by the work time table creation unit and the work set by the worker capability setting unit The work time for each worker required for each work part is set based on the worker ability for each worker. By doing so, it is possible to perform an accurate simulation considering the ability of each worker.

  Further, the work process simulation method according to an embodiment includes a work process and a work performed by the plurality of workers set by the work process setting unit when the plurality of workers process the plurality of types of workpieces. The work time for each worker required for each work process is set based on the worker ability for each worker set by the worker ability setting means.

  According to the work process simulation method of the above-described embodiment, when a plurality of types of workpieces are processed by a plurality of workers, the work process set by the work process setting unit and the worker ability setting respectively responsible for the plurality of workers are set. The work time for each worker required for each work process is set based on the worker ability for each worker set by the means. By doing so, it is possible to perform an accurate simulation considering the ability of each worker.

  Further, in the work process simulation method according to an embodiment, at least one of the plurality of workers performs a plurality of work processes so that the work balance can cope with variations in the weighted average time within a predetermined range. It is characterized by being in charge.

  According to the work process simulation method of the embodiment, at least one of a plurality of workers is in charge of a plurality of work processes so that the work balance can cope with the variation in the weighted average time within a predetermined range. For example, each worker in each work process that sequentially processes the work does not have a work to be processed in the work process in charge, and there is a work waiting to be processed in another work process. By processing a work process having a workpiece, the number of workpieces waiting to be processed is reduced and the work efficiency is improved.

  Further, the work process simulation method according to an embodiment includes a work process in which at least one of the plurality of workers is in charge of the work process in which each of the plurality of workers is set by the worker charge setting unit. When the simulation step is repeated under the condition that the process is not changed, each setting condition when the number of workpieces to be processed in the predetermined time is the largest is set as the optimum condition.

  According to the work process simulation method of the above-described embodiment, in the work process in which a plurality of workers set by the worker charge setting unit are respectively in charge, the work process in which at least one of the plurality of workers is in charge. When the simulation step is repeated under the invariable conditions, each setting condition when the number of workpieces processed in a predetermined time is the largest is set as the optimum condition. Thereby, each setting condition of the flow work which minimizes the waiting time of a plurality of workers can be obtained, and a work process for performing a large amount and efficiently can be realized. Here, “each setting condition” includes setting of a work part to be processed in each work process and setting of work processes each of which is handled by a plurality of workers.

Further, the work process simulation apparatus of the present invention is a work process simulation method when a plurality of workers sequentially process a plurality of types of workpieces in a flow operation, and for each of the types of the workpieces with respect to the plurality of types of workpieces. The work process setting step of setting the process of the work part of the plurality of types of work to each work process of the flow work by the work process setting means based on the result of measuring or estimating the work time in each work part When,
A work time table creating step for creating a work time table showing work time at each work site for each work type by the work time table creating means, and the plurality of types of work are sequentially input to the first step of the flow work. The loading sequence is set based on the loading sequence setting step for setting the loading sequence at the loading sequence setting unit, the work time table created by the working time table creating unit, and the loading sequence set by the loading sequence setting step. And a simulation step of simulating each work process of the above-described flow work by a simulation means so as to minimize the waiting time of the plurality of workers for the work.

  Further, the work process simulation method of the present invention is a work process simulation method when a plurality of workers sequentially process a plurality of types of workpieces in a flow operation, and for each of the types of the workpieces with respect to the plurality of types of workpieces. The work process setting step of setting the process of the work part of the plurality of types of work to each work process of the flow work by the work process setting means based on the result of measuring or estimating the work time in each work part A work time table creating step for creating a work time table showing work time in each work process for each work type by the work time table creating means, and the work time table created by the work time table creating means; Based on the occurrence probability of the workpiece, a probability distribution table creation means for creating a probability distribution table of work time in each work process for each type of the workpiece The flow work is performed on the simulation work data in which the plurality of types of works are randomly generated based on the probability distribution table creation step to be created and the probability distribution table created by the probability distribution table creation step. And a simulation step of performing simulation by a simulation means so as to minimize the waiting time of a plurality of workers.

  According to the work process simulation method of the above embodiment, based on the result of measuring or estimating the work time at each work site for each type of work with respect to the plurality of types of work, the work of the types of work is performed. The processing of the part is set by the work process setting means in each work process of the above flow work. Next, a work time table showing the work time in each work process for each work type is created by the work time table creating means. Further, based on the work time table created by the work time table creating means and the work occurrence probability, the work time probability distribution table for each work part for each work type is created by the probability distribution table creating means. And based on the probability distribution table created by the probability distribution table creating means, the work waiting time of a plurality of workers is minimized with respect to the simulation work data in which a plurality of types of workpieces are randomly generated. Each work process of the flow work is simulated by the simulation means. As a result, it is possible to reduce the waiting time of each worker and to plan a work process that can efficiently and efficiently produce (or dismantle) a product in a large amount by a flow work. Here, the simulation work data may be created based on a sample population in which the multi-type work used for creating the probability distribution table is randomly generated, It may be created based on an arbitrary occurrence probability.

