JP2014089562A - Production control system, and production control method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a production control system which can draft a production plan based on a current state of progress and taking into account restoration planning, in the case that a power cut or the like occurs.SOLUTION: A storage section 62 of a production control server 60 includes: process supplementary information which is review information of a work process in the event of impediment occurrence at a workspace; and facility supplementary information which is information for enabling a facility used in the work process to be in an operable state in the event of the impediment occurrence. A processing section 61 of the production control server 60, when accepting that an impediment such as a power cut has occurred, obtains information from a work result collection server 70, that is received from a tag reader disposed at the work space, and determines whether work is in progress or not on the basis of the obtained information, and when the work is in progress, executes reviewing of the work process related to an instruction 1, on the basis of the process supplementary information and the facility supplementary information.

Description

  The present invention relates to a production management system and a production management method capable of creating a production plan in consideration of a recovery plan based on a current progress situation when a scenario such as a power failure occurs.

  With the recent deterioration of the power supply situation in Japan and overseas, there is an increased risk of planned power outages and large-scale power outages due to insufficient power supply. When a power outage occurs, the production activities in the manufacturing industry are interrupted. Moreover, even if the power outage is restored, it is necessary to investigate the current progress, and the production activities cannot be resumed immediately.

  However, in the manufacturing industry, production within the deadline is forced, so it is necessary to change the production plan to take into account the inactive time due to power outages and put the production activity on track. The current situation depends on it.

  On the other hand, a manufacturing plan drafting device that quickly drafts a manufacturing plan corresponding to a sudden change in the manufacturing site due to disturbance such as equipment failure and eliminates a time zone during which the manufacturing plan cannot be provided is disclosed (for example, Patent Documents) 1). The manufacturing plan planning device searches for similar cases from a case information storage table that holds the situation of previous planning as a case by using the similar case searching unit, and corrects the planning condition by the planning condition correcting unit. Based on the revised planning conditions, a short-term manufacturing plan (first manufacturing plan) is drafted by the first manufacturing plan drafting means, and after the first manufacturing plan drafting, the second manufacturing plan drafting means changes to the first manufacturing plan. A subsequent manufacturing plan (second manufacturing plan) is drawn up. If the re-planning determination unit takes time to formulate the second production plan, the process returns to the first production plan drafting unit, and the production plan is drafted again immediately after the drafted first production plan. After the second manufacturing plan is drafted, the case drafting means holds the presently drafted situation as a case in the case information storage table.

Japanese Patent Laid-Open No. 7-152832

  The manufacturing plan planning apparatus described in Patent Document 1 receives in-process information from a production management system, a manufacturing process management system, or the like, and performs a manufacturing plan. However, the current situation is that a production plan cannot be made unless the production management system and the manufacturing process management system properly obtain in-process information.

  The present invention is an invention for solving the above-described problems, and a production management system capable of drafting a production plan that takes into account a recovery plan based on the current progress when a scenario such as a power failure occurs and The purpose is to provide a production management method.

  In order to achieve the above object, the production management system of the present invention is configured such that a predetermined work for a work object is divided into a plurality of work processes, and the plurality of work processes are performed in respective separate work spaces. The time concerning the work of the worker in the space is an instruction (for example, a document that holds the IC tag (for example, the work specifying IC tag 1T) in which information specifying the content of the predetermined work is written and describes the work process. And a production management server having a processing unit and a storage unit, which is managed using the instruction 1), and a place (as a place where the worker in the work space places the instruction during work) For example, the IC tag of the instruction attached to the box B12a) and placed at the place is detected, the information is read, and the IC tag is newly detected. A tag reader (for example, reader / writer B12b) that transmits information on the IC tag to the work record collection server at the timing when the IC tag is no longer detected, and information from the tag reader is received, and the time related to the work is determined. A work performance collection server to be managed.

  The production management server is used in process supplement information (for example, basic unit / process supplement information 622), which is review information of a work process when an obstruction event occurs in a work space, and in a work process when an obstruction event occurs. A storage unit that stores equipment supplement information (for example, basic unit / equipment supplement information 623) that is information for making the equipment operable, and an input unit that inputs that an inhibition event has occurred When it is accepted that an inhibition event has occurred from the input unit (for example, step S101), the information received from the tag reader is acquired from the work record collection server (for example, step S103), and work is being performed based on the acquired information. (For example, step S106), and when the work is in progress, based on the process supplement information and the equipment supplement information, Performing teeth (e.g., step S108) and having a processing unit.

