JP2021174541A - Production lead time analysis method and production lead time analysis system - Google Patents

Abstract

To provide a production lead time analysis method and a production lead time analysis system that can quickly identify a problem which prolongs a production lead time.SOLUTION: A production lead time analysis system in question is comprised of: a work record information collection unit that collects work record information of each related process for each product, the work record information including a work start time and a work end time of the process; a process work time calculation unit that calculates a process work time based on the work record information for each process of each product, the process work time being a time difference between the work start time and the work end time of the process; a process standard work time acquisition unit that acquires a corresponding process standard work time for each process of the product; and a process delay time calculation unit that, for each process of each product, calculates a delay time of the process work time with respect to the corresponding process standard work time in the process and sets the delay time as a process delay time of the process.SELECTED DRAWING: Figure 1

Description

The present invention relates to a production lead time analysis method and a production lead time analysis system for analyzing the production lead time of a product.

In commercial transactions, as customer needs diversify and competition between companies intensifies, it is necessary for production companies to meet the production lead times required by customers. Even if the price and quality of the goods are ideal at the ordering stage, if it takes a long time to deliver, the order may flow to the competitors. Companies use various IT technologies to collect production lead times at that time in order to shorten production lead times, but the use of data is not yet sufficient, and for problem analysis and on-site improvement, Since human experience and knowledge are mainly used, it lacks reliability and versatility.

Patent Document 1 describes that in order to manufacture and mount a circuit, a plurality of steps are sequentially performed, and a specific facility is used in each step. In general equipment, the production lead time of a product is not limited to considering the theoretical working time, because it changes depending on the process difference, the number of products processed in a unit time, the processing speed and the working time. The waiting time between processes also needs to be taken into account. In order to comply with the production plan, it is necessary to accurately measure the target lead time of the production lot, which is a unit put into the production line, but at present, it is mainly dealt with by human experience, and such technology In response to the problem, Patent Document 1 describes a method for measuring the target lead time for semiconductor and IC manufacturers, which is based on the performance data of each process equipment and the theoretical working time of the product of each process equipment. In addition to calculating the utilization rate, the waiting time in each process is calculated using the utilization rate of each process equipment, and finally, the total value of the waiting time in each process and the theoretical working time of the product are added to obtain the target lead time. Is configured to calculate.

Chinese Patent Application Publication No. 101727098

However, lot production and production line production methods and equipment such as semiconductor and IC manufacturers according to Patent Document 1 are only technologies applied to production lines and lack versatility. Further, Patent Document 1 optimizes the production plan by accurately measuring the target lead time to shorten the production lead time, but the production lead time itself is not analyzed, so that the production is produced. It is not possible to know at what stage inside the lead time the standby occurred, so it is not possible to pinpoint the production site and shorten the production lead time.

The present invention has been made to solve the above technical problems, and provides a production lead time analysis method for analyzing the production lead time of one or more products, and the product is one or more semi-finished products. The semi-finished product is processed and formed through one or a plurality of steps, and the production lead time analysis method includes the following steps. That is, it is a work record information collection step for collecting work record information of each related process for each product, and the work record information includes a step including a work start time and a work end time of the process, and each product. For each process, the process work time calculation step of calculating the process work time based on the work record information, and the process work time is the time difference between the work start time and the work end time of the process. , The process standard work time acquisition step for acquiring the corresponding process standard work time for various processes of the product, and the process work time for each process of the product with respect to the corresponding process standard work time in the process. A process delay time calculation step that calculates the delay time and uses it as the process delay time of the process.

The production lead time analysis method may also be configured as follows. That is, the process stagnation time for calculating the process stagnation time of the process for each process excluding the slowest process and the slowest process in the product among the processes used for the processing formation of each semi-finished product in each product. Further including a calculation step, the process stagnation time is a time difference between the work end time of the process and the work start time of the next process of the process.

The production lead time analysis method may also be configured as follows. That is, a process in which the process delay time exceeds the preset process delay threshold is determined to be an abnormal delay process, and a process in which the process stagnation time exceeds the preset process stagnation threshold is regarded as an abnormal stagnation process. An abnormality determination step for determination, a step for displaying at least one of the process work time of each process, the process standard work time of various processes, and process abnormality information, and the process abnormality information is a step of displaying each process. Includes at least one of the process delay time, the process stagnation time of each process, the abnormal delay rate of the process, the abnormal stagnation rate of the process, the identification information of the abnormal delay process, and the identification information of the abnormal stagnation process. Also includes display steps and.

This allows you to intelligently, visually and quickly identify problem processes that prolong production lead time, take pinpoint measures to avoid unnecessary waiting time, and reduce product production lead time. Production lead time can be shortened.

The production lead time analysis method may also be configured as follows. That is, it is a product production lead time calculation step for calculating the product production lead time based on the work record information for each product, and the product production lead time is each step collected in the work record information collection step. Among the steps, the step that is the time difference between the work start time of the earliest process and the work end time of the latest process, the product standard production lead time acquisition step for acquiring the product standard production lead time corresponding to the product, and the above-mentioned For each product, the abnormality determination step further includes a product delay time calculation step of calculating the delay time of the product production lead time with respect to the product standard production lead time of the product and using it as the product delay time of the product. In the above, a product whose product delay time exceeds a preset product delay threshold is further determined to be an abnormally delayed product, and in the display step, the product production lead time, the product standard production lead time, and the product standard production lead time of each product are determined. At least one of the product abnormality information is further displayed, and the product abnormality information is at least one of the product delay time, the product abnormality delay rate, the average delay time, and the identification information of the abnormality delay product of each product. Including one.

This allows you to pinpoint and avoid unnecessary wait times by identifying problem products that intelligently, visually and quickly prolong production lead times in order to reduce product production lead times. , The production lead time of the product can be shortened.

