JP2014119959A - Progress management system and progress management device - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a progress management system, and a progress management device for efficiently managing progress of a manufacturing line.SOLUTION: A progress management system 10 includes: a finished product input detection part 6; a sign input detection part 8; a progress management device 50; and an alarm presentation part 80. In a manufacturing line 16 including one or more processes, the finished product input detection part 6 detects passage of a finished product to be input from the final process of the line to a finished product storage space 28. A take-up detection part 8 detects take-up of the finished product from the finished product storage space 28. In the progress management device 50, a line management part 60 counts the number N of detected input finished products and the number M of taken up finished products, and determines presence/absence of delay by comparing difference M-N between the number M of taken up finished products and the number N of input finished products with the number of determined delay. The alarm presentation part 80 raises an alarm when it is determined that there is the delay.

Description

  The present invention relates to a production management technique, and more particularly to a progress management system and a progress management apparatus.

Today, with the diversification of consumer needs and remarkable technological innovation, the construction and operation of production systems that can respond to market demands are increasingly important in the manufacturing industry.
One of the production management methods of a system in which the manufacturing process is connected in multiple stages and an inventory store is installed between the processes is a post process take-up method. This is to adjust the manufacturing pace so that the subsequent process takes the required quantity from the finished product store of the previous process when necessary, and the previous process is manufactured according to the subsequent process. It is a method to do.

An information transmission tool called “Kanban” is widely used to monitor the status of the subsequent process. For example, “Kanban” is attached to each product, and when the subsequent process takes the product from the previous process, the “Kanban” attached to the product is returned to the previous process. The returned “kanban” serves as a purchase order, and the previous process starts processing a new product with the receipt of the “kanban” from the subsequent process.
According to the post process take-up method, the number of production can be adjusted autonomously even when there is a wave of demand, and the work-in-process inventory can always be kept below a certain number.

On the other hand, there are cases where the manufacturing is executed in accordance with a production plan established to complete a certain amount of production within a certain period of time, for example, in the case of high-mix low-volume production or short delivery.
In either case, it is important to manage the progress by assigning personnel according to the required manufacturing pace, detecting when a delay occurs, grasping the situation, and implementing measures.

  For example, in Patent Document 1, in a hand-assembled line where multi-skilled workers share work flexibly, performance data relating to work progress is acquired, and among the pieces of performance information included in the work performance data, a predetermined value is obtained. A production management device is described that counts the number of items that do not satisfy the above condition as the number of abnormalities for each process and outputs the counted number of abnormalities.

JP 2007-140625 A

According to the Kanban system, even if there is a wave in demand, the status of taking over from the subsequent process and the status of manufacturing start are visualized by Kanban, so that the production pace can be adjusted as appropriate based on the number of Kanban residences.
Specifically, for example, when a worker in the post process takes the finished product in the previous process, the kanban is removed from the finished product and the kanban is returned to the kanban post in the previous process. On the other hand, the worker at the head of the previous process line takes out the kanban from the kanban post at the start of work for each product.
Workers and managers in the previous process determine whether or not production pace adjustment is necessary by looking at the number of kanbans in the kanban post. And, for example, if the number of kanbans in the kanban post is larger than usual, arrange support workers, or if the number of kanban stays is small, place some workers on other lines or other work Take measures such as

However, for example, in the case of a production line with a small number of required productions per day, since the interval at which the kanban rotates is long, the number of kanbans in the kanban post changes and the production delay is difficult to judge.
For example, in the case of a production line with an average number of kanbans in a kanban post, even if the number of kanbans in the post increases by 1 to 2, for example, does this eventually disappear due to fluctuations caused by the timing of product pick-up or work start? It is difficult to understand whether countermeasures are required due to an increase in demand or work delays.

Furthermore, since a production line with a small number of required productions per day generally has a long tact time, it takes time to recover after taking measures against delays.
For example, even if the number of products is a delay of one to two, depending on the tact time, it may be necessary for one hour or more to recover. In this case, a so-called waiting time is generated in the subsequent process, or overtime occurs without being able to make up within the scheduled work time.

  The present invention has been made in view of these problems, and an object thereof is to provide a progress management system and a progress management apparatus for efficiently managing the progress of a production line.

  In order to solve the above-described problems, a progress management system according to an aspect of the present invention detects a passage of a finished product that is input from a final process of the line to a finished product storage place in a production line including one or more steps. Finished product input detection unit, take-off detection unit that detects the pickup of the finished product from the finished product storage area, and counts the detected number N of finished products and the number M of finished products received, and counts the number M of finished products received and the finished product input A line management unit that determines the presence or absence of a delay by comparing the difference M−N of the number N with a delay determination number, and an alarm presenting unit that issues an alarm when it is determined that there is a delay.

