JP2015099429A - Production management method and production management device - Google Patents

Abstract

PROBLEM TO BE SOLVED: To prevent that a steady operator comes into a waiting state, and aid of an aid person is frequently required, in an assembly line where a tablet is used.SOLUTION: When tablets are stayed exceeding a predetermined number during assembly work of a steady operator, aid is requested to an aid person. A product whose cycle time is the closest to an aid object cycle time is selected as an aid object product to be assembled by the aid. The aid object cycle time is calculated by adding a weighted average of cycle times calculated from cycle times and production frequencies of a plurality of kinds of products to be planed to be assembled and a delay time. The aid object product is displayed at the top of an order table 31 of a display 14. The aid person assembles the aid object product displayed on the order table 31.

Description

  The present invention relates to a production management method and a production management apparatus.

  In the product assembly line, there are a case where a plurality of workers handle one type of product for each process, and a case where one worker assembles a plurality of types of products. In these assembly lines, when work delay occurs, it is devised so that the production plan is not hindered by support from a supporter.

  For example, when a single type of product is manufactured by a plurality of workers in charge of each process, a conventional method for supporting the work by the supporter is, for example, calculating a work delay time and performing future cumulative work. A process whose delay time is equal to or longer than the reference time is specified from a plurality of processes. Then, the identified process is set as a process requiring support. The supporter immediately rushes to the process that needs support and provides support.

  In the case of a mixed flow line in which one worker assembles a plurality of types of products, the supporter assembles the product to be assembled next, thereby eliminating the work delay. Here, in the mixed flow line, the maximum work in progress may be regulated using a tablet. For example, a certain amount of tablets are stored in a shooter, and when a product is assembled, a regular worker takes one tablet from the shooter and assembles the top product in the sequence table. The order table summarizes the order of products to be assembled in a list format in advance, and the order table displays product information repeatedly in a pattern determined according to the manufacturing ratio in order to level the load on the operator. The product assembled on the line is pulled out from the lane behind the line at a predetermined tact time, at which time the tablet is returned to the shooter. The tact time is calculated, for example, by dividing the operation time of the production line by the number of products assembled in one day. The weighted average of the actual cycle time is set longer than the tact time. Here, when the number of tablets accumulated in the shooter exceeds a predetermined number, the supporter enters support. The cheerer takes one tablet from the shooter and assembles the top product on the order table on the cheering line. The supporter supports the regular worker until the number of tablets accumulated in the shooter falls below the set number.

JP 2010-1228819 A

However, in an assembly line using a tablet, if a cheerer works too much, a regular worker may be in a waiting state. In addition, in this type of assembly line, it is preferable that the number of calls to the supporter is small, but when the supporter is requested to perform a work with a small load despite the long delay time, You will have to enter into support three times. As described above, in an assembly line using a conventional tablet, it is easy for a regular worker to enter a waiting state or to frequently ask for support from a supporter.
This invention is made | formed in view of such a situation, and it aims at supporting a stationary worker efficiently as one viewpoint.

  According to one aspect of the embodiment, a work delay time in a production line that manufactures a plurality of types of products is detected, and a support time is calculated by adding the delay time to a weighted average of the cycle times of the plurality of products. The product having a cycle time corresponding to the support time is selected by comparing the support time and the cycle time of the product, and the information of the selected product is output so that the supporter can view it. A production management method is provided.

  According to another aspect of the embodiment, a detection unit that detects a work delay time in a production line that manufactures a plurality of types of products, and a weighted average of cycle times of the plurality of products are added to the delay time. A time calculation unit that calculates a support time, a selection unit that selects the product having a cycle time corresponding to the support time by comparing the support time and the cycle time of the product, and the selected product There is provided a production management device including a support content management unit that creates data for requesting a supporter to manufacture.

  With one support, the time delay can be brought close to zero to reduce the number of support and prevent waiting for a regular worker.

