JP2016181220A - Work management device - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a work management device that compares a state of a target of work and a behavior of a worker with the standard of work and displays a result of the comparison to recognize the cause of large deviation of work from a reference value.SOLUTION: The standard of work stored in a storage part is the optimal values obtained in advance regarding time required for a movement to take out components to be used for assembly, time required for a movement to take out tools to be used for assembly, and time required for an actual assembly movement. The standard of work is compared with time required for a movement to take out components to be used for assembly, time required for a movement to take out tools to be used for assembly, and time required for an actual assembly movement that are measured in an actual assembly process.SELECTED DRAWING: Figure 8

Description

  The present invention relates to a work management apparatus used for grasping the suitability of assembly work at an assembly work site for assembling products and the like.

  In order to reduce production man-hours during assembly work, it is necessary to analyze work waste, overwork, and unevenness to improve work. Conventionally, for example, the time required for actual work is actually measured with a stopwatch or the like, and the work is improved based on the actual measurement result. In recent years, it has become possible to grasp the working time by using the IT equipment such as various terminals and the operator himself / herself sequentially inputting the working state and the like.

  In Patent Document 1, in order to promote the work by the worker and maintain the work efficiency of the worker, a storage unit that stores a skill value indicating the work ability of the worker, and the work of the worker according to the skill value Work status with a calculation unit that calculates the reference value that serves as a reference and a display unit that displays the actual work status of the worker as the actual value, and the reference value is displayed on the display unit so that the actual value can be compared. A display device is disclosed.

JP 2010-55167 A

  According to the work status display device described in Patent Document 1, it is possible to recognize the difference between the actual work time and the reference value, but it is possible to recognize the cause of such a difference. I can't do it.

  The present invention has been made to solve the above-described problems, and compares the state of the work object and the behavior of the worker with the work standard, and displays the comparison result, thereby deviating from the standard value. An object of the present invention is to provide a work management apparatus that can recognize the cause of a large work.

  The invention according to claim 1 is a storage unit that stores a reference of work, first detection means that detects a state of a work object, second detection means that detects a behavior of an operator, and the first detection. A comparison means for comparing the state of the work object detected by the means and the behavior of the worker detected by the second detection means with the reference of the work stored in the storage unit; and a comparison result by the comparison means And a display means for displaying.

  The invention according to claim 2 is the invention according to claim 1, further comprising third detection means for detecting a state of a tool used for work, wherein the comparison means is detected by the third detection means. The state of the tool is compared with the work standard stored in the storage unit.

  According to a third aspect of the present invention, in the first or second aspect of the present invention, the first detection means includes a sensor that detects that the work object has been carried out or carried in.

  According to a fourth aspect of the present invention, in the second aspect of the present invention, the third detection means includes a sensor that detects that the tool has been carried out.

  The invention according to claim 5 is the invention according to any one of claims 1 to 4, wherein the second detection means is photographed by a camera for photographing an area including the worker, and the camera. And an image processing unit that performs image processing on the image.

  According to the invention described in claim 1, the cause of the work having a large deviation from the reference value by comparing the state of the work object and the behavior of the worker with the work standard and displaying the comparison result. Can be recognized.

  According to the second to fourth aspects of the present invention, the cause of the work having a large deviation from the reference value is displayed in more detail including the tool state by comparing the tool state with the work reference. It becomes possible to do.

  According to the fifth aspect of the present invention, the problem of the worker's behavior can be recognized in more detail by detecting the worker's behavior based on the result of image processing of the image captured by the camera. It becomes possible.

It is a schematic diagram of the production line to which the work management device concerning this invention is applied. It is a schematic diagram which shows the principal part of the cell C1 in the production line to which the work management apparatus which concerns on this invention is applied. It is a side view which shows typically the operation | work operation | work of the worker M in the cell C1 in the production line to which the work management apparatus which concerns on this invention is applied. FIG. 3 is a schematic plan view of a component tray 31 placed on a tray mounting table 11, 15, 21, 25. It is explanatory drawing which shows the state which accommodates the components 32 in the components tray 31. FIG. It is explanatory drawing which shows the state which mounts the tool on the tool mounting base. It is a block diagram which shows the control system of the work management apparatus which concerns on this invention. It is a flowchart which shows the management operation | movement of the assembly work by the work management apparatus which concerns on this invention. It is a flowchart which shows the management operation | movement of the assembly work by the work management apparatus which concerns on this invention. It is a flowchart which shows the management operation | movement of the assembly work by the work management apparatus which concerns on this invention. It is a flowchart which shows the management operation | movement of the assembly work by the work management apparatus which concerns on this invention. It is a flowchart which shows the management operation | movement of the assembly work by the work management apparatus which concerns on this invention. It is a flowchart which shows the management operation | movement of the assembly work by the work management apparatus which concerns on this invention.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings. FIG. 1 is a schematic diagram of a production line to which a work management apparatus according to the present invention is applied. FIG. 2 is a schematic view showing the main part of the cell C1 in the production line to which the work management apparatus according to the present invention is applied, and FIG. 3 is a side view schematically showing the work operation of the worker M in the cell C1. FIG. Although FIG. 3 shows a case where two workers M are arranged in the cell C1, the worker M may be one or more than three.