  Another aspect of the present invention is a progress management device. This device acquires information on the passage of the finished product that is input from the final process of the line into the finished product storage area from the finished product input detection unit in a production line including one or more processes, and completes the finished product from the finished product storage area. The work status acquisition unit that acquires the pickup information from the pickup detection unit, the acquired number N of finished product inputs and the number M of finished product pickups are counted, and the difference MN between the number M of finished product pickups and the number N of finished product inputs is calculated. A line management unit that determines whether or not there is a delay compared to the number of delay determinations, and an alarm control unit that controls the alarm presenting unit to issue an alarm when it is determined that there is a delay.

  It should be noted that any combination of the above-described constituent elements and a representation obtained by converting the expression of the present invention between a method, an apparatus, a system, a program, and the like are also effective as an aspect of the present invention.

  According to the present invention, the progress of the production line can be managed efficiently.

It is a figure which shows the structure of the progress management system and manufacturing line concerning embodiment of this invention. It is a flowchart which shows the manufacturing line progress management procedure by a progress management system. It is a flowchart which shows the procedure of the progress monitor process of FIG. It is a flowchart which shows the process progress management procedure by a progress management system.

First, an outline will be described.
The progress management system according to the embodiment of the present invention compares a production rate of a line with a product take-up pace of a subsequent line in a production line that produces products by a flow operation one by one, such as an assembly process. Then, it is determined whether or not there is a delay in the production pace with respect to the demand. If the delay state continues, the operator or progress manager is urged to take measures by, for example, lighting the signal tower in red.

  The progress management system according to the embodiment of the present invention further measures the time from the start of work to the arrival of a check point such as when using a certain part or tool, for each process constituting the production line, and based on the time. The presence or absence of a delay in the process is determined. And if it is delayed, for example, warning the operator and manager by yellow lighting of the signal tower for the process, and if the delayed state continues, for example, the red light of the signal tower for the process Encourage managers to take action.

Details will be described below.
FIG. 1 shows the configuration of a progress management system 10 and a production line 16 according to an embodiment of the present invention.
In the production line 16, the production pace is determined by a post-process take-up method. The process of the production line 16 includes a first process 20, a second process 22, a third process 24, based on a tact time set in accordance with an average product take-up pace in a subsequent process, that is, a subsequent production line or a shipping process. The process is divided into fourth steps 26. The fourth step 26 is the final step of the production line 16. One worker is assigned to each process.

Between the first step 20 and the second step 22, between the second step 22 and the third step 24, and between the third step 24 and the fourth step 26, the first step 20, the second step 22, and the second step 22, respectively. A place (not shown) for a product for which the operations up to the third step 24 have been completed is provided as a buffer.
The production line 16 further includes a finished product place 28 for placing a finished product that has completed all the processes of the production line 16, and a purchase order from a subsequent production line or a shipping process (hereinafter collectively referred to as “subsequent line”). The kanban chute 30 is a kanban storage means that functions as a kanban.

The finished product storage 28 is configured in a first-in first-out manner, and includes a finished product input unit and a finished product take-out unit (not shown).
The kanban chute 30 includes a kanban inlet and a kanban outlet not shown. The kanban chute 30 is loaded with the kanban removed from the finished product when the finished product placed in the finished product yard 28 is picked up by the subsequent line of the production line 16. The kanban chute 30 is configured by, for example, a slope-shaped accommodation unit, and may include a kanban inlet above the slope and a kanban outlet below the slope.

When the worker in the first step 20 completes the assigned work for one product, the worker places the product in the product storage area between the second step 22 and the product. Then, one kanban (not shown) is taken out from the kanban chute 30, one work target product is taken out from a finished product storage place (not shown) in the production line of the previous process of the production line 16, and the taken out kanban is taken as the work target. The work of the first step 20 is started in association with the product.
When the workers in the second step 22, the third step 24, and the fourth step 26 complete the assigned work for one product, they place the product in the product place and the finished product place 28 on the next process side, respectively. One work target product for which the work from the product place on the process side to the previous process has been completed is picked up, and a new work is started.

  In this specification, work-in-progress and semi-finished products in the middle of work are also called “products”. A product that has completed all the processes of a specific production line is also called a “finished product” of the production line. In other words, the “finished product” includes work-in-process products and semi-finished products that are to be further worked on later lines.

  Although the production line 16 including four processes is shown in FIG. 1, the configuration of the production line 16 is not limited to this, and the number of processes according to resources such as machines, tools, workers, and production plans can be increased. Can be divided. The progress management system 10 according to the present invention is applicable to a production line 16 including an arbitrary number of processes.

