JP2014026611A - Required conveyance staff number calculation program, required conveyance staff number calculation device and required conveyance staff number calculation method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To calculate smaller number of conveyance staffs.SOLUTION: A required conveyance staff number calculation program makes a computer calculate the number of conveyance staffs who convey parts. The program makes the computer execute a classification processing for classifying a plurality of processes using parts into a process or a plurality of processes, and a processing for calculating the number of conveyance staffs required in order to convey parts for each process classified according to the classification processing.

Description

  The present invention relates to a conveyance personnel number calculation program, a conveyance personnel number calculation apparatus, and a conveyance personnel number calculation method.

  In designing a production line of a factory, the design is performed so that the working time of each process constituting the production line is the shortest and uniform. In addition to the assembly workers, parts shelves and the like are arranged at the work places of each process. Parts necessary for the process are supplied to the parts shelf.

  The parts are supplied to the parts shelf by a worker called “Mizusumashi” who plays a role of physical distribution in the factory. The calculation of Mizusumi's workforce forms part of the design of the factory production line. From the viewpoint of cost reduction or the like, it is desirable that the production line is designed so as to minimize the number of workers in the range as long as sufficient parts can be supplied to the parts shelf.

  Conventionally, a simulation in a factory has been executed in order to calculate the number of migratory staff (for example, Patent Document 1 and Patent Document 2).

JP 2003-114709 A JP 2003-141436 A

  However, in the case of a simulation, a simulation for one day is required even for parts having a supply frequency of about once or twice a day.

  Moreover, it is necessary to perform simulation for every number of Mizusumi personnel. Specifically, the simulation is repeated while changing the number of Mizusumi personnel, such as when the number of Mizushima is one or two, and the optimum number of Mizusumashi personnel is derived by comparing the simulation results.

  Therefore, when simulation is used, the calculation of the number of Mizusumi personnel tends to be prolonged.

  Therefore, an object of one aspect is to calculate a smaller number of transport personnel.

  In one proposal, there is provided a transport personnel number calculation program for causing a computer to calculate the number of transport personnel that transport a part, and a classification process for classifying a plurality of processes using parts into one process or a plurality of processes, And causing the computer to execute a process of calculating the number of transport personnel required to transport the parts for each process classified by the classification process.

  According to one aspect, a smaller number of transport personnel can be calculated.

It is a figure which shows the hardware structural example of the manpower calculation apparatus in embodiment of this invention. It is a figure which shows the function structural example of the manpower calculation apparatus in embodiment of this invention. It is a flowchart for demonstrating an example of the process sequence which a number calculation apparatus performs. It is a figure which shows the structural example of a process information storage part. It is a figure which shows the structural example of a calculation table. It is a figure which shows the structural example of a components conveyance information storage part. It is a figure for demonstrating the conveyance unit and case occupation rate of the components C. FIG. It is a figure which shows the structural example of a movement time memory | storage part. It is a figure which shows an example of the conveyance path | route which makes all the processes the charge range. It is a figure which shows the example of the 1st classification result of the record of a calculation table. It is a figure for demonstrating the conveyance path | route of each charge range after a division | segmentation. It is a figure which shows the example of the 2nd classification result of the record of a calculation table. It is a figure which shows the example of the calculation table by which the order of the process 2 and the process 3 was replaced.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings. FIG. 1 is a diagram illustrating a hardware configuration example of a personnel number calculation device according to an embodiment of the present invention. 1 includes a drive device 100, an auxiliary storage device 102, a memory device 103, a CPU 104, an interface device 105, a display device 106, an input device 107, and the like, which are connected to each other via a bus B. .

  A program that realizes processing in the personnel number calculation device 10 is provided by the recording medium 101. When the recording medium 101 on which the program is recorded is set in the drive device 100, the program is installed from the recording medium 101 to the auxiliary storage device 102 via the drive device 100. However, the program need not be installed from the recording medium 101 and may be downloaded from another computer via a network. The auxiliary storage device 102 stores the installed program and also stores necessary files and data.

  The memory device 103 reads the program from the auxiliary storage device 102 and stores it when there is an instruction to start the program. The CPU 104 realizes functions related to the personnel number calculation device 10 according to a program stored in the memory device 103. The interface device 105 is used as an interface for connecting to a network. The display device 106 displays a GUI (Graphical User Interface) or the like by a program. The input device 107 is a keyboard, a mouse, or the like, and is used for inputting various operation instructions.

  An example of the recording medium 101 is a portable recording medium such as a CD-ROM, a DVD disk, or a USB memory. An example of the auxiliary storage device 102 is an HDD (Hard Disk Drive) or a flash memory. Both the recording medium 101 and the auxiliary storage device 102 correspond to computer-readable recording media.

  FIG. 2 is a diagram illustrating a functional configuration example of the personnel number calculation device according to the embodiment of the present invention. In FIG. 2, the personnel number calculation device 10 includes a calculation table generation unit 111, a transport load calculation unit 112, an overall lap time calculation unit 113, an initial value calculation unit 114, an assignment determination unit 115, a partial lap time calculation unit 116, and the number of personnel. A calculation unit 117, a process replacement unit 118, a personnel number determination unit 119, and an output unit 120 are included. Each of these units is realized by processing executed by the CPU 104 by a program installed in the personnel number calculation device 10.