  According to the present invention, when a scenario such as a power outage occurs, it is possible to devise a production plan that incorporates a recovery plan based on the current progress.

It is a figure which shows the production management system which concerns on embodiment of this invention. It is a figure which shows the structure of a production management server. It is a figure which shows an example of a production plan. It is a figure which shows an example of the data structure of basic unit information, (a) It is basic unit information according to a process, (b) is basic unit and process supplement information, (c) is basic unit and equipment supplement information. is there. It is a figure which shows an example of the data structure of process equipment information. It is a figure which shows an example of the data structure of product process information. It is a figure which shows an example of the data structure of instruction information. It is a figure which shows an example of the data structure of the work performance information at the time of scenario generation. It is a figure which shows the position of the instruction | indication collected from the work performance collection system. It is a flowchart which shows the process of a recovery production planning part. It is a figure which shows an example of a recovery production plan, (a) is the production plan shown in FIG. 3, (b) is a recovery production plan.

Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings.
FIG. 1 is a diagram showing a production management system according to an embodiment of the present invention. The production management system SS includes a work space 10 having a work management terminal B11 and a work management terminal B12, a work space 20 having a work management terminal B21 and a work management terminal B22, and a work having a work management terminal B31 and a work management terminal B32. A space 30, a work space 40 having a work management terminal B 41 and a work management terminal B 42, a production management terminal 50, a production management server 60, a work performance collection server 70, and an administrator terminal 80 are configured. . The work management terminals B11, B12, B21, B22, B31, B32, B41, B42, the production management terminal 50, the production management server 60, the work performance collection server 70, and the administrator terminal 80 are a LAN (Local Area Network) or the like. The network 90 is connected.

  Here, the work related to the work W, which is a work object (also referred to as a product), is divided into four work processes (processes W01 to W04, also simply referred to as “processes”), and the work space 10 to the work space 40, respectively. The case where it carries out by is demonstrated. Note that the number of work steps is not limited to four, but may be any number as long as it is two or more. The work related to the workpiece W is, for example, a production work of a control panel or the like, but may be other work. Also, it is assumed that the workpiece W and the instruction 1 to be paired are carried together.

  The production management terminal 50 is a terminal that issues an instruction 1 when work is required, and registers the work content in the storage unit 62 of the production management server 60. The instruction 1 is an instruction for an operator to perform a production work. The production management terminal 50 includes a processing unit 51, a keyboard 53, a display device 54, an IC tag reader / writer 55, and a printer 56. The processing unit 51 includes an instruction issuing unit 52 that issues an instruction 1. In response to an instruction from the instruction issuing unit 52, the printer 56 having a rewritable function for rewritable the instruction 1 is output. Further, the reader / writer 55 writes information for specifying the work in the work specifying IC tag 1T according to an instruction from the instruction issuing unit 52. The information specifying the work is, for example, an instruction number, a product / semi-product number, and the number of workers. The work identification IC tag 1T uses a non-contact wireless IC tag such as RFID (Radio frequency identification) and is attached to the document of the instruction 1.

  The production management server 60 includes a processing unit 61 and a storage unit 62. The production management server 60 manages the information of the instruction 1 in the storage unit 62 and, when a scenario such as a power failure occurs, a recovery plan based on the current progress status. It is a server that makes a production plan that takes into account. Details will be described later with reference to FIG.

  The work space 10 to the work space 40 are spaces where the workers 17 to 47 perform work for each work process. The work space 10 to the work space 40 may be arranged far away depending on the work content. Here, processing is performed by a processing machine such as cutting and pressing (process W01), welding is performed by a welding machine (process W02), parts are assembled (process W03), and finally, painting is performed by a coating machine (process W04). The flow will be described as an example.

  The work space 10 includes a first stock area 11, a second stock area 12, work management terminals B 11 and B 12, and a display unit 13 that displays information related to work on the work W. The worker 17 is a person who performs work in the work space 10. The first stock area 11 is a place where the work W before work is placed. The work management terminal B11 is installed in the vicinity of the first stock area 11. The second stock area 12 is a place where the work W after work is placed. The work management terminal B12 is installed in the vicinity of the second stock area 12. Specifically, in the process W01 in the work space 10, the work W placed in the first stock area 11 is processed by the processing machine and placed in the second stock area 22.