  The progress management system 10 according to the present embodiment monitors the progress of the production line 16 and determines whether there is a delay. When the progress management device 50 determines that there is a delay, for example, work with light or sound is performed. A warning presenting unit 80 that informs a user such as a manager or a progress manager, and a plurality of detection units that detect the passage of a product or a kanban in order to monitor the progress of the production line 16.

The alarm presenting unit 80 includes a line alarm presenting unit (not shown) that informs the user of the delay of the entire manufacturing line 16 and a process alarm presenting unit (not shown) that informs the user of the delay for each process included in the manufacturing line 16. including. The process alarm presenting unit may be provided in each of all the processes included in the production line 16, and may be provided in each of one or more processes requiring progress management.
Instead, the alarm presentation unit 80 may be configured as one alarm presentation unit for notifying the user of the delay of the entire production line 16 and the delay of the process included in the production line 16.

  The plurality of detection units are a first start detection unit 2a and a second start detection unit that respectively detect the work start of the first step 20, the second step 22, the third step 24, and the fourth step 26 included in the production line 16. 2b, third start detection unit 2c, and fourth start detection unit 2d (hereinafter collectively referred to as “start detection unit 2”), a stage that is a criterion for delay determination in each process (hereinafter referred to as “check point”) The first checkpoint detection unit 4a, the second checkpoint detection unit 4b, the third checkpoint detection unit 4c, and the fourth checkpoint detection unit 4d (hereinafter collectively referred to as the first checkpoint detection unit 4a). (Also referred to as “checkpoint detection unit 4”), the finished product input detecting unit 6 for detecting the input of the finished product to the finished product storage 28, and the kanban shredded from the finished product when the finished product is picked up Including signboard supply detecting section 8 for detecting a sign to be inputted to the bets 30.

  The finished product input detection unit 6 is provided in the vicinity of the finished product input unit of the finished product storage site 28, and an operator of the fourth step 26, which is the final step of the production line 16, finishes the work of the fourth step and completes the finished product. When entering the storage site 28, the passage of the finished product to be input is detected.

The kanban input detection unit 8 is provided in the vicinity of the input port of the kanban chute 30, and detects the passage of the kanban that is removed from the finished product and put into the kanban chute 30 when an operator on the subsequent line picks up the finished product from the finished product storage site 28. Detect. In other words, it can be said that the kanban input detection unit 8 detects the receipt of the finished product from the finished product storage site 28. In this specification, the kanban insertion detector 8 is also referred to as “take-off detector 8”.
In addition, the pick-up detection part 8 may be provided in the finished product taking-out part of the finished product storage place 28 (not shown). In this case, the pick-up detection unit 8 detects the passing of the finished product by detecting the passage of the finished product when the worker on the subsequent line picks up the finished product on the production line 16 from the finished product take-out unit of the finished product storage site 28. Detect.

The start detection unit 2 detects the work start timing of each process included in the production line 16. Specifically, when the worker of the process picks up the next work target product from the previous process, the passage of the work target product is detected.
In this way, by using the sensors that detect passage as the start detection unit 2, the finished product input detection unit 6, and the take-off detection unit 8, an effective progress management system with a simple configuration and low cost can be realized.

  For example, when a work instruction display display such as an assembly procedure is installed at the work place of each process, the start detection unit 2 performs an input operation for instructing display start, such as pressing of a start button or a display tap by an operator, for example. May be detected. Thereby, the structure for the existing work instruction display display can be utilized without providing a separate passage sensor. Accordingly, an effective progress management system can be realized with a simpler configuration and at a lower cost.

The checkpoint detection unit 4 detects that the work of the process has progressed to a checkpoint that is a criterion for delay determination. The check point is, for example, at the start or end of use of a specific part or tool (hereinafter, collectively referred to as “in use”). For example, when the operator opens or closes a drawer, which is a component storage means (not shown), in order to take out a predetermined part from the parts shelf, the checkpoint detection unit 4 These movements are detected when the lid of the parts box is opened / closed or the like when it is taken out or returned from the shelf.
The checkpoint detection unit 4 also moves the tool when the operator picks up a specific tool used at a certain stage of the process or returns the tool to the place, and whether there is a tool at the place. May be detected.

  In this way, it is possible to reliably detect that the manufacturing operation has reached the checkpoint by using the parts accommodating means and tools that are actually used for the manufacturing operation. Further, since the actual operation is detected, it is possible to detect the progress to the checkpoint at a low cost and with a simple configuration such as a transmission sensor or a mechanical mechanism.