The production lead time analysis method may also be configured as follows. That is, it is a semi-finished product production lead time calculation step for calculating the semi-finished product production lead time based on the work record information for each semi-finished product of the said semi-finished product, and the semi-finished product production lead time is the semi-finished product. A step that is the time difference between the work start time of the earliest process and the work end time of the latest process among the processes used for the processing formation, and the corresponding semi-finished product standard production lead time for various semi-finished products of the product. For each semi-finished product of the semi-finished product, the delay time of the semi-finished product production lead time with respect to the corresponding semi-finished product standard production lead time of the semi-finished product is calculated. The semi-product delay time calculation step is the semi-product delay time of the semi-finished product, and the semi-product stagnation time calculation step is to calculate the semi-product stagnation time of the semi-finished product for each of the plurality of semi-products used for mutual assembly. The semi-finished product stagnation time is the time difference between the work end time of the latest step of the process used for the processing formation of the semi-finished product and the work start time of the earliest step of the step related to mutual assembly. In the abnormality determination step, a semi-product whose semi-product delay time exceeds a preset semi-product delay threshold is determined to be an abnormal delay semi-product, and the semi-product stagnation A semi-finished product whose time exceeds a preset semi-finished product stagnation threshold is determined to be an abnormally stagnant semi-finished product, and in the display step, the semi-finished product production lead time of each semi-finished product and the semi-finished product standard production of each semi-finished product The lead time and at least one of the semi-product abnormality information are further displayed, and the semi-product abnormality information includes the semi-product delay time of each semi-product, the semi-product stagnation time of each semi-product, and the semi-product abnormality. It includes at least one of a delay rate, an abnormal stagnation rate of a semi-finished product, an identification information of the abnormally delayed semi-product, and an identification information of the abnormally stagnant semi-product.

This allows you to pinpoint and avoid unnecessary wait times by identifying problematic semi-finished products that intelligently, visually and quickly prolong production lead times in order to reduce product lead times. However, the production lead time of the product can be shortened.

The production lead time analysis method may also be configured as follows. That is, in the process standard work time acquisition step, for various processes of the product, the process standard work time is calculated by removing an abnormal value from the process work time of the process of each product.

As a result, the process standard working time can be obtained more accurately.

The present invention further provides a production lead time analysis system that analyzes the production lead time of one or more products, wherein the product is processed by one or more semi-finished products through one or more steps. The semi-finished product is processed and formed through one or a plurality of steps, and the production lead time analysis system includes the following. That is, it is a work record information collecting unit that collects work record information of each related process for each product, and the work record information includes a work start time and a work end time of the process, and each product. The process work time calculation unit calculates the process work time based on the work record information for each process, and the process work time is the time difference between the work start time and the work end time of the process. , The process standard work time acquisition unit that acquires the corresponding process standard work time for various processes of the product, and the process work time for each process of the product with respect to the corresponding process standard work time in the process. A process delay time calculation unit that calculates the delay time and uses it as the process delay time of the process.

The production lead time analysis system may also be configured as follows. That is, the process stagnation time for calculating the process stagnation time of the process for each process excluding the slowest process and the slowest process in the product among the processes used for the processing formation of each semi-finished product in each product. In the calculation unit, the process stagnation time further includes a time difference between the work end time of the process and the work start time of the next process of the process.

The production lead time analysis system may also be configured as follows. That is, a process in which the process delay time exceeds the preset process delay threshold is determined to be an abnormal delay process, and a process in which the process stagnation time exceeds the preset process stagnation threshold is regarded as an abnormal stagnation process. An abnormality determination unit for determining, a display unit for displaying at least one of the process work time of each process, the process standard work time of various processes, and process abnormality information, and the process abnormality information is each. At least one of the process delay time of the process, the process stagnation time of each process, the abnormal delay rate of the process, the abnormal stagnation rate of the process, the identification information of the abnormal delay process, and the identification information of the abnormal stagnation process. Including and further including.

This allows you to pinpoint and avoid unnecessary wait times by identifying problem processes that intelligently, visually and quickly prolong production lead times in order to reduce product production lead times. , The production lead time of the product can be shortened.

The production lead time analysis system may also be configured as follows. That is, it is a product production lead time calculation unit that calculates a product production lead time based on the work record information for each of the products, and the product production lead time is each collected by the work record information collection unit. The time difference between the work start time of the earliest process and the work end time of the latest process, the product standard production lead time acquisition unit that acquires the product standard production lead time corresponding to the product, and the product standard production lead time acquisition unit. For each of the products, the abnormality determination includes a product delay time calculation unit that calculates the delay time of the product production lead time with respect to the product standard production lead time of the product and sets it as the product delay time of the product. The unit further determines that the product whose product delay time exceeds the preset product delay threshold is an abnormally delayed product, and the display unit indicates the product production lead time, the product standard production lead time, and the product standard production lead time of each product. And at least one of the product abnormality information is further displayed, and the product abnormality information includes the product delay time of each product, the product abnormality delay rate, the average delay time, and the identification information of the abnormality delay product. Includes at least one.

This allows you to pinpoint and avoid unnecessary wait times by identifying problem products that intelligently, visually and quickly prolong production lead times in order to reduce product production lead times. , The production lead time of the product can be shortened.

The production lead time analysis system may also be configured as follows. That is, it is a semi-finished product production lead time calculation unit that calculates a semi-finished product production lead time based on the work record information for each semi-finished product of the said semi-finished product, and the semi-finished product production lead time is the semi-finished product. The time difference between the work start time of the earliest process and the work end time of the latest process among the processes used for the processing formation, and the corresponding semi-finished product standard production lead time for various semi-finished products of the product. For each semi-finished product of the semi-finished product and the semi-finished product, the delay time of the semi-finished product production lead time with respect to the corresponding semi-finished product standard production lead time of the semi-finished product is calculated. A semi-product delay time calculation unit that calculates the semi-product delay time of a semi-product, and a semi-product stagnation time calculation unit that calculates the semi-product stagnation time of the semi-product for each of a plurality of semi-products used for mutual assembly. The semi-finished product stagnation time is the time difference between the work end time of the latest step of the process used for the processing formation of the semi-finished product and the work start time of the earliest step of the step related to mutual assembly. Further, the abnormality determination unit further determines that the semi-product whose semi-product delay time exceeds the preset semi-product delay threshold is an abnormal delay semi-product, and the semi-product stagnation. A semi-finished product whose time exceeds a preset semi-finished product stagnation threshold is determined to be an abnormally stagnant semi-finished product. At least one of the production lead time and the semi-finished product abnormality information is displayed, and the semi-finished product abnormality information includes the semi-finished product delay time of each semi-finished product, the semi-finished product stagnation time of each semi-finished product, and the semi-finished product abnormality. It includes at least one of a delay rate, an abnormal stagnation rate of a semi-finished product, identification information of the abnormally delayed semi-product, and identification information of the abnormally stagnant semi-product.

