JP3203918B2 - Neck process detection device - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a neck process finding apparatus for analyzing the operation status of a line in, for example, a production factory to find a process that becomes a bottleneck.

[0002]

2. Description of the Related Art Conventionally, in a production plant line, an operator records a stop record including a stop time of a line stop generated for each line and a cause of the stop, and based on the stop record, an average tact value (operating time). / Number of workpieces)
The operation status was analyzed based on the average tact value and the like. The stop record is written by hand on a predetermined sheet.

[0003]

However, in the above-described conventional line operating condition analyzing method, the average tact value (operating time / operating time / operation time) of each line is consequently determined based on the stop record entered by the operator. The number of workpieces). In addition, since the stop record is written by hand by a worker, there is a case where a worker temporarily forgets to record a so-called short stop, which is a temporary cutting stop.

[0004] For this reason, it is difficult to grasp the production results in the entire shop, and there is a problem that it is impossible to determine which line is the cause of the decrease in the production results. Further, there is a problem that it is difficult to grasp accurate operation data because there is a possibility that a recording omission or the like may occur.

The present invention has been made to alleviate such conventional inconveniences. A neck process finding apparatus capable of grasping accurate production results in the entire shop and finding a process which becomes a bottleneck is provided. The purpose is to provide.

[0006]

SUMMARY OF THE INVENTION In order to achieve the above object, the present invention provides a method for managing a plurality of lines provided in a shop.
This is a device that monitors the operating status to find the
The failure stop time that records the failure stop time of each line
Recording means and hand waiting to determine the occurrence of hand waiting for each line
Occurrence determination means and when it is determined that hand waiting has occurred
At the time of hand-paused stop to monitor hand-paused stop time of each line
Monitoring means, line tact measuring means for measuring and recording the line operation time of each line and counting the production results, and management means for setting the break time of each line ,
Excluding time overlapping with rest time from the breakdown stop time
A is the cumulative total of the actual stoppage time,
The actual hand-held stop except the time overlapping with the rest time
B for the total of the period, C for the total line operation time, and the actual production
If D, (A + B + C) × D / (A + C)
In addition, each product that can be produced if there is no waiting time
It is characterized in that a neck process calculating means for calculating a single production capacity of a line and a process which is a bottleneck among the plurality of lines are found by comparing the single production capacity for each line.

[0007]

The present invention thus constructed operates as follows.

The failure stop time recording means measures and records the time from the stop of the line due to a failure to the restart of the line as the line failure stop time based on the operation information and the failure stop information of each line.

The hand waiting time monitoring means measures and records the hand waiting time using the hand waiting judgment logic.

The line tact measuring means measures and records the line tact from the first equipment start to the last equipment stop and counts the production results.

In the management means, a break time and the like are set.
Based on the break time set here, record the breakdown stop time
Monitoring of downtime and waiting time recorded by means
From the hand-waiting stop time recorded by the means , the actual failure stop time and hand-waiting stop time excluding the rest time are calculated.

In the neck step calculating means, the failure stop time is recorded.
Monitoring of the stoppage time measured by the recording means and the stoppage time
The independent production capacity is calculated on the basis of the waiting time measured by the means and the line operation time and production results measured by the line tact measuring means.

The single production capacity indicates how much production was possible if there were no hand-held downtime , and the single production capacity = ( total line operation time + total failure stop time + manual operation time). Waiting and stopping time total ) x actual production / ( when line is operating )
(Cumulative total + cumulative failure downtime).

The operating status is analyzed by comparing the single production capacity for each line. Therefore, it is possible to grasp accurate production results in the entire shop and find a bottleneck process.

[0015]

An embodiment of the present invention will be described below with reference to the drawings. FIG. 1 is a block diagram showing a schematic configuration of a neck process finding apparatus according to the present invention, and shows only a portion related to the gist of the present invention.

A vehicle assembly shop 10 will be described as an example of a shop comprising a plurality of lines.

The body assembly shop 10 includes a front floor line 12, a rear floor line 14, an engine compartment (encon) line 16, a floor main line 18, a body main line 20, and an additional line 22.
Of each line.