FIG. 1 is a diagram showing an example of a schematic configuration of a production management system according to an embodiment of the present invention. FIG. 2 is a diagram showing an example of a sequence table of the production management system according to the embodiment of the present invention. FIG. 3 is a diagram showing an example of a cycle time database of the production management system according to the embodiment of the present invention. FIG. 4A is a flowchart showing an example of processing of the production management system according to the embodiment of the present invention. FIG. 4B is a flowchart showing an example of processing of the production management system according to the embodiment of the present invention. FIG. 5 is a diagram illustrating an example of a state where a cheerer takes out one tablet from the shooter in the production management system according to the embodiment of the present invention. FIG. 6 is a diagram showing an example of an order table in which a support target product is displayed at the top in the production management system according to the embodiment of the present invention. FIG. 7 is a production management system according to an embodiment of the present invention, in which (a) shows an example of a change in progress accompanying support of the embodiment, and (b) and (c) are accompanied by support of a comparative example. It is a figure which shows an example of the change of a progress condition.

The objects and advantages of the invention will be realized and attained by means of the elements and combinations particularly pointed out in the appended claims.
The foregoing general description and the following detailed description are exemplary and explanatory only and are not intended to limit the invention.

FIG. 1 shows a schematic configuration of an assembly factory including a production management system.
The assembly factory 1 has a production line 2 on which a regular worker works and a support line 3 that is a production line on which a supporter works. The assembly factory 1 is provided with a shooter 5 for storing a tablet 4 as a work amount control member. In the shooter 5, a container capable of accommodating a plurality of tablets 4 is disposed so as to be inclined. On one end side of each line 2, 3, a parts shelf 7 in which parts used for product assembly are stored is arranged. At the other end of each of the lines 2 and 3, finished product lanes 2A and 3A for temporarily placing the finished product and the tablet 4 are provided. The finished product is collected every predetermined time based on the production plan table 6.

  Here, this embodiment can be used for, for example, a production method (post-process production) in which the previous process starts production in accordance with the post-process, and the tablet 4 regulates the maximum work-in-process amount in the production line 2. Used to do. That is, in the production line 2, products can be assembled by the number of tablets 4. Further, in the production line 2, as many as the number of tablets 4 can be assembled at a time, regardless of the planning instruction. In addition, this embodiment can also be used in an assembly factory that regulates the maximum in-process amount using means other than the tablet 4.

  The assembly factory 1 is provided with a production management device 10 that controls assembly operations. The production management device 10 includes a processing device 11 that performs various data processing. The processing device 11 includes a detection unit 12 (delay detection unit 17) that detects the staying amount of the tablet 4 in the shooter 5, and an input unit that is operated when a regular worker or a supporter takes the tablet 4 from the shooter 5. 13 (delay detection unit 17). Moreover, the production management apparatus 10 includes a display unit 14 (output unit) that outputs a sequence table 31 that displays products to be assembled so that a regular worker or a supporter can check. As an output unit, instead of the display unit 14 or in addition to the display unit 14, a device that transmits the contents of the order table 31 to a regular worker or a supporter by voice may be provided. Furthermore, the production management apparatus 10 includes a notification unit 15 that notifies a supporter of a support request. The display unit 14 and the notification unit 15 are connected to the processing device 11.

  The processing device 11 includes, for example, a computer that can execute a predetermined process by executing a management program. When the processing device 11 is a computer, the processing device 11 includes a CPU (Central Processing Unit), a storage device such as a RAM (Random Access Memory) and an HDD (Hard Disk Drive), a data input device such as a mouse and a keyboard, and the like. It is comprised including. The processing device 11 includes a time calculation unit 21, a selection unit 22, a support content management unit 23, and a data processing unit as characteristic components for managing a regular worker's work and a supporter's work. The function can be divided into 24. Further, the processing device 11 includes a storage device 25, and the storage device 25 stores an order table 31 and a cycle time database 32 for each product.

  Here, the time calculation unit 21 calculates the support time necessary for eliminating the work delay. The selection unit 22 selects a product manufactured by the supporter, that is, a product to be supported. The support content management unit 23 notifies the supporter of the content requested for support when support is required. The data processing unit 24 creates an order table 31 and a cycle time database 32.