This allows you to pinpoint and avoid unnecessary wait times by identifying problematic semi-finished products that intelligently, visually and quickly prolong production lead times in order to reduce product lead times. However, the production lead time of the product can be shortened.

The production lead time analysis system may also be configured as follows. That is, the process standard work time acquisition unit calculates the process standard work time by removing an abnormal value from the process work time of the process of each product for various processes of the product.

As a result, the process standard working time can be obtained more accurately.

According to the present invention, in order to shorten the production lead time of a product, by identifying the problem of prolonging the production lead time intelligently, visually and quickly, pinpoint measures are taken to eliminate unnecessary waiting time. This can be avoided and the production lead time of the product can be shortened.

It is a block diagram which showed the structure of the production lead time analysis system 100 of Example 1. FIG. (A) shows an example of the work record information collected by the work record information collecting unit 101, and (b) shows the semi-finished products SM00001 to SM00004 to be assembled to the product of the product serial number P0000001 in the product PRD01. The Gantt chart for time on the horizontal axis is shown, and (c) shows the Gantt chart for time of four steps for processing and forming the semi-finished product of the semi-finished product serial number BD9AD01 in the semi-finished product SM00002. It is a graph which shows the analysis result of the process analysis unit 103 displayed on the display unit 105 in Example 1. FIG. It is a block diagram which shows the structure of the production lead time analysis system 200 of Example 2. It is a graph which shows the analysis result of the product analysis unit 201 displayed on the display unit 105 in Example 2. FIG. It is a block diagram which shows the structure of the production lead time analysis system 300 of Example 3. FIG. It is a graph which illustrated the situation of the production lead time of four semi-finished products of Example 3. It is a graph which shows the analysis result of the semi-finished product analysis unit 301 displayed on the display unit 105 in Example 3. FIG. It is a flow chart which shows the production lead time analysis method of Example 4. It is a graph for demonstrating the principle that the stagnation time occurs between two processes before and after a processing process. It is a graph for demonstrating the principle that the stagnation time occurs between each semi-finished product assembled in the same product. It is a graph for demonstrating the comparison between the actual working time of a process, and the standard working time of a process.

Hereinafter, modes for carrying out the present invention will be described. In the field of manufacturing, including manual manufacturing and machine manufacturing, the time required from ordering to delivery of a product usually includes processing work time, transportation time and stagnation time. Of these, the time when the ratio is the highest and the reduction is most feasible is the stagnation time. There are two main causes of stagnation, the first is that there is no seamless connection between the processes that are executed sequentially. For example, as shown in FIG. 10, when the horizontal direction of the paper is set as the time axis, there is a time difference between the work end time of the previous process and the work start time of the subsequent process in the two sequentially executed processes. In that case, unnecessary stagnation time occurs.

Second, each semi-finished product that can be assembled into the same product is not produced at the same time. For example, as shown in FIG. 11, when the horizontal direction of the paper is the time axis, it is assumed that a certain product is formed by assembling three semi-finished products, and that the three semi-finished products are assembled after the production is completed. In this case, since the production completion times of the three semi-finished products shown in the figure are not the same, unnecessary stagnation time occurs in the semi-finished products 1 and the semi-finished products 2.

In order to eliminate the above stagnation time as much as possible, unless it is clarified which process or which semi-finished product the stagnation occurs, the production flow can be improved pinpointly and the production lead time of all products. It is not possible to realize the shortening effect of.

Further, shortening of processing work time and transportation time is considered. In processes centered on manual work, standardization of work is often insufficient, so the time required varies even if the same process is carried out or the same product or semi-finished product is produced. In this regard, by establishing standard work, it is possible to realize pinpoint improvements in process work, product production, and semi-finished product production. For example, as shown in FIG. 12, a process standard work time is set for a certain process, and the time difference between the actual work time of the process and the process standard work time is set as the process delay time. A process with a long time is recognized as a process requiring improvement (for example, a process delay threshold may be set for determination). As a result, the production lead time of all products can be shortened more reliably.

Based on the above technical idea, the present invention analyzes the production lead time of one or more products by using the process work record information collected at the site in order to shorten the production lead time of the product in the manufacturing industry. A lead time analysis method and system are provided.

Next, the production lead time analysis method and system of the present invention will be described with reference to specific examples.

In the production lead time analysis system of this embodiment, the production lead time of a certain product PRD01 is analyzed, and each of the product PRD01 is processed by a plurality of semi-finished products through a plurality of steps, and each semi-finished product is processed. It is processed and formed through a plurality of steps.

As shown in FIG. 1, the configuration of the production lead time analysis system 100 includes a work record information collecting unit 101, a storage unit 102, a process analysis unit 103, an abnormality determination unit 104, and a display unit 105.

Here, the work record information collecting unit 101 collects the work record information of each related process for each of the product PRD01. As shown in FIG. 2A, for example, the work record information includes the work start time and work end time of each process, and the data source may be collected in real time at the manufacturing site or introduced from another database. May be done. Each of the product PRD01 is processed by assembling the semi-finished products SM00001 to SM000010, and each semi-finished product is processed and formed through a plurality of steps. It is processed and formed by the four steps of DDL-04. As an example, FIG. 2 (b) shows explanatory views for time of the semi-finished products SM00001 to SM00004 attached to the product with the product serial number P0000001 in the product PRD01, and FIG. 2 (c) shows the semi-finished product. Shown is a Gantt chart for time of four steps for processing and forming a semi-finished product of serial number BD9AD01 in SM00002.

The storage unit 102 stores the work record information collected by the work record information collection unit 101, and the storage format of the work record information in the storage unit 102 is not limited to FIG. 2A, and other It may be in the form.