  The work space 20 includes a first stock area 21, a second stock area 22, work management terminals B 21 and B 22, and a display unit 23 that displays information related to work on the work W. The worker 27 is a person who performs work in the work space 20. The first stock area 21 is a place where the work W before work is placed. The work management terminal B21 is installed in the vicinity of the first stock area 21. The second stock area 22 is a place where the work W after work is placed. The work management terminal B22 is installed in the vicinity of the second stock area 22. Specifically, in the process W02 in the work space 20, the work W placed on the first stock area 21 is welded with a welding machine and then placed on the second stock area 22.

  The work space 30 includes a first stock area 31, a second stock area 32, work management terminals B 31 and B 32, and a display unit 33 that displays information related to the work of the work W. The worker 37 is a person who performs work in the work space 30. The first stock area 31 is a place where the work W before work is placed. The work management terminal B31 is installed in the vicinity of the first stock area 31. The second stock area 32 is a place where the work W after work is placed. The work management terminal B32 is installed in the vicinity of the second stock area 32. Specifically, in the process W03 in the work space 30, the work W placed on the first stock area 31 is assembled and placed on the second stock area 32.

  The work space 40 includes a first stock area 41, a second stock area 42, work management terminals B41 and B42, and a display unit 43 that displays information related to work on the work W. The worker 47 is a person who performs work in the work space 40. The first stock area 41 is a place where the work W before work is placed. The work management terminal B41 is installed in the vicinity of the first stock area 41. The second stock area 42 is a place where the work W after work is placed. The work management terminal B42 is installed in the vicinity of the second stock area 42. Specifically, in the process W04 in the work space 40, the work W placed in the first stock area 41 is painted with a coating machine and placed in the second stock area 42.

  The work management terminal B11 is attached to the side of the box B11a (placement place) having a slot and the box B11a, reads the IC tag (work identification IC tag 1T, worker identification IC tag), and the read information The reader / writer B11b is transmitted to the work result collection server 70.

  The box B11a is a box into which the instruction 1 is inserted. When the reader / writer B11b confirms the communication with the IC tag when the instruction 1 is inserted into the box B11a, the reader / writer B11b reads the information of the IC tag, and the work result collection server 70 reads the communication start information with the IC tag and the work content. And information to identify. The communication start information includes the ID of the work management terminal B11 and the communication start time. The information specifying the work content includes, for example, the ID of the instruction 1, the product number of the product / semi-finished product to be manufactured, and the number. Further, when the reader / writer B11b confirms that the communication with the IC tag is disconnected when the instruction 1 is taken out from the box B11a, the reader / writer B11b specifies the communication end information with the IC tag and the work content to the work result collection server 70. And send information. The communication end information includes the ID of the work management terminal B11 and the communication end time. The information specifying the work content includes, for example, the ID of the instruction 1, the product number of the product / semi-finished product to be manufactured, and the number. Note that a plurality of instructions (a plurality of IC tags) may be placed in the box B11a.

  Similarly, the work management terminal B12 includes a box B12a (placement place) having an insertion slot, a reader / writer B12b attached to the side of the box B12a, reading an IC tag, and transmitting the read information to the work record collection server 70. It has.

  Other work management terminals B21, B22, B31, B32, B41, and B42 have the same configuration as the work management terminal B11.

  Note that the IC tag embedded in the instruction 1 is preferably a battery-mounted type, for example, if it is a battery-unmounted type and obtains power from received radio waves because it is easy to achieve downsizing and cost reduction. There may be. The timing for reading the information of the IC tag by the work management terminals B11, B12, B21, B22, B31, B32, B41, B42 may not be always, but may be every predetermined time (for example, 10 seconds). .

The operations of the workers 17 to 47 will be described using the worker 17 as an example.
Before starting the work, the worker 17 puts an IC tag for worker identification (not shown) into the box B12a of the work management terminal B12. The worker identification IC tag may be attached to the employee ID card. When performing work related to the workpiece W, the worker 17 first takes out the instruction 1 input to the work management terminal B11 and inputs the instruction 1 to the box B12a of the work management terminal B12. Then, the work W placed in the first stock area 11 is installed in the processing machine, and the work on the work W is performed with reference to the instruction on the screen of the display unit 13.