  Further, the work process simulation method according to an embodiment includes a work process in which at least one of the plurality of workers is in charge of the work process in which each of the plurality of workers is set by the worker charge setting unit. When the simulation step is repeated under the condition that the process is not changed, each setting condition when the number of workpieces to be dismantled within a predetermined time is the largest is set as the optimum condition.

  According to the work process simulation method of the above-described embodiment, in the work process in which a plurality of workers set by the worker charge setting unit are respectively in charge, the work process in which at least one of the plurality of workers is in charge. When the simulation step is repeated under an invariable condition, each setting condition when the number of workpieces to be dismantled within a predetermined time is the largest is set as the optimum condition. Thereby, each setting condition of the flow work which minimizes the waiting time of a plurality of workers is obtained.

  Further, the work process simulation apparatus of the present invention is a work process simulation method when a plurality of workers sequentially process a plurality of types of workpieces in a flow operation, and for each of the types of the workpieces with respect to the plurality of types of workpieces. The work process setting step of setting the process of the work part of the plurality of types of work to each work process of the flow work by the work process setting means based on the result of measuring or estimating the work time in each work part A work time table creating step for creating a work time table showing work time in each work process for each work type by the work time table creating means, and the work time table created by the work time table creating means; Based on the occurrence probability of the workpiece, a probability distribution table creation means for creating a probability distribution table of work time in each work process for each type of the workpiece The flow work is performed on the simulation work data in which the plurality of types of works are randomly generated based on the probability distribution table creation step to be created and the probability distribution table created by the probability distribution table creation step. And a simulation step of simulating by a simulation means so as to minimize the waiting time of a plurality of workers.

  Also, the waste recycling method of the present invention is a waste recycling method for disassembling and recycling waste, and using any one of the above work process simulation methods. It is characterized in that a work process is set and a dismantling process plan is created.

  Further, the waste recycling method of the present invention is a waste recycling method for disassembling and recycling waste to set the work process using the work process simulation apparatus. And creating a dismantling treatment plan.

  In one embodiment, the waste recycling method is characterized in that the waste is a product waste selected from the group consisting of an air conditioner, a television, a refrigerator, and a washing machine.

  As is clear from the above, according to the work process simulation method of the present invention, the work time required to assemble (or disassemble) the product is predicted, and the production (or disassembly) of the product that could not be handled only by the cell method is performed. It is possible to realize a work process that is efficiently performed in large quantities by the flow work.

  Hereinafter, the working process simulation method and the working process simulation apparatus according to the present invention will be described in detail with reference to the illustrated embodiments.

  FIG. 1 is a block diagram showing a schematic configuration of a work process simulation apparatus using a work process simulation method according to an embodiment of the present invention. In the work process simulation apparatus of this embodiment, a plurality of work parts having a common work site are provided. A demolition work process of a dewatering washing machine as an example of a workpiece of a variety is simulated.

  In FIG. 1, 1 is a first work time table creation unit as an example of work time table creation means, 2 is a weighted average time calculation unit, 3 is a second work time table creation unit, and 4 is a simulation as an example of simulation means. , 5 is a simulation result determination unit, 6 is a work process setting unit as an example of work process setting, 7 is a worker capability table creation unit as an example of worker capability setting means, and 8 is an example of worker charge setting means. An operator charge setting unit 9 is an input order setting unit 9 as an example of an input order setting unit, and 10 is a probability distribution table generation unit as an example of a probability distribution table generation unit. This work process simulation apparatus is a personal computer that executes a work process simulation program.

  The work process setting unit 6 sets the processing of the work parts of the various types of work in each work process of the flow work. For example, as shown in FIG. 4, when there are work parts A to F, in work processes 1, 2, and 3 that should be handled by three workers, parts A, B, C, Parts D and E are assigned to work process 2 and part F is assigned to work process 3. Here, the work site assigned to one process has a good balance of the weighted average time of each work process calculated by the weighted average calculation unit described later according to the procedure of the dismantling work and the length of each work time. In combination, settings are made so that the bias does not become large and the work time of a specific work process does not become short or long. Alternatively, a bias may be provided in the weighted average time of each work process in consideration of the ability of the worker in the worker ability table created by the worker ability table creating unit described later.

  The first work time table creation unit 1 is configured to set a work time at each work site and a work process set by the work process setting unit 6 for each type of work for a sample population in which multiple types of work are randomly generated. Based on the above, a first work time table (shown in FIG. 5) indicating the work time in each work process for each type of work is created.

The weighted average time calculation unit 2 obtains a weighted average time for each work process of the flow work based on the first work time table created by the first work time table creation unit 1. For example, in work process 1 shown in FIG.
Work time of parts A, B, and C of product 1 with an occurrence probability of 10% 19 seconds Work time of parts A, B, and C of product 2 with an occurrence probability of 25% Parts A, B of product 3 with an occurrence probability of 30% , C work time 28 seconds Product 4 part A, B, C work time 30% occurrence probability 10% product 5 part A, B, C work time 20 seconds occurrence probability 5% occurrence probability 5% From the working time of the parts A, B and C of the product 6 from 37 seconds, the weighted average time of the working process 1 is
19 x 0.1 + 27 x 0.25 + 28 x 0.3
+ 30 × 0.2 + 20 × 0.1 + 37 × 0.05 ≒ 27 [seconds]
It becomes. Similarly, the weighted average times of the work steps 2 and 3 are 28 seconds and 22 seconds, respectively.