  The manpower calculation device 10 also uses a process information storage unit 131, a component conveyance information storage unit 132, a travel time storage unit 133, and the like. Each of these storage units can be realized by using, for example, a storage device connected to the auxiliary storage device 102 or the manpower calculation device 10 via a network.

  With the functional configuration described above, the manpower calculation device 10 in a production line of a certain product (hereinafter referred to as “product A”) is referred to as a plurality of work processes (hereinafter simply referred to as “processes”) constituting the production line. ) To calculate the number of transport personnel (hereinafter referred to as “Mizusumashi”) who transport parts to the work place.

  The process information storage unit 131 stores information on each process of the product A (hereinafter referred to as “process information”). The process information includes the number of parts used in each process.

  The component conveyance information storage unit 132 stores, for each type of component, information related to the conveyance of that type of component.

  The moving time storage unit 133 stores the moving time of the warehouse and each of the steps in the production line of the product A. A warehouse is a storage place for parts. For example, Mizusumashi loads parts on a cart in a warehouse and transports the parts to each process by the cart.

  The calculation table generation unit 111 generates a temporary table that is used for calculating the number of personnel of the mizusumi.

  The transport load calculating unit 112 calculates the ratio of the volume of each part used in each process to the single transportable amount of the strain. The ratio is referred to as “transport load” in the present embodiment.

  Based on the movement time between processes stored in the movement time storage unit 133, the total turn time calculation unit 113 requires a time required for one Mizushima to carry parts to all processes in the production line of the product A ( Hereinafter, it is referred to as “overall lap time”).

  Based on the assembly time of one process and the number of parts used for one product A in each process, the initial value calculation unit 114 calculates the total turnaround time for the load capacity of one mizusumi. The ratio (or ratio) of the quantity of parts used in all processes is calculated. The smallest integer value equal to or greater than the ratio is set as the initial value of the number of Mizusumi personnel.

  The assignment determination unit 115 determines a sharing method by a plurality of strains corresponding to the number of personnel calculated by the initial value calculation unit 114 or the personnel number calculation unit 117 for the conveyance of the parts. By determining the sharing method, the parts transporting operation to each process is divided into the number of personnel. It is determined which each machine is responsible for conveying which part of which process.

  The partial turn time calculation unit 116 transports a part once to the process for which the corresponding part is transferred for each of the connection parts transported based on the movement time between processes stored in the movement time storage part 133. The required time (hereinafter referred to as “partial lap time”) is calculated.

  The number-of-persons calculation unit 117 is configured to calculate the quantity of parts used in the process in which the mizusumi is in charge during the partial rounding time for each sushi system that is responsible for the transportation of the parts. Calculate the ratio (or ratio). The number-of-persons calculation unit 117 calculates the total value of the ratios calculated for each strain, and sets the minimum integer value equal to or greater than the total value as the number of workers in the strain.

  The process replacement unit 118 updates the calculation table so that the calculation of the number of personnel is executed in a state where the process order is changed with respect to the process whose work order can be changed.

  The number-of-persons determination unit 119 determines one of the numbers of personnel calculated by the initial value calculation unit 114 or the number of personnel calculation unit 117 as the number of personnel to be finally output. More specifically, if the number of personnel calculated by the personnel number calculation unit 117 is smaller than the initial value calculated by the initial value calculation unit 114, the personnel number determination unit 119 performs processing performed by the assignment determination unit 115 and the subsequent units. Repeat. When the process is repeated, the personnel number determination unit 119 determines that the number of personnel newly calculated by the personnel number calculation unit 117 is smaller than the number of personnel calculated by the personnel number calculation unit 117 during the previous processing. For example, the processing executed by the sharing determination unit 115 and the subsequent steps is further repeated. When the repetitive condition is not satisfied, the personnel number determination unit 119 determines the number of personnel.

  The output unit 120 outputs the result of determining the number of personnel.

  Hereinafter, a processing procedure executed by the manpower calculation device 10 will be described. FIG. 3 is a flowchart for explaining an example of a processing procedure executed by the personnel number calculation device. The process in FIG. 3 is started in response to an instruction input from the user via the input device 107, for example.

  In step S101, the calculation table generation unit 111 reads the process information stored in the process information storage unit 131, and generates a calculation table based on the process information. The generated calculation table is stored in the memory device 103 or the auxiliary storage device 102, for example.

  FIG. 4 is a diagram illustrating a configuration example of the process information storage unit. In FIG. 4, the process information storage unit 131 stores a record for each assembly work. One record includes items such as an ID, a process name, a part name, a quantity, and a replacement flag. In the present embodiment, the assembling work refers to work performed using one type of component in one process. Therefore, the process in which a plurality of types of parts are used includes a plurality of assembly operations.

  ID is an identifier of a record or assembly work. The process name is an identification name of the process to which the assembling work belongs. The part name is an identification name of a part used in the assembly work. The quantity is a quantity (for example, the number) in which the part related to the part name is used in the assembly work. The replacement flag is information for identifying a process whose order can be changed. In other words, the processes having the same value stored in the replacement flag indicate that the order can be switched. FIG. 4 shows an example in which the order of step 2 and step 3 is interchangeable.

  In the process information storage unit 131 shown in FIG. 4, records are stored in the order of processes and the order of assembly work.

  FIG. 5 is a diagram illustrating a configuration example of a calculation table. In FIG. 5, the calculation table includes a record for each assembly operation. One record includes an ID, a process name, a part name, a quantity, a transportable amount per time (hereinafter simply referred to as “transportable amount”), a transport load, a group ID, and the like.

