JP2623566B2 - Sorting instruction device for production system - Google Patents

Description

Description: TECHNICAL FIELD The present invention relates to a device for instructing sorting of processed component materials in a factory.

(Related Art) For example, in a sewing factory, a predetermined quantity is set as one distribution unit for each component material required for production, and the distribution unit is distributed in a production line. The determination of the distribution unit to be supplied to the production line, that is, the sorting operation has conventionally been performed manually.

(Problems to be Solved by the Invention) As a result, there has been a problem that as the number of types increases, the sorting work becomes troublesome and the burden on the administrator increases.

(Purpose) The present invention has been made in order to solve the above-mentioned conventional problems, and in determining the number of distribution units of processed part material to be flown on a production line, only inputting data for sorting. Therefore, it is an object of the present invention to provide a sorting instruction device that can easily determine the number of distribution units.

(Means for Solving the Problems) In the production system according to the present invention, a product is distributed in a production line by dividing a predetermined quantity into one distribution unit for each component material required for the production in order to divide production of the product. The number of the distribution units for each of the component materials based on the limit quantity of the component material allowed for the distribution unit and the quantity required for each of the component materials predetermined according to the target production quantity of the product And a display means for displaying the number of distribution units calculated by the calculation means for each component material.

(Operation) When sorting, the calculating means is based on a limit quantity of the component material allowed in one distribution unit and a quantity required for each component material predetermined according to a target production quantity of the product. Then, the number of the distribution units is calculated for each component material. Then, the display means displays the number of distribution units calculated by the calculation means for each of the component materials.

(Embodiment) An embodiment in which the present invention is embodied in a work instruction system of a sewing factory will be described below with reference to FIGS.

Various sewing machines (not shown) are installed in the sewing factory. Each sewing machine is assigned a machine number, and a terminal 2 is installed. Each of the terminals 2 is connected to the control unit 3, and each of the terminals 2 is depressed when starting the operation of one operation process and outputs a start signal to output a start signal, and the operation process is completed. An input device including an end switch for outputting an end signal when pressed down, an operator leaving key for outputting an intermediate leaving signal to the control unit 3 on the host side when the operator leaves the office, and a liquid crystal display. Devices (both not shown) are provided.

Further, the terminal 2 has a central processing controller and a buffer for the terminal, and the buffer stores data from the control unit 3. When an end signal is output to the central processing controller by turning on the end switch, data in a buffer in the terminal is visually displayed on the liquid crystal display device. In the central processing control device, the sewing machine on which the terminal device 2 is installed starts a predetermined sewing operation, and outputs a work instruction request signal before a scheduled time to end the operation.

A control unit (hereinafter, referred to as CPU) 3 as arithmetic means constituted by a central processing control device includes a read-only memory (hereinafter, referred to as ROM) 4 for storing various control programs such as a sorting operation program, and a calculation result at that time. A read / write memory (hereinafter referred to as RAM) 5 and a clock 11 for storing input data from the input device 7 and various data created and edited by the CPU 3 performing arithmetic processing. The external storage device 6 is connected. The external storage device 6 includes various memory units such as an operator data memory unit, a machine data memory unit, a manufacturing priority order memory unit, a manufacturing item processing procedure memory unit, a work data memory unit, an operation memory unit, and a cutting information memory unit. Have.

The RAM 5 includes a worker data memory unit, a machine data memory unit, a manufacturing priority order memory unit, a manufacturing item processing procedure memory unit, and a work data memory unit similar to those of the external storage device 6, and at the start of the work command system. External storage device 6
The various data stored in advance in the RAM 5 are transferred to the corresponding memory unit of the RAM 5.

The worker data memory section stores the names of all workers in the factory and the skills possessed by each worker as shown in the memory map of FIG. 2, and the skills possessed are of a level corresponding to the skill level of the skills. Assigned according to the number, the smaller the number, the higher the skill level. For example, in the case of “A1” and “A2” in FIG. 2, the skill level of “A1” is higher. As shown in the memory map of FIG. 3, the machine data memory section stores a machine number, a function possessed by each sewing machine, and data indicating a busy sign indicating a use state of the sewing machine. As shown in the memory map of FIG. 4, the manufacturing priority memory section stores manufacturing items such as clothes and shoes such as shirts, the manufacturing priority determined for each item, and the lot of parts divided into the item rice. Data representing a number is stored.