  Moreover, the order table 31 is data created in order to notify a regular worker or a supporter of the manufacturing order of a plurality of products. Specifically, the order table 31 is a list in which drawing numbers indicating product types are arranged. In the example of FIG. 2, they are arranged in the order of BAAADAACAABA. Each of A, B, C, and D corresponds to a figure number that identifies one type of product, and one alphabet is assigned to each product. In this case, the product specified by the drawing number B arranged at the top of the list is manufactured first, and thereafter the products are manufactured in the order of A → A → A → D →. Moreover, AAADAACAAB is set as one set, and this is repeated a plurality of times. The order table 31 only needs to display information for specifying the product to be assembled, and numbers and specific names can be used. In addition, only information on a product to be assembled next may be displayed on the display unit 14.

  As illustrated in FIG. 3, the cycle time database 32 has a configuration in which drawing number information 35, cycle time information 36, and manufacturing frequency information 37 are associated with each other. For example, the data in the first row shows that the cycle time of the product of figure number A is 5 minutes, and the frequency with which this product is manufactured on the manufacturing line is 70%. The cycle time database 32 can be updated every day or every predetermined time according to the production plan. When updating the contents of the cycle time database 32, it is input from a data input device (not shown) of the processing device 11. Further, new data may be transmitted from the production plan table 6.

  As shown in FIG. 1, the detection unit 12 is configured to output a signal when the number of tablets 4 stored in the shooter 5 exceeds a set number. As an example of such a detection unit 12, it is possible to arrange the light emitting element 41 and the light receiving element 42 one by one with the shooter 5 interposed therebetween. The two elements 41 and 42 are arranged at positions where the optical path is blocked by the tablet 4 when the tablet 4 is present at a position exceeding the delay reference line L1 set on the shooter 5. For example, when the time during which the light receiving element 42 cannot receive the light from the light emitting element 41 continues for a predetermined time, the detecting unit 12 has the tablet 4 in that region, that is, the tablet 4 stays beyond the delay reference line L1. If so, a signal to that effect is output. For example, the signal is at a low level when the tablet does not exceed the delay reference line L1, and rises to a high level when the tablet exists beyond the delay reference line. Another example of the detection unit 12 is an imaging device. The imaging device acquires an image of the shooter 5, and the processing device 11 checks the presence or absence of the tablet 4 that exceeds the delay reference line L1 by image processing.

For the input unit 13, for example, a switch pressed by a regular worker or a supporter who takes one tablet 4 from the shooter 5 is used.
Examples of the notification unit 15 include a lamp that lights when a support request is made, and a speaker. Moreover, you may comprise so that the data which ask for support may be transmitted to the portable terminal which a supporter owns.

Next, a method for assembling a product using the production management apparatus 10 will be described mainly with reference to the flowcharts of FIGS. 4A and 4B.
First, in step S101, the data processing unit 24 of the processing device 11 checks whether or not there is a tablet 4 that exceeds the delay reference line L1. Specifically, the data processing unit 24 acquires a signal from the detection unit 12. For example, when a signal indicating that the delay reference line L1 is not exceeded is output from the detection unit 12, the data processing unit 24 determines in step S102 that there is no tablet 4 that exceeds the delay reference line L1, and step Return to S101. While step S101 to step S102 are repeated, the regular worker assembles the product as planned. That is, the regular worker takes out the tablets 4 from the shooter 5 one by one, assembles the products one by one according to the order table 31, and carries them to the finished product lane 2A.

  On the other hand, when a signal indicating that the delay reference line L1 has been exceeded is output from the detection unit 12, it is determined in step S102 that there is a tablet 4 that exceeds the delay reference line L1, and the process proceeds to step S103. In step S103, the time calculation unit 21 of the processing device 11 starts counting the delay time. In subsequent step S104, the support content management unit 23 of the processing device 11 outputs a support request signal to the notification unit 15, and the notification unit 15 calls the supporter by, for example, lighting a lamp. Further, in step S105, the support content management unit 23 confirms the arrival of the supporter. The supporter takes one tablet 4 from the shooter 5 in response to the call and operates the input unit 13. The processing device 11 waits by repeating step S105 and step S106 until a signal indicating that the input unit 13 has been operated is output. And as shown in FIG. 5, if the input part 13 is operated by the supporter, it will progress to step S107 and the processing apparatus 11 will complete | finish the count of delay time. Further, in step S108, the support content management unit 23 cancels the supporter's call. Thereby, the notification unit 15 stops the supporter's call by turning off the lamp, for example.