A neck process finding device 24 according to the present invention is connected to each of the above-mentioned lines. In the embodiment shown in FIG. 1, the neck process finding device 24 connected to the floor main line 18 will be described. .

The neck process finding device 24 includes a failure stop recording function unit 26, a hand-waiting monitoring function unit 28, a line tact measurement function unit 30, and each of these function units connected to the floor main line 18. Independent management function unit 32, failure stop recording function unit 26, hand waiting monitoring function unit 2
8, a neck step calculation function unit 34 connected to the line tact measurement function unit 30 and the management function unit 32. The above-described failure stop recording function unit 26 functions as failure stop time recording means, and the hand waiting monitoring function unit 28 serves as hand waiting occurrence determining means.
The line tact measurement function unit 30 functions as a line tact measurement unit, the management function unit 32 functions as a management unit, and the neck process calculation function unit 34 functions as a neck process calculation unit. I do.

As shown in FIG. 2, the failure stop recording function unit 26 measures the time from the stop of the line due to the occurrence of the failure to the restart of the line based on the line failure timing signal. In the example illustrated in FIG. 2, when a failure occurs in the facility 1, a line failure stop is performed from the rising of the failure signal to the rising of the line operation signal due to the restart of the line stopped due to the failure. It is measured and recorded as time.

The hand waiting time monitoring means measures and records the hand waiting time using the hand waiting judgment logic. This waiting logic will be described with reference to FIG.

In the hand waiting determination process, first, it is determined whether the drop lifter is ready to be received (S
1) If the preparation for acceptance is completed, the monitoring timer is started (S2).

Then, it is determined whether or not the work has arrived at the drop lifter (S3). Here, if the workpiece does not arrive at the drop lifter, it is determined whether the value of the monitoring timer has exceeded the set value (S4). If the value of the monitoring timer has exceeded the set value, it is determined that hand waiting has occurred. Then (S
5) The value of the monitoring timer is regarded as the waiting time (S6),
The process returns to the work arrival determination processing (S3). On the other hand, if the value of the monitoring timer does not exceed the set value, it is determined that the waiting time is a normal waiting time, and the process returns to the work arrival determination processing (S3).

The above-mentioned work arrival determination processing (S3)
In the case where the workpiece arrives at the drop lifter, the monitoring timer value determined to be the hand waiting time in each of the above-described processes (S4, S5, S6) is recorded as the hand waiting time (S7). (S8).

The line tact measurement function unit 30 measures and records the time from the start of the first facility to the stop of the last facility as a line tact,
Count production results.

The measurement of the line tact will be described with reference to FIG. As shown in FIG. 4, the line tact is calculated as the total of the T / F transport time (A), the locating pin return time and the clamp return time (B), and the robot tact (C) in each step.

In the management means, a break time and the like are set.
Break time, which is set here, outage time and measured in outage recording unit described above, from the hand waiting the stopping time measured at hand waiting monitoring unit 28, to eliminate the time and duplicate intermission Use for By performing such processing, it is possible to ascertain the actual failure stop time and hand-stop time .

[0028] In the neck step calculating function unit 34, the outage time measured by the outage recording function unit 26, and hands waiting the stopping time measured at hand waiting monitoring unit 28 was measured with a line tact measurement function unit 30 line Calculate independent production capacity based on operating hours and production results. This stand-alone production capacity indicates how much production would be possible if there were no waiting time on a certain line, for example, how many cars could be produced. = ( Total line operating time + Total failure stopping time + Total waiting time ) × Production result / ( Line operating time
(Cumulative total + cumulative failure downtime).

By finding and comparing the above-mentioned single production capacity for each line, it is possible to find a bottleneck process.

In the neck process found in this way, if the measured line tact may exceed the target value or if the line tact is larger than the past line tact, the robot teaching is performed. It can be determined that the production capacity of the process is reduced due to a defect or a delay in the work of the worker. Therefore, it is possible to improve the production capacity in the neck process by improving the teaching of the robot or providing guidance to the worker.