  The meaning of ID, process name, part name, and quantity is the same as the meaning of the item of the same name in the record of the process information storage unit 131. In step S101, the ID, process name, part name, and quantity value of each record stored in the process information storage unit 131 are directly transferred to the calculation table. Therefore, the same number of records as the process information storage unit 131 are stored in the calculation table.

  The values of the transportable amount, the transport load, and the group ID are stored according to the execution of steps described later. The transportable amount is the maximum value of the quantity that can be transported by one Mizusumi in a single transport for the part related to the part name. In the present embodiment, a single mizusumi uses a single carriage to carry parts. Therefore, the quantity that can be transported by one Mizusumi in one transport is the quantity that can be transported by one truck or can be loaded on one truck.

  The transport load is a ratio of the quantity to the transportable amount. The group ID is information for identifying the difference between the ridges responsible for the conveyance of the parts related to each assembly work. Initially, since the calculation is performed assuming that there is only one Mizusumi who is in charge of conveying parts for all processes, the value of the group ID is blank.

  Subsequently, the conveyance load calculation unit 112 refers to the component conveyance information storage unit 132 and calculates a conveyance load related to each record stored in the calculation table (S102).

  FIG. 6 is a diagram illustrating a configuration example of the component conveyance information storage unit. The component transport information storage unit 132 stores a component name, a transport unit, a case occupation rate, and a transportable amount for each component (component type).

  The transport unit is the quantity per case of the parts related to the part name. The case refers to a container or a package in which a part is stored when the part is transported. The shape and size of the case may be different for each type of component. In this embodiment, an example in which conveyance is performed in units of cases will be described. Accordingly, the transport unit is a quantity per case.

  The case occupancy is the occupancy of the case in the carriage used by Mizusumi for conveying parts. The transportable amount is synonymous with the transportable amount in the calculation table. In the present embodiment, the calculation result of transport unit ÷ case occupancy is the transportable amount.

  For example, in FIG. 6, for part C, the transport unit is “2” and the case occupancy is “70”. When this state is expressed in a diagram, it is as shown in FIG.

  FIG. 7 is a diagram for explaining a conveyance unit and a case occupancy rate of the part C. FIG. 7 shows an example in which there are two parts C per case, and the case occupies 70% of the cart.

  In step S <b> 102, the calculation table generating unit 111 transcribes the portable amount corresponding to the component name of the record from the component conveyance information storage unit 132 into each record of the calculation table. In addition, the calculation table generation unit 111 calculates quantity / portable amount for each record in the calculation table, and stores the calculation result in the transport load of each record. As a result, the calculation table is in the state shown in FIG.

  Subsequently, the total lap time calculation unit 113 refers to the travel time storage unit 133 and, when one mizusumi sets all the processes of the production line of the product A as the responsibilities, the entire lap time calculation unit 113 corresponds to one round of the conveyance route in the responsibilities. Is calculated (S103). The assigned range refers to a range in which Mizusumi is responsible for transporting parts, and in this embodiment, a combination of a process and a part is a minimum unit. Therefore, the assigned range may be divided in the same process.

  FIG. 8 is a diagram illustrating a configuration example of the travel time storage unit. In FIG. 8, the movement time storage unit 133 stores time necessary for movement with respect to a combination of warehouses or processes arranged in the row direction and warehouses or processes arranged in the column direction (hereinafter referred to as “movement time”). Is stored). Note that the unit of travel time is seconds.

  In the present embodiment, the transfer route when the entire process is in charge is a transfer route as shown in FIG.

  FIG. 9 is a diagram illustrating an example of a conveyance route that covers all processes. In FIG. 9, the section r1 between the warehouse and the process 1, the section r2 between the process 1 and the process 2, the section r3 between the process 2 and the process 3, the section r4 between the process 3 and the process 4, and the process 4 and the warehouse. The conveyance path including the section r5 is a conveyance path for one round of all the processes.

  Therefore, in step S103, the total lap time calculation unit 113 acquires the travel time corresponding to each of the sections r1 to r5 from the travel time storage unit 133, and calculates the total value of the acquired travel times. According to the examples of FIGS. 8 and 9, the calculation results are as follows.

40 + 20 + 20 + 20 + 50 = 150 (seconds)
Subsequently, the initial value calculation unit 114 calculates the initial value of the number of personnel of the volunteer using the following formula (1) (S104).

{(Circuit time in charge range x 120%) ÷ assembly time} x Σ (number of parts required for one product ÷ load capacity) (1)
Here, the assembly time is also referred to as tact time, and refers to the work time of one process. In a production line, since the work time of each process is generally substantially uniform, it can be said that the assembly time is an interval at which a finished product is produced. The assembly time is stored in advance in the auxiliary storage device 102, for example.

  Therefore, the first term {(around time of the assigned range × 1.2) ÷ assembly time} indicates how many products are produced while Mizusumi goes around the assigned range. The movement time for one round is multiplied by 1.2 in consideration of the time required for operations such as arrangement or arrangement of parts on the parts shelf in each process. Therefore, the numerical value of 1.2 may be changed as appropriate.

  The second term Σ (number of parts required for one product ÷ transportable amount per time) is the number of times of transport required per product or how many times the transportable amount Indicates whether the part is used. Σ indicates that the value in parentheses is calculated for each type of part, and the sum of the calculation results is calculated.

