JP2010128819A - Support process determination system and support process determination method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a support process determination method capable of automatically determining which process is required to be supported by an instructor to advance a line most smoothly. <P>SOLUTION: The support process determination method which is a procedure to be performed in a support process determination system installed in a production line includes: a step of storing operation delay time obtained by subtracting the standard operation time of each product from real operation time practically required for a worker to perform the operation of each product at any time as an operation result in each process included in the production line; a step (step S12) of calculating future accumulative operation delay time when products are sequentially charged into respective processes in future based on operation results and a production plan indicating the order of products allowed to flow into the production line; steps (steps S14, S15) of specifying a process that the calculated accumulative operation delay time is not less than reference time to be a reference for determining the delay of the production line; and steps (steps S17 to S19) of determining the specified process as a process requiring support. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a support process determination system and a support process determination method for determining a process that needs support in a production line process.

  In the production line, when a worker is newly arranged in a process that is not sufficiently learned, such as immediately after a process change, a work instruction device that instructs the work procedure of the worker is arranged in the process (for example, a patent Reference 1). The work instruction device displays work items of the process in order. When all work items are completed, the end of the process is input by the worker.

  By the way, in order to make up for work delays and work mistakes, experienced instructors (supporters) are arranged on the production line. The instructor is in charge of a plurality of processes, for example, around 15 processes, and when the worker is late or misses the work, he or she rushes to the worker's process and supports the work. Here, the worker informs the instructor of the work delay or the like by pulling the string arranged on the production line.

However, in the above system, it is up to the operator to determine whether to call an instructor for support. Therefore, it is unclear whether the judgment is appropriate. In particular, since the worker does not know the past work time record, the type of product that will flow in the future, and the amount of work, the worker is not always able to call the instructor appropriately. When an instructor is called, there may be unavoidable line stops. Workers tend not to call instructors until they are sure that the line will stop.
JP 2002-304210 A

  The present invention has been made in view of the above circumstances, and provides a support process determination system and a support process determination method capable of automatically determining which process is most smoothly performed when an instructor is supported for which process. For the purpose.

  The support process determination system of the present invention includes a first storage unit, a second storage unit, a third storage unit, a calculation unit, and a determination unit. A 1st memory | storage part memorize | stores the standard operation time of each product and the reference | standard time used as the reference | standard for judging the delay of this production line for every process included in a production line. The second storage unit stores the work delay time obtained by subtracting the standard work time of each product from the actual work time actually required for the work of each product for each process as work results. To do. A 3rd memory | storage part memorize | stores the production plan which shows the kind and order of the product sent to a production line. The calculation unit calculates a future cumulative work delay time when products are sequentially introduced into each process in the future based on the work results and the production plan. The determination unit identifies a process in which the calculated cumulative work delay time is equal to or longer than a reference time, and determines that the process needs support.

  The support process determination method of the present invention is a procedure executed by a support process determination system provided in a production line, and executes the following steps. For each process included in the production line, the work delay time obtained by subtracting the standard work time of each product from the actual work time actually required for the work of each product is stored as work results as needed. . Based on the actual work and a production plan indicating the order of products to be sent to the production line, a future cumulative work delay time when products are sequentially introduced into each process in the future is calculated. A process in which the calculated cumulative work delay time is equal to or longer than a reference time serving as a reference for determining a delay in the production line is determined and determined as a process requiring support.

  According to the support process determination system of the present invention, since the cumulative work delay time is predicted and calculated based on the work results and the production plan, it is possible to automatically determine in advance a process that is likely to require support in the future. . Therefore, it is not necessary for the worker to determine the work delay by himself. Also, for a supporter such as an instructor supporting the process, a process that requires objective support can be obtained instead of the subjective judgment of the worker. It is possible to prevent a production line from being stopped by identifying a process that may cause the production line to be stopped in the future as a process requiring assistance.