  Further, the worker capability table creating unit 7 creates a worker capability table (shown in FIG. 13) in which the standard values are set to 100% and the capabilities of the workers are summarized as relative values. In FIG. 13, “worker 1” is 130%, “worker 2” is 100%, and “worker 3” is 90%. Here, “Worker 1” is a person who has a low ability to process in 1.3 times the standard work time, and “Worker 2” is a standard ability to process in the standard work time. “Worker 3” indicates that the skilled worker is highly skilled in processing with a work time of 0.9 times the standard work time.

  In addition, the second work time table creation unit 3 includes the first work time table created by the first work time table creation unit 1 and the worker ability table created by the worker ability table creation unit 7. Based on the worker ability table, a second work time table (see FIGS. 14A, 14B, and 14C) corresponding to each worker's ability is created.

  In addition, the worker charge setting unit 8 sets work processes each of which is handled by a plurality of workers for each work process for which the work site is set by the work process setting unit 6. For example, as in the worker assignment table (linear type) shown in FIG. 7A, the workers 1 to 3 are set to perform only the work processes that should be handled, or the worker assignment shown in FIG. 7B. As shown in the table (cooperative type), the workers 1 to 3 make settings for performing the preceding and following work processes in addition to the main work process. 7B, in the three work processes No. 1 to No. 3, the worker in charge of the No. 1 work process has no previous work process, and the work in charge of the No. 3 work process. There is no work process behind.

  In addition, the simulation unit 4 is based on the second work time table created by the second work time table creation unit 3 and the work processes in charge of the plurality of workers set by the worker charge setting unit 8. The work process of the flow work is simulated with respect to the simulation work data set by the input order setting unit 9.

  The simulation result determination unit 5 determines the simulation result from the simulation unit 4.

  FIG. 2 is a flowchart for explaining the processing of the work process simulation apparatus. The simulation work data is set in advance by the input order setting unit 9.

  First, in step S1, a work process is set by the work process setting unit 6 from the work time of each work part for each type of work in the sample population and the data of the common work part of the work in the sample population.

  Next, a first work time table (shown in FIG. 5) is created by the first work time table creating unit 1 in step S2.

  Next, in step S3, the weighted average time calculation unit 2 calculates the weighted average time based on the first work time table and the occurrence probability for each work type of the sample population.

  Next, in step S4, it is determined whether there is a large gap in the weighted average time for each process. If it is determined that there is a large gap in the weighted average time for each process, the process returns to step S1 and the work process setting unit 6 resets the work process, while there is no large gap in the weighted average time for each process. If it is determined, the process proceeds to step S5.

  Next, in step S5, the worker ability table creation unit 7 creates a worker ability table (shown in FIG. 13).

  Next, based on the worker ability table created by the worker ability table creating unit 7 in step S6, the second work time table creating unit 3 performs the second work time table (FIGS. 14A and 14B). , Shown in FIG. 14 (c).

  In step S7, the worker charge setting unit 8 sets the worker charge (shown in FIG. 7).

  Then, the simulation unit 4 performs a simulation based on the second work time table created by the second work time table creation unit 3 in step S8 and the worker charge set by the worker charge setting unit 8. Details of the simulation will be described later with reference to the flowchart of FIG.

  Next, in step S9, the simulation result determination unit 5 determines whether or not the work efficiency is optimum. If the work efficiency is optimum, the process is terminated. If the work efficiency is not optimum, the process is terminated. Proceed to S10.

  Next, if it is determined in step 10 that the work process is to be reviewed, the process returns to step S1, while if it is determined that the work process is not to be reviewed, the process proceeds to step S11.

  Next, when it is determined in step S11 that the worker charge setting is to be changed, the process returns to step S7, whereas when it is determined that the worker charge setting is not to be changed, the process proceeds to step S12.

  If it is determined in step S12 that the worker ability table is to be changed, the process returns to step S5. On the other hand, if it is determined that the worker ability table is not to be changed, this process is terminated.

  Steps S1 to S8 shown in FIG. 2 are repeated for the simulation work data set by the input order setting unit 9, and the setting conditions of the work process setting unit 6 (setting of work parts to be processed in each work process) And worker capability table creation unit 7 (a table listing the ratio of work time required for a worker to perform a specific work for each worker and each work) and setting conditions of worker charge setting unit 8 (multiple tasks The setting conditions of the work process setting unit 6 and the worker ability table when a simulation result with the largest number of workpieces processed within a predetermined time can be obtained by appropriately changing the setting of the work process each person is responsible for) The setting conditions of the creation unit 7 and the setting conditions of the worker charge setting unit 8 are set as optimum conditions. Thereby, the optimal condition which can implement | achieve the work process for performing efficiently in large quantities can be obtained. Note that the simulation parameter to be changed to obtain the optimum condition may be simulation work data or the like according to a change in the work group actually processed in the flow operation.