  Therefore, the calculation result of Expression (1) indicates the ratio of the number of parts used during one round of the conveyance path in the assigned range to the single transportable amount. That is, it can be said that the calculation result of Expression (1) is a value indicating how many parts are required or used with respect to the transportable amount during one round of the transport path. Or it can be said that the calculation result of Formula (1) shows the number of conveyances required during one round of the conveyance route of the assigned range. Furthermore, it can be said that the calculation result of the formula (1) is a value indicating how many work volumes are required per round time of the transport route. The amount of work here refers to a transport work for one round of the transport path as a unit.

  Hereinafter, the value obtained as the calculation result of Expression (1) is referred to as “necessary work amount”.

  In step S104, the assigned range is all processes, and the circulation time of all processes, that is, the total circulation time is 150 seconds as described above. Therefore, if the tact time is 60 seconds, the required work amount in the present embodiment is as follows.

(150 × 1.2 ÷ 60) × 0.905 = 2.715
In addition, 0.905 is the calculation result of the second term of Formula (1). The calculation result of the second term matches the total transport load value of the record corresponding to the assigned range in the calculation table. In step S104, it is the total value of the transport loads of all records in the calculation table.

  Subsequently, the initial value calculation unit 114 sets the minimum integer value equal to or greater than the value of the operation result as the initial value of the number of personnel of the strain and substitutes the initial value into the variable N (S105). The variable N is a variable for storing the minimum value of the number of personnel of Mizusumashi. At the time of step S105, since the initial value calculated in step S104 is the lowest value, the initial value is substituted into the variable N.

  In other words, the above calculation result requires that the number of parts is 2.715 times as large as the transportable amount per time during the entire rounding time, and 2.715 times of parts transportation are required. It indicates that there is a certain amount of work or 2.715 people. Therefore, it is considered that the occurrence of component breakage in any one of the steps can be avoided if the conveyance is performed by three people. Therefore, 3 which is the smallest integer value of 2.715 or more is set as the initial value of the number of personnel of the mizusumi.

  Subsequently, the assignment determination unit 115 divides the assigned range into the number of values of the variable N (S106). The division of the assigned range means sharing of parts by a plurality of mitsusuma. The division of the assigned range is realized by classification of record groups stored in the calculation table. That is, the assignment determination unit 115 classifies the record groups stored in the calculation table into groups corresponding to the number of values of the variable N. At this time, the assignment determination unit 115 performs grouping of the record groups so that the total value of the transport loads of the records belonging to each group becomes substantially equal. One form of substantially equality is that the difference in the total value of the transport loads of each group is as small as possible. For example, when grouping into two groups, group A and group B, the group of record groups is such that the difference between the total transport load for group A and the total transport load for group B is minimized. Division may be performed. In addition, when classified into three or more groups, the difference between the total value of the transport load between the group having the minimum total value of the transport load and the group having the maximum total value of the transport load is minimized. Grouping may be performed.

  In the present embodiment, when the assignment determination unit 115 assigns a plurality of processes to one mizusumi, the division determination unit 115 performs grouping so that the plurality of processes that one mizusushi takes charge are continuous.

  Subsequently, the sharing determination unit 115 stores the grouping result in the calculation table (S107). Specifically, the same value is stored in the group ID of the records classified into the same group. Different values are stored in the group IDs of the records classified into different groups.

  FIG. 10 is a diagram illustrating an example of the first classification result of records in the calculation table. In this embodiment, since the value of the variable N is 3, FIG. 10 shows the result of classifying the records in the calculation table into three groups, groups A, B, and C. In the group ID of the record belonging to each group, an alphabet for identifying the group to which the record belongs is recorded. As a result, the conveyance of the parts is shared by the three mizusumi, and the assigned range of each is recorded in the calculation table.

  The total transport load of records belonging to group A is 0.266. The total transport load of records belonging to group B is 0.350. The total transport load of records belonging to group B is 0.289.

  Hereinafter, the assigned ranges related to the groups A, B, and C are referred to as assigned ranges A, B, and C.

  In FIG. 10, the charge range B and the charge range C overlap with respect to the process C. However, in the process C, the parts included in the charge range B and the parts included in the charge range C are different. This is because in this embodiment, a combination of a process and a component is the minimum unit.

  If it is desired to set the process as the minimum unit, such a restriction may be provided. In this case, classification may be performed so that the same process is not included in two or more assigned ranges.

  In addition, an upper limit value of the number of processes included in one assigned range may be set. In this case, classification may be performed so that the number of processes included in one assigned range is equal to or less than the upper limit value.

  In the classification of the calculation table, the classification need not necessarily be performed in the order of records in the calculation table. As long as there is a combination in which the total transport load is more nearly uniform, regarding the assembling operations belonging to the same process, the responsible ranges may be switched regardless of the order. Specifically, if the record with ID 5 is included in the charge range C and the records with IDs 6, 7, and 8 are set as the charge range B, the difference in transport load between the three charge ranges becomes smaller. If so, classification may be performed as such.

  Subsequently, the partial lap time calculation unit 116 calculates a partial lap time of the assigned range related to the assigned range for each assigned range after division (S108). When the assigned range is divided as shown in FIG. 10, the transport route of each assigned range is as shown in FIG. 11, for example.