As shown in the memory map of FIG. 5, the processing procedure memory unit 5 for each manufacturing item stores the name of the processing operation required for manufacturing the above-mentioned manufacturing item such as a shirt, the normal wearing procedure for performing the operation, and the operation. And data representing the required skills and functions of the machine, standard time data required to perform the work, and component materials required to perform the work.

As shown in the memory map of FIG. 6, the work data memory section includes the production item, the lot number, the work name, a pre-work completed sign indicating whether or not the work can be started, and the work performed. Based on transmission data from the terminal device 2, data indicating a processing sign indicating whether or not the work has been completed and a processed sign indicating whether the work has already been completed are stored. .

As shown in the memory map of FIG. 7, the operation memory unit is instructed work data in which the CPU 3 gives a work command at that time after the start of the system operation, that is,
A worker name, a lot number, a work name, a number of the terminal device 2 which transmitted the work command (hereinafter, referred to as a terminal number),
The command times at which the work commands were given are stored in the order in which the commands were given. Also, the external storage device 6
Is provided with a performance data memory section, and stores performance data for each sewn product and for each worker based on an end signal input from the terminal device 2.

The cutting information memory section stores the total lot number, size, and color (hereinafter, referred to as cutting information for each manufacturing item) for each manufacturing item. The cutting information for each manufacturing item includes a cutting information. The identification data indicating whether or not is completed.

An input device 7 composed of a keyboard is connected to the CPU 3, and stores data such as a worker name in each memory section of the external storage device 6 by input operation of provided keys. or. The input device 7 includes a sorting mode key operated when sorting work parts, a work command mode setting key operated when setting the work command mode, an operator input key, a report creation mode key, and a report item selection. Various keys such as a key and a next day work command mode key are provided. The communication device 9 transmits the data output from the CPU 3 to each terminal device 2. The display device 8 as a display means is connected to the CPU 3 and displays various display data output from the CPU 3. The printer 10 is connected to the CPU 3 and prints out various print data output from the CPU 3.

At the start of sewing, the CPU 3 transfers the contents of various memories from the external storage device 6 to the RAM 5, reads out the data stored in the manufacturing priority order memory section and the manufacturing item processing procedure memory section of the RAM 5, and should be manufactured with priority. The work name and the lot number are stored in the work data memory unit according to the work order of the manufactured item. At this time, the pre-processed signature is stored in an area of the processed signature corresponding to the first-ranked task name among the task names performed for each lot number of each manufactured item.

Further, the CPU 3 detects the worker name of the worker to be engaged in the work via the input device 7 and holds the stored skills corresponding to the worker names stored in the worker data memory unit. Is read and stored. Further, the CPU 3 searches the work data memory section for the work being processed by the worker, reads one work name that can be the next work after the work according to the read priority, and corresponds to the read work name. The necessary skills and functions to be performed are read from the processing procedure memory for each manufacturing item and stored.

The CPU 3 is configured to determine whether or not the required skill is included in the stored skills of the worker, and when the required skill is not included, read the next-ranked work name from the next work candidate memory unit. . Further, the CPU 3 reads the functions of the sewing machine that are not used in the order of the machine number from the machine data memory unit,
It is configured to sequentially determine and select whether or not the stored necessary functions are included, and read out the next-ranked work name when not included.

The CPU 3 visually displays the stored work name and the corresponding manufacturing item and lot number on the display device of the terminal device 2 via the communication device 9 and displays the selected machine number on the display device of the terminal device 2. Is configured to be visually displayed. The CPU 3 is configured to store the in-use sign corresponding to the machine number in the machine data memory unit and to store the in-process sign corresponding to the work name in the work data memory unit. In this way, the work name and the sewing machine to be used are allocated to the worker, and the sewing work is started.