  Here, in step S109, the time calculation unit 21 of the processing device 11 acquires the weighted average CT0 of the cycle time of the day. The weighted average CT0 of the cycle time is calculated based on the current cycle time database 32. In the example of FIG. 3, the weighted average CT0 of the cycle times of the products A to D = (5 minutes × 0.7) + (8 minutes × 0.1) + (16 minutes × 0.1) + (20 minutes × 0 .1) = 7.9 minutes.

  Subsequently, in step S110, the time calculation unit 21 calculates a support target cycle time CT (support time). The support target cycle time CT is calculated by a weighted average CT0 of CT = delay time + cycle time of the day. Next, in step S111, the selection unit 22 determines the selection target range. The selection target range is, for example, a figure number for one pattern in the order table 31. In step S112, the cycle time within the selection target range is referred to, and in step S114 and step S115, the selection unit 22 selects a support target product from the selection target range. Here, the support target product is a product with a figure number having a cycle time closest to the support target cycle time CT.

When there are a plurality of support target products in the selection target range in step S115, the selection unit 22 selects the product with the lowest figure number as the support target product through the processing of step S116 and step S117. Then, the process proceeds to step S118. On the other hand, if there is only one support target product in the selection target range, the process proceeds from step S115 to step S118.
In step S118, the selection unit 22 specifies the support target product, and changes the order of the assembly candidate figure numbers. Specifically, based on a command from the selection unit 22, the data processing unit 24 creates data in which the support target product is arranged at the top of the order table 31 and outputs the data to the display unit 14. Since the display unit 14 displays the figure number for identifying the product to be supported at the top, the supporter browses the order table 31 displayed on the display unit 14, and displays the first number in the order table 31. Assemble the product number of the support item placed above.

  Here, a specific example of the processing from step S109 to step S118 will be described. It is assumed that the steady worker needs to support after starting to assemble the product of the figure number B displayed at the top of the order table 31 of FIG. At this time, if the delay time before the supporter operates the input unit 13 is, for example, 8 minutes, the weighted average CT0 of the cycle time calculated from FIG. 3 is 7.9 minutes. The cycle time CT is 8 minutes + 7.9 minutes = 15.9 minutes. Accordingly, the processing device 11 searches the cycle time database 32 for the figure number closest to 15.9 minutes of the support target cycle time CT. In this case, since the cycle time of the figure number C is 16 minutes and is closest to the support target cycle time CT, the figure number C is selected as the support target product. Since there is only one target, the replacement work of the order table 31 is immediately executed. As a result, as shown in FIG. 6, the figure number C is displayed at the top of the order table 32 displayed on the display unit 14.

  When the order table 31 is exchanged, the figure number C is first searched. In the example of FIG. 2, the figure number C exists eighth from the top. That is, normally, after assembling the products with the seven figure numbers from the top, the product with the figure number C is first assembled. However, as shown in FIG. 6, the figure number C of the product requested to be assembled by the next supporter, that is, the supporter is changed to C by exchanging the figure number C to the top. The supporter takes out the part of the figure number C confirmed in the order table 32 from the parts shelf 7 and assembles the product on the support line 3. The assembled product is transported to the finished product lane 3A. In addition, while a cheerer assembles the product of figure number C, a regular worker assembles the product of figure number A next to the order table 32. Since the cycle time of the figure number A is 5 minutes, the stationary worker can assemble three products of the figure number A according to the order table 32 while the supporter assembles one product of the figure number C. In this way, while the supporter is assembling a product having a cycle time close to the support target cycle time CT, the regular worker assembles other products. As a result, the delay time in the production line 2 is eliminated.

  The effect of this embodiment will be described with reference to FIG. In FIG. 7, the horizontal axis indicates the number of times of support, and the vertical axis indicates the progress with respect to the production plan. That is, the zero point in the vertical direction is the progress as planned, and a delay time occurs below the zero point. In addition, above the zero point, it shows that it is ahead of plan. Here, FIG. 7A shows an example of production management by the production management apparatus 10. On the other hand, FIGS. 7B and 7C show comparative examples.