  When the work on the work W is completed, the worker 17 takes out the instruction 1 contained in the box B12a to the work management terminal B12 and places the instruction 1 and the work W on the second stock area 12. When the worker 17 changes with another worker, the worker specifying IC tag contained in the box B12a is taken out to the work management terminal B12, and the worker specifying IC tag of the worker to be replaced is taken as the work management terminal. The box B12a is loaded into B12. Thereby, the worker in the work space 10 can be specified.

  The work result collection server 70 is a server that manages the work time of the issued instruction 1 and analyzes the work time and loss time for each instruction, and includes the production management terminal 50, work management terminals B11, B12, B21, and B22. , B31, B32, B41, B42, and information from the administrator terminal 80 are stored. The work record collection server 70 includes a processing unit 71 and a storage unit 72.

  The work record collection server 70 stores the registration information from the production management terminal 50 in the storage unit 72. The work record collection server 70 also receives information from the work management terminals B11, B12, B21, B22, B31, B32, B41, and B42, that is, information for specifying communication start information and work contents, communication end information, and work contents. Is received in the storage unit 72. The received information is recorded with time information (time stamp) including date. The processing unit 71 of the work record collection server 70 calculates, for example, a work time for each instruction from the information in the storage unit 72 and stores the calculation result in the storage unit 72.

  The administrator terminal 80 visualizes the loss time generated in addition to the standard cost by searching the work result collection server 70 for each work item for the work result of the work process occurring in the manufacturing process. It is a terminal used for analyzing the cause of occurrence of The monitoring items include, for example, a loss time generation process, a loss time generation line, a loss time generation factory, and a loss time generation time zone / period.

  The processing units 51, 61, 71 can be realized by, for example, a CPU (Central Processing Unit). The storage units 62 and 72 can be realized by, for example, a RAM (Random Access Memory) or an HDD (Hard disk drive) device.

  FIG. 2 is a diagram illustrating a configuration of the production management server. The production management server 60 has a processing unit 61 for processing a production plan, a storage unit 62 for storing data when processing a production plan, inputs data, and inputs an operation command (for example, an obstruction event has occurred). An input unit 63 that displays data, a display unit 64 that displays data, and a communication unit 65 that communicates with other servers via the network 90.

  The storage unit 62 is configured by, for example, the above-described RAM or HDD device. As described above, the processing unit 61 is realized by executing a program on the RAM or HDD by the CPU. The input unit 63 is a device for inputting an instruction to a computer such as a keyboard and a mouse, and inputs an instruction for starting a program. The display unit 64 is a display or the like, and displays an execution status or an execution result of processing by the production management server 60. The communication unit 65 exchanges various data and commands with other servers via the network 90.

  The processing unit 61 creates a production plan (hereinafter referred to as a recovery production plan) that takes into account the recovery plan based on the current progress when a scenario such as a power outage occurs. A recovery production planning unit 612, an instruction management unit 613 that manages the instruction 1 based on the production plan, and a recovery instruction management unit 614 that manages the instruction 1 based on the recovery production plan are included.

  The storage unit 62 includes basic unit information 621 (see FIG. 4A) for managing standard time, lead time, etc. (hereinafter referred to as basic units) of work processes based on the production plan, and supplementary information on basic units. Basic unit / process supplement information 622 (see FIG. 4B) for each scenario when the scenario occurs, supplementary information for the basic unit, and basic unit / equipment supplement information 623 for each scenario when the scenario occurs (See FIG. 4 (c)), process contents for each process, process equipment information 624 (see FIG. 5) which is information on the equipment used, and product process information 625 (product process information necessary for producing a product) 6), instruction information 626 (see FIG. 7) which is product instruction information, work result information 627 (see FIG. 8) which is work information acquired from the work result collection server 70 when a scenario occurs, and a product Equipment in production Production plan information 628 (see FIGS. 3 and 11A), which is information of a production plan that takes into account, and recovery production plan information 629 (FIG. 11B), which is information of a recovery production plan when a scenario occurs. Etc.) are stored. Details of each information will be described later with reference to FIGS. 3 to 8 and FIG.