  According to the support process determination method of the present invention, the cumulative work delay time is predicted and calculated based on the work results and the production plan, so that a process that may be required in the future can be automatically determined in advance. . Therefore, it is not necessary for the worker to determine the work delay by himself. Also, for a supporter such as an instructor supporting the process, a process that requires objective support can be obtained instead of the subjective judgment of the worker. It is possible to prevent a production line from being stopped by identifying a process that may cause the production line to be stopped in the future as a process requiring assistance.

  Embodiments of the present invention will be described below with reference to the drawings. Hereinafter, a case where a vehicle flows as a product on a production line and parts are attached and assembled will be described.

(First embodiment)
FIG. 1 is a schematic diagram showing a support process determination system, FIG. 2 is a diagram showing a schematic configuration of a data processing device, FIG. 3 is a diagram showing a work navigation device installed on a production line, and FIG. 4 is shown on a monitor. It is a figure which shows the example of work content.

  As shown in FIG. 1, the support process determination system is a system installed on a production line, and includes a data processing device 10 and a plurality of work instruction devices (hereinafter referred to as work navigation) 20. A plurality of work navigators 20 are connected to the data processing apparatus 10, and work instructions including future production plans such as which products are to be processed in order are input. The data processing device 10 develops necessary information in each of the work navigations 20a to 20d.

  As illustrated in FIG. 2, the data processing device 10 includes a storage unit 12, a display unit 14, and a control unit 16. The storage unit 12 functions as a first storage unit, a second storage unit, and a third storage unit. As the first storage unit, the storage unit 12 stores, for each process included in the production line, a standard work time of each product and a reference time serving as a reference for determining the delay of the production line. As the second storage unit, the storage unit 12 is a work obtained by subtracting the standard work time of each product from the actual work time actually required for the work of each product for each process of the production line. The delay time is stored as a work record at any time. As the third storage unit, the storage unit 12 stores a production plan indicating the type and order of products to be sent to the production line.

  The display unit 14 is a user interface and displays various types of information. For example, the display unit 14 displays the contents stored in the storage unit 12. The display unit 14 can also display information accumulated in the work navigation 20 such as work results and work delay times.

  The control unit 16 is connected to the storage unit 12 and the display unit 14 and controls the entire data processing apparatus 10. The control unit 16 functions as a calculation unit and a determination unit, and calculates a future work delay time for each process or determines a process that needs support. The detailed operation of the control unit 16 will be described later.

  The work navigation 20 is arranged in each process of the production line. The work navigator 20 instructs the worker as to the work content for the product flowing in the arranged process based on the production plan from the data processing device 10 as an instruction device. The work navigation 20 is installed in the processes of workers A, B, and D, for example, as shown in FIG. In this case, the workers A, B, and D are relatively unskilled workers, and perform the work while confirming the work content taught from the work navigation. On the other hand, the worker C is a veteran worker who is familiar with the work procedure and does not need to be instructed in the work process by the work navigation. Thus, it is preferable that the work navigation 20 is arranged in a process of a relatively unfamiliar worker. In the production line, when the work of unfamiliar workers A, B, and D is delayed, an instructor X is arranged to assist the work toward the delayed process. The instructor X is in charge of a plurality of processes and stands by in preparation for work delays.

  A monitor 22 is connected to each work navigation 20. The monitor 22 displays the work content and indicates the work necessary for the worker in each process. For example, when a suspension that is a part is attached to a vehicle that is a product, a part number and a picture of the part are displayed on the monitor 22 as shown in FIG. In particular, features such as the color of the mark attached are shown so as not to be mistaken for other parts of the same type.

  The work navigation 20 operates as follows.

  FIG. 5 is a flowchart showing a flow of operations of the work navigation. FIG. 5 shows one operation arranged in a certain process among the plurality of work navigations 20.

  First, the work navigation 20 confirms whether a new product has flowed into the process in charge and the work has started (step S1). For example, the work navigation 20 confirms with a sensor that the product flowing through the conveyor has entered the process in charge, and determines that the work has started. Here, the work navigation 20 functions as a confirmation unit. If the work is not started (step S1: NO), the work navigation 20 waits until the work starts. When the work is started (step S1: YES), the work navigation 20 displays the work content for the product to be processed on the monitor 22 and instructs the worker (step S2). Here, the work navigation 20 functions as an instruction unit.