  This production line is for producing products by the cell production method, and is composed of a plurality of cells C1, C2,... Cn. FIG. 1 shows only the cell C1 and the cell C2 among the plurality of cells.

  The cell C1 includes a work table 13 including a fixing table 14 for fixing a product 40 to be assembled (see FIG. 3) and a pair of detection units 41 for detecting the loading of components. The work table 13 is carried in from a preceding cell (not shown) by a plurality of transport rollers 10, and is transported to the next cell C2 after the assembly of necessary parts is completed.

  Around the work table 13 conveyed in the center of the cell C1, a pair of tray mounting tables 11 and 15 for mounting the component tray 31 and a tool mounting table 12 for mounting various tools 34 (see FIG. 2), A collection shelf 16 for collecting the used component tray 31, a personal computer 17, a display unit 18 such as a liquid crystal display panel, and a foot switch 19 are arranged. As shown in FIG. 3, a plurality of cameras 51 for photographing the inside of the cell C1 are arranged on the ceiling 50 in the cell C1 region. The tool 34 described in this specification is a concept including not only a pure tool such as a screwdriver or a spanner but also a jig as an auxiliary tool.

  Similarly, the cell C2 includes a work table 23 including a fixing table 24 for fixing the product 40 to be assembled and a pair of detection units for detecting the loading of parts. The work table 23 is carried in from the cell C1 in the previous stage by the plurality of transport rollers 10, and is transported to the next cell (not shown) after assembling necessary parts.

  Around the work table 23 conveyed in the center of the cell C2, like the cell C1, a pair of tray mounting tables 21 and 25 for mounting component trays, a tool mounting table 22 for mounting various tools, and use A collection shelf 26 for collecting used component trays, a personal computer 27, a display unit 28 such as a liquid crystal display panel, and a foot switch 29 are arranged. Similar to the cell C1, a plurality of cameras for photographing the inside of the cell C2 are arranged on the ceiling of the cell C2 region. Such a configuration is the same for other cells.

  FIG. 4 is a schematic plan view of the component tray 31 mounted on the tray mounting table 11, 15, 21, 25 described above. FIG. 5 is an explanatory view showing a state in which the component 32 is stored in the component tray 31.

  The component tray 31 is formed with a recess for mounting various components 32 to be assembled to the product 40. Each component 32 is mounted in a recess formed in the component tray 31. As shown in FIG. 5, a sensor 33 for detecting the presence or absence of the component 32 is disposed in the recess. The sensor 33 is, for example, an optical sensor, and the output signal in a state where the component 32 is arranged in the recess shown in FIG. 5A and the component 32 is arranged in the recess shown in FIG. 5B. The presence / absence of the component 32 is detected based on the difference in the output signal in the state where it is not provided. For this reason, it is detected by the action of the sensor 33 that each component 32 has been removed from the component tray 31.

  FIG. 6 is an explanatory diagram showing a state in which the tool 34 is mounted on the tool mounting table 12 described above.

  The tool mounting table 12 is formed with a recess for mounting a tool 34 used for assembling the component 32 to the product 40, and each tool 34 is placed in the recess formed in the tool mounting table 12. Installed. A sensor 35 for detecting the presence / absence of the tool 34 is disposed in the recess. This sensor 35 is also an optical sensor, for example, and an output signal in a state where the tool 34 is arranged in the recess shown in FIG. 6A and the tool 34 arranged in the recess shown in FIG. 6B. The presence / absence of the tool 34 is detected based on the difference in the output signal in a state where the tool 34 is not provided. For this reason, it is detected by the action of the sensor 35 that each tool 34 has been removed from the tool mounting table 12. The tool mounting table 22 in the cell C2 has the same configuration as the tool mounting table 12 in the cell C1.

  FIG. 7 is a block diagram showing a control system of the work management apparatus according to the present invention.