Also, the CPU 3 waits until the work of one lot is completed and an end signal from the terminal unit 2 is generated. When the signal is generated, the CPU 3 sets the machine number of the sewing machine in which the terminal unit 2 is installed. Correspondingly, the in-use sign in the machine data memory is erased. Further, in both modes, the CPU 3 deletes the corresponding in-process sign in the work data memory unit, stores the processed sign, and at the same time stores the previous work sign corresponding to the next-ranked work name, and performs the above-described allocation. Configured to do the work,
Further, the CPU 3 adds the actual number of sewings produced based on the end signal inputted from each terminal 2 at that time, and stores the calculation result in a predetermined storage area of the external storage device 6. .

Thereafter, each time the work instruction request signal generated from each terminal 2 is generated, the CPU 3 sets the name of the next work to be performed, the machine number to be used, and the slot number. The terminal 2 and the machine number of the sewing machine are visually displayed on the liquid crystal display of the terminal 2.

The operation of the work command system configured as described above will be described.

First, the operation for sorting will be described with reference to the flowchart of FIG.

Cutting information for each manufactured item is stored in advance in the cutting information memory unit of the external storage device 6 by an input operation of the input device 7, and cutting is completed for cutting information for each manufactured item that has been cut. Identification data is assigned.

In this state, when an administrator (hereinafter, referred to as an operator) turns on a sorting mode key of the input device 7, the CPU 3 sets the sorting mode. Then, when the names of the production items to be sorted and the lot numbers thereof are input, the CPU 3 displays a message "Is sorting first?" On the display device 8. Next, when the operator selects YES on the input device 7 (Step 1, hereinafter, the step is represented by S), the CPU 3 reads the cutting information memory section in S2, and determines whether or not the cutting of the manufacturing item is completed. Is determined based on the read identification data. If it is determined in S2 that the cutting is completed based on the identification data, the CPU 3 stores the cutting information in the RAM 5
(S3), and in S4, all the component materials of the production item are transferred to the predetermined storage area of the RAM 5 based on the work process table of the production item processing procedure memory section of the external storage device 6 in S4.

Next, the CPU 3 determines the number of bundles for the first sewing product in S5 and
The number of component materials of the bundle is determined. Note that a bundle refers to a bundle that constitutes one lot, and each lot is composed of a plurality of bundles, and circulates in the production line for each bundle unit. The number of bundles for the first sewing product is determined by the following equation.

(AB) / C = Q ... R where A is the total number of sewn products, B is the currently sorted number, C is the maximum frequency of one bundle, Q is the quotient, and R (≧ 0).
Is the remainder. The total number A of the sewn products, the currently sorted number B, and the maximum frequency C are stored in the external storage device 6 by the input device 7 in advance, and are read out when performing this calculation.

If the remainder is R> 0, the CPU 3 determines the number of bundles to be Q + 1, and if R = 0, the number of bundles is Q
Is determined. Further, the CPU 3 determines the number of component materials constituting each bundle based on the following equation.

(AB) / Q = Y... T Here, Y is the quotient and T (≧ 0) is the remainder.

Based on the result of this operation, the number of component materials is (Y + 1)
T bundles and Y bundles of component materials are determined as {AB- (Y + 1) .T} / Y bundles. The CPU 3 stores the determined result in a predetermined storage area of the RAM 5.

When the operator operates the print key in S6, based on the result of S5, the CPU 3 performs the bundling instruction table in the lot number of the production item to be sorted, ie, the cutting information stored in the RAM 5 and the cutting information related to the production item. The name of the component material to be processed and the calculation result of S5 (the number of bundles and the number of component materials constituting each bundle) are printed out to the printer 10. In the case where the print key is not operated and the save key is input in S6, those data are transferred from the RAM 5 to the external storage device 6 and stored.

When the CPU 3 determines that the sorting is not the first in S1, the operator inputs the lot number of the manufactured item in S7 in order to create a necessary sorting instruction table list. By this input operation, the CPU 3 transfers data for creating a sorting instruction table list corresponding to the lot number of the manufacturing item stored in the external storage device 6 to the RAM 5 in advance, and then proceeds to S6.

If it is determined in S2 that the cutting has not been completed based on the identification data, the sorting mode ends.

Next, the operation in the work command mode will be described with reference to FIG.

