JP2007047926A - System, method, and program for work distribution management - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To distribute element work so as to improve a line balance ratio while satisfying a target tact time. <P>SOLUTION: A work distribution management system comprises means for: distributing the element work to direct operators (S10) so as to satisfy designated conditions regarding the target tact time and a target line balance ratio on the basis of work procedures, the target tact time, and subtotal time of the element work identified by identification numbers of the element work; measuring actual work time per one product for direct operators according to work distribution results (S31); calculating an actual line balance ratio on the basis of the actual work time (S36); redistributing the element work (S40) when determining that the actual line balance ratio is less than the target line balance ratio (No at S37); recalculating the actual line balance ratio (S61); recalculating the actual line balance ratio (S66); distributing the element work to the whole operators including indirect operators so as to satisfy designated conditions (S70) when determining that the actual line balance ratio is not the target line balance ratio or over (No at S67); and outputting the work distribution results. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a work distribution management device, a work distribution management method, and a work distribution management program, and more particularly, to a work distribution management device, a work distribution management method, and a work distribution management program suitable for distributing work.

  2. Description of the Related Art Conventionally, in a production line for assembling various products, there is a work distribution table creation support system that distributes element work for each process or for each worker so that processing can be performed within a set cycle time (for example, Patent Document 1). reference).

In addition, work is distributed based on the takt time, work is performed using the work distribution results, the work execution results are collected, and the work in each process in which the production process in the production line is shared by the work subject When the balance of time (hereinafter referred to as “line balance”) does not satisfy a certain standard, there is a line balance management device that redistributes work based on collected work execution results and optimizes line balance (for example, Patent Document 2).
JP 2002-215860 A (pages 3-6, FIGS. 7-17) JP 2003-108217 A (paragraphs 0046-0057, FIG. 10)

  However, the work distribution table creation support system disclosed in Patent Document 1 measures the work time for each element work, and implements work distribution using the measurement result. Sex is not considered.

  That is, the work time depends on the skill level of the worker, but according to the technique of Patent Document 1, work distribution is not performed in consideration of the difference in skill level between the workers. For this reason, when the work distribution result is applied as it is, there is a possibility that production is not performed as planned. Further, according to the technique of Patent Document 1, no consideration is given to improving the production target value when production is not performed as planned.

  Further, the line balance management device disclosed in Patent Document 2 sets a reference time for each element work and performs work distribution. The work is actually performed on the production line based on the work distribution result. When the line balance in the work does not satisfy the target value, the element work is redistributed among direct workers who directly perform the manufacturing work on the production line, and the line balance is improved so as to satisfy the target value.

  However, according to the technique of Patent Document 2, it is possible to improve the line balance, but as a result of improving the line balance, the tact time of the production line increases, resulting in a decrease in the production amount of the product. There is a problem that the production plan may not be achieved in the end.

  Further, according to the techniques disclosed in Patent Document 1 and Patent Document 2, an indirect worker (for example, a line leader) who indirectly performs manufacturing work by directly assisting the worker performs element work. There is a problem that is not considered.

  FIG. 22 is a diagram illustrating a time zone for work of an indirect worker. Referring to FIG. 22, the main work of indirect workers is to confirm each direct worker at the time of starting up the production line from 9:00:00, 11:10, 13:55, and 16: 5. For example, there is a response to operations that occur regularly, such as a response to operations that occur irregularly, such as when work delays or equipment troubles occur. For this reason, the other time is an idle time during which the indirect worker does not substantially perform the manufacturing work.

  The present invention has been made to solve the above-described problems, and an object of the present invention is work distribution management capable of distributing work so as to improve line balance while satisfying tact time. An apparatus, a work distribution management method, and a work distribution management program are provided.

  In order to solve the above-described problem, according to an aspect of the present invention, the work distribution management device directly performs a plurality of elemental operations in which a manufacturing process in a product manufacturing line is divided in advance on the manufacturing line. Manage distribution to multiple direct work subjects.

  In addition, the work distribution management device includes an element work storage unit, a basic time storage unit, a tact time storage unit, a first work distribution unit, an actual work time measurement unit, an actual line balance rate calculation unit, and a reprocessing Unit, a second work distribution unit, and an information output unit.

  The element work storage unit stores in advance element work identification information that can identify each element work so that the work order in which each element work is performed in the manufacturing process can be specified. The basic time storage unit stores in advance the basic time required for each element work in the manufacturing process in association with the element work identification information. The tact time storage unit stores in advance a tact time obtained by dividing a predetermined operation time of a production line within a predetermined period by a predetermined production scheduled quantity of the product during the predetermined period.

  The first work distribution unit is stored in the basic work storage unit, the work order of the elementary work identified by the elementary work identification information stored in the elementary work storage unit, the takt time stored in the takt time storage unit, and Element work is assigned to each direct work subject so that a predetermined condition regarding the tact time based on the basic time and the line balance ratio indicating the variation in work time required for the element work distributed to each direct work subject is satisfied. To distribute.

  The actual work time measuring unit measures the actual work time per product for each direct work subject performed according to the result distributed by the first work distribution unit. The actual line balance rate calculation unit calculates an actual line balance rate that indicates the variation in actual work time among direct work subjects, based on the actual work time measured by the actual work time measurement unit.

  When the actual line balance rate calculated by the actual line balance rate calculation unit is less than a predetermined target line balance rate, the reprocessing unit causes the first task distribution unit to redistribute the element work and measure the actual work time. The actual work time is re-measured by the unit, and the actual line balance rate is re-calculated by the actual line balance rate calculation unit.

  The second work distribution unit stores the element work storage unit when the actual line balance rate recalculated by the reprocessing unit does not exceed the target line balance rate or when the first work distribution unit cannot distribute the element work. In order to satisfy a predetermined condition based on the work order of the element work identified by the element work identification information, the tact time stored in the tact time storage unit, and the basic time stored in the basic time storage unit, The element work is distributed to each of the work subjects composed of a plurality of direct work subjects and at least one indirect work subject that indirectly assists the direct work subjects.

  The information output unit outputs the result distributed by the first work distribution unit or the second work distribution unit.

  According to the present invention, a tact based on the work order of the element work identified by the element work identification information stored in advance by the work distribution management device, the tact time stored in advance, and the basic time stored in advance. Element work is allocated to each direct work subject so as to satisfy the predetermined conditions regarding time and line balance ratio, and the actual work time per product for each direct work subject performed according to the assigned result is measured. The actual line balance rate is calculated based on the measured actual work time.

  If the calculated actual line balance ratio is less than the predetermined target line balance ratio, the element work is redistributed, the actual work time is remeasured, and the actual line balance ratio is recalculated.

  In addition, when the recalculated actual line balance ratio does not exceed the target line balance ratio, or when the element work cannot be allocated, the work order of the element work identified by the pre-stored element work identification information is stored in advance. The element work is distributed to each of the work subjects including the indirect work subject so as to satisfy a predetermined condition based on the tact time and the basic time stored in advance. Then, the distributed result is output.

  As a result, line balance can be improved while satisfying the tact time even when the element work cannot be allocated only by the direct work subject or when the target line balance ratio cannot be achieved when the element work is assigned only to the direct work subject. Therefore, it is possible to provide a work distribution management device capable of distributing the element work so that it can be performed.

  Preferably, the first work distribution unit is distributed to the direct work subjects under the condition that the work order of the elementary work identified by the elementary work identification information stored in the elementary work storage unit does not cross between the respective direct work subjects. The unit work time per product obtained by adding the basic times stored in the basic time storage unit corresponding to each element work directly for each work subject does not exceed the tact time stored in the tact time storage unit. The target line balance is the line balance ratio obtained by dividing the total time of the basic time stored in the condition and the basic time storage unit by the time obtained by multiplying the maximum unit work time of the unit work hours by the number of work subjects directly Allocate the element work directly to the work subject so as to satisfy the condition that exceeds the rate.

  In addition, the second work distribution unit includes a condition that the work order of the element work identified by the element work identification information stored in the element work storage unit does not cross between the work subjects, and the unit work time of each work subject. The condition that does not exceed the tact time stored in the tact time storage unit, and the total time of the basic time stored in the basic time storage unit are divided by the time obtained by multiplying the maximum unit work time directly by the number of work subjects. The element work is distributed to the work subject so that the condition that the line balance ratio is equal to or higher than the target line balance ratio is satisfied.