  The work management apparatus includes a ROM that stores an operation program necessary for controlling the apparatus, a RAM that temporarily stores data and the like during control, and a CPU that executes logical operations, and a control unit 1 that controls the entire apparatus. Is provided. The control unit 1 is connected to a storage unit 2 that stores a reference for work when performing assembly work on the production line described above. The control unit 1 is also connected to the above-described cell C1, cell C2,... Cell Cn. This control unit 1 is connected to the personal computers 17, 27,... In each cell C1, cell C2,. The control unit 1 functions as a comparison unit according to the present invention that compares the state of the part 32 as the work object and the behavior of the worker M with the work reference stored in the storage unit 2.

  The standard of work stored in the storage unit 2 is the time required for the operation of taking out the parts 32 used for assembly, the time required for the operation of taking out the tool 34 used for assembly, and the time required for the actual assembly operation. Is an optimum value obtained in advance. The criteria for this work are the time required to take out the parts 32 used for assembly measured in the actual assembly process, the time required to take out the tool 34 used for assembly, and the actual assembly operation. Compared with each of the time required for. The storage unit 2 is not limited to the one directly connected to the control unit 1, but may be attached to a computer connected by a network or the like.

  Here, the optimum value of the time required to take out the part 32 used for assembly is set in advance based on the size and weight of the part 32. On the other hand, in the cell C1, the actual time required for the operation of taking out the parts 32 used for assembling is from the time when the sensor 33 shown in FIG. 5 detects that the parts 32 are taken out from the parts tray 31. The time until the person M places the component 32 on the detection unit 41 of the workbench 13 and the detection unit 41 detects it is measured.

  Further, the optimum value of the time required for taking out the tool 34 used for assembly is set in advance based on the weight and contents of the tool 34. On the other hand, the actual time required for the operation of taking out the tool 34 used for assembling is from the time when the sensor 35 shown in FIG. 6 detects that the tool 34 is taken out from the tool mounting table 12 in the cell C1. It is measured as the time to the point in time when it is detected that the use of the tool 34 is started. 7 that the use of the tool 34 has started, the controller 1 shown in FIG. 7 performs image processing on the image of the tool 34 taken by the camera 51 shown in FIG. 3, and the image processed image is stored in advance. Recognized by comparison with a reference image. In addition, when using what can measure applied force, such as a torque driver, as the tool 34 and using what can transmit this measured value to the control part 1 by radio | wireless communication, the tool 34 is used. On the other hand, the time point when the load is applied may be recognized as the time point when the use of the tool 34 is started.

  Further, the time required for the actual assembly operation is set in advance based on the nature of the work. On the other hand, the actual time required for the actual assembling operation is that the image of the worker M taken by the camera 51 shown in FIG. 3 is image-processed by the control unit 1 shown in FIG. The recognized image is recognized by comparing it with a previously stored reference image. The time required for the actual assembling operation is determined from the time when the use of the tool 34 is recognized as described above to the time when the sensor 35 shown in FIG. 6 returns the tool 34 to the tool mounting table 12. You may make it measure as time to.

  Next, the management operation for managing the assembly work of the product 40 by the work management apparatus according to the present invention in the production line described above will be described. FIGS. 8 to 13 are flowcharts showing the management operation of the assembly work by the work management apparatus according to the present invention. FIG. 8 shows a main routine, and FIGS. 9 to 13 show a subroutine. In the following description, a case where assembly work is performed in the cell C1 will be described.

  When starting the assembly work, first, the ID of the work order in the production work to be executed is designated (step S1). And the theoretical value template which shows the reference | standard of an operation | work is read from the memory | storage part 2 shown in FIG. 7 (step S2).

  Thereafter, the time required to take out the part 32 used for assembly is taken in as part acquisition time (step S3). Then, it is determined whether or not the component acquisition time is within the time a set in the theoretical value template (step S4). If this component acquisition time is within the set value a, the process proceeds to the next step. On the other hand, if the component acquisition time exceeds the set value a, the process proceeds to 1S, and the subroutine shown in FIG. 9 is executed.

  In this subroutine, the distance between the worker M and the part 32 is measured (step S21). When measuring this distance, the control unit 1 shown in FIG. 7 performs image processing on the image of the worker M and the image of the component 32 taken by the camera 51 shown in FIG. 3, and recognizes the distance between them. Executed. When the assembly is performed by a plurality of workers M, the distance between the worker M who should perform the assembly work of the part 32 and the part 32 is measured. As described above, the worker M who actually performs the assembly work is selected as the worker M in the following steps.