  Then, the work navigation 20 determines whether or not the displayed work content is completed (step S3). Whether the work content is completed is confirmed by the operator pressing a button provided on the work navigation 20 or touching the touch panel of the monitor 22. Here, the work navigation 20 functions as an input unit.

  If the completion of the work item is not confirmed (step S3: NO), the work navigation 20 displays the work content until the work item is completed. When the completion of the work content is confirmed (step S3: YES), the work navigation 20 measures the actual work time from the work start to the work completion for the work content, and transmits it to the data processing device 10 (step S4). . Here, the work navigation 20 functions as a measurement unit.

  The work navigation 20 determines whether or not all work has been completed (step S5). When all the operations are not completed (step S5: NO), that is, when there is a next product according to the production plan, the work navigation 20 returns to the operation of step S1 and waits until the next product flows. . When the work is finished (step S5: YES), the work navigation 20 finishes the operation.

  FIG. 6 is a diagram illustrating various set times stored in the storage unit, and FIG. 7 is a diagram illustrating an example of work performance data stored in the data processing apparatus 10.

  When the data processing apparatus 10 receives the actual work time from the work navigation 20, the data processing apparatus 10 reads the standard work time (standard work time) for the corresponding vehicle type in the corresponding process from the storage unit 12. Then, as shown in FIG. 6, the work delay time is calculated by subtracting the standard work time from the actual work time.

  Then, the work delay time is accumulated in the storage unit 12 as work results. Here, in the example illustrated in FIG. 7, the data of the vehicle type and the worker is accumulated for each work navigation 20. In the process in which the work navigation 20a is installed, the worker A, the worker B, and the worker C have been assigned so far, and the assembly work of the vehicle types a to e has been performed.

  According to FIG. 7, in the process in which the work navigation 20a is installed, the worker A has an average delay time of −5 seconds, a minimum delay time (Min) of −15 seconds, and a maximum delay time (Max). Is 10 seconds. Here, −5 seconds means that 5 seconds are left after the standard work time. Similarly, in the process in which the work navigation 20a is installed, the worker B has an average delay time of -5 seconds, a minimum delay time of -15 seconds, and a maximum delay time of 0 seconds for the vehicle a. Recognize.

  Thus, the minimum value, average value, and maximum value of the work delay time for each worker and vehicle type are updated and stored as needed. In this embodiment, since the worker A, the worker B, and the worker C do not work at the same time in the process of the same work navigation 20a, for example, the work delay time data for the vehicle type a of the work navigation 20a is , Collected at different dates and times. The work delay time data is similarly accumulated for the work navigation 20b and other work navigations 20.

  Note that the permissible time shown in FIG. 6 is a limit time that the production line must be stopped if it is delayed further. The reference time is set shorter than the allowable time, and is a reference for determining whether or not to call an instructor supporting the worker in the process. Details will be described as an operation of the data processing apparatus 10 described below.

  FIG. 8 is a flowchart showing the operation flow of the data processing apparatus, and FIG. 9 is a diagram showing a specific example of work delay predicted by the data processing apparatus.

  The data processing apparatus 10 predicts a future work delay using the work results collected as described above, and determines a process that needs assistance from the instructor. The operation of the data processing apparatus 10 is executed by the control unit 16.

  The control unit 16 refers to the work delay time of each process (step S10). This reference refers to the “progress” line in the table shown in FIG. This line shows the current work delay time. In the example shown in FIG. 9, it can be seen that the worker A, the worker B, and the worker C all have a work delay of 10 seconds.

  Subsequently, the control unit 16 refers to the work results and the production plan stored in the storage unit 12 (step S11), and calculates a future cumulative work delay (step S12). Here, the control unit 16 specifies 10 types of vehicles scheduled to be worked on in the future based on the production plan. And the time which an operator takes in the operation | work of each vehicle type is specified from the work performance data of FIG. The minimum work delay time, the average work delay time, and the maximum work delay time are accumulated to calculate a cumulative work delay time after 10 units. For worker A in FIG. 9, the minimum work delay time after 10 units is 5 seconds, the average work delay time is 75 seconds, and the maximum work delay time is 195 seconds.

