JP3545921B2 - In-process production status management device, in-process production status management method, and recording medium - Google Patents

Description

[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to an apparatus for grasping and managing a production state in a production line, and more particularly to an in-process production state management apparatus capable of measuring an accurate operation state of a production line and accurately grasping the production state.
[0002]
[Prior art]
Understanding and managing the production status on the production line leads to an improvement in productivity. As a method or an apparatus for grasping and managing such a production situation, the finished side of a production facility such as a production line or a production apparatus manually counts the work volume or detects the movement of the work on the finished side of the production facility. There is a type in which a detecting means is provided and a production status is obtained based on a detection signal output from the detecting means. Such a method or apparatus only manages the production results, and when a problem occurs in a process, it cannot specify which process the position of occurrence is. For this reason, investigation of the cause at the time of occurrence of an abnormality is delayed, and does not necessarily lead to improvement in productivity.
[0003]
As an apparatus for solving such a problem, there is a work analysis apparatus disclosed in Japanese Patent Application Laid-Open No. 8-5414.
[0004]
As shown in FIG. 10, the work analyzer 110 is installed on the side of the belt conveyor in a production line where the worker continuously assembles works continuously conveyed on the belt conveyor, and the distance and time between itself and the worker are set. Measuring device 112 for measuring data, a host computer 124 for analyzing data obtained from the measuring device 112, a display 126 for displaying the analysis result, and for performing communication between the measuring device 112 and the host computer 124. The communication function 122 of FIG.
[0005]
The measuring device 112 includes a distance measuring function 114 for measuring the distance to the worker, a time measuring function 116 for measuring the time at which the distance was measured by the distance measuring function 114, a distance measuring function 114, and a time measuring function 116. It stores the distance information and the time information output from the memory function 118 and controls a memory function 118 accessible from the host computer 124 via the communication function 122, and these distance measurement function 114, time measurement function 116, and memory function 118. And a control function 120 for performing the control.
[0006]
As the distance measuring function 114 of the measuring device 112, a distance measuring device such as an ultrasonic sensor or an optical sensor is used.
[0007]
Further, as shown in FIG. 11, the belt conveyor includes a plurality of plates 130 each having a built-in measuring device 112 on an end face.
[0008]
In the work analyzer 110, the distance between itself and the worker and the time at which the distance was measured are constantly measured by the measuring device 112 installed on the end face of the plate 130 of the belt conveyor. The distance information and the time information are stored in the memory function 118 and further transferred to the host computer 124 via the communication function 122. The host computer 124 obtains the worker's work time, work start position, work end position, work distance, work movement speed, work end return speed, and the amount of change thereof based on the distance information and the time information. This makes it possible to grasp the work situation. Further, the host computer 124 can display an instruction for each worker via the display 126 in real time.
[0009]
[Problems to be solved by the invention]
However, the work analyzer 110 of Japanese Patent Application Laid-Open No. 8-5414 does not have the concept of tact time. For this reason, the host computer 124 that measures the operation status of the production line such as the working time based on the measurement result obtains the grasp of the production status such as the consistency of the line balance between the processes managed with a certain tact time. It is difficult to do correctly.
[0010]
Further, since the measuring device 112 including the distance measuring function 114 such as an ultrasonic sensor or an optical sensor is arranged on the end face of the plurality of plates 130 of the belt conveyor as the detecting means, the mechanism becomes complicated. Furthermore, since the work time is measured based on the distance information between the worker and the belt conveyor, there is a possibility that a malfunction occurs when the worker makes a complicated movement.
[0011]
In addition, it is desirable for a line operation supervisor who is far from the position of each worker to easily determine a process in which an abnormality has occurred, and to determine the consistency of line balance between processes.
[0012]
Therefore, in the present invention, it is possible to improve the consistency of the line balance between processes, to reduce the loss time, and to improve the productivity, and to immediately alert the operator when an abnormality occurs, and to take an action. The line supervisor can detect abnormalities and take appropriate action immediately, or determine the consistency of the line balance between processes, simplifying the mechanism, accurate work time and loss It is an object of the present invention to provide an in-process production status management device and a recording medium capable of measuring time.
[0013]
[Means for Solving the Problems]
An in-process production status management device according to claim 1 of the present invention is an in-process production status management device for managing the in-process production status of a production line on which an operator continuously assembles a work. Detecting means for detecting a work start signal due to arrival of a pallet flowing on the production line and a work end signal due to payout and outputting a detection signal, and measuring a time at which the work start signal and the work end signal are measured. A time measuring unit that outputs time information, receives a detection signal output from the detecting unit and time information output from the time measuring unit, calculates work time and loss time, and sets a preset target work time and target tact time. A control unit including a control unit for comparing the time with the time, a target time setting unit for setting and storing the target work time and the target tact time, and the control means. And a management computer that calculates a work time and a loss time for each worker based on the output signal information, time information, target work time, and target tact time and displays a time chart for each worker. Features.
[0014]
In the in-process production status management device according to claim 2 of the present invention, in the in-process production status management device according to claim 1, the control means is configured such that the work time or loss time is greater than a target work time or target loss time. It is characterized by further including a warning means for giving a warning to an operator when the size is larger.
[0015]
According to a third aspect of the present invention, there is provided the in-process production status management apparatus according to the first or second aspect, wherein the detecting means is disposed at a work position of each worker on the production line. And a switch that takes a first state in response to the pallet being placed on the top and a second state in response to the removal of the pallet.
[0016]
According to a fourth aspect of the present invention, in the in-process production status management apparatus according to the third aspect, the detection means takes an ON state as the first state, and the second state And a switch that is turned off.