  FIG. 11 is a diagram for explaining a transport route of each assigned range after division. In FIG. 11, the same sections as those in FIG. 9 are denoted by the same reference numerals, and the description thereof is omitted.

  By dividing the assigned range, the section r6 and the section r7 are used as a transport route in any assigned range. That is, the conveyance route of the assigned range A including the process 1 and the process 2 includes the section r1, the section r2, and the section r6. The conveyance route of the assigned range B including the process 3 is a round trip of the section r7. The conveyance path of the assigned range C including the process 3 and the process 4 includes the section r7, the section r4, and the section r5.

  Therefore, 40 + 20 + 30 = 90 seconds is calculated as the partial lap time for the assigned range A based on the travel time of each section stored in the travel time storage unit 133. For the assigned range B, 30 + 30 = 60 seconds is calculated as the partial turn time. Further, for the assigned range C, 30 + 20 + 50 = 100 seconds is calculated as the partial turn time.

  Subsequently, the number-of-persons calculation unit 117 calculates a required work amount related to the assigned range using Formula (1) for each assigned range (S109). At this time, the partial lap time of the transfer route of the assigned range is substituted for the lap time of the assigned range. The assembly time is common at 60 seconds for all the assigned ranges. The value of the second term of Equation (1) is the total value of the transport loads of records belonging to the assigned range in the calculation table.

  Therefore, the required work amount in the charge range A is as follows.

(90 × 1.2 ÷ 60) × 0.266 = 0.4788
The required amount of work in charge range B is as follows.

(60 × 1.2 ÷ 60) × 0.350 = 0.42
The required amount of work in charge range C is as follows.

(100 × 1.2 ÷ 60) × 0.289 = 0.578
Subsequently, the personnel number calculation unit 117 determines whether or not the required work amount of all the assigned ranges is 1 or less (S110). That is, it is determined whether or not each person in charge can be transported alone. In the above example, the required work amount of all the assigned ranges is 1 or less.

  When the required work amount of all the assigned ranges is 1 or less (Yes in S110), the manpower number calculation unit 117 calculates the total value of the required work amounts calculated for each assigned range (S111). At this time, the decimal part is rounded up to be an integer. That is, a final integer value equal to or greater than the calculation result is obtained.

  In this embodiment, 0.4788 + 0.42 + 0.578 = 1.4768≈2. That is, when the assigned range is divided into three as shown in FIG. 10, the work amount for two persons is required as a whole.

  Subsequently, the personnel number determination unit 119 compares the total value calculated in step S111 with the value of the variable N (S112). When the total value is less than the value of the variable N (Yes in S112), the manpower determination unit 119 substitutes the total value for the variable N (S113). In the present embodiment, since the total value is 2 and the value of the variable N is 3, 2 is substituted into the variable N. That is, the minimum value of the total value and the value of the variable N is the value of the variable N.

  Subsequently, the personnel number determination unit 119 saves the contents of the current calculation table (S114). For example, a table for saving the contents of the calculation table (hereinafter referred to as “evacuation table”) is generated, and the contents of the calculation table are copied to the save table. Therefore, the save table has the same configuration as the calculation table. In the present embodiment, the contents shown in FIG. 10 are copied to the save table. Note that the save table is stored in the memory device 103 or the auxiliary storage device 102.

  The evacuation table is a table for storing candidates for the final result of the calculation processing of the number of personnel of the volunteer.

  Subsequently, the personnel number calculation device 10 repeats step S106 and subsequent steps. In step S106 executed for the second time, since the value of the variable N is 2, the assigned range of all processes is divided into two. That is, all the records in the calculation table are classified into two groups. At this time, the record groups are grouped so that the total transport load of the records belonging to each group is substantially equal. In the subsequent step S107, the grouping result is stored in the calculation table.

  FIG. 12 is a diagram illustrating an example of a second classification result of records in the calculation table. FIG. 12 shows a result of the records in the calculation table being classified into two groups, group A and group B. In the group ID of the group belonging to each group, an alphabet for identifying the group to which the record belongs is recorded. As a result, the conveyance of the parts is shared by the two workers, and the assigned range each of which is shared is recorded in the calculation table.

  In addition, the total value of the transport load of the records belonging to the group A (the assigned range A) is 0.616. The total value of the transport loads of records belonging to the group B (the assigned range B) is 0.289.

  In the subsequent step S108, the partial lap time is calculated as follows for each of the transfer route of the assigned range A and the transfer route of the assigned range B.

Partial lap time of transfer route of assigned range A = section r1 + section r2 + section r3 + section r7 = 40 + 20 + 20 + 30 = 110 seconds Partial lap time of transfer route of assigned range B = section r7 + section r4 + section r5 = 30 + 20 + 50 = 100 seconds In the following step S109 The required amount of work for each assigned range is calculated as follows.

Required work amount in charge range A = (110 × 1.2 ÷ 60) × 0.616 = 1.3552
Required work amount in charge range B = (100 × 1.2 ÷ 60) × 0.289 = 0.578
Here, the required work amount in the charge range A exceeds 1 (No in S110). In this case, the process proceeds to step S115. In step S115, the personnel number determination unit 119 determines whether or not there is a save table. In the present embodiment, the save table having the contents shown in FIG. 10 is generated (Yes in S115). That is, a candidate for a definite result has already been obtained. In this case, the process replacement unit 118 determines the presence / absence of a process that can be switched in order and has not yet been replaced (S116). This determination is made by referring to the replacement flag in the process information storage unit 131.