Next, each main information will be described with reference to FIGS.
FIG. 3 is a diagram illustrating an example of a production plan. The production plan information 628 includes each process for each product and is managed in time series. In the present embodiment, description will be made using the production process of the production management system SS shown in FIG. For example, the product X is managed in the order of a processing process, a welding process, an assembly process, and a painting process. The machining process, the welding process, the assembly process, and the painting process correspond to the processes W01, W02, W03, and W04 shown in FIG. The product Y is started as soon as the work in the machining process of the product X is completed, and is similarly managed in the order of the machining process, the welding process, the assembly process, and the painting process.

  FIG. 4 is a diagram showing an example of the data structure of the basic unit information. (A) Basic unit information for each process, (b) is basic unit / process supplement information, and (c) is a basic unit information. It is equipment supplement information. The basic unit information 621 shown in FIG. 4A includes a standard time ST, a lead time LT, a real lead time ratio (real LT ratio), and the like. The production plan shown in FIG. 3 is created in consideration of the lead time LT that has been a record in the past.

  Note that the work process lead time LT can be basically represented by the addition of the stagnation time, the work time, and the travel time. The real lead time ratio (real LT ratio) is calculated by the calculation of (working time / lead time) × 100 (%). Each time will be described later with reference to FIG.

  The basic unit / process supplement information 622 shown in FIG. 4B includes a scenario, a process when a scenario occurs, a recovery process, a process start where the process starts, an additional process, and the like. The basic unit / process supplement information 622 holds in advance how to perform a recovery operation when a scenario such as a power failure occurs. For example, the scenario includes a long power failure (long stop), an instantaneous power failure, and a planned power failure.

In addition, as a recovery response when a power failure occurs, for example,
・ Machining (punch, bending, etc.): Only the relevant process is reworked.
-Welding process: After repair work, restart from the middle of the process.
-Assembly process (such as housing assembly): Restart from the middle of the process.
・ Painting process (plating, painting): Scrap and start over.
There is.

  If the example shown in FIG.4 (b) is demonstrated concretely, in the case of a processing process by long-time power failure (long stop), it turns out that a recovery process is a processing process and sets a process from the beginning of a processing process. Moreover, in the case of a welding process with a long-time power outage (long stop), it can be seen that the restoration process is a welding process and the repair process is set in the middle of the welding process.

  The basic unit / equipment supplement information 623 shown in FIG. 4C includes a scenario, equipment, restoration response, time required for restoration, and the like. If the example shown in FIG.4 (c) is demonstrated concretely, in the case of an instantaneous power failure (instantaneous power failure), it turns out that a coating machine continues without responding to special restoration. Moreover, in the case of a long-time power outage (long stop), it can be seen that the coating machine needs an idling operation and requires a recovery time of 6 hours.

  That is, the basic unit / process supplement information 622 of the present embodiment starts from the beginning of a work process when an obstruction event occurs, a work process that becomes a target when the work is restored, and the work process that becomes the target. Or information including whether to start from the middle. Further, the basic unit / equipment supplement information 623 of the present embodiment includes information including equipment used in the work process, a coping method when the equipment is restored, and a time required for the coping method. .

  FIG. 5 is a diagram illustrating an example of a data structure of process facility information. The process facility information 624 includes a process ID, process contents, facilities, and the like. Specifically, when the process ID is W01, it is a machining process and a cutting machine is used. Moreover, when process ID is W02, it is a welding process and a welding machine is used.

  FIG. 6 is a diagram illustrating an example of a data structure of product process information. The product process information 625 includes products, necessary processes (process 01, process 02, process 03, process 04,...) And the like. Specifically, the product X is configured in the order of a process W01, a process W02, a process W03, and a process W04. The product Q is configured in the order of the process W05, the process W06, and the process W07. That is, referring to the process facility information 624 in FIG. 5, the product X is configured in the order of the machining process, the welding process, the assembly process, and the painting process, and the product Q includes the assembly process, the assembly process, and the brazing process. You can see that it is composed.

  FIG. 7 is a diagram illustrating an example of the data structure of the instruction information. The instruction information 626 includes an instruction ID, product, model number, product content, number of persons, work start date, work end date, and the like. Specifically, when the instruction ID is A01, the product X is a control panel with the model number X01, the number is 2, and the work is scheduled to start on October 12, 20XX, and will be finished within that day. I understand that.