  According to the present invention, the work distribution management device does not allow the work order of the element work to cross between the respective direct work subjects, and the unit work time per product for each direct work subject does not exceed the tact time. The element work is directly distributed to the work subject so that the condition and the condition that the line balance ratio is equal to or higher than the target line balance ratio are satisfied.

  Also, if the recalculated actual line balance ratio does not exceed the target line balance ratio, or if the element work cannot be allocated, the condition that the work order of the element work does not cross between the work subjects, the unit of each work subject The element work is distributed to the work subject so that the condition that the work time does not exceed the tact time and the condition that the line balance rate is equal to or higher than the target line balance rate are satisfied.

  Therefore, the work order of the element work is not mixed between the work subjects, the work time per product for each work subject does not exceed the tact time, and the line balance rate is equal to or higher than the target line balance rate. Work can be distributed.

  Preferably, the information output unit outputs, as a result, information indicating allocation of the element work allocated to the work subject by the first work distribution unit or the second work distribution unit, and is calculated by the actual line balance ratio calculation unit. The actual line balance ratio is further output.

  According to this invention, as a result of the element work being distributed by the work distribution management device, information indicating the allocation of the distributed element work to the work subject is output, and the calculated actual line balance ratio is further output. The

  For this reason, it is possible to inform the user of the result of distribution by the work distribution management device in an easy-to-understand manner.

  Preferably, the apparatus further includes a manufacturing number counting unit that counts the number of products whose actual work time is measured by the actual work time measuring unit.

  According to this invention, the number of products whose actual work time is measured is counted by the work distribution management device. For this reason, the progress of production can be grasped.

  Preferably, the apparatus further includes a manufacturing lead time calculating unit that calculates a manufacturing lead time obtained by summing up the actual work time measured by the actual work time measuring unit for all work subjects.

  According to this invention, the manufacturing lead time obtained by totaling the measured actual work time for all work subjects is calculated by the work distribution management device. For this reason, it is possible to grasp the time during which the product stays in the manufacturing process.

  Preferably, the actual work time measurement unit includes a first detection unit that detects a start point at which the product has entered the area where the work subject directly works, and a first work distribution unit or a second work distribution for one product. A second detection unit that detects an end point at which the element work allocated directly to the work subject by the unit ends, and an end point detected by the second detection unit and a start point detected by the first detection unit Based on this, actual work time is measured.

  According to the present invention, the actual work time is measured by the work distribution management device based on the detected start time and end time.

  Preferably, the actual work time measuring unit measures an average actual work time for a predetermined number of products as the actual work time.

  According to the present invention, the average actual work time for a predetermined number of products is measured as the actual work time by the work distribution management device. For this reason, it is possible to measure the actual work time with higher reliability as compared with the actual work time for one product.

  Preferably, an alarm unit is further provided that issues an alarm when the actual work time measured by the actual work time measurement unit exceeds the tact time stored in the tact time storage unit.

  According to the present invention, the work distribution management device issues an alarm when the measured actual work time exceeds the tact time. For this reason, it is possible to notify other work subjects that the work time of any direct work subject has exceeded the tact time. As a result, it is possible to prompt the user to redo the work distribution.

  According to another aspect of the present invention, in the work distribution management method, a plurality of element work in which a manufacturing process in a product manufacturing line is divided in advance to a plurality of direct work subjects who directly perform the manufacturing work in the manufacturing line. This is performed by a work distribution management device that manages the distribution of the work.

  Further, the work distribution management method includes a step of storing element work identification information capable of identifying each element work in advance so as to specify a work order in which each element work is performed in the manufacturing process, The basic time required for the element work is stored in advance corresponding to the element work identification information, and the predetermined operation time of the production line within the predetermined period is divided by the predetermined production scheduled quantity of the product during the predetermined period. Storing the tact time in advance.

  The work distribution management method further includes a tact time based on the work order of the element work identified by the element work identification information stored in advance, the tact time stored in advance, and the basic time stored in advance. A step of allocating the element work to each direct work subject so as to satisfy a predetermined condition relating to a line balance ratio indicating a variation in work time required for the element work assigned to each direct work subject, and the result of the distribution The step of measuring the actual work time per product for each direct work subject performed according to the above, and the actual line balance ratio indicating the variation in the actual work time among the direct work subjects based on the measured actual work time Calculating.

  In addition, the work distribution management method further redistributes the element work and re-measures the actual work time when the calculated actual line balance ratio is less than the predetermined target line balance ratio, and the actual line balance ratio. Recalculating.

  Further, the work distribution management method further includes an element identified by element work identification information stored in advance when the recalculated actual line balance ratio does not exceed the target line balance ratio or when the element work cannot be distributed. The element work is indirectly assisted by a plurality of direct work subjects and direct work subjects so as to satisfy predetermined conditions based on the work order of the work, the pre-stored tact time, and the pre-stored basic time. The method includes a step of allocating to each of the work subjects composed of at least one indirect work subject performing the manufacturing work, and a step of outputting the distributed result.

  According to the present invention, even when the element work cannot be allocated only by the direct work subject or when the target line balance ratio cannot be achieved when the element work is allocated only by the direct work subject, the line is achieved while satisfying the tact time. It is possible to provide a work distribution management method capable of distributing the element work so that the balance can be improved.

  According to still another aspect of the present invention, the work distribution management program includes a plurality of direct work subjects that directly perform a manufacturing work on a plurality of elemental work in which a manufacturing process in a product manufacturing line is divided in advance. It is executed by a work distribution management device that manages the distribution to

  The work distribution management program stores element work identification information that can identify each element work in advance so that the work order in which each element work is performed in the manufacturing process can be specified, The basic time required for the element work is stored in advance corresponding to the element work identification information, and the predetermined operation time of the production line within the predetermined period is divided by the predetermined production scheduled quantity of the product during the predetermined period. Storing the tact time thus obtained in advance.

  In addition, the work distribution management program includes a tact time based on a work order of element work identified by element work identification information stored in advance, a tact time stored in advance, and a basic time stored in advance. The step of allocating the element work to each of the direct work subjects so as to satisfy a predetermined condition regarding the line balance ratio indicating the variation in work time required for the element work directly distributed to the work subjects, and the distribution result is performed. Step of measuring the actual work time per product for each direct work subject, and calculating the actual line balance ratio indicating the variation in the actual work time among the direct work subjects based on the measured actual work time And executing a step.

  In addition, the work distribution management program redistributes the element work, re-measures the actual work time, and re-measures the actual line balance ratio when the calculated actual line balance ratio is less than the predetermined target line balance ratio. A step of calculating.

  In addition, the work distribution management program determines whether the recalculated actual line balance rate does not exceed the target line balance rate, or if the element work cannot be distributed, the element work identified by the pre-stored element work identification information. Indirect manufacturing work with the assistance of multiple direct work subjects and direct work subjects to satisfy predetermined conditions based on the work order, pre-stored tact time, and pre-stored basic time A step of allocating to each of the work subjects composed of at least one indirect work subject, and a step of outputting the distributed result.

  According to the present invention, even when the element work cannot be allocated only by the direct work subject or when the target line balance ratio cannot be achieved when the element work is allocated only by the direct work subject, the line is achieved while satisfying the tact time. It is possible to provide a work distribution management program capable of distributing the element work so that the balance can be improved.

  Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. Note that the same or corresponding parts in the drawings are denoted by the same reference numerals and description thereof will not be repeated.

  FIG. 1 is a schematic diagram showing an outline of a configuration of a production line 26 in the embodiment of the present invention.

  Referring to FIG. 1, the production line 26 includes a work area where each direct worker 30 works on a product being manufactured, and a work performed on a product being manufactured for each direct worker 30 is finished. And a connection area for delivering a product being manufactured to the worker 30 directly.

  The direct operator 30 is an operator who directly performs a manufacturing operation on the manufacturing line 26. In addition to the direct worker 30, a line leader 31 that is an indirect worker who indirectly assists the direct worker and indirectly performs the manufacturing work is assigned to the production line 26. The line leader 31 is a task that assists the worker directly, a task that occurs regularly, such as confirmation of the worker 30 at the time of starting up the production line, and a time when work delays or equipment troubles occur. And work that occurs irregularly. Note that a repair worker of the production line 26 may be included as an indirect worker.