  Also, the setting conditions of the work process setting unit 6 and the setting of the worker ability table creation unit 7 when the number of workpieces processed within the predetermined time obtained by repeating steps S1 to S8 shown in FIG. When there are a plurality of combinations of the conditions and the setting conditions of the worker charge setting unit 8, the setting conditions of the work process setting unit 6 and the setting of the worker capability table creation unit 7 when the total processing wait time of each work process is the smallest The combination of the condition and the setting condition of the worker charge setting unit 8 is set as the optimum condition. Thereby, the optimal condition which can implement | achieve the work process for performing efficiently in large quantities can be obtained more correctly.

  FIG. 3 is a flowchart for explaining processing performed by the worker in each work process every unit time in the simulation unit 7. The process shown in the flowchart of FIG. 3 is a thing that determines the process that each worker performs for each unit time in the case of the cooperative type shown in the worker charge table of FIG. In the flowchart of FIG. 3, the work process immediately preceding the work process in charge of the main person is referred to as “previous process”, and the work process next to the work process in charge of the main person is referred to as “post process”. In addition, if there is a work that the worker is actually working at the moment of making a determination in accordance with the flowchart of FIG. 3, the work is defined as “work in process”.

  First, in step S21, it is determined whether or not there is a work in progress. If it is determined that there is no work in progress, the process proceeds to step S26.

  Next, in step S26, it is determined whether or not there is a stock. If it is determined that the stock is present, the process proceeds to step S42, and the work of the main charge process of the stock is started. If it is determined that there is no stock, the process proceeds to step S29.

  Next, in step S29, it is determined whether or not the previous process is in charge. If it is determined that the previous process is not in charge, the process proceeds to step S48, and waiting is determined. If it is determined that the previous process can be handled, the process proceeds to step S30.

  Next, in step S30, it is determined whether or not there is inventory in the previous process. If it is determined that there is inventory in the previous process, the process proceeds to step S45, and the work for the previous process of the inventory is started. If it is determined that there is no inventory in the previous process, the process proceeds to step S49, and waiting is confirmed.

  If it is determined in step S21 that there is a work in process, the process proceeds to step S22.

  Next, in step S22, it is determined whether or not the processing of the work in progress has been completed. Continue to work on work in process. If it is determined that the work in process has been completed, the process proceeds to step S23.

  Next, in step S23, it is determined whether or not the end process is the main charge. If it is determined that the end process is the main charge, the process proceeds to step S24.

  Next, in step S24, the operator determines whether or not the post-process can be handled. If it is determined that the post-process can be handled, the process proceeds to step S25.

  Next, in step S25, it is determined whether or not the number of stocks in the subsequent process is greater than or equal to the set value. If it is determined that it is greater than or equal to the set value, the process proceeds to step S41, To do.

  If it is determined in step S23 that the end process is not the main charge, the process proceeds to step S27.

  Next, in step S27, it is determined whether or not the end process is a post process. If it is determined that the end process is not a post process, the process proceeds to step S46, and the work of the main inventory process is started. If it is determined that the end process is a subsequent process, the process proceeds to step S28.

  Here, also in the case where it is determined in step S24 that the post-process is not in charge and in the case where it is determined in step S25 that the stock quantity of the post-process is not equal to or larger than the set value, the process proceeds to step S28.

  Next, in step S28, it is determined whether or not the main charge is in stock. If it is determined that there is stock, the process proceeds to step S44, and the work of the main charge process for the inventory is started. If it is determined that there is no stock, the process proceeds to step S31.

  Next, in step S31, it is determined whether or not the previous process can be handled. If it is determined that the previous process cannot be handled, the process proceeds to step S50, and waiting is determined. If it is determined that the previous process can be handled, the process proceeds to step S32.

  Next, in step S32, it is determined whether or not there is a stock in the previous process. If it is determined that there is a stock, the process proceeds to step S47, and the work of the previous process in the previous process is started. If it is determined that there is no stock, the process proceeds to step S50, and waiting is confirmed.

  Here, in step S24, step S29, and step S31, whether or not the preceding process or the subsequent process can be handled is determined based on the worker charge setting set by the worker charge setting unit 8.

  In this way, each worker determines a process to be performed every unit time.

  FIG. 9 shows the simulation result of the simulation unit 4 and the working state of each working process per unit time. In this case, the worker charge setting unit 8 is set to perform only the work process that each worker should be responsible for (straight line type). As shown in FIG. 9, the number of workers is 3, and the work state is shown every 5 seconds when the work (ID 1 to 16) shown in FIG. Here, the simulation is performed for 360 seconds, and the number of work and the waiting time for each work process that each worker is in charge of are obtained as a result of the simulation.

    On the other hand, FIG. 10 shows the work state of each work process at predetermined time intervals based on the simulation result of the simulation unit 4. In this case, the worker charge setting unit 8 performs setting (cooperative type) for performing the preceding and following work processes in addition to the work processes to be handled by each worker. In FIG. 10, it is assumed that the second work time table is not created for each worker according to the ability of the worker, that is, the ability of all the workers is standard.