Checkpoints are determined based on the work content of the process.
When a plurality of parts are used in a process or when a plurality of tools are used, the last used part or tool used in the process may be set as a checkpoint. Thereby, it is possible to monitor the time required for almost the entire work content of the process.
Checkpoints may also be set when using parts and tools that are used before and after the end of work in which there is a large variation in required time, particularly by workers. As a result, monitoring can be performed only on work points that may become bottlenecks depending on circumstances, and further, the possibility of delay can be detected before the entire work of the process is completed, so that necessary countermeasures can be taken early.

  FIG. 1 shows an example in which the start detection unit 2 and the checkpoint detection unit 4 are provided in all of the first step 20, the second step 22, the third step 24, and the fourth step 26 of the production line 16. The detection unit 2 and the checkpoint detection unit 4 may be provided only in one or more processes included in the production line 16, for example, a process in which progress is particularly desired to be monitored.

  The progress management device 50 includes a work status acquisition unit 52 that acquires information on the progress of work in the production line 16 from the start detection unit 2, the check point detection unit 4, the finished product input detection unit 6, and the kanban input detection unit 8. An input / output unit 54 that accepts input from the user and presents progress information to the user, and initial values of parameters used for progress processing are acquired from the user via the input / output unit 54 or acquired from the storage unit 78 and set. A parameter setting unit 56, a line management unit 60 that manages the progress of the production line 16, a process management unit 70 that manages the progress of one or more of the processes included in the production line 16, An alarm control unit 76 that controls the alarm presenting unit 80 to issue an alarm when it is determined, and a description that stores information related to progress management such as parameter setting values and work results. And a part 78.

  The input / output unit 54 includes an input device (not shown) that acquires an instruction from the user and an output device (not shown) that presents progress information to the user. The input device includes, for example, a keyboard, a pointing device such as a mouse and a trackball, a touch panel, a microphone, and the like, and the output device includes, for example, a display and a speaker.

  The line management unit 60 includes a finished product input counting unit 62 that counts the number of finished product inputs, a finished product take-up counting unit 64 that counts the number of finished product receipts, and a line delay determination that determines whether there is a delay based on these count results. A portion 66 is provided.

In the finished product input counting unit 62, the finished product input detection unit 6 detects the input of the finished product to the finished product storage site 28, and the work status acquisition unit 52 receives the completed product input unit passing information from the finished product input detection unit 6. That is, when the finished product input information is acquired, the finished product input number N (N is an integer of 0 or more) is incremented. The number N of finished products input indicates the number of products that have been manufactured in the manufacturing line 16.
The finished product take-up counting unit 64 detects that the kanban insertion detection unit 8 has passed the kanban insertion port of the kanban chute 30, that is, the receipt of the finished product, and the work status acquisition unit 52 receives the completed product from the kanban insertion detection unit 8. When the receipt information is acquired, the number M of finished product receipts (M is an integer of 0 or more) is incremented.

  The work status acquisition unit 52 may acquire the finished product input information or the finished product collection information when the finished product input detection unit 6 or the kanban input detection unit 8 detects the input of the finished product or the receipt of the finished product. The finished product input information or the finished product collection information may be obtained at a predetermined data acquisition cycle.

  The line delay determination unit 66 calculates the difference M−N between the number M of finished product receipts and the number N of finished product inputs at the progress monitor interval Tr, and compares the delay determination number Pr with the delay determination number Pr. Specifically, the line delay determination unit 66 determines that there is a delay when the difference M−N between the number M of finished product receipts and the number N of finished product inputs exceeds the delay determination number Pr (Pr is an integer of 0 or more).

In this way, by monitoring the difference M-N between the number M of finished product pick-ups and the number N of finished product inputs, it is possible to make a delay judgment only by monitoring the number of kanbans indicating the order in the production line by the post-process take-up method using kanban However, it is possible to automatically determine the delay situation early even on a line with a small number of required production, which has been difficult in the past.
It also detects delays in demand taking into account both external factors such as changes in demand and changes in the manufacturing pace of subsequent lines, and internal factors such as changes in production pace and delays in the manufacturing line. it can.
Therefore, it is possible to reduce overtime and suppress waiting time in the post-process as well as inventory reduction, and efficient production becomes possible.

  If the line delay determining unit 66 determines that there is a delay, the alarm control unit 76 controls the alarm presenting unit 80 to notify the user of the occurrence of the delay. Specifically, for example, the alarm control unit 76 causes the alarm presenting unit 80 to turn on a rotating light or illumination in a color or manner indicating the occurrence of an abnormal situation, to display that a delay has occurred on an electronic bulletin board, or to sound a buzzer. , And announcements. The alarm control unit 76 may also output detailed information regarding the delay from an output device such as a display of the input / output unit 54.