  Further, any of the direct workers 30 may be a robot that automatically performs a manufacturing operation according to a program incorporated in advance. In addition, any of the work areas may be a manufacturing machine such as a machine tool that performs predetermined processing on a product.

  A moving device for moving a product such as a belt conveyor is provided in the connection region. The product may be handed over to the next worker. In the production line 26 shown in FIG. 1, products being produced are flowed from the left side to the right side of the figure.

  A sensor 21 that detects the passage of a product is provided for each unit at a connection portion between the connection area and the work area. For example, a proximity sensor can be used as the sensor 21. Further, a foot switch 22 is provided at the foot of the work position of the direct worker 30 so that the worker directly inputs that the manufacturing work for one product distributed to the direct worker has been completed.

  In addition, as long as the start time when the product has entered the work area can be detected, the device is not limited to the sensor 21 and may be another device. In addition, the present invention is not limited to the foot switch 22 as long as it is possible to detect the end point when the manufacturing work directly allocated to the workers is completed for one product, and other devices may be used.

  The work distribution management device 20 manages the distribution of a plurality of elemental work directly to the workers 30 based on signals from the sensors 21 and foot switches 22 and data stored in advance. The element work is each work in which the production process in the production line 26 is divided in advance. The work distribution management device 20 will be described in detail with reference to FIGS.

  A PC (Personal Computer) 23 and a printing device 24 are connected to the work distribution management device 20 via a network 25. The PC 23 and the printing device 24 output the information received from the work distribution management device 20.

  FIG. 2 is a block diagram showing an outline of the configuration of the work distribution management device 20 according to the embodiment of the present invention.

  Referring to FIG. 2, work distribution management device 20 includes a control unit 210, a memory 220, an input unit 230, an output unit 240, a communication unit 250, and an external storage device 260. The control unit 210, the memory 220, the input unit 230, the output unit 240, the communication unit 250, and the external storage device 260 are connected to each other via a bus. The work distribution management device 20 can be configured by a general PC or workstation.

  The control unit 210 includes a CPU (Central Processing Unit) and CPU peripheral circuits. The control unit 210 processes data input from the memory 220, the input unit 230, the communication unit 250, or the external storage device 260 in accordance with a program stored in the memory 220, and the memory 220, the output unit 240, the communication unit The processed data is output to 250 or the external storage device 260.

  The memory 220 includes a RAM (Random Access Memory) and a ROM (Read Only Memory) memory that electrically store data using semiconductor elements. In addition, a part of the storage area of the hard disk of the external storage device 260 may be used as a virtual memory. The memory 220 stores a program executed by the control unit 210, data to be processed by the program, temporary data when the program is executed, and data of the execution result of the program.

  The input unit 230 includes a keyboard and mouse input device. The input unit 230 receives data input from the user and outputs the received data to the control unit 210. Further, in the present embodiment, the input unit 230 includes the sensor 21 and the foot switch 22 described in FIG.

  The output unit 240 includes a display and a printer output device. The output unit 240 outputs information by displaying the information as an image or printing the information on paper in order to notify the user of the information received from the control unit 210.

  The communication unit 250 includes a terminal adapter or a modem communication device. The communication unit 250 transmits data received from the control unit 210 to another computer via the network 25, and outputs data received from another computer via the network 25 to the control unit 210.

  The external storage device 260 includes a storage device such as a hard disk drive, a flexible disk drive, an MO (Magneto-Optical disk) drive, a CD (Compact Disc) drive, or a DVD (Digital Versatile Disk) drive. The external storage device 260 records predetermined data or a program received from the control unit 210 magnetically or optically on the recording medium 270, or reads the predetermined data or program from the recording medium 270 and transfers it to the control unit 210. Examples of the recording medium 270 include a flexible disk, MO, CD-ROM, CD-R, CD-RW, DVD-ROM, DVD-R, DVD-RW, DVD-RAM, DVD + R, and DVD + RW.

  FIG. 3 is a functional block diagram showing an outline of functions of the work distribution management device 20 according to the embodiment of the present invention.

  Referring to FIG. 3, the work distribution management device 20 includes a data management unit 1, a work distribution unit 2, a work time collection unit 3, a line balance calculation unit 4, a data comparison unit 5, and an information output unit 6. Including.

  The functions of the data management unit 1 are realized by the control unit 210, the memory 220, and the external storage device 260. The data management unit 1 includes the data of the work time master 10 and the line condition master 11 given in advance, the work distribution result 12 as a result of processing by the work distribution management device 20, the work time measurement result 13, and Each data of the line balance rate calculation result 14 is stored.

  FIG. 8 is a diagram showing the work time master 10 stored in the data management unit 1 of the work distribution management device 20 according to the embodiment of the present invention.

  Referring to FIG. 8, the work time master 10 includes an identification number, a work content, a work replacement possibility code, a number of workers, each of a plurality of element work obtained by dividing a manufacturing process in a product manufacturing line in advance, Standard time and subtotal time are included.

  The identification number is a number for uniquely identifying an element work and indicates a work order in which the element work is performed in the manufacturing process. The work content indicates an outline of the content of the element work. The work replacement availability code is a code indicating whether or not it is possible to transfer the person in charge of the element work to another worker. If it is ○, transfer is possible, and if it is not marked, transfer is not possible. Indicates that it is possible.

  The number of workers indicates the number of repetitions of the element work. For example, when the number of workers in the element work for tightening the screw is “2”, the number of workers indicates that the place for tightening the screw is “2”.

  The standard time indicates a standard time required for the number of element works. The subtotal time indicates a required time for each element work, and is calculated by multiplying the standard time for each element work by the number of workers. The total time indicates a required time per product of the entire manufacturing process of the manufacturing line 26, and is calculated by adding the subtotal time for all the element operations.

  In FIG. 8, a working time master 10 relating to the assembly of a portable MD (MiniDisc) player is shown as an example. For example, for the element work with the identification number “3”, the work content is “the MD mechanism is attached to the center cabinet”, the work transfer is impossible, and the number of workers is “1”. The standard time is “10.50” seconds, and the subtotal time is “10.50” seconds.

  The element work with the identification number “14” is a work whose content is “take LCD (Liquid Crystal Display) unit”, the work can be transferred, and the number of workers is “1”. Yes, the standard time is “3.20” seconds, and the subtotal time is “3.30” seconds. The total time is “150.30” seconds.

  FIG. 9 is a diagram showing the line condition master 11 stored in the data management unit 1 of the work distribution management device 20 according to the embodiment of the present invention.

  Referring to FIG. 9, the line condition master 11 includes the number of direct workers, the number of line leaders, the number of production plans, the working hours, the total working hours, the target tact time, and the target line balance rate. And are included.

  The number of direct workers is the number of direct workers. The number of line leaders is the number of line leaders who are indirect workers. The production plan number is the number of product production plans. Working hours are the hours when the worker works directly. The total working hours is the sum of working hours.

  The tact time is a time indicating how long a product must be manufactured, and the tact time (seconds) = operating time (seconds) of a predetermined period (for example, one day) / required of a predetermined period Calculated using the quantity (piece) formula. The tact time is determined by determining the operation time and the required quantity. The target tact time is a tact time determined as a target.

  The line balance ratio is a ratio indicating the variation in unit work time per product among the direct workers required for the element work allocated directly to the workers, and is used to manufacture one product in the manufacturing process. The time required is calculated by dividing the unit work time of the direct worker who requires the most time among the direct workers by the number of direct workers. That is, the line balance ratio = the sum of unit work times of all direct workers (seconds) / (maximum unit work time (seconds) of the direct worker having the largest unit work time × number of direct workers (person)) Thus, the line balance rate is calculated. The target line balance ratio is a line balance ratio predetermined as a target.

  In the line condition master 11 of FIG. 9, the number of direct workers is “5”, the number of line leaders is “1”, the number of production plans is “900”, and the working time is “09”. : 00 to 11:00, “11:10 to 13:10”, “13:55 to 15:55”, and “16:05 to 18:05”, and the target line balance ratio is “90”%. is there.