The operator name and possessed skills are stored in advance in the operator data memory section of the external storage device 6 by operating the input device 7,
The machine data memory unit stores the machine numbers and their functions. Further, the manufacturing priority memory unit stores data indicating the manufacturing items of clothing such as shirts, the manufacturing priority determined for each item, and the lot number of parts divided for each item. The processing procedure memory for each item is stored in the memory section, for example, a work name necessary for manufacturing the above-mentioned manufacturing item of clothing such as a shirt, a processing sequence for performing the work, a required skill required for performing the work, and a required function of the machine. The data stored in each of the memory units is stored in the RAM 5 at the start of the work command system.
Are transferred to the respective memory units corresponding to Then, the data of the absentee is deleted by operating the worker delete key of the input device 7 and inputting the code number of the absentee on the day in the worker data memory section of the RAM 5.

The work data in the RAM 5 is a pre-worked sign and a processed sign corresponding to each work. Various types of signatures during processing are stored in accordance with the work state being performed at that time.

When the operation command mode setting key of the input device 7 is turned on, the CPU 3 sets the operation command mode. Now, when a work instruction request signal is input to the CPU 3 from the terminal device 2 (S1
1) Based on the work instruction request signal, the CPU 3 releases the protection so that the next work process can be read out from the RAM 5, and then executes the work process currently being worked (under processing) stored in the work data memory unit. A search is performed on the basis of the sign during processing, and a next work step after the searched work step and a work step for which the previous work completed sign has been completed and for which there is no working sign and processed sign are further searched (S12).

In S13, the CPU 3 determines whether or not there is a work step that can be started from the searched next work based on the data stored in the work data memory unit.If not, the next step is read out in S19. Performs the same processing. If it is determined in S13 that there is a next work that can be started, in S14 the optimum conditions such as possessed skills and necessary functions in the next work (for example, the skill level of the worker, the group to which the worker belongs, the optimum work place) And the like, and if there is no optimum condition, proceed to S19 to read the next work candidate, perform the same processing in S13 and S14, and store all the checked next work candidates in the RAM 5 Store in storage area.

Then, in step S15, the next work stored in the RAM 15 is selected from the next work based on the optimum condition checked, and the next work is performed so that no instruction is given for the next work process other than the selected optimum next work process. Is protected (S16). Further, the CPU 3 operates the selected work instruction data,
That is, data such as a work process, a machine number (that is, a terminal number), and a lot number are transmitted to the terminal device 2 that has output the work instruction request signal (S17). When transmitted to the terminal device 2, the CPU 3 stores the transmitted data and the name of the worker who has given the work command to the operation memory section of the external storage device 6, and stores the command time at which the work command was given in clock 11 (S18). On the other hand, the terminal device 2 stores the transmitted work instruction data in the buffer, displays the optimal work instruction stored in the buffer on the liquid crystal display device, and gives the work instruction.

When an end signal is generated, the CPU 3 detects the machine number of the sewing machine in which the terminal 2 is installed based on the end signal, and deletes the in-use sign corresponding to the machine number in the machine data memory unit. Then, the in-process sign corresponding to the work name in the work data memory unit is deleted, the processed sign is stored, and the pre-processed sign corresponding to the work name of the next order to the work name is stored.

In S14, the check of the optimum work place means that when the worker finishes the work after the expected work time (= standard time of the work × correction rate) in a certain work, the work process specified next is the same place ( In other words, if it is possible to work with the same sewing machine), or if it is not possible to work in the same place, it is determined whether the worker can work with a sewing machine in the same group to which the worker belongs. The shortest moving distance is the optimal work place. If there is no optimal work place, the result is stored in a predetermined storage area of the RAM 5, and the CPU 3 sends the result to the equipment (machine) based on the processing result stored in the predetermined area of the RAM 5 at the time of checking the optimum work place. Integrates processing to determine if there is a degree of load, calculates the load of all facilities for each facility, for each group to which the facility belongs, and stores the calculation results in a predetermined storage area of the RAM 5 for each work day. I do.

When the CPU 3 inputs a start signal generated when starting one work process and an end signal generated when the work process ends from the terminal device 2, the CPU 3 refers to the clock 11 to input the input time to execute the work process. The processing time is calculated, and the efficiency of the work process is calculated based on the calculation result and the standard time data of the corresponding work process stored in the processing procedure memory unit for each manufactured item. At this time, calculations are performed for each work process, for each worker, and for each group to which the worker belongs, and the calculation results are stored in a predetermined storage area of the RAM 5 for each work day.