  FIG. 8 is a diagram illustrating an example of a data structure of work performance information when a scenario occurs. This will be described with reference to FIG. The work result information 627 includes an instruction ID, an instruction input time to the box B11a of the work management terminal B11, an instruction extraction time (instruction extraction time) from the box B11a of the work management terminal B11, and an operation management terminal B12 to the box B12a. The order entry time, the instruction take-out time from the box B12a of the work management terminal B12, the process ID, the worker ID, and the like are included.

  Specifically, from the work result collection result with the instruction ID A01, the dispatcher carries the work W into the first stock area 11 of the work space 10 (process ID is W01) and puts it into the box B11a of the work management terminal B11. Instruction 1 with instruction ID A01 is input at 9:00 on October 12, 20XX. When worker 17 (worker ID is MM1) starts work, he retrieves instruction 1 from box B11a of work management terminal B11 at 9:15 on October 12, 20XX. It can be seen that the instruction 1 is put into the box B12a of the work management terminal B12 and the instruction 1 is taken out at 9:40 on October 12, 20XX. The work record information 627 shown in FIG. 8 is an example, and details will be described with reference to FIG.

  FIG. 9 is a diagram showing the positions of the instructions collected from the work performance collection system. FIG. 9 is a time chart showing the position of each instruction and the determination result based on the production plan information 628 shown in FIG. The time chart shown in FIG. 9 shows the positions (in the work management terminal B11) of the instruction A01 corresponding to the product X, the instruction A02 corresponding to the product Y, the instruction A03 corresponding to the product Z, and the instruction A04 corresponding to the product P. Box B11a etc.) and the determination results of each time (such as the stagnation time in process W01).

  If this is seen, regarding the work W related to the work according to the instruction A01, the work result collection server 70 can surely understand which work process (W01, etc.) and what state (stagnation, processing or movement) has occurred. I understand that.

  For example, in the case of the instruction A01, the time at the work management terminal B11 is set as the stagnation time, the time at the work management terminal B12 is set as the work time, and the elapsed time from the work management terminal B11 to the work management terminal B21 is grasped as the travel time. be able to.

  Further, by determining the position of the instruction when a scenario occurs (when an event is input), it is possible to determine whether it is necessary to redo the work for each scenario. In the case of the event input example indicated by the solid line arrows shown in FIG. 9, the order A01 is in the middle of work, and the order A02 is also in the middle of work. As a result, when it is determined that the work is in progress, it is necessary to make a recovery work plan based on FIGS. 4B and 4C. Details will be described with reference to FIG.

  FIG. 10 is a flowchart showing the processing of the recovery production planning unit. This will be described with reference to FIGS. 1 and 2 as appropriate. When the recovery production planning unit 612 receives an event from the administrator terminal 80 (step S101), the recovery production planning unit 612 acquires a production plan from the production plan information 628 (step S102). An event means notifying the production management server 60 that a power failure has occurred. The event may be notified by the administrator that a power failure has occurred, or the production management server 60 may detect and determine that a power failure has occurred. That is, the production management server 60 and the work record collection server 70 are usually equipped with a UPS (Uninterruptible Power Supply) for data protection, but a power failure occurs at the production site due to the use of the UPS. Can be detected. Note that the work management terminal B11 and the like have a large number of devices, so a UPS or the like is not always provided.

  The recovery production planning unit 612 obtains work performance information 627 when an event is input by inquiring of the work performance collection server 70 (step S103), and acquires basic unit / process supplement information 622, basic unit / equipment supplement information 623. The basic unit supplement information is acquired from (step S104).

  The recovery production planning unit 612 performs the processing from step S106 to step S108 for each instruction (step S105). In step S106, the recovery production planning unit 612 determines whether or not the target process when the event is input is a work time. Whether or not it is a work time is determined by whether or not the instruction is located at the work management terminals B12, B22, B32, and B42. When the target process is working time (step S106, Yes), the recovery production planning unit 612 determines whether or not there is a long-time power failure (step S107), and in the case of a long-time power failure (step S107, Yes), FIG. (B) Based on the scenario shown in FIG. 4C, the process order is reset or the target process is adjusted (step S108), and the process proceeds to step S109.

  On the other hand, in step S106, when the target process is not the working time (step S106, No), the process proceeds to step S109. In Step S107, when it is not a power failure for a long time (Step S107, No), it progresses to Step S109.