  The total working hours is calculated in advance by adding the working hours and is “480” minutes. The target tact time is calculated in advance from the formula of total working hours (seconds) / planned number of production (units) = 480 (minutes) × 60 (seconds / minute) / 900 (units), and is “32” seconds / unit. .

  The function of the data management unit 1 may be realized by another computer different from the work distribution management device 20. In this case, each data of the work time master 10, the line condition master 11, the work distribution result 12, the work time measurement result 13, and the line balance rate calculation result 14 stored in another computer is sent from the work distribution management device 20. In response to a request, communication is performed via the communication unit 250 and the network 25.

  Returning to FIG. 3, the function of the work distribution unit 2 is realized by the control unit 210, the memory 220, and the external storage device 260. The work distribution unit 2 refers to the work time master 10 and the line condition master 11 stored in the data management unit 1 and distributes element work to workers including direct workers and indirect workers. The work distribution unit 2 stores the work distribution result in the data management unit 1 as the work distribution result 12.

  The worker confirms the screen on which the work distribution result 12 is displayed on the PC 23 or the paper printed by the printing device 24, and performs the manufacturing work on the production line 26 according to the work distribution stored in the work distribution result 12. Do.

  The function of the work time collection unit 3 is realized by the control unit 210, the memory 220, the input unit 230, and the external storage device 260. The work time collection unit 3 determines the per-product per product based on the start time point detected based on the signal from the sensor 21 and the end time point detected based on the signal from the foot switch 22. Collect actual work time. The work time collection unit 3 stores the collected actual work time in the data management unit 1 as the work time measurement result 13.

  The function of the line balance calculation unit 4 is realized by the control unit 210, the memory 220, and the external storage device 260. The line balance calculation unit 4 calculates an actual line balance rate based on the actual work time collected by the work time collection unit 3. The line balance calculation unit 4 stores the calculated actual line balance rate in the data management unit 1 as the line balance rate calculation result 14.

  The function of the data comparison unit 5 is realized by the control unit 210, the memory 220, and the external storage device 260. The data comparison unit 5 compares the target line balance rate stored in the line condition master 11 with the actual line balance rate stored in the line balance rate calculation result 14. Further, the target tact time stored in the line condition master 11 is compared with the actual work time stored in the work time measurement result 13. Then, the data comparison unit 5 determines whether or not the condition described in FIG. 4 is satisfied.

  The function of the information output unit 6 is realized by the control unit 210, the memory 220, the output unit 240, the communication unit 250, and the external storage device 260. The information output unit 6 includes the work distribution stored in the work distribution result 12 of the data management unit 1, the actual work time stored in the work time measurement result 13, the actual line balance rate stored in the line balance rate calculation result 14, and the like. Is output to the display of the output unit 240, the PC 23 or the printing device 24.

  FIG. 4 is a flowchart showing a flow of work distribution processing executed by the work distribution management device 20 according to the embodiment of the present invention.

  With reference to FIG. 4, first, in step S <b> 10, the control unit 210 of the work distribution management device 20 directly executes an inter-worker distribution process.

  FIG. 5 is a flowchart showing the flow of direct worker allocation processing executed by the work distribution management device 20 according to the embodiment of the present invention.

  Referring to FIG. 5, in step S <b> 11, control unit 210 reads a subtotal time of element work from work time master 10. In step S <b> 12, the control unit 210 reads the number of workers, the target tact time, and the target line balance ratio directly from the line condition master 11.

  Then, in step S13, the control unit 210 averages the unit work time per product, which is the sum of the subtotal times of the distributed element work, without interchanging the work order of the element work directly between the workers. The element work is directly distributed to the workers.

  In step S21, the control unit 210 determines whether or not the unit work time of each direct worker is equal to or shorter than the target tact time. When it is determined that it is equal to or shorter than the target tact time (YES in step S21), in step S22, the control unit 210 calculates a line balance rate based on the unit work time.

  In step S23, the control unit 210 determines whether or not the line balance rate calculated in step S22 is equal to or greater than the target line balance rate. If it is determined that the target line balance ratio is equal to or higher than the target line balance ratio (YES in step S23), the control unit 210 stores the work distribution as the work distribution result 12 in the data management unit 1 in step S24. Thereafter, control unit 210 advances the process to be executed to step S28.

  On the other hand, if it is determined that it is not less than the target tact time (NO in step S21), or if it is determined that it is not equal to or greater than the target line balance rate (NO in step S23), in step S25, the control unit 210 It is determined whether or not the element work transfer in step S26 has been performed a predetermined number of times (for example, 10 times).

  If it is determined that the element work has not been transferred a predetermined number of times (in the case of NO in step S25), in step S26, the control unit 210 is an element work that is directly distributed to workers with a long unit work time, One element work whose work replacement availability code is ○ is transferred to one of the previous and subsequent direct workers. Then, the control part 210 returns the process to perform to step S21.

  On the other hand, if it is determined that the element work has been transferred a predetermined number of times (YES in step S25), in step S27, the control unit 210 sets the best work distribution out of the predetermined number of times as the work distribution result 12 to the data management unit. 1 is stored. Thereafter, control unit 210 advances the process to be executed to step S28.

  In step S28, the control unit 210 causes the data management unit 1 to output the work distribution stored as the work distribution result 12 to the output unit 240. Thereafter, the control unit 210 returns the process to be executed to the work distribution process which is the caller process of the direct worker distribution process.

  FIG. 11 is a first diagram showing a work distribution result by the work distribution management device 20 according to the embodiment of the present invention.

  Referring to FIG. 11, the element work with identification numbers “1” to “7” is identified as the first process, and the element work with identification numbers “8” to “13” is identified as the second process. Element work with numbers “14” to “20” is the third step, element work with identification numbers “21” to “25” is the fourth step, and identification numbers “26” to “31”. The element work up to "is the fifth step, and each element work is directly distributed to the workers.

  The unit work time, which is a subtotal of the time required for the first to fifth steps, is “28.80” seconds, “31.10” seconds, “28.10” seconds, “31.90” seconds, respectively. “30.40” seconds. Thus, each unit work time satisfies the target tact time of 32 seconds.

  Also, since the process with the longest element work time is the fourth process, the line balance ratio = (28.80 + 31.10 + 28.10 + 31.90 + 30.40) / (31.90 × 5) × 100 = 94.23 Calculated as a percentage. In this way, the line balance rate satisfies 90%, which is the target line balance rate. The total time is “150.30” seconds as described in the work time master 10 of FIG.

  Returning to FIG. 4, in step S <b> 31, the control unit 210 measures the actual work time directly performed by the worker according to the work distribution stored as the work distribution result 12 in the data management unit 1. The actual work time is measured by calculating the difference between the end time from the foot switch 22 and the start time from the sensor 21.

  Note that the measurement of the actual work time is not limited to only one measurement, and an average value of measured values measured a predetermined number of times may be measured.

  FIG. 12 is a first diagram showing a work time measurement result 13 by the work distribution management device 20 according to the embodiment of the present invention.

  Referring to FIG. 12, the actual work times of the first to fifth steps are “26.00” seconds, “31.50” seconds, “37.00” seconds, and “32.00” seconds, respectively. "30.40" seconds. The actual work time of the entire manufacturing process, which is the sum of the actual work times of the respective processes, is “156.90” seconds. Note that the unit work time of each process of the work distribution result is the same as that described in FIG. The total time of the unit work time is “150.30” seconds as described in FIG.

  Returning to FIG. 4, in step S <b> 32, the controller 210 counts the number of manufactured products by counting signals from any of the sensors 21 or the foot switches 22 in the manufacturing line 26.

  In step S33, the control unit 210 calculates the manufacturing lead time by adding the actual work time of each direct worker for one product. For the actual work time described with reference to FIG. 12, the manufacturing lead time is 156.90 seconds.

  In step S34, the controller 210 determines whether or not the actual work time measured in step S31 is equal to or shorter than the target tact time. When it is determined that the actual work time is not less than the target tact time (NO in step S34), in step S35, the control unit 210 indicates that one of the actual work times exceeds the target tact time. Alarm at. Thereafter, control unit 210 advances the process to be executed to step S40. In the example described with reference to FIG. 12, “37.00” seconds in the actual work time does not satisfy the target tact time of 32 seconds.