  The control unit 16 compares the cumulative average work delay time after 10 units with the reference time (step S13). The reference time is different for each product and process. Therefore, the control unit 16 compares the reference time for the work of the product after 10 units in the corresponding process with the average work delay time. In the case of the worker A in FIG. 9, the product after 10 units in the process-1 is the vehicle type b. Therefore, the reference time when working the vehicle type b in the process-1 is compared with the average work delay time 75 seconds. . The reference time is, for example, about 2/3 of the allowable time, as shown in FIG. The allowable time is set as, for example, half of the standard work time.

  The control unit 16 determines whether there is a step longer than the reference time (step S14). If there is no process longer than the reference time (step S14: NO), there is no possibility of the production line being stopped, so the process returns to step S10 and the process is repeated. When there is a process longer than the reference time (step S14: YES), the control unit 16 specifies the corresponding process (step S15).

  The control unit 16 determines whether the identified process is a plurality of processes (step S16). When it is not a plurality of processes (step S16: NO), the control unit 16 determines that the identified process is a process that needs assistance from the instructor X (step S17).

  When there are a plurality of processes (step S16: YES), the control unit 16 weights the work delay time of the identified process (step S18). For example, the control unit 16 applies a larger coefficient to the processes upstream of the plurality of processes. The delay time of the most upstream process is multiplied by 1.5, the next is multiplied by 1.3, the next is multiplied by 1.1, and so on.

  For each process, the control unit 16 calculates a ratio of the weighted cumulative work delay time to the standard work time, and determines a process having the maximum ratio as a process requiring support (step S19).

  The control unit 16 displays the process determined to require support on the display unit 14 and the monitor 22 (step S20). As a result, it is possible to know a process that requires objective support based on a future production plan. Preferably, the specified process is directly notified to the instructor X who actually supports the work. In this case, the process is notified to a portable terminal such as a PDA or a mobile phone carried by the instructor. As a result, the instructor can immediately know the process that needs assistance. Alternatively, only the monitor 22 arranged in the process determined to require support may be notified that support is required.

  The control unit 16 determines whether or not the work is finished (step S21). The end of work is, for example, a case where today's production plan is finished. When the work is not finished (step S21: NO), the control unit 16 repeats the processing from step S10. When the work is finished (step S21: YES), the control unit 16 stops its operation.

  According to the support process determination system of the above-described embodiment, the cumulative work delay time is predicted and calculated based on the work results and the production plan. Therefore, processes that are likely to require support in the future are automatically determined in advance. it can. Therefore, it is not necessary for the worker to determine the work delay by himself. In addition, for the instructor who supports the process, it is possible to obtain a process that requires objective support instead of the subjective judgment of the operator. As a result, the instructor X supports a process that may cause the production line to be stopped in the future, and can prevent the production line from being stopped.

  In particular, since the process for which support is determined to be required is notified, when the instructor X supporting the process is notified, the instructor X can immediately reach the process. In addition, when a process requiring assistance is notified to the worker through the monitor 22 of the work navigation 20, the worker can immediately ask the supporter for support regardless of his / her own judgment.

  Even when a plurality of processes are specified, it is possible to automatically determine a process that needs the most support in the future by weighting.

  The process in which the ratio of the weighted cumulative work delay time with respect to the standard time is the largest is determined as the process requiring support. Thereby, even if the standard work time which differs for every product differs for every process, it can standardize and the process with the highest degree of work delay can be judged.

  The process that needs the most support is judged after weighting and correcting the process in the upstream. Therefore, it is possible to determine a process that needs support in consideration of the fact that the upstream process has a higher influence on the production line.

  Further, according to the embodiment, as shown in FIG. 5, the work navigation 20 instructs the work content to the worker, and the worker finishes the work, so the work is finished properly. As a result, it is possible to accumulate the work results of the worker with high accuracy.