The process analysis unit 103 is used for analyzing the work time of each process, and includes a process work time calculation unit 106, a process standard work time acquisition unit 107, a process delay time calculation unit 108, and a process stagnation time calculation unit 109.

Here, the process work time calculation unit 106 calculates the process work time for each process of the product PRD01 based on the work record information shown in FIG. 2A and stores it in the storage unit 102, and stores the process in the storage unit 102. The work time means the time difference between the work start time and the work end time of the process, that is, the processing time for completing the process. As a result, the corresponding process working time is stored in each process of the product PRD01.

The process standard work time acquisition unit 107 acquires the corresponding process standard work time for each process of the product PRD01 and stores it in the storage unit 102. As shown in FIG. 12 above, the concept of the process standard working time here is for determining the corresponding process delay time in comparison with the process working time of each relevant process of the product PRD01. In the examination of the process standard work time acquisition method, for example, regarding the process standard work time of the process of the process code L1-ASM-01, among the work record information stored in the storage unit 102, each process L1-ASM of the product PRD01 For the process work time of -01, the Smirnov-Grabs test is used to remove abnormal values from it and the remaining data are averaged, and the average value is also used as the process standard work time of process L1-ASM-01. good. As a result, the process standard working time is correspondingly stored in each process of the product PRD01.

The process delay time calculation unit 108 calculates the delay time of the process work time with respect to the corresponding process standard work time in the process for each process of the product PRD01, and stores it in the storage unit 102 as the process delay time of the process. do. As a result, the process delay time is correspondingly stored in each process of the product PRD01.

The process stagnation time calculation unit 109 calculates and stores the process stagnation time of each process other than the latest process among the processes used for processing and forming each of the product PRD01 and each of the semi-finished products SM00001 to SM000010. Store in unit 102. That is, the process stagnation time calculation unit 109 refers to each process of the product PRD01 except for the latest process of the processes used for processing and forming each semi-finished product and the latest process of all products. The stagnation time is calculated and stored in the storage unit 102, and the process stagnation time here is the time difference between the work end time of the process and the work start time of the next process of the process.

Here, first, since the slowest process in the product is the last process in the first place, the process stagnation time is not calculated. Further, the "process used for processing and forming a semi-finished product" means each step for forming the semi-finished product, for example, if the semi-finished product is completed by assembling a plurality of other semi-finished products. The "latest process among the processes used for processing and forming" of the semi-finished product is the assembling process of mutually assembling these other semi-finished products (when there are a plurality of assembling steps, the slowest one). Assembling process). If the semi-finished product is completed by assembling a plurality of other semi-finished products and then processed through a few steps, or if it is not completed by assembling a plurality of other semi-finished products, the semi-finished product is said. The "latest step among the steps used for processing and forming" of a product means the last step of a plurality of steps for producing the semi-finished product. As a result, the corresponding process stagnation time is stored in each of the products PRD01 except for the latest process for processing and forming the semi-finished product and the latest process in the product.

The abnormality determination unit 104 determines the process delay time and process stagnation time of each process using a preset threshold value stored in the storage unit 102. Specifically, the abnormality determination unit 104 determines that, among the respective processes of the product PRD01, the process whose process delay time exceeds the preset process delay threshold is the abnormal delay process, and each of the product PRD01. Of the above steps, a step in which the step stagnation time exceeds a preset process stagnation threshold is determined to be an abnormal stagnation step.

The display unit 105 displays the analysis result of the process analysis unit 103 in the production lead time analysis system 100 of this embodiment to the outside. As shown in FIG. 3, the abnormal delay rate and the abnormal stagnation rate of each process in the plurality of products PRD01 produced in a certain period may be displayed in a graph format. The abnormal delay rate and the abnormal stagnation rate of the process are calculated as process abnormality information by a calculation unit (not shown) based on the data of each item and stored in the storage unit 102, and the user can also use the graph on the computer display interface. By clicking various parts of, the process standard work time of each process, the process work time of a certain process, and other process abnormality information (for example, process delay time of each process, process stagnation time of each process, abnormal delay) It is also possible to acquire the process code and other identification information determined to be a process, the process code determined to be an abnormally stagnant process and other identification information, etc.). The analysis result of the process analysis unit 103 is shown as an example in FIG. 3, but the illustrated format is not limited to this.

Thus, according to this embodiment, in order to shorten the production lead time of the product, pinpoint measures are taken by locating the problematic process that prolongs the production lead time intelligently, visually and quickly. It is possible to avoid unnecessary waiting time and shorten the production lead time of the product.

As shown in FIG. 4, the configuration of the production lead time analysis system 200 of this embodiment has the same configuration as the production lead time analysis system 100 of the first embodiment, and further includes a product analysis unit 201, which is the production of each product. It is used for lead time analysis and includes a product production lead time calculation unit 202, a product standard production lead time acquisition unit 203, and a product delay time calculation unit 204.

Here, the product production lead time calculation unit 202 calculates and stores the product production lead time for each of the product PRD01 (that is, products having the same product number but different product serial numbers) based on the above-mentioned work record information. The product production lead time stored in the unit 102 is the work start time of the earliest process and the work of the latest process among the processes collected by the work record information collecting unit 101 stored in the storage unit 102. It means the processing time for producing the product, which is the time difference from the end time. As a result, each of the product PRD01 stores the corresponding product production lead time.

The product standard production lead time acquisition unit 203 acquires the product standard production lead time corresponding to the product PRD 01 and stores it in the storage unit 102. The definition of product standard production lead time here is similar to the process standard working time described above and is used to determine the corresponding product delay time as compared to each product production lead time of product PRD01. The method of acquiring the product standard production lead time is also similar to the process standard working time. For example, in each product production lead time stored in the storage unit 102, an abnormal value is removed by using the Smirnov-Grabs test, and the remaining value is removed. The data may be averaged and the average value may be used as the product standard production lead time of the product PRD01. As a result, the product standard production lead time is stored in the storage unit 102 for the product PRD01.

The product delay time calculation unit calculates the delay time of the product production lead time of the product with respect to the product standard production lead time for each of the product PRD01, and stores it in the storage unit 102 as the product delay time of the product. As a result, each of the product PRD01 is correspondingly stored in the product delay time.