  On the other hand, when it is determined that the actual work time is equal to or shorter than the target tact time (YES in step S34), in step S36, the control unit 210 calculates an actual line balance rate based on the actual work time. The actual line balance ratio is calculated by dividing the total work time of all direct workers by the maximum actual work time of each direct worker multiplied by the number of direct workers. Is done.

  FIG. 13 is a first diagram showing a line balance ratio calculation result 14 by the work distribution management device 20 according to the embodiment of the present invention.

  Referring to FIG. 13, the actual line balance ratio which is the line balance ratio with respect to the actual work time = (26.00 + 31.50 + 37.00 + 32.00 + 30.40) / (37.00 × 5) = 84.81%. The Note that the line balance rate for the work distribution result 12 is “94.23”% as described in FIG.

  Returning to FIG. 4, in step S <b> 37, the control unit 210 determines whether or not the actual line balance rate is equal to or higher than the target line balance rate. If it is determined that the target line balance ratio is equal to or greater than the target line balance ratio (YES in step S37), control unit 210 returns the process to be executed to step S31.

  On the other hand, when it is determined that the actual line balance rate is not equal to or greater than the target line balance rate (NO in step S37), the control unit 210 executes post-measurement distribution processing in step S40. In the example described with reference to FIG. 13, the actual line balance rate is 84.81%, and thus does not satisfy the target line balance rate of 90%.

  FIG. 6 is a flowchart showing the flow of post-measurement distribution processing executed by the work distribution management device 20 according to the embodiment of the present invention.

  Referring to FIG. 6, in step S <b> 41, control unit 210 performs one element work before and after one element work that is an element work that is directly allocated to a worker with a long actual work time and that has a work replacement propriety code. Transfer directly to the worker.

  In the example described with reference to FIG. 12, the actual work time of the direct worker in the third step is the longest. Therefore, the element work “take LCD unit” can be transferred to the previous direct worker, or “the screw is moved to the upper cabinet”. The “tightening” element work is transferred to the direct operator later. However, according to the work time master 10 described with reference to FIG. 8, the work replacement propriety code of the element work “tighten the screw to the upper cabinet” is unmarked, and the work replacement propriety code of the element work “take LCD unit” is ○ As such, the element work “take LCD unit” is transferred to the previous direct operator.

  In step S51, the control unit 210 determines whether or not the actual work times of all direct workers are equal to or shorter than the target tact time. When it is determined that it is not less than the target tact time (YES in step S51), in step S52, the control unit 210 calculates a line balance rate based on the actual work time.

  In step S53, the control unit 210 determines whether or not the line balance rate calculated in step S52 is equal to or greater than the target line balance rate. If it is determined that the target line balance ratio is equal to or greater than the target line balance ratio (YES in step S53), the control unit 210 stores the work distribution as the work distribution result 12 in the data storage unit 1 in step S54. Thereafter, control unit 210 advances the process to be executed to step S58.

  On the other hand, when it is determined that it is not less than the target tact time (NO in step S51), or when it is determined that it is not equal to or more than the target line balance ratio (NO in step S53), in step S55, the control unit 210 It is determined whether or not the element work transfer in step S56 has been performed a predetermined number of times (for example, 10 times).

  If it is determined that the element work has not been transferred a predetermined number of times (in the case of NO in step S55), in step S56, the control unit 210 is an element work that is directly distributed to workers with a long actual work time, One element work whose work replacement availability code is ○ is transferred to one of the previous and subsequent direct workers. Then, the control part 210 returns the process to perform to step S51.

  On the other hand, when it is determined that the element work has been transferred a predetermined number of times (YES in step S55), the best work distribution out of the predetermined number of times is stored in the data management unit 1 as the work distribution result 12 in step S57. Thereafter, control unit 210 advances the process to be executed to step S58.

  In step S58, the control unit 210 causes the output unit 240 to output the work distribution stored in the data management unit 1 as the work distribution result 12. Thereafter, the control unit 210 returns the process to be executed to the work distribution process that is the caller process of the post-measurement distribution process.

  FIG. 14 is a second diagram showing a work distribution result 12 by the work distribution management device 20 according to the embodiment of the present invention.

  Referring to FIG. 14, as a result of execution of the post-measurement distribution process, element work with identification numbers “1” to “8” is the first step, and elements with identification numbers “9” to “14” The work is the second process, the element work with the identification numbers “15” to “20” is the third process, the element work with the identification numbers “21” to “25” is the fourth process, The element work with the identification numbers “26” to “31” is the fifth step, and each element work is directly distributed to the workers.

  The unit work times of the first to fifth processes are “31.10” seconds, “32.00” seconds, “24.90” seconds, “31.90” seconds, and “30.40” seconds, respectively. It is. Thus, each unit work time satisfies the target tact time of 32 seconds.

  Also, since the process with the longest element work time is the second process, the line balance ratio = (31.10 + 32.00 + 24.90 + 31.90 + 30.40) / (32.00 × 5) = 93.94% Calculated. In this way, the line balance rate satisfies 90%, which is the target line balance rate. The total time is “150.30” seconds as described in the work time master 10 of FIG.

  Returning to FIG. 4, in step S <b> 61, similarly to step S <b> 31, the control unit 210 measures the actual work time performed directly by the worker according to the work distribution stored as the work distribution result in the data management unit 1.

  FIG. 15 is a second diagram showing a work time measurement result by the work distribution management device 20 according to the embodiment of the present invention.

  Referring to FIG. 15, the actual work times of the first to fifth steps are “30.50” seconds, “35.00” seconds, “24.00” seconds, and “32.00” seconds, respectively. "30.40" seconds. The actual work time of the entire manufacturing process, which is the total of the actual work time of each process, is “151.90” seconds. Note that the unit work time of each process of the work distribution result is the same as that described in FIG. The total time of the unit work time is “150.30” seconds as described with reference to FIG.

  Returning to FIG. 4, in step S62, as in step S32, the control unit 210 counts the number of manufactured products. In step S63, the manufacturing lead time is calculated as in step S33. For the actual work time described in FIG. 15, the manufacturing lead time is 151.90 seconds.

  In step S64, as in step S34, the control unit 210 determines whether or not the actual work time measured in step S61 is less than or equal to the target tact time. When it is determined that the actual work time is not less than the target tact time (NO in step S64), in step S65, as in step S35, the control unit 210 exceeds any of the actual tact times. The output unit 240 warns the effect. Thereafter, control unit 210 advances the process to be executed to step S70. In the example described with reference to FIG. 15, “35.00” seconds of the actual work time does not satisfy the target tact time of 32 seconds.

  On the other hand, when it is determined that the actual work time is less than or equal to the target tact time (YES in step S64), in step S66, as in step S36, the control unit 210 performs the actual line balance rate based on the actual work time. Is calculated.

  FIG. 16 is a second diagram showing a line balance ratio calculation result 14 by the work distribution management device 20 according to the embodiment of the present invention.

  Referring to FIG. 16, the actual line balance ratio, which is the line balance ratio with respect to the actual work time, is calculated as (30.50 + 35.00 + 24.00 + 32.00 + 30.40) / (35.00 × 5) = 86.80%. The Note that the line balance ratio for the work distribution result 12 is “93.94”%, as described with reference to FIG.

  Returning to FIG. 4, in step S <b> 67, as in step S <b> 37, the controller 210 determines whether or not the actual line balance rate is equal to or higher than the target line balance rate. When it is determined that the target line balance ratio is equal to or higher than the target line balance ratio (YES in step S67), control unit 210 returns the process to be executed to step S61.

  On the other hand, when it is determined that the actual line balance rate is not equal to or higher than the target line balance rate (NO in step S67), the control unit 210 executes the inter-worker allocation process in step S70. In the example described with reference to FIG. 16, the actual line balance rate is 86.80%, which does not satisfy the target line balance rate of 90%.

  FIG. 7 is a flowchart showing the flow of all worker allocation processing executed by the task distribution management device 20 according to the embodiment of the present invention.

  Referring to FIG. 7, in step S <b> 71, control unit 210 reads the subtotal time of the element work from work time master 10. In step S72, the control unit 210 reads the number of workers, the target tact time, and the target line balance rate directly from the line condition master 11.

  Then, in step S73, the control unit 210 per unit product, which is the total of the subtotal time of the distributed element work without interleaving the order of the element work among all workers including indirect workers such as line leaders. The element work is distributed to all the workers so that the unit work time is directly averaged among the workers.