  As shown in FIG. 10, the number of workers is 3, and the work state per second when the workpieces (ID1 to ID4) shown in FIG. Here, work ID 1 is product 1, work ID 2 is product 4, work ID 3 is product 3, and work ID 4 is product 3. Further, the simulation is performed for 60 seconds, and the number of work and the waiting time for each work process that each worker is in charge of are obtained as a result of the simulation.

  On the other hand, in FIG. 11, a second work time table is created for each worker according to the ability of the worker in the worker ability table shown in FIG. 13, and a similar simulation is performed. As a result of the simulation, it can be seen that the work waiting time 1 handled by the worker 1 with low ability is delayed, so that the waiting time increases as a whole.

  Further, paying attention to the weighted average time obtained from the first work time table shown in FIG. 5, work process 1 is 27 seconds, work process 2 is 28 seconds, work process 3 is 22 seconds, and the balance is poor. I understand that. Therefore, the worker charge setting unit 8 changes the worker charge table (linear type) shown in FIG. 7 (a) to the worker charge table (cooperative type) shown in FIG. By increasing the worker's assignment, the work balance of the work steps 1 to 3 is improved.

  As described above, according to the above work process simulation method and work process simulation apparatus, it is possible to reduce the waiting time of each worker and realize a work process in which product production (or disassembly) is performed in a large quantity and efficiently by a flow work. can do. In addition, by effectively utilizing the work process simulation obtained by the work process simulation method and the work process simulation apparatus, the work time required for disassembling a mixed variety of workpieces is predicted. The dismantling of various types of workpieces that could not be handled can be carried out in large quantities and efficiently by flow work.

  Further, for each work process in which a work part to be processed by the work process setting unit 6 is set, the worker charge setting unit 8 causes one worker to be in charge of one work process as shown in FIG. 7A. For each work site, and the cooperative setting shown in FIG. 7 (b), which is also responsible for the work processes before and after the work process (main work process) handled by each worker. When the work times are different, the work time of each work process can be flattened.

  In addition, for each work process of the flow work set by the work process setting unit 6, a work process that a plurality of workers are responsible for is set by the worker charge setting unit 8, thereby the work process that the worker is responsible for. According to the setting, it is possible to easily grasp the work status of each work process of the flow work.

  Further, in the work process in which a plurality of workers set by the worker charge setting unit 8 are respectively in charge, when at least one of the plurality of workers is in charge of a plurality of work processes, Criteria for determining the work process for each type of workpiece by each worker in charge of the process (in-process in the main process, availability of pre-process and post-process, availability of pre-process and post-process, etc. Since the simulation result also fluctuates due to the setting change of (), it is possible to plan a work process with less waiting time for each worker.

  In addition, when at least one of the processing plan of the plurality of types of workpieces for each type of the plurality of types of workpieces or the occurrence probability for each type of the plurality of types of workpieces is sequentially input to the first work process of the flow work By setting the input order by the input order setting unit 9, the input order at the time of simulation can be determined so as to be closer to the input order of the workpieces actually input to the first work process of the flow work.

  In addition, the work process setting unit 6 sets work parts to be processed in each work process so that variation in the weighted average time for each work process of the flow work calculated by the weighted average time calculation unit 2 is reduced. Therefore, the processing amount in each work process can be flattened, and work efficiency can be improved.

In addition, when a plurality of workers process the plurality of types of workpieces, the workers for each worker created by the first work time table created by the first work time creation unit and the worker ability table creation unit 7 By setting the work time for each worker required for each work process based on the ability, an accurate simulation considering the ability of each worker can be performed. For example, when there is a difference in the ability of the worker in charge of each work process, the work process setting unit 6 sets the work part to be processed in each work process according to the difference in the ability of the worker. Optimal work process can be set up. In this case, as shown in FIG. 15, an operator capability table is created in which the capabilities of the workers 1, 2, and 3 are summarized for each of the operation steps 1 to 3. In this worker ability table, the standard value is set to 100% and the ability of each worker is set as a relative value. The larger the numerical value, the lower the ability and the lower the numerical value, the higher the ability. Here, “130%” is the ability to process with 1.3 times the standard work time, and “90%” is 0.9 times the standard work time. Is the ability to Based on the worker capability table shown in FIG. 15, a second work time table is created according to the capabilities of the workers 1, 2, and 3, as shown in FIGS.

  Here, in another embodiment of the present invention, when a plurality of types of workpieces are processed by a plurality of workers, the worker capability table created by the worker capability table creation unit 7 is as shown in FIG. The worker ability may be set for each common work part of the work of the sample population. In this case, as shown in FIG. 17, an operator capability table is created in which the capabilities of the workers 1, 2, and 3 are summarized for each of the work parts A to F. In this worker ability table, the standard value is set to 100% and the ability of each worker is set as a relative value. The larger the numerical value, the lower the ability and the lower the numerical value, the higher the ability. Here, “130%” is the ability to process with 1.3 times the standard work time, and “90%” is 0.9 times the standard work time. Is the ability to Based on the worker ability table shown in FIG. 17, as shown in FIGS. 18 (a) to 18 (c), each work for each type of work in the sample population according to the ability of the workers 1, 2, and 3 is performed. Set the working time of the part. Thereafter, based on the work process set by the work process setting unit 6, a first work time table is created by the first work time table creating unit, and a simulation is performed.