  The line delay determination unit 66 further counts the number of continuous line delays determined continuously with delay and the progress monitoring interval Tr. Specifically, the line delay determination unit 66 increments a variable X (X is an integer of 0 or more) indicating the number of continuous line delays when it is determined that there is a delay, and the line continuous delay number X when it is determined that there is no delay. To the initial value 0.

  When it is determined that there is a delay, when the value of the line continuous delay count X is equal to or smaller than a preset line continuous delay allowable count Sr (Sr is an integer equal to or greater than 0), the line delay determination unit 66 sends a warning to the alarm control unit 76. Deliver information indicating that one level of delay has occurred. The alarm control unit 76 controls the alarm presenting unit 80 to issue an alarm by the first method indicating the occurrence of the first level delay. The first level of delay refers to a delay or potential delay that does not require immediate action. As an alarm in the first method, the alarm presenting unit 80, for example, turns on the rotating lamp in a color or manner that calls attention, such as yellow, or emits a buzzer for a short time.

  On the other hand, when it is determined that there is a delay, if the value of the continuous line delay number X exceeds the allowable continuous line delay number Sr, the line management unit 60 indicates that a second level delay has occurred in the alarm control unit 76. Pass information. The alarm control unit 76 controls the alarm presenting unit 80 to issue an alarm by the second method indicating the occurrence of the second level delay. The second level of delay refers to a level of delay that requires immediate action. As the second type of alarm, the alarm presenting unit 80, for example, turns on a rotating lamp or illumination in a color or manner indicating a warning such as red, or emits a buzzer sound for a long time.

At this time, the alarm control unit 76 may operate the production line 16 to stop the production line 16. For example, the alarm control unit 76 displays a notice of work stoppage on an instruction display installed in front of the worker, sends a work stop announcement from a speaker, or stops the operation of a machine or tool used for the work. May be.
When the work on the production line 16 is stopped by the alarm control unit 76 or by the worker or progress manager, the progress manager takes measures to eliminate the delay. For example, it is specified in which process the delay occurs, and the number of workers is increased, a defective tool is replaced, the work procedure is confirmed, or changed to eliminate the delay. Thereafter, when the person in charge of progress management inputs a restart instruction via the input / output unit 54, for example, pressing a start button, the manufacturing line 16 is restarted and manufacturing is started.

  In this way, by making a determination in two stages, the first level and the second level, the user is notified of the possibility of a subtle delay, and even in a line with a small number of required productions, which has conventionally been difficult to determine the delay. This eliminates the effects of fluctuations in the number of kanbans and can automatically detect delays in demand.

The process management unit 70 measures the required time from the start of work to the arrival of the checkpoint for at least one process to be monitored among the processes included in the line, and the measured required time and allowable work time. A process delay determination unit 74 that compares and determines whether there is a delay in the process is included.
The parameter setting unit 56 may set the monitoring target process by acquiring the selection information of the monitoring target process from the user via the input / output unit 54 at the start of operation of the production line 16, for example. The monitoring target process may be determined by reading the monitoring target process information stored in advance.

The work status acquisition unit 52 further includes a timer for time measurement (not shown). The work status acquisition unit 52 uses the posting timer to acquire the time when the start detection unit 2 detects the start of work and the time when the checkpoint detection unit 4 detects the arrival of the reference stage.
The required time measurement unit 72 measures the elapsed time from the work start time acquired by the work status acquisition unit 52 to the reference stage arrival time.

  The process delay determination unit 74 compares the elapsed time tw from the work start time to the reference stage arrival time (hereinafter also referred to as “actual work time tw”) with a preset allowable work time Ts, and delays the process. The presence or absence of is determined. Specifically, the process delay determination unit 74 determines that there is no delay when the actual work time tw is equal to or less than the allowable work time Ts, and determines that there is a delay when the actual work time tw exceeds the allowable work time Ts.

When the process delay determining unit 74 determines that there is a delay, the alarm control unit 76 controls the alarm presenting unit 80 and issues a warning to the user. Specifically, for example, the alarm control unit 76 causes the alarm presenting unit 80 to turn on a rotating light or illumination in a color or manner indicating the occurrence of an abnormal situation, to display that a delay has occurred on an electronic bulletin board, or to sound a buzzer. Or make announcements. The alarm control unit 76 may also output detailed information regarding the delay from an output device such as a display of the input / output unit 54.
The alarm presentation unit 80 may issue an alarm in such a manner that a process in which a delay occurs can be understood. For example, it is possible to turn on only the alarm presenting section provided for the process in which the delay has occurred, and display the identifier of the process in which the delay has occurred, that is, the name, number, symbol, etc. indicating the process on the electronic bulletin board. May be.