  When there is no corresponding process (No in S116), the output unit 120 outputs the value of the variable N and the contents of the save table as a processing result (S117). The value of the variable N is output as the number of workers in the office. The contents of the evacuation table are output as information indicating the range of responsibility and transport route of each mizusumi. The output form is not limited to a predetermined one such as display on the display device 106, storage in the auxiliary storage device 102, or printing on a printer (not shown).

  On the other hand, as shown in FIG. 4, when the process 2 and the process 3 can be interchanged and no interchange is performed with respect to the process (Yes in S116), the process replacement unit 118 selects the process 2 and the process 2 in the calculation table. The order of step 3 is changed (S118). Subsequently, step S106 and subsequent steps are repeated. As the order is changed, the group ID of each record is cleared.

  FIG. 13 is a diagram illustrating an example of a calculation table in which the order of step 2 and step 3 is switched. Comparing FIG. 13 with FIG. 5, the process name of the record whose ID value is 5, 6, 7, or 8 that was the record of process 3 in FIG. 5 is “process 2”. Further, the process name of the record whose ID value is 3 or 4 which is the record of process 2 in FIG. 5 is “process 3”. Also, the order of the new process 2 record and the new process 3 record is switched.

  Note that the value of the process name is replaced with respect to the record to be replaced because the location of the process is also identified by the process name in the present embodiment. That is, changing the order of the steps also means changing the work place of the steps. That is, the work place of the process 3 so far becomes the work place of the process 2 so far, and the work place of the process 2 so far becomes the work place of the process 3 so far. Therefore, even if step 2 and step 3 are interchanged, the travel time information storage unit shown in FIG. 8 may be used in step S106 and subsequent steps that are subsequently executed.

  If the total value of the work amount for each assigned range is less than the variable N in step S112 as a result of changing the order of the processes, the value of the variable N is updated with the total value (S113). Further, the contents of the calculation table shown in FIG. 13 are copied to the save table (S114).

  When the calculation result is confirmed as it is, the user can recognize that the number of the workers can be reduced by changing the order of the steps.

  On the other hand, in step S115, when there is no evacuation table (No in S115), the manpower number calculation unit 117 adds 1 to the variable N and repeats step S106 and subsequent steps. As an example of the case where the evacuation table does not exist, for example, in the state of FIG. In this case, the value of the variable N becomes 4 by adding 1 to the variable N. Therefore, in step S106 and subsequent steps, calculation is performed for the case of sharing by four people.

  If the required work amount of all the assigned ranges is 1 or less in the state where the calculation table is shown in FIG. 12 (Yes in S110), the manpower calculation unit 117 calculates the total value of the required work amount. And the total value is converted to an integer (S111). Subsequently, the personnel number determination unit 119 determines whether or not the total value is less than N (S112). When the total value is N or more (No in S112), since the number of personnel already calculated cannot be reduced in the current process order, Step S115 and subsequent steps are executed. On the other hand, when the total value is less than N (Yes in S112), it has been found that the number of personnel can be further reduced, and therefore Step S113 and subsequent steps are executed.

  As described above, according to the present embodiment, it is possible to calculate the number of workers in the plant without executing a simulation in the factory. Therefore, it is possible to shorten the calculation time for the number of the less mizusumi staff.

  Further, when sharing with a plurality of strains, the responsible range of each strain is determined based on the transport load. For example, the assigned range is determined so that the conveyance load of each mizusumi is substantially equal. Therefore, it is possible to equalize the workload of Mizusumashi in charge of each assigned range.

  In the present embodiment, an example in which the number of personnel is calculated for all processes of the product A has been described, but the number of personnel may be calculated for some processes of the product A. In this case, information regarding the part of the process only needs to be stored in the process information storage unit 131.

  In addition, parts may be transported in a factory by an automated guided vehicle (AGV). In such a case, the present embodiment may be applied to the calculation of the number of automatic guided vehicles. That is, the “number of personnel” in the present embodiment includes the number of automatic guided vehicles.

  In the present embodiment, a mizusumi or an automated guided vehicle is an example of a transporter. The initial value calculation unit 114 is an example of a first calculation unit. The manpower calculation unit 117 is an example of a second calculation unit.

  As mentioned above, although the Example of this invention was explained in full detail, this invention is not limited to such specific embodiment, In the range of the summary of this invention described in the claim, various deformation | transformation・ Change is possible.