In this embodiment, each product delay time of the product PRD01 is determined by the abnormality determination unit 104 also using a preset threshold value stored in the storage unit 102. Specifically, the abnormality determination unit 104 determines that each of the product PRD01 products whose product delay time exceeds the preset product delay threshold value is an abnormality delay product.

The display unit 105 displays the analysis result of the product analysis unit 201 in the production lead time analysis system 200 of this embodiment to the outside. When each of the plurality of products PRD01 to PRD10 produced in a certain period of time is analyzed using the production lead time analysis system 200 of this embodiment, as shown in FIG. 5, the abnormal delay rate and the average delay of each product are analyzed. The number of days may be displayed in a graph format. The product abnormality delay rate and the average delay days are calculated as product abnormality information by a calculation unit (not shown) based on the data of each item and stored in the storage unit 102, and the user can also use the graph on the computer display interface. By clicking various parts of, the product standard production lead time of each product, the product production lead time of a certain product, and other product abnormality information (for example, the product delay time of each product, the abnormality delay product is determined). It is also possible to obtain the product number and the order number, etc.). The analysis result of the product analysis unit 201 is shown as an example in FIG. 5, but the illustrated format is not limited to this.

Thereby, according to this embodiment, in order to shorten the production lead time of the product, pinpoint measures are taken by identifying the problem product that prolongs the production lead time intelligently, visually and quickly. It is possible to avoid unnecessary waiting time and shorten the production lead time of the product.

As shown in FIG. 6, the configuration of the production lead time analysis system 300 of this embodiment has the same configuration as that of the production lead time analysis system 100 of the first embodiment, and further includes a semi-finished product analysis unit 301. It is used for the analysis of the production lead time of the semi-finished product, and includes the semi-finished product production lead time calculation unit 302, the semi-product standard production lead time acquisition unit 303, the semi-product delay time calculation unit 304, and the semi-product stagnation time calculation unit 305.

Here, the semi-finished product production lead time calculation unit 302 calculates the semi-finished product production lead time for each semi-finished product of the product PRD01 based on the above-mentioned work record information and stores the semi-finished product production lead time in the storage unit 102. The product production lead time is the time difference between the work start time of the earliest process and the work end time of the latest process among the processes used for processing and forming the semi-finished product, which is stored in the storage unit 102. It means the processing time for processing and forming a product. As a result, the semi-finished product production lead time is correspondingly stored in each semi-finished product.

The semi-finished product standard production lead time acquisition unit 303 acquires the corresponding semi-finished product standard production lead time for each semi-finished product of the product PRD01 and stores it in the storage unit 102. The definition of the semi-finished product standard production lead time here is similar to the process standard working time described above, and the corresponding semi-finished product delay time is determined by comparing with the semi-finished product production lead time of each of the semi-finished products of the product PRD01. Used to do. The method for acquiring the semi-finished product standard production lead time is also similar to the process standard working time. For example, in the semi-finished product production lead time of each semi-finished product stored in the storage unit 102, the Smirnov-Grabs test is performed. The abnormal value may be removed and the remaining data may be averaged, and the average value may be used as the semi-finished product standard production lead time of the semi-finished product of the product PRD01. As a result, the storage unit 102 stores the semi-finished product standard production lead time for the semi-finished product of the product PRD01.

The semi-finished product delay time calculation unit 304 calculates the delay time of the semi-finished product production lead time for each semi-finished product of the product PRD01 with respect to the corresponding semi-finished product standard production lead time, and calculates the delay time of the semi-finished product production lead time. It is stored in the storage unit 102 as the product delay time. As a result, each semi-finished product of the product PRD01 stores the corresponding semi-finished product delay time.

The semi-finished product stagnation time calculation unit 305 calculates the semi-finished product stagnation time of the semi-finished product for each of a plurality of semi-finished products assembled in the same product, and the semi-finished product stagnation time here is the processing of the semi-finished product. This is the time difference between the work end time of the latest step of the steps used for forming and the work start time of the earliest step of the steps related to the mutual assembly.

Regarding "mutual assembly" here, for example, the semi-finished product C is processed and formed after the semi-finished product A and the semi-finished product B are assembled, and the final product is formed by assembling the semi-finished product C and the semi-finished product D. If so, the semi-finished product A and the semi-finished product B are "two semi-finished products used for mutual assembly", and the semi-finished product C and the semi-finished product D are "two semi-finished products used for mutual assembly".

In order to simplify the explanation, FIG. 7 shows the production lead times of the above four semi-finished products. The production of the semi-finished product A starts at time t0, the production is completed at time t1, and the production of the semi-finished product B is completed at time t2. From time t2 to t3, both semi-finished products A and B are stagnant. From t3 to t4 are the assembly process of the semi-finished product A and the semi-finished product B, that is, the "process related to the mutual assembly of the semi-finished product A and the semi-finished product B". The assembly process is completed at time t4, and the assembly is completed. Then, after a processing process for a certain period of time (time t4 to t6), the production of the semi-finished product C is completed at time t6. Production of the semi-finished product D was completed at time t5, and between the time t6 and t7, both the semi-finished products C and D were stagnant. From t7 to t8 are the assembly process of the semi-finished product C and the semi-finished product D, that is, the "process related to the mutual assembly of the semi-finished product C and the semi-finished product D". Is completed and the product is obtained. In this example, as can be seen from the above definition, the semi-product stagnation time of semi-product A is (t3-t1), the semi-product stagnation time of semi-product B is (t3-t2), and the semi-product stagnation time of semi-product C is. (T7-t6), the semi-finished product stagnation time of the semi-finished product D is (t7-t5).

As a result, each semi-finished product in each of the product PRD01 stores the corresponding semi-finished product stagnation time.

In this embodiment, the abnormality determination unit 104 also determines the semi-product delay time of each semi-finished product of the product PRD01 by using a preset threshold value stored in the storage unit 102. Specifically, the abnormality determination unit 104 determines that a semi-finished product having a semi-finished product delay time exceeding a preset semi-finished product delay threshold value in each of the product PRD01 is an abnormal delay semi-finished product, and semi-finished in each of the product PRD01. A semi-finished product whose product stagnation time exceeds a preset semi-finished product stagnation threshold is determined to be an abnormally stagnant semi-finished product.