In this way, by monitoring the work results for each process in addition to the delay of the entire production line 16, it is possible to automatically detect the delay status of each process in the production line 16 as well as the delay of the entire production line 16. The cause can be easily identified.
A plurality of check points may be provided in one process. As a result, the cause of the delay can be specified in more detail and automatically, particularly for the process to be monitored.

  The process delay determination unit 74 further counts the number of occurrences of continuous process delay determined continuously with delay for each process. Specifically, the process delay determination unit 74 increments a variable Z (Z is an integer of 0 or more) indicating the number of continuous delay occurrences of the process when determining that there is a delay, and the process delay when determining that there is no delay. The value of the continuous delay occurrence count Z is reset to zero.

  When it is determined that there is a delay, if the value of the continuous delay occurrence number Z of the process is equal to or less than the preset process continuous delay allowable number Qr (Qr is an integer of 0 or more), the process delay determination unit 74 performs alarm control. Information indicating that a first level delay has occurred is passed to the unit 76. The alarm control unit 76 controls the alarm presenting unit 80 to issue an alarm by the first method indicating the first level delay occurrence. As an alarm in the first method, the alarm presenting unit 80, for example, turns on the rotating lamp in a color or manner that calls attention, such as yellow, or emits a buzzer for a short time.

  On the other hand, when it is determined that there is a delay, if the value of the continuous delay occurrence count Z exceeds the process continuous delay allowable count Qr, the process delay determination section 74 indicates that a second level delay has occurred in the alarm control section 76. Pass the information. The alarm control unit 76 controls the alarm presenting unit 80 to issue an alarm using the second method indicating the occurrence of the second level delay. As the second type of alarm, the alarm presenting unit 80, for example, turns on a rotating lamp or illumination in a color or manner indicating a warning such as red, or emits a buzzer sound for a long time.

  In this way, by determining in two stages of the first level and the second level, the user is notified of the possibility of a subtle delay, and for example, when the work is delayed only once for some reason, etc. By eliminating the influence of fluctuations, a delay occurs every time, and a process that needs countermeasures can be automatically detected.

The parameter setting unit 56 sets parameters such as a data acquisition cycle, a progress monitoring interval Tr, a delay determination number Pr, a line continuous delay allowable number Sr, an allowable work time Ts, and a process continuous delay allowable number Qr, for example, before starting the production line. The value may be acquired from the user via the input / output unit 54, or the value set in advance and stored in the storage unit 78 may be read from the storage unit 78 when the production line is started.
The optimum values of the data acquisition cycle, progress monitoring interval Tr, delay judgment number Pr, allowable line continuous delay number Sr, allowable work time Ts, and allowable continuous process delay number Qr are the number of processes and configuration of the production line 16, tact time, Since it depends on the work contents, the required number of stock, etc., it is determined by empirical rules or simulations and experiments.

  In the present embodiment, the example in which the present invention is applied to the production line 16 that determines the product production pace by the post-process take-up method has been described. However, the progress management method by the process management unit 70 includes the first process 20 and the second process. For example, when the step 22, the third step 24, and the fourth step 26 are configured by a belt conveyor, the present invention is also applicable to a push-type production line that sequentially produces from the previous step and sends it to the subsequent step.

The operation according to the above configuration is as follows.
FIG. 2 is a flowchart showing a progress management procedure of the production line 16 by the progress management system 10.
First, when the operation of the production line 16 is started, when the user inputs an operation start instruction via the input / output unit 54 by pressing a start button, for example, the parameter setting unit 56 sets the number N of finished products and the number M of finished products taken. The initial value of the line continuous delay count X is set to 0 (S10).
Subsequently, the parameter setting unit 56 acquires the values of the progress monitoring interval Tr, the delay determination number Pr, and the allowable line continuous delay number Sr from the user via the input / output unit 54, or reads and sets the values from the storage unit 78 (S12). ). From the start of the operation of the production line 16 (S14) to the end of the operation (S22), the work status acquisition unit 52 monitors the work performance of the production line 16 and the status of the subsequent production line in units of progress monitor intervals Tr. (S16).

  FIG. 3 is a flowchart showing the procedure of the progress monitoring process (S16) of FIG. When the pick-up detection unit 8 detects pick-up of the finished product on the production line 16 and the work status acquisition unit 52 acquires the pick-up information of the finished product from the pick-up detection unit 8 (Y in S40), the finished product pick-up counting unit 64 The take-in number M is incremented (S42). When the work status acquisition unit 52 does not acquire the finished product collection information (N in S40), the finished product collection counter 64 does not increment the finished product collection number M.