  FIG. 10 is a diagram showing the line work conditions of the line leader of the production line 26 in this embodiment.

  Referring to FIG. 10, the work hours of the direct workers are all the working hours described in FIG. 9, whereas the line leader has ancillary work, so it is engaged in manufacturing work for 10 minutes after the start of working hours. The line work conditions of the line leader are determined so as not to be the time to perform.

  Specifically, the time that the line leader is directly engaged in manufacturing is “9:10 to 11:00”, “11:20 to 13:10”, “14:05 to 15:55”, and “16:15”. ~ 18: 05 ". The line work conditions of the line leader are also stored in the line condition master 11 described above with reference to FIG.

  In step S81, the control unit 210 determines whether or not the unit work times of all workers are equal to or less than the target tact time. When it is determined that it is equal to or shorter than the target tact time (YES in step S81), in step S82, the control unit 210 calculates a line balance rate based on the unit work time.

  In step S83, the control unit 210 determines whether or not the line balance rate calculated in step S82 is equal to or greater than the target line balance rate. If it is determined that the target line balance ratio is equal to or higher than the target line balance ratio (YES in step S83), the control unit 210 stores the work distribution as the work distribution result 12 in the data management unit 1 in step S84. Thereafter, control unit 210 advances the process to be executed to step S88.

  On the other hand, if it is determined that it is not less than the target tact time (NO in step S81), or if it is determined that it is not equal to or greater than the target line balance ratio (NO in step S83), in step S85, the control unit 210 It is determined whether or not the element work transfer in step S86 has been performed a predetermined number of times (for example, 10 times).

  If it is determined that the element work has not been transferred a predetermined number of times (in the case of NO in step S85), in step S86, the control unit 210 is an element work that is directly distributed to workers with a long unit work time, One element work whose work replacement availability code is ○ is transferred to one of the previous and subsequent direct workers. Then, the control part 210 returns the process to perform to step S81.

  On the other hand, if it is determined that the element work has been transferred a predetermined number of times (YES in step S85), in step S87, the control unit 210 sets the best work distribution out of the predetermined number of times as the work distribution result 12 to the data management unit. 1 is stored. Thereafter, control unit 210 advances the process to be executed to step S88.

  In step S88, the control unit 210 causes the output unit 240 to output the work distribution stored as the work distribution result 12 in the data management unit 1. Thereafter, the control unit 210 returns the process to be executed to the work distribution process that is the caller process of the inter-worker distribution process.

  FIG. 17 is a third diagram showing a work distribution result 12 by the work distribution management device 20 according to the embodiment of the present invention.

  Referring to FIG. 17, the element work with identification numbers “1” to “8” is identified as the first process, and the element work with identification numbers “10” to “14” is identified as the second process. Element work with numbers “15” to “20” is the third process, element work with identification numbers “21” to “25” is the fourth process, and identification numbers “26” to “31”. The element work up to "is the fifth step, and each element work is directly distributed to the workers. In addition, the element work with the identification number “9” is distributed to the line leader who is an indirect worker.

  The unit work time, which is a subtotal of the time required for the first to fifth steps, is “31.10” seconds, “27.60” seconds, “24.90” seconds, “31.90” seconds, respectively. “30.40” seconds. Thus, each unit work time satisfies the target tact time of 32 seconds.

  Further, since the process with the longest element work time is the fourth process, the line balance ratio = (31.10 + 27.60 + 24.90 + 31.90 + 30.40) / (31.90 × 5) × 100 = 91.47 Calculated as a percentage. In this way, the line balance rate satisfies 90%, which is the target line balance rate. Further, the total time is 150.30 seconds in the work time master 10 of FIG. 8, but is “145.90” seconds because the element work is allocated to the line leader.

  Returning to FIG. 4, in step S <b> 91, as in step S <b> 31, the control unit 210 measures the actual work time performed directly by the worker according to the work distribution stored as the work distribution result 12 in the data management unit 1. Note that the actual work time performed by all workers including the line leader may be measured.

  FIG. 18 is a third diagram showing a work time measurement result 13 by the work distribution management device 20 according to the embodiment of the present invention.

  Referring to FIG. 18, the actual work times of the first to fifth steps are “30.50” seconds, “29.00” seconds, “24.00” seconds, and “32.00” seconds, respectively. "30.40" seconds. The actual work time of the entire manufacturing process, which is the total of the actual work time of each process, is “145.90” seconds. Note that the unit work time of each process of the work distribution result is the same as that described with reference to FIG. The total time of the unit work time is “145.90” seconds as described in FIG.

  Returning to FIG. 4, in step S92, as in step S32, the control unit 210 calculates the manufacturing lead time. For the actual work time described with reference to FIG. 18, the manufacturing lead time is 145.90 seconds.

  In step S94, as in step S34, the controller 210 determines whether or not the actual work time measured in step S91 is equal to or less than the target tact time. When it is determined that the actual work time is not less than the target tact time (NO in step S94), in step S95, the control unit 210 indicates that one of the actual work times exceeds the target tact time. Alarm at. Thereafter, control unit 210 returns the process to be executed to step S70. In the example described with reference to FIG. 18, all actual work times satisfy the target tact time of 32 seconds.

  On the other hand, when it is determined that the actual work time is less than or equal to the target tact time (YES in step S94), in step S96, as in step S36, the control unit 210 performs the actual line balance rate based on the actual work time. Is calculated.

  FIG. 19 is a third diagram showing a line balance ratio calculation result 14 by the work distribution management device 20 according to the embodiment of the present invention.

  Referring to FIG. 19, the actual line balance ratio which is the line balance ratio with respect to the actual work time = (30.50 + 29.00 + 24.00 + 32.00 + 30.40) / (32.00 × 5) = 91.19%. The Note that the line balance rate for the work distribution result 12 is “91.47”% as described in FIG.

  Returning to FIG. 4, in step S <b> 97, as in step S <b> 37, the control unit 210 determines whether or not the actual line balance rate is equal to or higher than the target line balance rate. If it is determined that it is equal to or higher than the target line balance ratio (YES in step S37), control unit 210 returns the process to be executed to step S91.

  On the other hand, when it is determined that the actual line balance rate is not equal to or higher than the target line balance rate (NO in step S97), the control unit 210 executes the inter-worker allocation process again in step S70. In the example described with reference to FIG. 19, the actual line balance rate is 91.19%, which satisfies the target line balance rate of 90%.

  FIG. 20 is a display screen diagram illustrating an example of a screen displayed on the PC 23 connected to the work distribution management device 20 according to the embodiment of the present invention.

  Referring to FIG. 20, the PC 23 acquires data from the data management unit 1 of the work distribution management device 20 via the network 25, thereby displaying data such as an actual line balance rate and an actual work time. A similar screen can be displayed on the output unit 240 of the work distribution management device 20.

  The display screen of FIG. 20 shows that the target tact time is 32 seconds, the line balance rate for the work distribution result is 91.47%, and the actual line balance rate is 91.19%. Is displayed.

  At the bottom of the screen, for each direct worker in each process, the unit work time in the work distribution result is displayed in the “target work time” field, and the actual work time is 5 in the “work time actual measurement value” field. The product is displayed, and the average value of the actual work time for the five products is displayed in the “average of measured values” column.

  A graph is displayed in the middle of the screen. In this graph, the bold line indicates the target tact time, the hatched bar graph indicates the “average of actual measurement values” of each direct worker, and the unhatched bar graph indicates the “target work time” of each worker. Indicates.

  FIG. 21 is a diagram showing an example of a printing result printed by the printing device 24 connected to the work distribution management device 20 in the embodiment of the present invention.

  Referring to FIG. 21, the printing device 24 displays data such as an actual line balance rate and an actual work time by acquiring information from the data management unit 1 of the work distribution management device 20 via the network 25.

  The print result in FIG. 21 shows that the target tact time is 32 seconds, the line balance rate for the work distribution result is 91.47%, and the actual line balance rate is 91.19%. Shown in

  At the bottom of the screen, for each direct worker in each process, the unit work time in the work distribution result is displayed in the “Target work time” column, and the average value of the actual work time for five products is “actual value” Is displayed in the "Average of" column.