  And it is judged whether this distance is below the distance a1 set in the theoretical value template (step S22). When this distance is less than or equal to a1, the control unit 1 determines that the part 32 has been properly taken out but the skill of the worker M is insufficient, and a warning display indicating “insufficient worker skill” is displayed. Is displayed on the display unit 18 shown in FIG. 1 (step S23). On the other hand, if this distance exceeds a1, the control unit 1 determines that the part 32 has not been properly removed, and displays a warning message “part set failure” on the display unit 18 shown in FIG. Display (step S24). In this case, the worker M moves the component 32 to an appropriate position. Thereafter, the process proceeds to 1E (step S5), and proceeds to the next step S6 shown in FIG.

  Next, the time required for taking out the tool 34 used for assembly is taken in as the tool setting time (step S6). Then, it is determined whether or not the tool setting time is within the time b set in the theoretical value template (step S7). If this tool set time is within the set value b, the process proceeds to the next step. On the other hand, if the tool setting time exceeds the set value b, the process proceeds to 2S and the subroutine shown in FIG. 10 is executed.

  In this subroutine, the distance between the worker M and the tool 34 is measured (step S31). When measuring this distance, the control unit 1 shown in FIG. 7 performs image processing on the image of the worker M and the image of the tool 34 taken by the camera 51 shown in FIG. 3, and recognizes the distance between them. Executed.

  And it is judged whether this distance is below the distance b1 set in the theoretical value template (step S32). When this distance is less than or equal to b1, the control unit 1 determines that the tool 34 has been properly taken out but the operator M is not skilled, and a warning display indicating “insufficient operator skill” is displayed. Is displayed on the display unit 18 shown in FIG. 1 (step S33). On the other hand, if this distance exceeds b1, the control unit 1 determines that the tool 34 has not been properly removed, and displays a warning message “defective tool set” on the display unit 18 shown in FIG. It is displayed (step S34). In this case, the worker M moves the tool 34 to an appropriate position. Thereafter, the process proceeds to 2E (step S8), and proceeds to the next step S9 shown in FIG.

  Next, the time required for the actual assembly operation is taken as the actual work time (step S9). Then, it is determined whether or not the actual work time is within the time c set in the theoretical value template (step S10). If the actual work time is within the set value c, the process proceeds to the next step. On the other hand, if the actual work time exceeds the set value c, the process proceeds to 3S and the subroutine shown in FIG. 11 is executed.

  In this subroutine, the state of the tool 34 is measured (step S41). The state of the tool 34 is the difference between the angle at which each tool 34 is to be used and the angle of the actual tool 34, and this difference is measured in this step. At the time of measuring this difference, the control unit 1 shown in FIG. 7 performs image processing on the image of the tool 34 taken by the camera 51 shown in FIG. 3 and recognizes the angle. Then, it is determined whether or not the difference is within the difference d set in the theoretical value template (step S42). If this difference is not the set value d, the process proceeds to the next step. On the other hand, if this difference exceeds the set value d, the process proceeds to 4S, and a further subroutine shown in FIG. 12 is executed.

  In this further subroutine, the difference between the posture of the worker M and the direction of the tool 34 is measured (step S51). When measuring this difference, the control unit 1 shown in FIG. 7 performs image processing on the image of the worker M and the image of the tool 34 taken by the camera 51 shown in FIG. 3, and recognizes the angle between them. Executed.

  And it is judged whether this difference is below the angle d1 set in the theoretical value template (step S52). When this difference is d1 or less, the control unit 1 determines that the skill of the operator M is insufficient although the tool 34 is used at an appropriate angle, and is referred to as “insufficient operator skill”. A warning display is displayed on the display unit 18 shown in FIG. 1 (step S53). On the other hand, when the difference exceeds d1, the control unit 1 determines that the tool 34 is not being used at an appropriate angle, and displays a warning display “tool angle defect” as shown in FIG. 18 (step S54). In this case, the worker M corrects the tool 34 so that the tool 34 has an appropriate angle. Thereafter, the process proceeds to 4E (step S43), and proceeds to the next step S44 shown in FIG.

  Next, the work range is measured (step S44). This work range is the maximum movement area of the worker M, and this work range is measured in this step. When measuring the work range, the control unit 1 shown in FIG. 7 performs image processing on the image of the worker M photographed by the camera 51 shown in FIG. 3 and recognizes the maximum movement area. Then, it is determined whether or not the work range is within the range e set in the theoretical value template (step S45). If the work range is within the set value e, the process proceeds to the next step. On the other hand, if the work range exceeds the set value e, the process proceeds to 5S and a further subroutine shown in FIG. 13 is executed.

  In this further subroutine, the movement area of the worker M is measured (step S61). When the moving area is measured, the control unit 1 shown in FIG. 7 performs image processing on the image of the worker M taken by the camera 51 shown in FIG. It is executed by doing.