The display unit 105 displays the analysis result of the semi-finished product analysis unit 301 in the production lead time analysis system 300 of this embodiment to the outside. As shown in FIG. 8, the abnormal delay rate and the abnormal stagnation rate of each semi-finished product in the plurality of products PRD01 produced in a certain period may be displayed in a graph format. The abnormal delay rate and the abnormal stagnation rate of the semi-finished products are calculated as semi-finished product abnormality information by a calculation unit (not shown) based on the data of each item and stored in the storage unit 102, and the user can also use the computer display interface. By clicking various parts of the graph, the semi-finished product standard production lead time of each semi-finished product, the semi-finished product production lead time of one semi-finished product, and other semi-finished product abnormality information (for example, the semi-finished product delay of each semi-finished product) Obtain time, semi-product stagnation time of each semi-finished product, semi-product number and rank number determined to be abnormally delayed semi-finished product, semi-product number and rank number determined to be abnormally stagnant semi-finished product, etc.) be able to. The analysis result of the semi-finished product analysis unit 301 is shown exemplary in FIG. 8, but the illustrated format is not limited to this.

Thereby, according to this embodiment, in order to shorten the production lead time of the product, pinpoint measures are taken by identifying the problematic semi-finished product that prolongs the production lead time intelligently, visually and quickly. It is possible to avoid unnecessary waiting time and shorten the production lead time of the product.

In this embodiment, regarding the production lead time analysis method, a flow chart of the production lead time analysis method is shown in FIG.

In the production lead time analysis method, the production lead time of a certain product PRD01 is analyzed, and each of the product PRD01 is processed by a plurality of semi-finished products through a plurality of steps, and each semi-finished product has a plurality of semi-finished products. It is processed and formed through a process.

First, in step S901, the work record information of each related process is collected for each of the products PRD01, and the work record information includes the work start time and the work end time of the process. Since it is the same as 1, the description thereof will be omitted.

Next, in step S902, for each process of the product PRD01, the process work time is calculated based on the above work record information, and the process work time is the time difference between the work start time and the work end time of the process. means.

Next, in step S903, the corresponding process standard working time is acquired for each process of the product PRD01. Since the definition of the process standard working time is the same as that in the first embodiment, the description thereof will be omitted.

Next, in step S904, for each process of the product PRD01, the delay time of the process work time of the process with respect to the corresponding process standard work time is calculated and used as the process delay time of the process. Since the specific definition of the process delay time is the same as that of the first embodiment, the description thereof will be omitted.

Next, in step S905, the process stagnation time of the process is set for each process excluding the latest process and the slowest process in the product among the processes used for processing and forming each semi-finished product in each product PRD01. The calculated process stagnation time is the time difference between the work end time of the process and the work start time of the next process of the process. Since the specific definition of the process stagnation time is the same as that of the first embodiment, the description thereof will be omitted.

Next, in step S906, the production lead time of the product is calculated for each of the products PRD01 based on the work record information, and the product production lead time is the product production lead time of each process collected in the work record information collection step. This is the time difference between the work start time of the earliest process and the work end time of the latest process.

Next, in step S907, the product standard production lead time corresponding to the product PRD01 is acquired, and the definition of the product standard production lead time is the same as that of the second embodiment, and thus the description thereof will be omitted.

Next, in step S908, for each of the products PRD01, the delay time of the product production lead time of the product with respect to the product standard production lead time is calculated and used as the product delay time of the product. Since the specific definition of the product delay time is the same as that of the second embodiment, the description thereof will be omitted.

Next, in step S909, the semi-finished product production lead time is calculated for each semi-finished product of the product PRD01 based on the work record information, and the semi-finished product production lead time is the step used for processing and forming the semi-finished product. This is the time difference between the work start time of the earliest process and the work end time of the latest process. Since the "step used for processing and forming" is the same as that of the first embodiment, the description thereof will be omitted.

Next, in step S910, the corresponding semi-finished product standard production lead time is acquired for each semi-finished product of the product PRD01. Since the definition of the semi-finished product standard production lead time is the same as that of the third embodiment, the description thereof will be omitted.

Next, in step S911, for each semi-finished product of the product PRD01, the delay time of the semi-finished product production lead time of the semi-finished product with respect to the corresponding semi-finished product standard production lead time is calculated, and the semi-finished product delay of the semi-finished product is calculated. Let it be time. Since the specific definition of the semi-finished product delay time is the same as that of the third embodiment, the description thereof will be omitted.

Next, in step S912, the semi-finished product stagnation time of the semi-finished product is calculated for each of the plurality of semi-finished products used for mutual assembly, and the semi-finished product stagnation time is included in the process used for processing and forming the semi-finished product. This is the time difference between the work end time of the latest process and the work start time of the earliest process among the processes related to mutual assembly. Since the specific definition of the semi-product stagnation time is the same as that of the third embodiment, the description thereof will be omitted.

Next, in step S913, an abnormality determination is performed, and specifically, a process in which the process delay time exceeds the preset process delay threshold is determined to be an abnormal delay process, and the process stagnation time is preset. A process that exceeds the stagnation threshold is determined to be an abnormal stagnation process, a product that exceeds the product delay threshold with a preset product delay threshold is determined to be an abnormal delay product, and a semi-product delay time is preset. A semi-finished product that exceeds the delay threshold is determined to be an abnormally delayed semi-finished product, and a semi-finished product that exceeds the preset semi-product stagnation threshold is determined to be an abnormally stagnant semi-finished product.

Next, in step S914, the display is performed. Specifically, the analysis result related to the process, the analysis result related to the product, and the analysis result related to the semi-finished product are displayed. Since the specific display contents are the same as those in the first to third embodiments, the description thereof will be omitted. At this point, the flow ends.