When the finished product input detection unit 6 detects the input of the finished product to the finished product storage 28 and the work status acquisition unit 52 acquires the finished product input information from the finished product input detection unit 6 (Y in S44), the finished product is input. The counting unit 62 increments the finished product input number N (S46). When the work status acquisition unit 52 does not acquire the finished product input information (N in S44), the finished product input counting unit 62 does not increment the completed product input number N.
The processing from step S40 to step S46 is repeated until the progress monitoring interval Tr elapses (N in S48). When the progress monitoring interval Tr elapses (Y in S48), the progress monitoring process for one unit ends.

Returning to FIG.
The line delay determination unit 66 calculates a difference M−N between the number M of finished product pick-ups and the number N of finished product inputs. If the difference M−N exceeds the delay determination number Pr (N in S18), it is determined that there is a delay. .
In this case, the line delay determination unit 66 further compares the line continuous delay count X with the line continuous delay allowable count Sr (S24). When the line continuous delay number X is equal to or less than the line continuous delay allowable number Sr (Y of S24), the line delay determination unit 66 determines that a first level delay has occurred, and the alarm control unit 76 generates an alarm presenting unit 80. Is controlled and a warning is issued by a first method such as lighting of a yellow rotating lamp (S26). Then, the line delay determination unit 66 increments the line continuous delay count X (S28).

On the other hand, when the line continuous delay number X exceeds the line continuous delay allowable number Sr (N in S24), the line delay determination unit 66 determines that a second level delay has occurred, and the alarm control unit 76 presents an alarm. The unit 80 is controlled to issue an alarm in the second method indicating that the production line 16 should be stopped, such as lighting of a red rotating lamp (S30).
As a result, the production line 16 is stopped (S32), and after appropriate measures are taken (S34), the production line 16 is resumed (S36). The line delay determination unit 66 resets the line continuous delay count X to the initial value 0 (S38).

When the difference M−N between the number M of finished product pick-ups and the number N of finished product inputs is equal to or less than the delay judgment number Pr (Y in S18), the line delay judgment unit 66 judges that there is no delay, and the value of the line continuous delay number X Is reset to the initial value 0 (S20).
Until the production line 16 operation is completed (S22), the line progress monitor and the line delay determination process in steps S16 to S38 are repeated.

FIG. 4 is a flowchart showing a procedure in which the progress management system 10 manages the progress of one process to be monitored among the processes included in the production line 16.
First, when the operation of the production line 16 is started, when the user inputs an operation start instruction via the input / output unit 54 by pressing the start button, for example, the parameter setting unit 56 sets the initial value of the process continuous delay count Z to 0. Set (S50). The parameter setting unit 56 also acquires the value of the process continuous delay allowable number of times Qr from the user via the input / output unit 54, or reads out and sets it from the storage unit 78 (S52).
From the start of operation of the production line 16 (S54) to the end of operation (S66), the work status acquisition unit 52 monitors the work performance of the process to be monitored.

The start detection unit 2 detects the start of manufacturing work of a new product in the process (S56), and the work status acquisition unit 52 counts the manufacturing work start time of the process based on the information obtained from the start detection unit 2. . The checkpoint detection unit 4 detects when the manufacturing operation reaches the checkpoint in the process (S58), and the work status acquisition unit 52 reaches the checkpoint based on the information obtained from the checkpoint detection unit 4. Time is measured.
Note that the start detection unit 2 and the check point detection unit 4 may each include a timekeeping timer, and in this case, the work status acquisition unit 52 receives the manufacturing work start time and the check from the start detection unit 2 and the check point detection unit 4, respectively. Get point arrival time.

The required time measuring unit 72 calculates the actual work time tw from the difference between the checkpoint arrival time and the manufacturing work start time (S60). If the actual work time tw exceeds the allowable work time Ts (N in S62), the process delay determination unit 74 determines that there is a delay.
In this case, the process delay determination unit 74 further compares the process continuous delay count Z with the process continuous delay allowable count Qr (S68). When the process continuous delay count Z is equal to or smaller than the process continuous delay allowable count Qr (Y in S68), the process delay determination unit 74 determines that a first level delay has occurred, and the alarm control unit 76 generates an alarm presentation unit 80. Is controlled and a warning is issued by the first method such as lighting of a yellow rotating lamp (S70). Then, the process delay determination unit 74 increments the process continuous delay count Z (S72).

On the other hand, when the process continuous delay count Z exceeds the process continuous delay allowable count Qr (N in S68), the process delay determination section 74 determines that a second level delay has occurred, and the alarm control section 76 outputs an alarm presentation section. 80 is controlled and a warning is issued in the second method indicating that the production line 16 should be stopped, for example, lighting of a red rotating lamp (S74).
As a result, the production line 16 is stopped (S76), and after appropriate measures are taken (S78), the production line 16 is resumed (S80). Then, the process delay determination unit 74 resets the process continuous delay count Z to the initial value 0 (S82).