  And it is judged whether this movement area is below the area e1 set in the theoretical value template (step S62). When the moving area is equal to or less than e1, the control unit 1 determines that the worker M is properly moved but lacks the skill of the worker M, and warns that the worker M is insufficient. The display is displayed on the display unit 18 shown in FIG. 1 (step S63). On the other hand, when the moving area exceeds e1, the control unit 1 determines that the moving operation at the time of the work of the worker M is inappropriate, and displays a warning message “malfunction” in FIG. Is displayed on the display unit 18 (step S64). In this case, the worker M corrects the operation at the time of work. Thereafter, the process proceeds to 5E (step S46), and proceeds to the next step S47 shown in FIG.

  Next, the quality of the component 32 is determined (step S47). In this embodiment, the quality of the part 32 is the difference between the dimension of the part 32 and its set value, and this difference is measured in this step. When the quality of the component 32 is determined, the control unit 1 shown in FIG. 7 performs image processing on the image of the component 32 photographed by the camera 51 shown in FIG. 3 and recognizes the dimensions thereof. Then, it is determined whether or not the difference between the dimension of the component 32 and its set value is within the range f set in the theoretical value template (step S48).

  When the difference between the dimension of the part 32 and the set value is equal to or less than the range f set in the theoretical value template, the control unit 1 is appropriate for the part 32 but other abnormality has occurred. And displays a warning display “other abnormality” on the display unit 18 shown in FIG. 1 (step S49). On the other hand, if the difference between the dimension of the part 32 and its set value exceeds the range f set in the theoretical value template, the control unit 1 determines that the part 32 is defective, and “part failure” Is displayed on the display unit 18 shown in FIG. 1 (step S50). In this case, the worker M replaces the part 32 with an appropriate one. Thereafter, the process proceeds to 3E (step S11), and proceeds to the next step S12 shown in FIG.

  If there is an operation related to the next ID, the process returns to step S1 and the process is repeated. On the other hand, when the work is completed for all IDs, the worker 40 presses the foot switch 19 shown in FIG. 1 to move the product 40 that has completed all the assembly work in the cell C1 together with the work table 13 to the next cell. Carry out to C2.

  As described above, according to the work management apparatus according to the present invention, the work delay is detected by detecting and comparing the work object and the state and behavior of the work object with respect to the standard of each work. It is possible to analyze whether it is caused by various causes, which can lead to improvement of work.

  The sensors 33 and 35 used for monitoring the working state may be sensors that detect physical contact as well as sensors that optically detect the component 32 and the tool 34. Further, various other sensors can be used as these sensors 33 and 35.

  In the above-described embodiment, each determination result and various types of abnormality are displayed. However, the data is stored as data without being displayed, and data for executing display at any timing for analysis. May be stored as

  Furthermore, in the above-described embodiment, the method of moving the work tables 13 and 23 by the transport roller 10 has been described, but the present invention is not limited to such a form. Further, the present invention can be applied even when a production method in which all the assemblies are performed at one place is adopted instead of the cell production method described above.

DESCRIPTION OF SYMBOLS 1 Control part 2 Memory | storage part 11 Tray mounting table 12 Tool mounting table 13 Working table 14 Fixed table 15 Tray mounting table 16 Collection shelf 17 Personal computer 18 Display unit 21 Tray mounting table 22 Tool mounting table 23 Working table 24 Fixed table 25 Tray mounting Stand 26 Collection shelf 27 Personal computer 28 Display unit 31 Component tray 32 Component 33 Sensor 34 Tool 35 Sensor 40 Product 41 Detection unit 51 Camera C1 Cell C2 Cell M Worker

Claims (5)

A storage unit for storing work standards;
First detection means for detecting the state of the work object;
A second detection means for detecting the behavior of the worker;
Comparison means for comparing the state of the work object detected by the first detection means and the behavior of the worker detected by the second detection means with the work reference stored in the storage unit;
Display means for displaying a comparison result by the comparison means;
A work management apparatus comprising: The work management apparatus according to claim 1,
Further comprising third detecting means for detecting the state of the tool used for the work,
The comparison means is a work management device that compares the state of the tool detected by the third detection means with a reference of work stored in the storage unit. In the work management device according to claim 1 or 2,
The first detection means is a work management apparatus including a sensor that detects that the work object has been carried out or carried in. The work management apparatus according to claim 2,
The third detection means is a work management device including a sensor for detecting that the tool has been carried out. In the work management device according to any one of claims 1 to 4,
The second detection means is a work management device including a camera that captures an area including the worker and an image processing unit that performs image processing on an image captured by the camera.

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