  In addition, although the said embodiment demonstrated the case where one worker was arrange | positioned at one process in a production line, it is not limited to this. A plurality of workers may be arranged in one process. In this case, the storage unit 12 of the data processing apparatus 10 accumulates a delay time for each worker in one process.

  Further, in the above embodiment, the work delay is determined by predicting the cumulative work delay time when a product after 10 units is processed from the currently processed product. However, it is not limited to predicting after 10 vehicles. Work delays after any number of units such as after one unit or after 100 units may be predicted.

  In the above embodiment, the accumulation of the average work delay time is predicted and compared with the reference time. However, the accumulation of the minimum work delay time or the accumulation of the maximum work delay time may be compared with the reference time. For example, the accumulation of the maximum work delay time after 3 units or the minimum work delay time after 20 units may be compared with the reference time.

  According to the above-described embodiment, the process for which assistance is required is automatically determined by the data processing apparatus 10, and the description of the case where the operator himself determines that assistance is required is omitted. However, as shown in FIG. 3, it is preferable to arrange the support request string 30 along the belt conveyor of the production line. The workers A to D can call the instructor X by pulling the string 30 to turn on the lamp of their process. Usually, when the operator himself pulls the string 30, an emergency is required, so the instructor X gives priority to the support request by the string 30 over the data processing device 10.

(Second Embodiment)
In the first embodiment, only when there is a process whose work delay time is equal to or longer than the reference time, it is determined that the process needs assistance. On the other hand, in the second embodiment, even when there is no process whose work delay time is equal to or longer than the reference time, a process having the longest work delay time is determined as a process requiring assistance.

  FIG. 10 is a flowchart showing an operation flow of the data processing apparatus according to the second embodiment. Below, the same step number is attached | subjected about the process which overlaps with the flowchart of 1st Embodiment shown in FIG. 8, and the specific description is abbreviate | omitted.

  The control part 16 of the data processing apparatus 10 performs step S10-13. The control unit 16 determines whether there is a process in which the cumulative work delay time after 10 units is longer than the reference time (step S14). When there is a process longer than the reference time (step S14: YES), the control unit 16 executes the processes of steps S15 to S19 of the first embodiment.

  When there is no process longer than the reference time (step S14: NO), the control unit 16 determines whether the instructor X is a hand (step S30). Whether or not the instructor X is a hand is determined by receiving a signal from the mobile terminal held by the instructor X. The portable terminal of the instructor X is provided with a supportable setting unit that sets whether or not the worker is in a supportable state. If the instructor X does not support the process and there is no other work, the instructor X sets that support is possible in the portable terminal in order to notify that he is a handrail. For example, it is set that support is possible by pressing a specific button of the mobile terminal.

  If the instructor X is not a handrail (step S30: NO), the process returns to the control unit 16 and step S10. When the instructor X is a handrail (step S30: YES), the control unit 16 weights the average work delay time of each process (step S31). The weighting is the same as in step S18. A higher factor is applied to the upstream process.

  For each process, the control unit 16 calculates the weighted cumulative average work delay time ratio with respect to the standard work time, and determines the process having the maximum ratio as a process requiring support (step S32). .

  The control unit 16 displays the process determined to require support on the display unit 14 and the monitor 22 (step S20).

  As described above, in the second embodiment, when the instructor X is free, by setting that support is possible with the mobile terminal, it is determined that the process requires support even in a process that is not delayed more than the reference time. it can. Therefore, it is possible to shorten the time when the instructor X is free and improve the operating rate. Furthermore, since a process that is not delayed more than the reference time can be preliminarily supported using the free time of the instructor X, it is possible to more reliably prevent an operation delay leading to a line stop.

FIG. 1 is a schematic diagram showing a support process determination system. It is a figure which shows schematic structure of a data processor. It is a figure which shows a mode that the work navigation apparatus was installed in the production line. It is a figure which shows the example of the work content shown on a monitor. It is a flowchart which shows the flow of operation | movement of work navigation. It is a figure which shows the various setting time memorize | stored in a memory | storage part. 3 is a diagram illustrating an example of work performance data stored in the data processing apparatus 10. FIG. It is a flowchart which shows the flow of operation | movement of a data processor. It is a figure which shows the specific example of the work delay estimated by a data processor. It is a flowchart which shows the flow of operation | movement of the data processor which concerns on 2nd Embodiment.