  Also, when there is no work to be processed in the work process in charge and there is a work waiting to be processed in the work process immediately before the work process in charge or the work process next to the work process in charge, the process waits. By processing the workpieces, it is possible to reduce the number of workpieces waiting to be processed and improve the work efficiency, and to check and instruct the presence or absence of workpieces waiting to be processed and to perform other work processes. It can be simplified. In addition, not only before and after the work process, but also by performing the process of another work process with a workpiece waiting to be processed, the number of workpieces waiting to be processed is reduced, and the work efficiency can be improved.

  Further, in the work process in which the plurality of workers set by the worker charge setting unit 8 are respectively in charge, the simulation step is performed under the condition that the work process in charge of at least one of the plurality of workers is unchanged. When the number of workpieces to be processed within a predetermined time is the optimum condition, the setting conditions for the flow work that minimizes the waiting time for a plurality of workers can be obtained. As a result, it is possible to realize a work process for efficiently performing a large amount.

  In addition, the above-mentioned processing of various types of workpieces is dismantling for the purpose of recycling. In particular, multiple types of workpieces are randomly input to the work flow, and are the same type and the state of the workpiece varies depending on the usage environment, etc. Even in this case, it is possible to set up a work process that can efficiently disassemble a large variety of workpieces in large quantities.

  Examples of work sites in the demolition work process of the dewatering washing machine of the above embodiment include, for example, an upper plate screw, an upper plate hose, an upper plate demolition, a dehydration lid, a pulsator, a suspension rod, a case inversion, an upper tank, a pulsator, and a flange. There are screws, separation of water tank and dewatering tank, dewatering flange, balancer, dewatering parts and so on.

  In the above embodiment, the work process simulation method and the work process simulation apparatus for the demolition work of the dewatering washing machine have been described. However, the present invention is not limited to the dehydration washing machine, and can be applied to the dismantling work of various electric products. Moreover, you may apply the work process simulation method and work process simulation apparatus of this invention not only to a dismantling work process but to a production work process.

  In addition, as a work process simulation method according to another embodiment of the present invention, a work process simulation method when a plurality of workers sequentially process a plurality of types of work in a flow work, On the other hand, based on the result of measuring or estimating the work time in each work part for each type of work, the work part setting process is performed on each work process of the flow work by the work part setting process. The work process setting step to be set, the work time table creating step for creating the work time table indicating the work time in each work process for each work type by the work time table creating means, and the work time table creating means The work time probability distribution table at each work site for each work type is confirmed based on the work time table and the work occurrence probability. Based on the probability distribution table creation step created by the distribution table creation means and the probability distribution table created by the probability distribution table creation step, the above flow for the simulation work data in which the plurality of types of workpieces are randomly generated There may be provided a simulation step of simulating the work by a simulation means so as to minimize the waiting time of a plurality of workers.

  The work process simulation method according to another embodiment will be described in detail. The probability distribution table creation unit 10 is based on a predetermined occurrence probability for each work type of the sample population and a work time (shown in FIG. 4) at each work site for each work type. A work time probability distribution table (shown in FIG. 6) in each work process in which work sites are set is created for each worker in the worker ability table. For example, FIG. 6 shows the occurrence probability and work time for each work (IDs 1 to 6) in the work steps 1 to 3. In this way, by using virtual work data in which various kinds of work are generated randomly for each work process for simulation, as if a large number of work data is handled, In FIG. 6, the number of work data is 6, but it is possible to simulate as if 6 × 6 × 6 = 256 work data is handled.

In this way, by effectively utilizing this work process simulation method, the work time required for the assembly (or disassembly) of mixed multi-product products is predicted, and multi-product production that could only be handled by the cell method ( Alternatively, it is possible to realize a work process for efficiently performing a large amount of dismantling) in a flow work.

  Unlike the above embodiment, as shown in FIG. 12, the work time probability distribution for each work site is measured from the sample population, and the work type is determined based on the work time probability distribution for each work site. The work time of each work process may be calculated every time. In other words, a probability distribution indicating the work time probability distribution for each work part based on the result of measuring the work time at each work part for each work type for a sample population in which multiple types of work occur randomly A work part probability distribution table creation step for creating a table by the work part probability distribution table creation means, and a work process setting means for setting the processing of the work parts of the above-mentioned various types of work to each work process of the above-mentioned flow work. Based on the process setting step, the probability distribution of the work time for each work part of the probability distribution table created by the work part probability distribution table creating means and each work process in which the work part is set by the work process setting means, Simulate flow work with simulation means for work data for simulation that randomly generated various types of work By may be working process simulation method and a simulation step to grasp the working state of each working step of the assembly line. In this case, the randomness in each work process can be made more reliable.

  By the way, the function of the work process simulation apparatus of the above-described embodiment is realized by a work process simulation program recorded on a program recording medium. Therefore, such a work process simulation program can be recorded on a computer-readable program recording medium and provided as a program product.