Thereby, according to this embodiment, in order to shorten the production lead time of the product, measures are taken pinpointly by identifying the problem of prolonging the production lead time intelligently, visually and quickly. It is possible to avoid unnecessary waiting time and shorten the production lead time of the product.
<Modification example>

Although each embodiment of the present invention has been illustrated and described above, as will be apparent to those skilled in the art, the present invention is not necessarily limited to each embodiment having all the configurations described. The configuration of another embodiment can be added to the configuration of one embodiment without departing from the technical idea of the invention, and another configuration can be added, deleted, or replaced with respect to a part of the configuration of each embodiment. It can be performed. An example of such a modification will be described below.

For example, the production lead time analysis system may include the product analysis unit 201 of the second embodiment and the semi-product analysis unit 301 of the third embodiment at the same time, and may not include the process analysis unit 103 of the first embodiment. Only the product analysis unit 201 of 2 or the semi-product analysis unit 301 of Example 3 may be included.

Further, the process analysis unit 103 of the first embodiment can calculate only the process delay time without including the process stagnation time calculation unit 109. Similarly, the semi-finished product analysis unit 301 of the third embodiment can calculate the semi-finished product. It is also possible to calculate only the semi-finished product delay time without including the stagnation time calculation unit 305.

Further, in each of the above embodiments, the analysis of a plurality of product PRD01 processed by a plurality of semi-finished products is described, but the product may be processed by only one semi-finished product, and in this case, the semi-finished product is used. Since there is no mutual assembly between products, the "latest process among the processes used for processing and forming" of the semi-finished product is the slowest process in all products. Further, each semi-finished product may be processed and formed through only one type of process, or only one product may be analyzed.

Further, in each of the above examples, the process standard working time of a certain process is calculated by averaging after removing abnormal values from a plurality of process working times of the process of each product using the Smirnov-Grabs test. However, the calculation method is not limited to this, and may be another data processing method other than the Smirnov-Grabs test. Further, the process standard work time may be acquired by calculation based on existing data, or may be artificially set in advance. For example, the process work time using an industry standard may be used. The product standard production lead time and the semi-finished product standard production lead time may also be acquired or preset by another calculation method for the same reason as described above.

Further, the production lead time analysis method of Example 4 includes steps S902 to S905 relating to process analysis, steps S906 to S908 relating to product analysis, and steps S909 to S912 relating to semi-finished product analysis, which are executed between them. The order is not limited to the above, and may be executed sequentially or simultaneously according to another execution order. Further, the production lead time analysis method may include only steps related to process analysis, only steps related to product analysis, or only steps related to semi-finished product analysis. In this case, step S913 may be included. In the abnormality determination step and the display step of step S914, only the corresponding target is determined and displayed.

Claims (12)