Explanation of symbols

10 data processing device,
12 storage unit,
14 Display section,
16 control unit,
20 Each work navigation,
22 Monitor,
30 strings.

Claims (12)

For each process included in the production line, a first storage unit that stores a standard work time of each product and a reference time serving as a reference for determining the delay of the production line;
Second memory for storing the work delay time obtained by subtracting the standard work time of each product from the actual work time actually required for the work of each product for each process as work results. And
A third storage unit for storing a production plan indicating the type and order of products to be sent to the production line;
Based on the work results and the production plan, a calculation unit for calculating a future cumulative work delay time when products are sequentially introduced into each process in the future;
A determination unit that identifies a process in which the calculated cumulative work delay time is equal to or greater than the reference time, and determines that the process needs support;
A support process determination system. It further has an indicating device installed in the process,
The pointing device is
A confirmation unit for confirming the start of work in the process;
An instruction unit for instructing the worker about the work content of the process;
An input unit for inputting the end of work by the worker who has finished the work;
A measurement unit that measures the time from the start of work to the input to the input unit as an actual work time;
The support process determination system according to claim 2, comprising:   The support process determination system according to claim 1, further comprising a notification device that notifies a process determined to require support by the determination unit. The notification device is a mobile terminal,
The portable terminal is provided with a support availability setting unit that sets whether or not a supporter supporting the work of each process can support,
In the support availability setting unit, when the supporter is set to be able to support, the determination unit is configured for the standard work time even if a process with the work delay time equal to or longer than the reference time is not specified. The support process determination system according to claim 3, wherein the process having the largest work delay time ratio is determined as a process requiring support.   When there are a plurality of specified processes, the determination unit determines that a process having the largest ratio of the cumulative work delay time to the standard work time among the specified processes is a process requiring assistance. Item 5. The support process determination system according to any one of Items 1 to 4.   When there are a plurality of specified processes, the determination unit corrects the cumulative work delay time of the upstream process by weighting more than the downstream process, and then has the largest ratio to the standard work time. 6. The support process determination system according to claim 5, wherein the process is determined to be a process that requires support. A procedure executed by a support process determination system provided in the production line,
For each process included in the production line, the work delay time obtained by subtracting the standard work time of each product from the actual work time actually required for the work of each product is stored as work results as needed. Steps,
Based on the work results and a production plan indicating the order of products to be sent to the production line from now on, calculating a future cumulative work delay time when products are sequentially inserted into each process in the future;
A step in which the calculated cumulative work delay time is greater than a reference time that is a reference for determining a delay in the production line, and a step that determines that the process needs support;
A method for determining a support process. For each process, confirming the start of work,
Instructing the operator of the process of the work content;
Receiving an input of work completion by the worker who finished the work;
Measuring the time from the start of the work to the acceptance of the end of the work as the actual work time;
The support process determination method according to claim 7, further comprising:   The support process determination method according to claim 7, further comprising a notification step of notifying a process determined to require support by the determination unit. In the notification step, a portable terminal held by a supporter who supports the work of each process is notified of a process that needs support,
The portable terminal further includes a step of accepting an input as to whether or not the supporter can support,
When it is input that the supporter can support, in the determination step, even if the process is not specified in the specifying step, a process in which the ratio of the work delay time to the standard work time is the largest, The method of determining a support process according to claim 9, wherein the process is determined to require a support.   In the determining step, when there are a plurality of specified processes, a process in which a ratio of the cumulative work delay time to the standard work time is the largest among the specified processes is determined as a process requiring assistance. The support process determination method according to any one of Items 7 to 10.   In the determination step, when there are a plurality of specified processes, the cumulative work delay time of the upstream process is corrected by weighting more than the downstream process, and the process having the largest ratio to the standard work time 12. The support process determination method according to claim 11, wherein the process is determined to be a process requiring support.

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