  The computer readable program recording medium may be a ROM (Read Only Memory) program medium, or may be a program medium that is loaded into and read from an external auxiliary storage device. In any case, the program reading means for reading the work process simulation program from the program medium may have a configuration in which the program medium is directly accessed and read, or provided in a RAM (Random Access Memory). The program storage area may be loaded, and the program storage area may be accessed and read. It is assumed that a load program for loading from the program medium into the program storage area of the RAM is stored in advance in the main unit.

  Here, the program medium is configured to be separable from the main body side, and includes a tape system such as a magnetic tape and a cassette tape, a magnetic disk such as a flexible disk and a hard disk, a CD-ROM (Compact Disc-Read Only Memory), an MO. (Magnet Optical disk) disc, MD (mini disc), optical disc such as DVD (Digital Versatile Disc), card system such as IC (integrated circuit) card and optical card, mask ROM , EPROM (Erasable Programmable Read Only Memory), EEPROM (Electronically Erasable Programmable Read Only Memory), flash ROM, etc. It is.

  In addition, when the work process simulation apparatus in the above embodiment includes a modem, a LAN card, and the like and can be connected to a communication network including the Internet, the program medium is downloaded from the communication network, etc. Even if it is a medium that carries the program in a fluid way, there is no problem. In this case, the download program for downloading from the communication network is assumed to be stored in advance in the main unit or installed from another program recording medium.

  Note that what is recorded on the program recording medium is not limited to a program, and data can also be recorded.

FIG. 1 is a block diagram showing a schematic configuration of a work process simulation apparatus using a work process simulation method according to an embodiment of the present invention. FIG. 2 is a flowchart for explaining the processing of the work process simulation apparatus. FIG. 3 is a flowchart for explaining a process performed by a worker in each work process per unit time in the simulation of the work process simulation apparatus. FIG. 4 shows the result of measuring or estimating the work time at each work site for each type of work for the plurality of kinds of work. FIG. 5 is a diagram showing a first work time table. FIG. 6 is a diagram showing a work time probability distribution table in each work process. FIG. 7 (a) is a diagram showing the worker assignment table (straight type), FIG. 7 (b) is a diagram showing the worker assignment table (cooperative type), and FIG. 7 (c) is another worker. It is a figure which shows a charge table (cooperation type). FIG. 8A is a diagram showing virtual work data in which a variety of workpieces for simulation are randomly generated, and FIG. 8B is a diagram in which a variety of workpieces for other simulations are randomly generated. It is a figure which shows virtual work data. FIG. 9 is a diagram showing the work state of each work process of the flow work per unit time based on the simulation result of the simulation unit. FIG. 10 is a diagram illustrating a work state of each work process of the flow work per unit time based on the simulation result of the simulation unit. FIG. 11 is a diagram showing a work state of each work process of a flow work every predetermined time based on the simulation result following FIG. FIG. 12 is a diagram for explaining the calculation of the work time for each work process for each work type based on the work time establishment distribution for each work part. FIG. 13 is a diagram showing a worker capability table for each worker. FIG. 14 (a) is a diagram showing a second work time table of the worker 1, FIG. 14 (b) is a diagram showing a second work time table of the worker 2, and FIG. 14 (c) is a diagram of the worker. 3 is a diagram showing a second work time table of FIG. FIG. 15 is a diagram showing a worker capability table for each work process for each worker. 16A is a diagram showing the second work time table of the worker 1, FIG. 16B is a diagram showing the second work time table of the worker 2, and FIG. It is a figure which shows the 2nd work time table | surface of a person. FIG. 17 is a diagram showing a worker capability table of each work part for each worker. FIG. 18A is a diagram showing the work time of each work site for each work type of the sample population of worker 1, and FIG. 18B is the work time of each work type of the sample population of worker 2. FIG. 18C is a diagram showing the work time of each work site for each type of work in the sample population of the worker 3.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 ... 1st work time table | surface preparation part 2 ... Weighted average time calculation part 3 ... 2nd work time table | surface preparation part 4 ... Simulation part 5 ... Simulation result determination part 6 ... Work process setting part 7 ... Worker capability table preparation part 8 ... Worker charge setting part 9 ... Input order setting part 10 ... Probability distribution table creation part

Claims (16)