Regarding the above description, the following items are further disclosed.
(Appendix 1)
A transport personnel number calculation program for causing a computer to calculate the number of transport personnel that transport parts.
A classification process for classifying a plurality of processes using parts into one process or a plurality of processes;
A process of calculating the number of transport personnel required to transport the parts for each process classified by the classification process;
A program for calculating the number of transport personnel for causing the computer to execute the above.
(Appendix 2)
A transportation personnel number calculation program for causing a computer to calculate the number of transportation personnel that transport parts for a plurality of processes,
Based on the assembly time of each process and the number of parts used for one product in each process, the first required time required for the transport personnel to go around the transport path for transporting the parts to a plurality of processes Calculating the first ratio of the total quantity of the respective parts used in each of the plurality of steps to the transportable amount of the transport personnel,
In the case of sharing the transportation of parts for the plurality of processes by the transportation personnel corresponding to the minimum integer value equal to or greater than the first ratio, the assembly time and the parts used for one product in each process For each of the transport personnel, based on the quantity, the process of the transport personnel responsible for the second required time required to go around the transport path for transporting the parts to the process responsible for the transport personnel Calculating the second ratio of the total quantity of each part used in each to the carry capacity;
Causing the computer to execute a process of outputting a minimum value of a minimum integer value equal to or greater than the first ratio and a minimum integer value equal to or greater than a total value of the second ratio as a value indicating the number of transport personnel. Transportation personnel number calculation program.
(Appendix 3)
For each process and part, for the quantity used for one product, calculate the ratio of the transport personnel to the transportable amount,
The transfer personnel number calculation program according to appendix 2, which causes the computer to execute a process of determining a process to be handled by each transfer person in charge of the plurality of processes based on the ratio calculated for each process and part.
(Appendix 4)
Supplementary note that causes the computer to execute a process of determining a process in charge of each of the transport personnel when the order of the process is switched based on information stored in the storage unit and indicating a process whose order can be switched. 3. The transport number calculation program according to 3.
(Appendix 5)
Causing the computer to repeat the process of calculating the second ratio by replacing the first ratio by the second ratio calculated in the process of calculating the second ratio;
In the process of outputting, the smallest integer value equal to or larger than the total value of the second ratio calculated last is the second ratio calculated in the process of calculating the second ratio one time before. The transfer personnel number calculation program according to any one of appendices 2 to 4, wherein when the minimum integer value equal to or greater than the total value coincides, the integer value is output as a value indicating the number of transfer personnel.
(Appendix 6)
A transport personnel number calculating device that calculates the number of transport personnel that transport parts for a plurality of processes,
Based on the assembly time of each process and the number of parts used for one product in each process, the first required time required for the transport personnel to go around the transport path for transporting the parts to a plurality of processes A first calculation unit that calculates a first ratio of the total quantity of the parts used in each of the plurality of steps to the transportable amount of the transport personnel,
In the case of sharing the transportation of parts for the plurality of processes by the transportation personnel corresponding to the minimum integer value equal to or greater than the first ratio, the assembly time and the parts used for one product in each process For each of the transport personnel, based on the quantity, the process of the transport personnel responsible for the second required time required to go around the transport path for transporting the parts to the process responsible for the transport personnel A second calculation unit that calculates a second ratio of the total quantity of the respective parts used in each to the load capacity;
A transport unit having a minimum integer value equal to or greater than the first ratio and an output unit that outputs a minimum value among minimum integer values equal to or greater than the total value of the second ratio as a value indicating the number of transport personnel. Number calculation device.
(Appendix 7)
For each of the steps and parts, a third calculation unit that calculates the ratio of the transport personnel to the transportable amount for the quantity used for one product;
The conveyance number calculation device according to appendix 6, further comprising: a determination unit that determines a process to be handled by each conveyance person who shares the plurality of processes based on the ratio calculated for each of the processes and parts.
(Appendix 8)
The assignment determination unit determines a process to be handled by each of the transportation personnel when the order of the process is changed based on information stored in the storage unit and indicating a process whose order can be changed. The transport number calculation device described.
(Appendix 9)
The second calculation unit repeats the process of calculating the second ratio by replacing the first ratio by the calculated second ratio,
The output unit is the sum of the second ratios calculated in the process of calculating the second ratio one time before the smallest integer value equal to or greater than the total value of the second ratios calculated last. The transport number calculation device according to any one of appendices 6 to 8, wherein when the minimum integer value equal to or greater than the value matches, the integer value is output as a value indicating the number of transport personnel.
(Appendix 10)
A method for calculating the number of conveyance personnel in which a computer calculates the number of conveyance personnel that convey parts for a plurality of processes,
Based on the assembly time of each process and the number of parts used for one product in each process, the first required time required for the transport personnel to go around the transport path for transporting the parts to a plurality of processes Calculating the first ratio of the total quantity of the respective parts used in each of the plurality of steps to the transportable amount of the transport personnel,
In the case of sharing the transportation of parts for the plurality of processes by the transportation personnel corresponding to the minimum integer value equal to or greater than the first ratio, the assembly time and the parts used for one product in each process For each of the transport personnel, based on the quantity, the process of the transport personnel responsible for the second required time required to go around the transport path for transporting the parts to the process responsible for the transport personnel Calculating the second ratio of the total quantity of each part used in each to the carry capacity;
The computer executes a process of outputting a minimum value of a minimum integer value equal to or greater than the first ratio and a minimum integer value equal to or greater than the total value of the second ratio as a value indicating the number of transport personnel. Method for calculating the number of transport personnel.
(Appendix 11)
For each process and part, for the quantity used for one product, calculate the ratio to the transportable amount of the carrier,
The method of calculating the number of transporting personnel according to appendix 10, wherein the computer executes a process of determining a process to be handled by each transporting staff responsible for the plurality of processes based on the ratio calculated for each of the processes and parts.
(Appendix 12)
Supplementary note that the computer executes a process of determining a process in charge of each of the transport personnel when the order of the process is changed based on information stored in the storage unit and indicating a process whose order can be changed. 11. A method for calculating the number of transport personnel according to 11.
(Appendix 13)
The computer repeats the process of calculating the second ratio by replacing the first ratio by the second ratio calculated in the process of calculating the second ratio,
In the process of outputting, the smallest integer value equal to or larger than the total value of the second ratio calculated last is the second ratio calculated in the process of calculating the second ratio one time before. The method for calculating the number of transport personnel according to any one of appendices 10 to 12, wherein when the minimum integer value equal to or greater than the total value coincides, the integer value is output as a value indicating the number of transport personnel.