Further, when the optimal work instruction is selected, the CPU 3 stores the skills of the worker given the instruction and the work group to which the worker belongs, and stores the composition ratio and level of the skills on a daily basis for each worker and for each worker. RAs are divided into groups to which they belong
It is stored in a predetermined storage area of M5.

In addition, the CPU 3 learns how much the worker has mastered for each lot number of the work process when performing a new work process (that is, the time required for the work when the same work is performed is mastered). Then, the degree of shortening is obtained by referring to the data of the work efficiency for each worker, and the result is stored in a predetermined storage area of the RAM 5 for each work day.

Also, the CPU 3 calculates the efficiency of each production item and the efficiency of each work process of the production item based on various data calculated at that time and stored in a predetermined storage area of the RAM 5, and similarly calculates the storage area of the RAM 5. To be stored.

Then, various performance data on work stored in the RAM 5, various skill data, various efficiency data, proficiency data,
Various load data and the like are transferred to and stored in the external storage device 6 by operating a storage key of the input device 7.

Next, a description will be given of a case where the worker has been on the way to work or has left the work halfway while the machining operation is being performed continuously, with reference to the flowchart shown in FIG.

When the operator operates the operator input key of the input device 7, the CPU 3 determines in S21 that he / she is on the way to work, and in S22, the operator inputs the code number of the worker on the way with the numeric keypad of the input device 7. The CPU 3 transfers the worker data corresponding to the code number from the worker data memory section of the external storage device 6 to the worker data memory section of the RAM 5,
U3 issues a work command based on the newly added data in the worker data memory section of RAM5.

That is, in S23, a work instruction routine having the same steps as those in the flowcharts from S12 to S16 shown in FIG. 8 is performed to determine an optimal work instruction, and in S24, the work place, work contents, etc. are displayed on the display device 8 on the host side. Is displayed, and in S25, the CPU 3 is the terminal 2 of the equipment to which the attendant should be on the way.
Then, the work command such as the work place and the work content shown in S24 is transmitted. The contents of the transmission and the instructed time are stored in the external storage device 6.
In the operation memory section of the
It returns to the main routine shown in the figure.

 Next, a case where the worker leaves the office halfway will be described.

When the worker operates the worker retirement key of the terminal 2, a halfway retirement signal is output to the CPU 3, and the CPU 3 determines in S21 that the retirement is halfway based on the signal. In step S26, when the worker who leaves the office inputs the code number of the worker leaving the office with the numeric keypad of the input device (not shown) of the terminal 2, the CPU 3
Receives the code number, and determines whether or not the end signal of the work related to the work process that previously gave an instruction as to whether or not the worker is currently operating is input from the terminal 2 where the worker is located. It is determined (S27).

If the end signal has not been input in S27, it is determined as YES, and the result is stored in a predetermined storage area of the RAM 5 based on the input of the work results (the number of processed pieces, work process) up to that point from the terminal device 2. Then, the CPU 3 transfers the work result to the storage area of the external storage device 6 for storing the result data in S29.
When the end signal is input in S27, the CPU 3 determines NO, and shifts to S29. That is, the operation results (the number of processed parts and operation steps) up to that point are transferred from the RAM 5 to the storage area of the external storage device 6 where the result data is stored. Then, the CPU 3 deletes the worker data corresponding to the code number of the leaving worker in the worker data memory section of the RAM 5. Thereafter, the process returns to the main routine shown in FIG.

Next, the report creation mode will be described with reference to the flowchart shown in FIG.

When the work command mode is ended and the save key of the input device 7 is operated, the CPU 3 stores various performance data, various skill data, various efficiency data, proficiency data, various load data, and the like in the work stored in the RAM 5. The data is transferred to the external storage device 6 and stored.

Next, when the operator turns on the report creation mode key of the input device 7, the CPU 3 sets the report creation mode, and various operation results data, various skill data, various efficiency data, proficiency data, various load data, and the like. From the external storage device 6 to the RAM 5. Then, the CPU 3 displays (1) worker, (2) manufacturing item, (3) equipment,
(5) A menu of a work history table is displayed, which shows what work or command was performed in the past.