  Note that in step S106, the processing unit 61 determines the time related to the work from the time when the work identifying IC tag 1T is newly detected by the tag reader (for example, the reader / writer B12b) to the time when the tag reader is no longer detected. The time is assumed to be the work time in the work space, and it can be determined that the work is in progress when an obstruction event (for example, a power failure) occurs during the work time.

  Moreover, in step S101, the production management server 60 has an uninterruptible device that supplies power when a power failure occurs, and when a power supply is received from the uninterruptible device, an obstruction event has occurred. Can be determined.

  Finally, the recovery production planning unit 612 prepares a recovery production plan by adjusting the work process of each instruction (step S110). An example of the recovery production plan will be described with reference to FIG.

  FIG. 11 is a diagram illustrating an example of the recovery production plan, where (a) is the production plan shown in FIG. 3 and (b) is the recovery production plan. FIG. 11A is the production plan information 628 shown in FIG. When the event input is at 13:30 shown in FIG. 9 (see solid line arrow), it is understood that the instruction A01 is at the position of the work management terminal B42 and is within the work time. Similarly, it can be seen that the instruction A02 is at the position of the work management terminal B32, the instruction A03 is at the position of the work management terminal B22, and the instruction A04 is at the position of the work management terminal B12, and each is within the work time. Accordingly, it is necessary to review the work process of the products X, Y, Z, and P corresponding to the instructions A01 to A04.

  FIG. 11B is an example of the recovery production plan information 629 of the recovery production plan. Product X is in the process of painting (within work hours) when an event is input (when a power failure occurs), and there is a power outage for a long time, so the basic unit / process supplement information 622 in FIG. Based on this, after the restoration, it will be redone from the beginning of the machining process. Further, the coating machine is required to idle for 6 hours based on the basic unit / equipment supplement information 623 in FIG. Product Y is being assembled for a long time when an event is input (when a power failure occurs), but the work starts from the middle of the assembly process based on the basic unit / process supplement information 622 in FIG. 4B. be able to. Product Z is in the welding process at the time of event input (when a power failure occurs) and has been out for a long time. Therefore, based on the basic unit / process supplement information 622 in FIG. To start from the middle of the welding process. Since the product P is in the machining process at the time of event input (when a power failure occurs) and has a power outage for a long time, the machining process starts from the beginning based on the basic unit / process supplement information 622 in FIG. .

  The processing process for the product P is set after the processing process for the product X is completed. In addition, the painting process is performed on the product Y after the idling of the coating machine is completed, and the recovery production process is performed in the order of the product X, the product Z, and the product P.

  In the present embodiment, since the work performance collection server 70 grasps the position of the instruction in detail, the production management server 60 can appropriately determine whether or not the work is actually performed in a predetermined process. it can. For example, in FIG. 9, if the event is input at 12:30 (see the broken line arrow), the instruction A01 is in the moving time, the instruction A02 is in the stagnation time of the work management terminal B31, and the instruction A03 is The position of the work management terminal B21 is in the stagnation time, and the instruction A04 is in the stagnation time of the position of the work management terminal B11. In this case, it can be determined that it is not necessary to review the production plan.

  In the present embodiment, for example, two work management terminals B11 and B12 are arranged in the work space 10, but the present invention is not limited to this. Only the work management terminal 12 may be installed in the work space 10. In this case, the work process lead time LT can basically indicate other times including work time, stagnation time and travel time. The real lead time ratio (real LT ratio) is calculated by the calculation of (work time / (work time + other time)) × 100 (%).

  In this embodiment, in addition to basic unit information such as ST / LT for processes and facilities in production activities, for example, behavior such as restoration work when a scenario such as a power failure occurs (such as whether there is a return to work or equipment startup time) The basic unit supplementary information representing is stored in advance. When a scenario occurs, the work process and facility information at the time of scenario occurrence can be collected from the work record collection server 70. Then, it is possible to make a recovery production plan that takes into account the production activity status at the time of the scenario from the generated scenario (for example, power failure) and the collected work process, facility information, and basic unit supplemental information. This makes it possible to formulate a production plan that is close to the actual recovery activity in the event of a facility outage due to a power failure or the like, thereby reducing production loss costs due to rework or the like.