  A graph is displayed in the middle of the screen. In this graph, the bold line indicates the target tact time, the hatched bar graph indicates the “average of actual measurement values” of each direct worker, and the unhatched bar graph indicates the “target work time” of each worker. Indicates.

  As described above, according to the work distribution management device 20 in this embodiment, the element work stored in advance in the work time master 10 by the control unit 210 as described in Step S10 and Steps S11 to S28. Based on the work order of the element work identified by the identification number, the target tact time stored in the line condition master 11 in advance, and the subtotal time which is the required time for each element work stored in the work time master 10 in advance. The element work is distributed to each direct worker so as to satisfy predetermined conditions regarding the target tact time and the target line balance ratio.

  Further, as described in step S31, the control unit 210 measures the actual work time per product for each direct worker performed according to the distributed work distribution result 12, and as described in step S36. The actual line balance rate is calculated based on the measured actual work time.

  If the controller 210 determines in step S37 that the calculated actual line balance ratio is less than the predetermined target line balance ratio, as described in steps S40 and S41 to S58, Element work is redistributed. Then, as described in step S61, the actual work time is re-measured by the controller 210, and the actual line balance ratio is recalculated as described in step S66.

  If the control unit 210 determines in step S67 that the recalculated actual line balance rate is not equal to or higher than the target line balance rate, as described in steps S70 and S71 to S88, the work time is previously set. A predetermined condition based on the work order of the element work identified by the identification number stored in the master 10, the target tact time previously stored in the line condition master 11, and the subtotal time previously stored in the work time master 10 The element work is distributed to all workers including indirect workers such as line leaders so as to satisfy the above. Then, as described in step S28, step S58, and step S88, the control unit 210 outputs the distributed work distribution result 12.

  In addition, in the direct worker distribution processing in step S10 or the post-measurement distribution processing in step S40, when the element work cannot be distributed so as to satisfy a predetermined condition, the all worker distribution processing in step S70 is performed. Also good.

  As a result, even if the element work cannot be allocated only by the direct worker or the target line balance ratio cannot be achieved when the element work is allocated only to the direct worker, the line balance ratio is satisfied while satisfying the target tact time. The element work can be distributed so that the process can be improved.

  Further, according to the work distribution management device 20 in this embodiment, as described in steps S11 to S28, the work order of the element work stored in the work time master 10 by the control unit 210 is set to each direct work. So as not to cross between the workers, the condition that the unit work time per product per worker directly does not exceed the target tact time, and the condition that the line balance ratio is equal to or higher than the target line balance ratio. Element work is distributed directly to workers.

  When the recalculated actual line balance ratio does not exceed the target line balance ratio or when the element work cannot be allocated, the control unit 210 performs the work order of the element work as described in steps S71 to S88. Are not intermingled among all workers including indirect workers such as line leaders, the condition that the unit work time of each worker does not exceed the target tact time, and the line balance ratio is equal to or higher than the target line balance ratio Element work is distributed to all workers so as to satisfy the condition.

  For this reason, the work distribution management device 20 prevents the work order of the element work from interchanging among the workers, the unit work time per product for each worker does not exceed the target tact time, and the line balance ratio becomes the target line. Elemental work can be distributed so that the balance rate is equal to or higher.

  Further, according to the work distribution management device 20 in this embodiment, as described in step S28, step S58, and step S88, the control unit 210 distributes the work as the work distribution result 12 to which the element work has been distributed. Information indicating the allocation of the element work to the worker is output, and the actual line balance ratio is further output.

  For this reason, it is possible to inform the worker of the work distribution result by the work distribution management device 20 in an easy-to-understand manner.

  Further, according to the work distribution management device 20 in this embodiment, as described in step S32, step S62, and step S92, the control unit 210 counts the number of products whose actual work time has been measured. The For this reason, the work distribution management device 20 can grasp the progress of production.

  Further, according to the work distribution management device 20 in this embodiment, as described in step S33, step S63, and step S93, the actual work time measured by the control unit 210 is totaled for all workers. The manufactured lead time is calculated. For this reason, the work distribution management device 20 can grasp the time during which the product stays in the manufacturing process.

  In addition, the work distribution management device 20 in this embodiment includes a sensor 21 that detects a start point when a product enters a work area where a worker directly works, and a product that has one element work that is directly distributed to the worker. And a foot switch 22 for detecting the end point. Then, as described in step S31, step S61, and step S91, the actual work time is measured by the control unit 210 based on the detected start time and end time.

  Further, according to the work distribution management device 20 in this embodiment, as described in FIG. 20, the average actual work time for a predetermined number (for example, 5) of products is measured as the actual work time by the control unit 210. The For this reason, it is possible to measure the actual work time with higher reliability as compared with the actual work time for one product.

  Further, according to the work distribution management device 20 in this embodiment, as described in step S35, step S65, and step S95, when the actual work time measured by the control unit 210 exceeds the tact time. An alarm will be issued. For this reason, it is possible to notify other workers that the actual work time of any one of the direct workers exceeds the target tact time. As a result, it is possible to prompt the user to redo the work distribution.

  In this embodiment, the invention has been described as the work distribution management device 20. However, the present invention is not limited to this, and a work distribution method for managing work distribution by executing the processes from FIGS. 4 to 7 in the work distribution management apparatus 20, and the processes from FIGS. 4 to 7 to the work distribution management apparatus 20. The invention can be understood as a work distribution program for managing work distribution by executing the above and a computer-readable recording medium recording the work distribution program.

  The embodiment disclosed this time should be considered as illustrative in all points and not restrictive. The scope of the present invention is defined by the terms of the claims, rather than the description above, and is intended to include any modifications within the scope and meaning equivalent to the terms of the claims.

It is the schematic which shows the outline of a structure of the manufacturing line in embodiment of this invention. It is a block diagram which shows the outline of a structure of the work distribution management apparatus in embodiment of this invention. It is a functional block diagram which shows the outline of the function of the work distribution management apparatus in embodiment of this invention. It is a flowchart which shows the flow of the work distribution process performed with the work distribution management apparatus in embodiment of this invention. It is a flowchart which shows the flow of the allocation process between direct workers performed with the work distribution management apparatus in embodiment of this invention. It is a flowchart which shows the flow of the after-measurement distribution process performed with the work distribution management apparatus in embodiment of this invention. It is a flowchart which shows the flow of the allocation process between all the workers performed with the work distribution management apparatus in embodiment of this invention. It is a figure which shows the work time master memorize | stored in the data management part of the work distribution management apparatus in embodiment of this invention. It is a figure which shows the line condition master memorize | stored in the data management part of the work distribution management apparatus in embodiment of this invention. It is a figure which shows the line work conditions of the line leader of the manufacturing line in this embodiment. It is a 1st figure which shows the work distribution result by the work distribution management apparatus in embodiment of this invention. It is a 1st figure which shows the work time measurement result by the work distribution management apparatus in embodiment of this invention. It is a 1st figure which shows the line balance rate calculation result by the work distribution management apparatus in embodiment of this invention. It is a 2nd figure which shows the work distribution result by the work distribution management apparatus in embodiment of this invention. It is a 2nd figure which shows the work time measurement result by the work distribution management apparatus in embodiment of this invention. It is a 2nd figure which shows the line balance rate calculation result by the work distribution management apparatus in embodiment of this invention. It is a 3rd figure which shows the work distribution result by the work distribution management apparatus in embodiment of this invention. It is a 3rd figure which shows the work time measurement result by the work distribution management apparatus in embodiment of this invention. It is a 3rd figure which shows the line balance rate calculation result by the work distribution management apparatus in embodiment of this invention. It is a display screen figure which shows the example of the screen displayed with PC connected with the work distribution management apparatus in embodiment of this invention. It is a figure which shows the example of the printing result printed with the printing apparatus connected with the work distribution management apparatus in embodiment of this invention. It is a figure which shows the time slot | zone of an indirect worker's work.

Explanation of symbols

  DESCRIPTION OF SYMBOLS 1 Data management part, 2 Work distribution part, 3 Work time collection part, 4 Line balance calculation part, 5 Data comparison part, 6 Information output part, 10 Work time master, 11 Line condition master, 12 Work distribution result, 13 Work time Measurement result, 14 line balance ratio calculation result, 20 work distribution management device, 21 sensor, 22 foot switch, 23 PC, 24 printing device, 25 network, 26 production line, 30 direct worker, 31 line reader, 210 control unit, 220 memory, 230 input unit, 240 output unit, 250 communication unit, 260 external storage device, 270 recording field.