(1) The menu of the workers is divided into small items such as a worker efficiency, a group efficiency, a worker skill, a group skill, and a worker proficiency. (2) Manufacturing items are divided into small items of efficiency by manufacturing item and efficiency of all manufacturing items. Further, (3) equipment is divided into small items of load by equipment, total equipment load, and load by equipment group.

The operator selects one of the above items with the report item selection key of the input device 7 (S31), and then selects S
At 32, the input of the calculation period is input by the ten keys of the input device 7. CPU3 corresponds to the period input in S33,
RAM5 data corresponding to the selected item one record at a time
Read from. Then, the CPU 3 sets S for each condition selected in S31.
Performs data accumulation processing during the period set in 32 (S3
Four). In S35, the CPU 3 determines whether or not the data in all the periods has been read, and if not, returns to S33. CP when reading data for all periods
U3 calculates the total at 36, and if the item requires the composition ratio, performs the calculation. If the calculation of the efficiency is required, calculates the efficiency.

Then, the CPU 3 displays various data of the calculated result on the display device 8 in S37 and prints the various data on the printer 10 in S38.

Next, the case of making a reservation for a work instruction tomorrow will be described with reference to the flowchart shown in FIG.

When the operator operates the next day work command mode key of the input device 7 after the work of the day is completed, the CPU 3 sets the next day work command mode. Then, when the operation of the operator delete key of the input device 7 and the code number of the absent tomorrow are input in S41, the CPU 3 deletes the data of the absent tomorrow from the worker data in the RAM 5.

Then, in S42, the CPU 3 rewrites the progress status to the work data memory unit based on the worker data other than the absences and the data stored in the various memory units at the end of today.
Then, in S43, the CPU 3 executes S12 to S16 shown in FIG.
A work instruction routine having the same steps as the flowcharts up to is performed to determine an optimal work instruction, and S44
To store the work place, work contents, and the like in a predetermined storage area of the RAM 5. In S45, the CPU 3 prints the worker tomorrow based on the worker data and the determined work place on the printer 10. Then, if this printed work instruction is given to a person who will start work tomorrow, the work of tomorrow can be started up quickly.

In this embodiment, as described above, absentees in factories,
The management of the production line can be performed flexibly and smoothly in response to the late or early leaver, and the adverse effects in the production line due to the occurrence of absent, late or early leave can be eliminated.

Further, in the present embodiment, it is possible to arbitrarily obtain a record of the past production activity in the factory and obtain various data, so that problems on the production line can be clarified and the production management can be easily performed. be able to.

In addition, since the work instruction of tomorrow can be given to the worker the day before, the work can be started up smoothly at the start of the work on the day.

It should be noted that the present invention is not limited to the all-date command, and can be arbitrarily changed without departing from the spirit of the present invention.

(Effects of the Invention) As described in detail above, in the present invention, when determining one distribution unit of a processing component material to be flown on a production line, simply inputting data for the sorting, the number of one distribution unit can be easily determined. It has an excellent effect that can be determined.

[Brief description of the drawings]

1 is an electric block diagram of one embodiment of the present invention, FIG. 2 is a worker data memory map, FIG. 3 is a machine data memory map, FIG. 4 is a manufacturing priority memory map, FIG. 5 is a processing procedure memory map for each manufacturing item, FIG. 6 is a work data memory map, FIG. 7 is an operation memory map, FIG. 8 is a flowchart in the sorting mode, and FIG. 9 is a work command mode. , FIG. 10 is a flowchart in the case of halfway in and out of work, FIG. 11 is a flowchart in the report creation mode, and FIG. 12 is a flowchart in the next day work instruction mode. 2 is a terminal device, 3 is a control unit (CP
U), 4 is a ROM, 5 is a RAM, 6 is an external storage device, 7 is an input device, 8 is a display device as display means, and 9 is a communication device.

Claims (1)

(57) [Claims] 1. A production system in which a predetermined quantity is distributed as one distribution unit in a production line for each part material required for the production in order to produce a product by division of labor. Calculating means for calculating the number of distribution units for each part material based on a limit quantity of the material and a necessary quantity for each part material predetermined according to a target production quantity of the product; Display means for displaying the number of distribution units calculated by the calculation means for each of the component materials, the sorting instruction apparatus for a production system.