1 Instruction 1T Work Identification IC Tag 10, 20, 30, 40 Work Space 50 Production Management Terminal 60 Production Management Server 61 Processing Unit 62 Storage Unit 63 Input Unit 70 Work Result Collection Server 71 Processing Unit 72 Storage Unit 80 Administrator Terminal 90 Network 611 Production Planning Department 612 Recovery Production Planning Department 613 Instruction Management Department 614 Recovery Instruction Management Department 621 Basic Unit Information 622 Basic Unit / Process Supplement Information (Process Supplement Information)
623 Basic unit / Facility supplement information (Facility supplement information)
624 Process facility information 625 Product process information 626 Instruction information 627 Work performance information 628 Production plan information 629 Restoration production plan information B11, B12, B21, B22, B31, B32, B41, B42 Work management terminal B12a Box (place)
B12b Reader / Writer (Tag Reader)
SS Production management system W Work object

Claims (9)

The predetermined work on the work object is divided into a plurality of work processes, and the plurality of work processes are performed in the respective separate work spaces, and the time related to the work of the worker in the work spaces is set as the predetermined work. A production management server that holds an IC tag in which information for specifying the contents is written and manages it using an instruction that is a document describing the work process;
It is installed in the work space, and is attached to a place defined as a place where the worker in the work space places the instruction during work. An IC tag of the instruction placed in the place is detected and detected. A tag reader that reads information and transmits information on the IC tag to the work performance collection server at a timing when the IC tag is newly detected and when the IC tag is no longer detected;
A work record collection server that receives information from the tag reader and manages time related to the work;
The production management server is:
In order to make the process supplemental information that is the review information of the work process when the obstruction event occurs in the work space and the equipment used in the work process when the obstruction event occurs into an operable state A storage unit for storing equipment supplement information, which is information of
An input unit for inputting that the inhibition event has occurred;
If it is accepted from the input unit that an obstruction event has occurred, the production management server obtains information received from the tag reader from the work record collection server, and whether or not work is being performed based on the obtained information And a processing unit for reviewing the work process related to the instruction based on the process supplement information and the equipment supplement information when the work is in progress. The process supplement information includes a work process when the inhibition event occurs, a work process that is a target when the work is restored, and whether to start from the beginning or midway of the target work process. The production management system according to claim 1, wherein the production management system is information. The equipment supplement information is information including equipment used in the work process, a coping method when the equipment is restored, and a time required for the coping method. production management system. When the processing unit determines that the work is in progress,
As the time related to the work, the time from the time when the IC tag is newly detected by the tag reader to the time when the tag reader is no longer detected is the work time in the work space.
The production management system according to claim 1, wherein when the inhibition event occurs during the work time, it is determined that the work is in progress. The production management system according to claim 1, wherein the inhibition event is a power failure. The production management server has an uninterruptible device that supplies power when the power failure occurs, and determines that the inhibition event has occurred when receiving power supply from the uninterruptible device. 6. The production management system according to claim 5, wherein The predetermined work on the work object is divided into a plurality of work processes, and the plurality of work processes are performed in the respective separate work spaces, and the time related to the work of the worker in the work spaces is set as the predetermined work. A production management server having a processing unit and a storage unit, which holds an IC tag in which information for specifying contents is written and manages using an instruction which is a document described about the work process;
It is installed in the work space, and is attached to a place defined as a place where the worker in the work space places the instruction during work. An IC tag of the instruction placed in the place is detected and detected. A tag reader that reads information and transmits information on the IC tag to the work performance collection server at a timing when the IC tag is newly detected and when the IC tag is no longer detected;
A work record collection server that receives information from the tag reader and manages time related to the work;
In the storage unit, operation supplementary information that is review information of the work process when an obstruction event occurs in the work space and equipment used in the work process when the obstruction event occurs are operated. It has equipment supplement information that is information to make it possible,
When the processing unit accepts that the inhibition event has occurred, the processing unit obtains information received from the tag reader from the work performance collection server, and determines whether the work is in progress based on the obtained information. When the work is in progress, the work management process relating to the instruction is reviewed based on the process supplement information and the equipment supplement information. The process supplement information includes a work process when the inhibition event occurs, a work process that is a target when the work is restored, and whether to start from the beginning or midway of the target work process. It is information. The production management method of Claim 7 characterized by the above-mentioned. The equipment supplement information is information including equipment used in the work process, a coping method when the equipment is restored, and a time required for the coping method. Production management method.

Images