Claims (10)

A work distribution management device that manages the distribution of a plurality of elemental operations in which manufacturing processes in a product manufacturing line are divided in advance to a plurality of direct work subjects that perform manufacturing operations directly in the manufacturing line,
Element work storage means for preliminarily storing element work identification information capable of identifying each of the element works so as to be able to specify a work order in which each of the element works is performed in the manufacturing process;
Basic time storage means for storing in advance the basic time required for each element work in the manufacturing process in association with the element work identification information;
A tact time storage means for preliminarily storing a tact time obtained by dividing a predetermined operating time of the production line within a predetermined period by a predetermined production scheduled quantity of the product during the predetermined period;
The work order of the element work identified by the element work identification information stored in the element work storage means, the tact time stored in the tact time storage means, and stored in the basic time storage means Based on the basic time, the element work is set so as to satisfy a predetermined condition regarding the tact time and a line balance ratio indicating a variation in work time required for the element work distributed to each direct work subject. First work distribution means for allocating to the direct work subject;
Actual work time measuring means for measuring one actual work time per product for each direct work subject performed according to the result distributed by the first work distribution means;
Based on the actual work time measured by the actual work time measuring means, an actual line balance ratio calculating means for calculating an actual line balance ratio indicating a variation in the actual work time between the direct work subjects;
When the actual line balance ratio calculated by the actual line balance ratio calculation means is less than a predetermined target line balance ratio, the element work is redistributed by the first work distribution means, and the actual work time measurement is performed. Re-measurement means for re-measuring the actual work time by means, and re-calculating the actual line balance ratio by the actual line balance ratio calculation means;
If the actual line balance ratio recalculated by the reprocessing means does not exceed a predetermined target line balance ratio, or if the element work cannot be distributed by the first work distribution means, the element work storage means Based on the work order of the element work identified by the stored element work identification information, the tact time stored in the tact time storage means, and the basic time stored in the basic time storage means In order to satisfy the predetermined condition, the element work is allocated to each of the plurality of direct work subjects and at least one indirect work subject that indirectly assists the direct work subject and performs the manufacturing work. Second work distribution means to perform,
A work distribution management apparatus comprising: information output means for outputting a result distributed by the first work distribution means or the second work distribution means. The first work distribution means includes a condition in which the work order of the element work identified by the element work identification information stored in the element work storage means does not cross between the direct work subjects, and the direct work. The unit work time per product obtained by adding the basic time stored in the basic time storage means corresponding to each element work distributed to the subject for each direct work subject, respectively, the tact time storage means The number of the direct work subjects in the maximum unit work time of the unit work hours, the total time of the basic time stored in the basic time storage means and the condition not exceeding the tact time stored in The element work is assigned to the direct work subject so that the line balance ratio divided by the time multiplied by is equal to or greater than the target line balance ratio. Minute and,
The second work distribution means includes a condition that the work order of the element work identified by the element work identification information stored in the element work storage means does not cross between the work subjects, and each of the work subjects. The condition that the unit work time does not exceed the tact time stored in the tact time storage means, and the total time of the basic time stored in the basic time storage means is set as the maximum unit work time. The work distribution management according to claim 1, wherein the element work is distributed to the work subjects so that a line balance ratio divided by the time obtained by multiplying the number of work subjects directly satisfies the target line balance ratio. apparatus.   The information output means outputs information indicating allocation of the element work allocated to the work subject by the first work distribution means or the second work distribution means as the result, and calculates the actual line balance ratio. The work distribution management device according to claim 1, further outputting an actual line balance ratio calculated by the means.   The work distribution management device according to claim 1, further comprising a manufacturing number counting unit that counts the number of products for which the actual work time is measured by the actual work time measuring unit.   The manufacturing lead time calculation means which calculates the manufacturing lead time which totaled the actual work time measured by the said actual work time measurement means about all the said operation subjects is further provided in any one of Claim 1 to 4 Work distribution management device. The actual work time measuring means is
First detection means for detecting a start time when the product has entered the area where the direct work subject works;
Second detection means for detecting an end point of completion of the element work distributed to the direct work subject by the first work distribution means or the second work distribution means for one product,
6. The actual work time is measured based on an end time point detected by the second detection unit and a start time point detected by the first detection unit. 6. Work distribution management device.   The work distribution management device according to any one of claims 1 to 6, wherein the actual work time measuring means measures an average actual work time for a predetermined number of the products as the actual work time.   8. The apparatus according to claim 1, further comprising alarm means for issuing an alarm when the actual work time measured by the actual work time measuring means exceeds the tact time stored in the tact time storage means. The work distribution management device according to any one of the above. Work distribution management performed by a work distribution management device that manages the distribution of a plurality of elemental work in which manufacturing processes in a product manufacturing line are divided in advance to a plurality of direct work subjects who directly perform the manufacturing work in the manufacturing line. A method,
Storing in advance the element work identification information capable of identifying each of the element works so that the work order in which each of the element works is performed in the manufacturing process can be specified;
Storing in advance the basic time required for each element work in the manufacturing process in association with the element work identification information;
Preliminarily storing a tact time obtained by dividing a predetermined operating time of the production line within a predetermined period by a predetermined production scheduled quantity of the product during the predetermined period;
The tact time and each of the direct times based on the work order of the element work identified by the pre-stored element work identification information, the tact time stored in advance, and the basic time stored in advance. Allocating the element work to each of the direct work subjects so as to satisfy a predetermined condition regarding a line balance rate indicating a variation in work time required for the element work to be distributed to the work subjects;
Measuring an actual work time per said product for each said direct work subject performed according to the allocated results;
Calculating an actual line balance ratio indicating a variation in the actual work time between the direct work subjects based on the measured actual work time;
When the calculated actual line balance ratio is less than a predetermined target line balance ratio, redistributing the element work, re-measuring the actual work time, and recalculating the actual line balance ratio; ,
When the recalculated actual line balance rate does not exceed a predetermined target line balance rate, or when the element work cannot be allocated, the element work identified by the element work identification information stored in advance is used. The element work is assisted by a plurality of the direct work subjects and the direct work subjects so as to satisfy the predetermined condition based on the work order, the pre-stored tact time, and the pre-stored basic time. Distributing to each of the work subjects comprising at least one indirect work subject performing the manufacturing work indirectly;
And a step of outputting the distributed result. Work distribution executed by a work distribution management device that manages the distribution of a plurality of elemental work in which manufacturing processes in a product manufacturing line are divided in advance to a plurality of direct work subjects who directly perform the manufacturing work in the manufacturing line. A management program,
Storing in advance the element work identification information capable of identifying each of the element works so that the work order in which each of the element works is performed in the manufacturing process can be specified;
Storing in advance the basic time required for each element work in the manufacturing process in association with the element work identification information;
Preliminarily storing a tact time obtained by dividing a predetermined operating time of the production line within a predetermined period by a predetermined production scheduled quantity of the product during the predetermined period;
The tact time and each of the direct times based on the work order of the element work identified by the pre-stored element work identification information, the tact time stored in advance, and the basic time stored in advance. Allocating the element work to each of the direct work subjects so as to satisfy a predetermined condition regarding a line balance rate indicating a variation in work time required for the element work to be distributed to the work subjects;
Measuring an actual work time per said product for each said direct work subject performed according to the allocated results;
Calculating an actual line balance ratio indicating a variation in the actual work time between the direct work subjects based on the measured actual work time;
When the calculated actual line balance ratio is less than a predetermined target line balance ratio, redistributing the element work, re-measuring the actual work time, and recalculating the actual line balance ratio; ,
When the recalculated actual line balance rate does not exceed a predetermined target line balance rate, or when the element work cannot be allocated, the element work identified by the element work identification information stored in advance is used. The element work is assisted by a plurality of the direct work subjects and the direct work subjects so as to satisfy the predetermined condition based on the work order, the pre-stored tact time, and the pre-stored basic time. Distributing to each of the work subjects comprising at least one indirect work subject performing the manufacturing work indirectly;
A work distribution management program that executes a step of outputting a distributed result.

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