  In the production management apparatus 10 shown in FIG. 7A, the work of the regular worker is delayed from the plan by the support target cycle time CT, for example, 15.9 minutes when the number of times of support is zero. Therefore, when the supporter assembles the figure number C, the support target cycle time CT becomes substantially zero with one support count. On the other hand, in the comparative example 1 shown in FIG.7 (b), a supporter assembles the product of the figure number A according to the order of the order table 32 of FIG. In this case, since the cycle time of the product of the figure number A is shorter than the support target cycle time CT, the support target cycle time CT is not canceled when the supporter assembles the product of the figure number A. For this purpose, the cheerer enters the second cheering operation and assembles the product of the third or fourth figure number A in the order table 32, for example. In this case, since the support target cycle time CT is not yet zero when the supporter assembles two products of the figure number A, there is a possibility that the third support is required. As described above, the production management apparatus 10 can eliminate the support target cycle time CT with a smaller number of times of support than in the first comparative example.

  Moreover, in the comparative example 2 shown in FIG.7 (c), the case where a supporter assembled the product of the figure number D with the longest cycle time in the order table 32 of FIG. 2 is shown. Since the cycle time of the product of Drawing No. D is 20 minutes and is longer than the support target cycle time CT, when the supporter cheers once, the progress becomes more than zero. In this case, since the actual work has progressed excessively with respect to the plan, if the work is continued in this state, the tablet 4 is not present on the shooter 5 and the stationary worker is likely to be in a waiting state. Thus, in the production management apparatus 10, it is easier to prevent the waiting state of the regular worker from occurring than in the second comparative example.

  As described above, the production management device 10 calculates the support target cycle time CT when a delay time occurs in the production line 2, and requests the supporter to assemble a product close to the support target cycle time CT. Therefore, it becomes possible to eliminate the delay time by one support. Therefore, it is possible to reduce the number of times of support and prevent waiting for a regular worker. The support target cycle time CT is calculated by the sum of the cycle time weighted average CT0 calculated from the cycle times of all the drawings A to D that may be manufactured and the manufacturing frequency and the delay time. Makes it easy to bring the time delay closer to zero. Moreover, since the production management apparatus 10 specified the product used as support object from support time, and produced the order table 31 which a supporter can browse the information, and made it display on the display part 14, a supporter is , You can easily check what you should do. At this time, since the support target product is arranged at the top of the order table 31 indicating the manufacturing order of the plurality of products, the support target product can be reliably notified to the supporter. It should be noted that the present embodiment also includes a management program for executing various processes, and storing the management program in a storage medium or in a downloadable state.

  The tablet 4 which is a work-in-progress control member has a function as a right letter for setting up one product, and controls the total number arranged on one production line 2 to prevent over-production and over-loading of the product. Used to prevent. The work amount control member may be, for example, a jig, pallet, card such as a kanban, or a movable terminal used for assembling the product. Further, production / transport instruction information, product type, information for instructing product storage location, and the like may be added to the work-in-process control member. The additional information may be described on the surface of the in-process control member, or may be displayed using electronic data. A plurality of such work-in-progress control members are arranged in a standby place (for example, the shooter 5) of the production line 2 based on the production plan, and one is taken out from the standby place when assembly of one product is started. When the assembled product is collected in the next process or the like, an in-process restriction member corresponding to the number of collected products is added to the standby place. Then, the production management device 10 executes each of the above-described processes to eliminate the delay time when the number of in-process restriction members staying at the standby location exceeds a predetermined value.

  All examples and conditional expressions given here are intended to help the reader understand the inventions and concepts that have contributed to the promotion of technology, and such examples and It is to be construed without being limited to the conditions, and the organization of such examples in the specification is not related to showing the superiority or inferiority of the present invention. While embodiments of the present invention have been described in detail, various changes, substitutions and variations can be made thereto without departing from the spirit and scope of the present invention.