DESCRIPTION OF SYMBOLS 10 Personnel number calculation apparatus 111 Calculation table production | generation part 112 Transport load calculation part 113 Whole circulation time calculation part 114 Initial value calculation part 115 Share determination part 116 Partial rotation time calculation part 117 Number calculation part 118 Process replacement part 119 Number confirmation part DESCRIPTION OF SYMBOLS 120 Output part 131 Process information storage part 132 Parts conveyance information storage part 133 Movement time storage part 100 Drive apparatus 101 Recording medium 102 Auxiliary storage apparatus 103 Memory apparatus 104 CPU
105 interface device 106 display device 107 input device B bus

Claims (7)

A transport personnel number calculation program for causing a computer to calculate the number of transport personnel that transport parts.
A classification process for classifying a plurality of processes using parts into one process or a plurality of processes;
A process of calculating the number of transport personnel required to transport the parts for each process classified by the classification process;
A program for calculating the number of transport personnel for causing the computer to execute the above. A transportation personnel number calculation program for causing a computer to calculate the number of transportation personnel that transport parts for a plurality of processes,
Based on the assembly time of each process and the number of parts used for one product in each process, the first required time required for the transport personnel to go around the transport path for transporting the parts to a plurality of processes Calculating the first ratio of the total quantity of the respective parts used in each of the plurality of steps to the transportable amount of the transport personnel,
In the case of sharing the transportation of parts for the plurality of processes by the transportation personnel corresponding to the minimum integer value equal to or greater than the first ratio, the assembly time and the parts used for one product in each process For each of the transport personnel, based on the quantity, the process of the transport personnel responsible for the second required time required to go around the transport path for transporting the parts to the process responsible for the transport personnel Calculating the second ratio of the total quantity of each part used in each to the carry capacity;
Causing the computer to execute a process of outputting a minimum value of a minimum integer value equal to or greater than the first ratio and a minimum integer value equal to or greater than a total value of the second ratio as a value indicating the number of transport personnel. Transportation personnel number calculation program. For each process and part, for the quantity used for one product, calculate the ratio of the transport personnel to the transportable amount,
The number-of-transportation-members calculation program according to claim 2, which causes the computer to execute a process of determining a process that each transporter who shares the plurality of processes takes charge of based on the ratio calculated for each of the processes and parts.   A request for causing the computer to execute a process of determining a process handled by each of the transport personnel when the order of the process is changed based on information stored in the storage unit and indicating a process whose order can be changed. Item 4. The number-of-conveyance-calculation program according to item 3. Causing the computer to repeat the process of calculating the second ratio by replacing the first ratio by the second ratio calculated in the process of calculating the second ratio;
In the process of outputting, the smallest integer value equal to or larger than the total value of the second ratio calculated last is the second ratio calculated in the process of calculating the second ratio one time before. 5. The program for calculating the number of transport personnel according to any one of claims 2 to 4, wherein the integer value is output as a value indicating the number of transport personnel when the integer value is equal to or smaller than a total integer value. A transport personnel number calculating device that calculates the number of transport personnel that transport parts for a plurality of processes,
Based on the assembly time of each process and the number of parts used for one product in each process, the first required time required for the transport personnel to go around the transport path for transporting the parts to a plurality of processes A first calculation unit that calculates a first ratio of the total quantity of the parts used in each of the plurality of steps to the transportable amount of the transport personnel,
In the case of sharing the transportation of parts for the plurality of processes by the transportation personnel corresponding to the minimum integer value equal to or greater than the first ratio, the assembly time and the parts used for one product in each process For each of the transport personnel, based on the quantity, the process of the transport personnel responsible for the second required time required to go around the transport path for transporting the parts to the process responsible for the transport personnel A second calculation unit that calculates a second ratio of the total quantity of the respective parts used in each to the load capacity;
A transport unit having a minimum integer value equal to or greater than the first ratio and an output unit that outputs a minimum value among minimum integer values equal to or greater than the total value of the second ratio as a value indicating the number of transport personnel. Number calculation device. A method for calculating the number of conveyance personnel in which a computer calculates the number of conveyance personnel that convey parts for a plurality of processes,
Based on the assembly time of each process and the number of parts used for one product in each process, the first required time required for the transport personnel to go around the transport path for transporting the parts to a plurality of processes Calculating the first ratio of the total quantity of the respective parts used in each of the plurality of steps to the transportable amount of the transport personnel,
In the case of sharing the transportation of parts for the plurality of processes by the transportation personnel corresponding to the minimum integer value equal to or greater than the first ratio, the assembly time and the parts used for one product in each process For each of the transport personnel, based on the quantity, the process of the transport personnel responsible for the second required time required to go around the transport path for transporting the parts to the process responsible for the transport personnel Calculating the second ratio of the total quantity of each part used in each to the carry capacity;
The computer executes a process of outputting a minimum value of a minimum integer value equal to or greater than the first ratio and a minimum integer value equal to or greater than the total value of the second ratio as a value indicating the number of transport personnel. Method for calculating the number of transport personnel.

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