When the actual work time tw is less than or equal to the allowable work time Ts (Y in S62), the line delay determination unit 66 determines that there is no delay, and resets the value of the process continuous delay count Z to the initial value 0 (S64).
The process progress monitor and process delay determination process from step S56 to step S82 is repeated until the production line 16 operation ends (S66).
When there are a plurality of monitoring target processes, the same progress monitoring and delay determination processing as those in FIG. 4 are executed for all the monitoring target processes.

  In the above, this invention was demonstrated based on embodiment. The present invention is not limited to the above-described embodiment, and an appropriate combination of the elements of the embodiment is also effective as an embodiment of the present invention. Various modifications such as design changes can be added to the embodiments based on the knowledge of those skilled in the art, and embodiments to which such modifications are added can be included in the scope of the present invention.

For example, in the embodiment, an example in which a passage sensor is used as the start detection unit 2, the check point detection unit 4, and the finished product input detection unit 6 has been described. However, these detection units are not limited to the passage sensor. A sensor capable of reading product identification information or the like from an RF tag or code such as an IC tag attached to each product or Kanban, such as a code reader, may be used. In this case, the work status acquisition unit 52 also acquires the product identifier read by each detection unit, and the process management unit 70 indicates that the product is defective when a delay occurs in a plurality of processes for one product. It is determined that there is a possibility, and the alarm control unit 76 controls the alarm presenting unit 80 to issue an alarm.
As a result, when the work delay is caused by a product defect rather than an operator or a tool, the cause can be automatically identified, and defective product screening can be performed.

  As described above, the present invention relates to production management technology, and is particularly applicable to a progress management system and a progress management apparatus.

  2 Start detection unit, 4 Check point detection unit, 6 Finished product input detection unit, 8 Kanban input detection unit, 10 Progress management system, 16 Production line, 28 Finished product storage, 30 Kanban shoot, 50 Progress management device, 52 Working situation Acquisition unit, 58, 60 line management unit, 70 process management unit, 76 alarm control unit, 80 alarm presentation unit.

Claims (7)

In a production line including one or more processes, a finished product input detection unit that detects the passage of the finished product that is input from the final process of the line to the finished product storage area;
A pick-up detection unit for detecting the pick-up of the finished product from the finished product storage;
Line management that counts the detected number N of finished products and the number M of finished products taken, and compares the difference MN between the number M of finished products received and the number N of finished products input with a delay judgment number to determine whether there is a delay. And
An alarm presentation unit that issues an alarm when it is determined that there is a delay;
A progress management system comprising:   The progress management system according to claim 1, wherein the take-up detection unit is a passage sensor that detects a kanban that is removed from a finished product and is put into a kanban chute.   The progress management system according to claim 1, wherein the take-up detection unit is a passage sensor that detects a finished product taken out from a take-out unit of a finished product storage area. The line management unit counts the number of continuous line delays determined continuously with a delay and at a predetermined time interval,
4. The alarm presenting unit issues a warning in a different manner depending on whether the number of continuous line delays is less than or equal to the allowable number of continuous line delays and when the allowable number of continuous line delays is exceeded. The progress management system according to any one of the above. A start detection unit that detects a timing at which work is started in at least one of the steps included in the line; and
In the one step, a checkpoint detection unit that detects that a manufacturing operation has reached a reference stage used as a measure of delay determination,
A process management unit that determines whether there is a delay in the process by comparing the elapsed time from the start of work in the one process to the arrival of the reference stage and the allowable work time,
The progress management system according to claim 1, further comprising: The process management unit counts the number of process continuous delays continuously determined as having delay in one process,
6. The warning presenting unit according to claim 5, wherein the warning presenting unit issues a warning in a different manner depending on whether the number of continuous process delays is less than or equal to the allowable number of continuous process delays and the allowable number of continuous process delays. The described progress management system. In a production line that includes one or more processes, the passing information of the finished product that is input from the final process of the line to the finished product storage area is obtained from the finished product input detection unit, and the finished product collection information from the finished product storage area is collected. A work status acquisition unit acquired from the detection unit;
Line management that counts the number N of finished product inputs and the number M of finished product pick-ups acquired and compares the difference MN between the number M of finished product receipts and the number N of finished product inputs with the delay judgment number to determine whether there is a delay. And
An alarm control unit that controls the alarm presenting unit to issue an alarm when it is determined that there is a delay;
A progress management device comprising:

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