The features of the above embodiment will be added below.
(Additional remark 1) The delay time of the operation | work in the manufacturing line which manufactures multiple types of products is detected, the support time is calculated by adding the delay time to the weighted average of the cycle times of the plurality of products, and the support time A production management method comprising: comparing the cycle times of the products, selecting the product having a cycle time corresponding to the support time, and outputting information on the selected product so that a supporter can view the information.
(Supplementary Note 2) A plurality of work-in-process control members that regulate the maximum work-in-process amount of the product manufactured in the production line are arranged on the production line, and the work-in-process control member starts manufacturing one product. Sometimes, one product is taken out from the standby location of the work amount control member, and one product after manufacture is added to the standby location when the product is carried out from the production line, and the delay time is the standby location. It is a time from when the number of stays of the work-in-progress control member exceeds a predetermined value until a signal indicating that the supporter has taken out one work-in-progress control member is input. The production management method according to claim 1.
(Supplementary Note 3) Outputting information on the selected product so that a supporter can view includes creating data in which the selected product is arranged at the top of a list indicating a manufacturing order. The production management method according to Supplementary Note 1 or Supplementary Note 2.
(Additional remark 4) The time which calculates the support time by adding to the delay time to the weighted average of the cycle time of the plurality of the products, the delay detection unit that detects the delay time of the work in the production line that manufactures a plurality of types of products A calculation unit, a selection unit that compares the support time and the cycle time of the product and selects the product having a cycle time corresponding to the support time, and an output unit that outputs information on the selected product. A production management device comprising:
(Additional remark 5) The said delay detection part detects that the staying number of the tablet which controls the maximum amount of work in progress in the said production line exceeded the predetermined value, and that the cheer took out one said tablet. The production management apparatus according to appendix 4, including an input unit that creates a signal to be indicated.
(Additional remark 6) It has a notification part which notifies a supporter of a support request, The production management apparatus of Additional remark 4 or Additional remark 5 characterized by the above-mentioned.
(Additional remark 7) The data processing part which creates the order table which has arrange | positioned the selected said product to the top of the list of the manufacturing order of several products, and outputs it to the said output part is described in Additional remark 4 characterized by the above-mentioned. Production management equipment.

2 Production line 3 Support line (production line)
4 tablets (in-process amount control member)
5 Shooter (standby place)
12 Detection part 13 Input part 14 Display part (output part)
DESCRIPTION OF SYMBOLS 15 Notification part 17 Delay detection part 21 Time calculation part 22 Selection part 24 Data processing part 31 Order table (information of selected product)
32 Cycle time database CT0 Cycle time weighted average CT Support cycle time (support time)

Claims (5)

Detects work delays in production lines that produce multiple types of products,
Add the delay time to the weighted average of the cycle times of a plurality of the products to calculate the support time,
Compare the support time and the cycle time of the product, select the product having a cycle time corresponding to the support time,
A production management method, wherein information of the selected product is output so that a supporter can view it. The production line includes a plurality of work-in-process control members that regulate the maximum work-in-process amount of the product manufactured in the production line, and the work-in-process control member is configured to start the production of one product. One is taken out from the waiting place of the quantity control member, and one is added to the waiting place when one of the manufactured products is taken out from the production line,
The delay time is from when the staying number of the in-process amount control member in the standby place exceeds a predetermined value until a signal indicating that the supporter has taken out one in-process amount control member is input. The production management method according to claim 1, wherein the production management method is a time period.   The outputting of the information on the selected product so as to be viewable by the supporter includes creating data in which the selected product is arranged at the top of a list indicating a manufacturing order. Or the production management method of Claim 2. A detection unit for detecting a work delay time in a production line for producing a plurality of types of products;
A time calculation unit for calculating a cheering time by adding to the delay time to a weighted average of cycle times of a plurality of the products;
A selection unit that compares the support time with the cycle time of the product and selects the product having a cycle time corresponding to the support time;
An output unit for notifying the supporter of information on the selected product;
A production management device comprising:   5. The production management according to claim 4, further comprising a data processing unit that creates a sequence table in which the selected products are arranged at the top of a list of manufacturing orders of a plurality of products and outputs the sequence table to the output unit. apparatus.

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