A production lead time analysis method for analyzing the production lead time of one or more products, wherein the product is processed by one or more semi-finished products through one or more steps, and the semi-finished product is one. Alternatively, in the production lead time analysis method, which is processed and formed through a plurality of steps.
It is a work record information collection step for collecting work record information of each related process for each product, and the work record information includes a step including a work start time and a work end time of the process.
It is a process work time calculation step for calculating the process work time based on the work record information for each process of each product, and the process work time is the time difference between the work start time and the work end time of the process. With a certain step
A process standard work time acquisition step for acquiring the corresponding process standard work time for various processes of the product, and a process standard work time acquisition step.
For each process of each product, a process delay time calculation step of calculating the delay time of the process work time with respect to the corresponding process standard work time in the process and using the process delay time of the process as the process delay time,
A production lead time analysis method characterized by including. A process stagnation time calculation step for calculating the process stagnation time of the process for each process excluding the latest process and the slowest process in the product among the processes used for the processing formation of each semi-finished product in each product. The production lead time analysis method according to claim 1, wherein the process stagnation time is a time difference between a work end time of the process and a work start time of the next process of the process. A process having a process delay time exceeding a preset process delay threshold is determined to be an abnormal delay process, and a process having a process stagnation time exceeding a preset process stagnation threshold is determined to be an abnormal stagnation process. Abnormality judgment step and
It is a step of displaying at least one of the process work time of each process, the process standard work time of various processes, and process abnormality information, and the process abnormality information is the process delay time of each process. A display step including at least one of the process stagnation time of the process, the abnormal delay rate of the process, the abnormal stagnation rate of the process, the identification information of the abnormal delay process, and the identification information of the abnormal stagnation process.
The production lead time analysis method according to claim 2, further comprising. It is a step of calculating the product production lead time for each product based on the work record information, and the product production lead time is the earliest step among the steps collected in the work record information collection step. The product production lead time calculation step, which is the time difference between the work start time and the work end time of the latest process,
The product standard production lead time acquisition step for acquiring the product standard production lead time corresponding to the product, and
For each product, the product delay time calculation step of calculating the delay time of the product production lead time with respect to the product standard production lead time of the product and using it as the product delay time of the product is further included.
In the abnormality determination step, a product whose product delay time exceeds a preset product delay threshold value is further determined to be an abnormality delay product.
In the display step, at least one of the product production lead time, the product standard production lead time, and the product abnormality information of each product is further displayed, and the product abnormality information is the product delay time of each product. The production lead time analysis method according to claim 3, wherein the product includes at least one of an abnormal delay rate, an average delay time, and identification information of the abnormally delayed product. For each semi-finished product of the semi-finished product, the step of calculating the semi-finished product production lead time based on the work record information, and the semi-finished product production lead time is one of the steps used for the processing formation in the semi-finished product. The semi-finished product production lead time calculation step, which is the time difference between the work start time of the earliest process and the work end time of the latest process,
For each of the semi-finished products of the above products, a semi-finished product standard production lead time acquisition step for acquiring the corresponding semi-finished product standard production lead time, and
For each semi-finished product of the semi-finished product, the delay time of the semi-finished product production lead time with respect to the corresponding semi-finished product standard production lead time of the semi-finished product is calculated, and the semi-finished product delay time is set as the semi-finished product delay time of the semi-finished product. Calculation steps and
It is a step of calculating the semi-finished product stagnation time of the semi-finished product for each of the plurality of semi-finished products used for mutual assembly, and the semi-finished product stagnation time is the most of the steps used for the processing formation of the semi-finished product. The semi-finished product stagnation time calculation step, which is the time difference between the work end time of the late process and the work start time of the earliest process among the processes related to the mutual assembly,
Including
In the abnormality determination step, a semi-product whose semi-product delay time exceeds the preset semi-product delay threshold is further determined to be an abnormal delay semi-product, and the semi-product stagnation time is preset. A semi-finished product that exceeds the above value is judged to be an abnormally stagnant semi-finished product.
In the display step, at least one of the semi-finished product production lead time of each semi-finished product, the semi-finished product standard production lead time of each semi-finished product, and the semi-finished product abnormality information is further displayed, and the semi-finished product abnormality information is displayed. , The semi-finished product delay time of each semi-finished product, the semi-finished product stagnation time of each semi-finished product, the abnormal delay rate of the semi-finished product, the abnormal stagnation rate of the semi-finished product, the identification information of the abnormally delayed semi-finished product, and the abnormal stagnant semi-finished product. The production lead time analysis method according to claim 3, wherein the production lead time analysis method includes at least one of the identification information of the above. A claim characterized in that, in the process standard work time acquisition step, for various processes of the product, the process standard work time is calculated by removing an abnormal value from the process work time of the process of each product. The production lead time analysis method according to any one of 1 to 5. A production lead time analysis system that analyzes the production lead time of one or more products, wherein the product is processed by one or more semi-finished products through one or more steps, and the semi-finished product is one. Alternatively, in the production lead time analysis system, which is processed and formed through a plurality of steps.
A work record information collection unit that collects work record information of each related process for each product, and the work record information includes a work start time and a work end time of the process, and a work record information collection unit.
It is a process work time calculation unit that calculates the process work time based on the work record information for each process of each product, and the process work time is the time difference between the work start time and the work end time of the process. There is a process work time calculation unit and
A process standard work time acquisition unit that acquires the corresponding process standard work time for various processes of the product, and a process standard work time acquisition unit.
For each process of each product, a process delay time calculation unit that calculates the delay time of the process work time with respect to the corresponding process standard work time in the process and sets it as the process delay time of the process.
A production lead time analysis system characterized by including. Process stagnation time calculation unit that calculates the process stagnation time of the process for each process excluding the slowest process and the slowest process in the product among the processes used for the processing formation of each semi-finished product in each product. The production lead time analysis system according to claim 7, wherein the process stagnation time is a time difference between a work end time of the process and a work start time of the next process of the process. A process having a process delay time exceeding a preset process delay threshold is determined to be an abnormal delay process, and a process having a process stagnation time exceeding a preset process stagnation threshold is determined to be an abnormal stagnation process. Abnormality judgment unit and
A display unit that displays at least one of the process work time of each process, the process standard work time of various processes, and process abnormality information, and the process abnormality information is the process delay time of each process. A display unit including at least one of the process stagnation time of each process, the abnormal delay rate of the process, the abnormal stagnation rate of the process, the identification information of the abnormal delay process, and the identification information of the abnormal stagnation process.
The production lead time analysis system according to claim 8, further comprising. A product production lead time calculation unit that calculates a product production lead time based on the work record information for each product, and the product production lead time is the product production lead time of each process collected by the work record information collection unit. The product production lead time calculation unit, which is the time difference between the work start time of the earliest process and the work end time of the latest process,
The product standard production lead time acquisition unit that acquires the product standard production lead time corresponding to the product, and the product standard production lead time acquisition unit.
For each of the products, a product delay time calculation unit that calculates the delay time of the product production lead time with respect to the product standard production lead time of the product and uses it as the product delay time of the product.
Including
The abnormality determination unit further determines that the product whose product delay time exceeds the preset product delay threshold value is an abnormality delay product, and further determines that the product is an abnormality delay product.
The display unit further displays at least one of the product production lead time, the product standard production lead time, and the product abnormality information of each product, and the product abnormality information is the product delay time of each product. The production lead time analysis system according to claim 9, wherein the product includes at least one of an abnormal delay rate, an average delay time, and identification information of the abnormally delayed product. A semi-finished product production lead time calculation unit that calculates a semi-finished product production lead time based on the work record information for each semi-finished product of each product, and the semi-finished product production lead time is the processing of the semi-finished product. The semi-finished product production lead time calculation unit, which is the time difference between the work start time of the earliest process and the work end time of the latest process among the processes used for formation,
A semi-finished product standard production lead time acquisition unit that acquires the corresponding semi-finished product standard production lead time for various semi-finished products of the above products.
For each semi-finished product of the semi-finished product, the delay time of the semi-finished product production lead time with respect to the corresponding semi-finished product standard production lead time of the semi-finished product is calculated, and the semi-finished product delay time is set as the semi-finished product delay time of the semi-finished product. Calculation part and
A semi-finished product stagnation time calculation unit that calculates the semi-finished product stagnation time of the semi-finished product for each of the plurality of semi-finished products used for mutual assembly. It further includes a semi-finished product stagnation time calculation unit, which is a time difference between the work end time of the latest process among the processes to be used and the work start time of the earliest process among the processes related to the mutual assembly.
The abnormality determination unit further determines that a semi-finished product having a semi-product delay time exceeding the preset semi-product delay threshold value is an abnormal delay semi-finished product, and the semi-product stagnation time is preset to a semi-product stagnation threshold value. A semi-finished product that exceeds the above value is judged to be an abnormally stagnant semi-finished product.
The display unit further displays at least one of the semi-finished product production lead time of each semi-finished product, the semi-finished product standard production lead time of each semi-finished product, and the semi-finished product abnormality information. , The semi-finished product delay time of each semi-finished product, the semi-finished product stagnation time of each semi-finished product, the abnormal delay rate of the semi-finished product, the abnormal stagnation rate of the semi-finished product, the identification information of the abnormally delayed semi-finished product, and the abnormal stagnant semi-finished product. The production lead time analysis system according to claim 9, wherein the production lead time analysis system includes at least one of the identification information of the above. 7. The process standard working time acquisition unit calculates the process standard working time by removing an abnormal value from the process working time of the process of each product for various processes of the product. The production lead time analysis system according to any one of 1 to 11.

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