Further, in the neck step finding device 24 according to the present invention, the failure rate can be calculated.

[0032] The failure rate, failure rate (%) = (outage time total) × 100 / (Lai
Total operation time + total failure stop time + total wait time
It is derived by the formula

Comparing the failure rate calculated in this way with another location, if the failure rate is higher than the other location, it is determined that the production capacity has decreased due to frequent failures. can do.

Further, in the neck step finding device 24 according to the present invention, at the time of the immediate termination, the total stop time is calculated for each immediate failure phenomenon. The logic for calculating the cumulative total stop time for each failure phenomenon will be described with reference to FIG.

In the process of calculating the total stop time for each fault phenomenon, first, the fault data is read, and the fault stop time and the fault phenomenon signal are fetched (S9).

Then, access the failure database,
A failure phenomenon similar to the read failure data is searched (S10). If there is data in the failure database related to the same phenomenon as the read failure data, the cumulative stop time is added to the failure database and recorded (S12). The failure data search processing described above (S1
0, S11) is performed for all the read failure data.

By sorting the data of the cumulative total stop time for each fault phenomenon calculated in this way in the descending order of the total stop time for each fault phenomenon, the fault record data is examined in the order of the cause of the fault which has been greatly related to the fault stop. be able to.

Based on the above processing, a neck process is found, and the neck process is improved by performing processes such as improvement of robot teaching, guidance of an operator, and elimination of a cause of a failure in the neck process. .

[0039]

According to the present invention as described above, according to the present invention, for each line, to record the outage recorded by fault stop time recording means, the hand waiting downtime <br/> by hand waiting stop time monitoring means While monitoring, the line operation time and the production result are measured by the line tact measuring means, and the break time and the like are set by the managing means. Then, the neck process calculating means calculates the single production capacity based on the data measured and recorded by each of the above means, and finds a process which becomes a neck.

Therefore, it is possible to accurately grasp the production capacity in the shop and easily analyze in which line the production capacity is reduced. Further, by improving the found neck process, the production efficiency can be improved.

[Brief description of the drawings]

FIG. 1 is a block diagram showing a schematic configuration of a neck process finding apparatus according to the present invention.

FIG. 2 is a time chart showing a line failure stop timing.

FIG. 3 is a flowchart of hand waiting determination logic.

FIG. 4 is an explanatory diagram showing a breakdown in a line tact.

FIG. 5 is a flowchart of a logic for calculating the total time of each failure phenomenon.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 10 Body assembly shop 12 Front floor line 14 Rear floor line 16 Engine compartment line 18 Floor main line 20 Body main line 22 Additional line 24 Neck process finding device 26 Failure stop recording function part 28 Hand waiting monitoring function part 30 Line tact measurement function Part 32 Management function part 34 Neck process calculation function part

──────────────────────────────────────────────────続 き Continued on the front page (58) Field surveyed (Int. Cl. ⁷ , DB name) G05B 15/00-15/02 B23Q 37/00-41/08

Claims (1)

(57) [Claims] 1. A plurality of lines provided in a shop
A device that monitors the operation status and finds the process that is the bottleneck
There is a failure stop time recorder that records the failure stop time of each line.
Step and hand waiting occurrence determining means for determining occurrence of hand waiting for each line
If, when the hand waiting is determined to have occurred, Temachi of each line
Hand waiting time monitoring means for monitoring the stop time, line tact measuring means for measuring and recording the line operation time of each line and counting the production results, and management means for setting the break time of each line. , Excluding time overlapping with rest time from the breakdown stop time
A is the cumulative total of the actual stoppage time,
The actual hand-held stop except the time overlapping with the rest time
B for the total of the period, C for the total line operation time, and the actual production
If D, (A + B + C) × D / (A + C)
In addition, each product that can be produced if there is no waiting time
Neck step of a neck step calculating means for calculating a single production capacity of the line, the single production capacity, characterized in that finding step which is a bottleneck in the plurality of lines by comparing for each line Discovery device.