It is a work process simulation method when a plurality of workers process a plurality of types of workpieces sequentially in a flow work,
Based on the result of measuring or estimating the work time at each work site for each type of work for the plurality of types of work, the processing of the work site of the plurality of types of work is performed for each work of the flow work. A work process setting step for setting the process by a work process setting means;
A work time table creating step for creating a work time table indicating the work time in each work process for each type of the work by the work time table creating means;
A loading order setting step for setting a loading order when the plurality of types of workpieces are randomly loaded into the first step of the flow work by a loading order setting means;
Minimizing the waiting time of the plurality of workers with respect to a workpiece that is input based on the operation time table created by the operation time table creating means and the input order set by the input order setting step. And a simulation step of simulating each work process of the above-mentioned flow work by a simulation means. In the work process simulation method according to claim 1,
A work process simulation method, characterized in that, for each work process of the flow work set by the work process setting means, work processes respectively handled by the plurality of workers are set by the worker charge setting means. In the work process simulation method according to claim 2,
When at least one of the plurality of workers is in charge of a plurality of work steps in the work steps each of the plurality of workers set by the worker charge setting means, A work process simulation method characterized by setting a criterion for determining a work process to be handled by a worker in charge of a process according to the status of the process. In the work process simulation method according to any one of claims 1 to 3,
Based on at least one of the processing plan for the plurality of types of workpieces for each type of the plurality of types of workpieces or the occurrence probability for each type of the plurality of types of workpieces, the first order of the flow work is performed by the input order setting means. A work process simulation method characterized by setting a loading sequence when sequentially loading. In the work process simulation method according to any one of claims 1 to 4,
Based on the probability of occurrence of each work type and the work time table created by the work time table creating means, the variation of the weighted average work time of each work process is within a predetermined range, A work process simulation method characterized in that the work process setting means sets the processing of the work parts of the plurality of types of work in each work process. In the work process simulation method according to claim 1,
When the plurality of types of workpieces are processed by the plurality of workers, the result of measuring or estimating the work time at each work site for each type of the workpiece and each of the workers set by the worker capability setting means A work process simulation method characterized in that the work time for each worker required for each work part is set based on the worker ability. In the work process simulation method according to any one of claims 1 to 5,
When each of the plurality of types of workpieces is processed by the plurality of workers, each of the workers set by the worker process setting means and each of the workers set by the worker capability setting means. A work process simulation method characterized by setting a work time for each worker required for each work process based on the worker ability. In the work process simulation method according to claim 5,
A work process simulation method, wherein at least one of the plurality of workers is in charge of a plurality of work processes so that the work balance can cope with variations in the weighted average work time within a predetermined range. . In the work process simulation method according to any one of claims 2 to 8,
In the work process in which each of the plurality of workers is set by the worker charge setting means, the simulation step is performed under a condition that the work process handled by at least one of the plurality of workers is unchanged. A work process simulation method characterized in that each setting condition when the number of workpieces to be processed within a predetermined time is the largest is the optimum condition. Based on the result of measuring or estimating the work time at each work site for each type of work for a plurality of types of work, the processing of the work site of the plurality of types of work is performed for each work process of the flow work. A work process setting step set by the work process setting means;
A work time table creating step for creating a work time table indicating the work time in each work process for each type of the work by the work time table creating means;
A loading order setting step for setting a loading order when the plurality of types of workpieces are randomly loaded into the first step of the flow work by a loading order setting means;
Minimizing the waiting time of the plurality of workers with respect to a workpiece that is input based on the operation time table created by the operation time table creating means and the input order set by the input order setting step. And a simulation step of simulating each work process of the above-mentioned flow work by a simulation means. It is a work process simulation method when a plurality of workers process a plurality of types of workpieces sequentially in a flow work,
Based on the result of measuring or estimating the work time at each work site for each work type for the plurality of work types, the work site processing of the multiple work types is performed for each work of the flow work. A work process setting step for setting the process by a work process setting means;
A work time table creating step for creating a work time table indicating the work time in each work process for each type of the work by the work time table creating means;
Probability of creating probability distribution table of work time in each work process for each work type by probability distribution table creating means based on the work time table created by the work time table creating means and the probability of occurrence of the work Distribution table creation step,
Based on the probability distribution table created in the probability distribution table creation step, the flow work is performed on the simulation work data in which the plurality of types of works are randomly generated, and the waiting time of the plurality of workers is minimized. And a simulation step of simulating by a simulation means. The work process simulation method according to claim 11,
In the work process in which each of the plurality of workers is set by the worker charge setting means, the simulation step is performed under a condition that the work process handled by at least one of the plurality of workers is unchanged. A work process simulation method characterized in that each setting condition when the number of workpieces to be processed within a predetermined time is the largest is the optimum condition. Based on the result of measuring or estimating the work time at each work site for each type of work for a plurality of types of work, the processing of the work site of the plurality of types of work is performed for each work process of the flow work. A work process setting step set by the work process setting means;
A work time table creating step for creating a work time table indicating the work time in each work process for each type of the work by the work time table creating means;
Probability of creating probability distribution table of work time in each work process for each work type by probability distribution table creating means based on the work time table created by the work time table creating means and the probability of occurrence of the work Distribution table creation step,
Based on the probability distribution table created in the probability distribution table creation step, the flow work is performed on the simulation work data in which the plurality of types of works are randomly generated, and the waiting time of the plurality of workers is minimized. And a simulation step of simulating by a simulation means.   A waste recycling method for disassembling waste to recycle it, wherein the work process is performed using the work process simulation method according to any one of claims 1 to 9, 11 or 12. A waste recycling method characterized by setting and creating a dismantling treatment plan.   A waste recycling method for disassembling and recycling waste to create a demolition processing plan by setting a work process using the work process simulation apparatus according to claim 10 or 13. A waste recycling method characterized by the above.   The waste recycling method according to claim 14 or 15, wherein the waste is a waste of a product selected from the group consisting of an air conditioner, a television, a refrigerator, and a washing machine. Recycling method.

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