[0017]
According to a fifth aspect of the present invention, in the in-process production status management apparatus, the management computer displays a warning for each worker when an abnormality further occurs.
An in-process production status management method according to claim 6 of the present invention is an in-process production status management method for managing an in-process production status of a production line on which an operator continuously assembles a work. A first step of detecting a work start signal due to arrival of a pallet flowing on a production line and a work end signal due to payout, and a detection signal for each worker detected in the first step and the signal is measured. A second step of measuring work time and loss time in response to the received time information, and comparing a preset target work time and target tact time with the work time and loss time obtained in the second step. A third step and calculating a work time and a loss time for each worker based on the target work time and the target tact time, and forming a time chart for each worker. And a fourth step Shimesuru.
A recording medium according to a seventh aspect of the present invention is characterized by storing a program for realizing the in-process production status management method according to the sixth aspect.
[0018]
BEST MODE FOR CARRYING OUT THE INVENTION
Hereinafter, an in-process production status management device according to one embodiment of the present invention will be described with reference to the drawings.
[0019]
FIG. 1 is a diagram showing a schematic configuration of an in-process production status management device according to an embodiment of the present invention.
[0020]
As shown in FIG. 1, an in-process production status management device 20 includes a belt in a production line in which a worker 22 assembles works continuously conveyed on a free-flow type belt conveyor 24 (hereinafter simply referred to as a belt conveyor). A detection unit 30 for detecting whether or not a pallet 28 on which a work flowing on the conveyor 24 is placed in the direction of the arrow 26 is located at the work position of each worker 22, and a detection signal obtained from the detection unit 30. A plurality of control devices 32 for obtaining the work status such as the work time of each worker 22 and a management device for grasping the production status such as the consistency of line balance between processes based on the work status of each control device 32. It comprises a computer 34 and a display 36 for displaying the production status.
[0021]
In the present invention, the means for exchanging signal information between the detection unit 30 and the control device 32 and the means for exchanging information between the control device 32 and the management computer 34 are configured by a wired system such as a LAN. Or a wireless system provided with a wireless wireless device.
[0022]
FIG. 2 is a diagram showing a schematic configuration and operation of a detection unit in the in-process production status management device according to the embodiment of the present invention.
[0023]
As shown in FIG. 2, the detection unit 30 is disposed at a position corresponding to a work position immediately below the pallet 28 on the conveyance path, and outputs a different voltage signal depending on whether or not the pallet 28 is placed. A detection device such as 40 is used. Alternatively, a foot sensor such as a photoelectric tube may be used.
[0024]
FIG. 3 is a diagram showing a schematic configuration of a control device in the in-process production status management device according to the embodiment of the present invention.
[0025]
As shown in FIG. 3, the control device 32 includes a voltage measurement unit 50 for receiving the voltage signal a of the detection unit 30 and outputting ON / OFF signal information, and a time measurement unit for measuring the time at which the voltage measurement is performed. Unit 52, a data storage unit 54 for storing signal information output from the voltage measurement unit 50 and time information output from the time measurement unit 52, and a data storage unit 54 for storing the voltage measurement unit 50, the time measurement unit 52, and the data storage unit 54. A control for performing a control, calculating a work situation such as a work time based on the signal information and the time stored in the data storage unit 54 and comparing it with a target value, and issuing a warning signal if necessary. A work time setting unit 58 for setting and storing a work time and a tact time as target values to be compared with a work time and the like in the control unit 56 and a tact time setting 60, and is composed of the working time warning unit 62 and the time loss warning unit 64 for issuing a warning to the operator receiving an alarm signal output by the control unit 56.
[0026]
Here, the output information b is ON / OFF signal information transmitted to the management computer 34 in accordance with the instruction request c from the management computer 34 to the control unit 56, time, target working time, and target tact time.
[0027]
Further, the voltage signal a may be transmitted from the detection unit 30 to the control device 32 at predetermined time intervals by time interruption, or the voltage signal a may be transmitted from the detection unit 30 according to an instruction request from the control device 32. .
[0028]
FIG. 4 is a diagram illustrating a schematic configuration of a management computer in the in-process production status management device according to the embodiment of the present invention.
[0029]
As shown in FIG. 4, the management computer 34 receives on / off signal information, time, target work time, and target tact time, which are information b output from each control device 32, and data for storing the data. A storage unit 70, a data processing unit 72 for calculating a production status such as a time chart for each worker based on data stored in the data storage unit 70, and a display unit for receiving and displaying the production status of the data processing unit 72. It comprises a data display section 74 for processing into data and displaying it on the display 36, a data storage section 70, a data processing section 72, and a control section 76 for controlling the data display section 74.
[0030]
Here, the output information b output from each control device 32 is an ON or OFF signal information transmitted to the management computer 34 in accordance with an instruction request c from the management computer 34 to the control unit 56 in each control device 32. , Time, target working time, and target tact time.
[0031]
Next, the operation of the in-process production status management device 20 according to the embodiment of the present invention is as follows.
[0032]
The processing of the detection unit 30 will be described with reference to FIGS.
[0033]
The detection unit 30 outputs the first voltage V1 in FIG. 5 when the pallet 28 is placed on the upper part of the limit switch 40 installed at the work position of the worker (FIG. 2B), When the pallet 28 is removed from the upper part of 40 (FIGS. 2A, 2C, and 2D), the second voltage V2 in FIG. 5 is output. A period 82 during which the first voltage V1 is output indicates a period during which the pallet is at the work position, and corresponds to a work time. A period 84 during which the second voltage V2 is output indicates a period during which the pallet is removed from the work position, and corresponds to a loss time. The total period 80 of the work time 82 and the loss time 84 is the tact time. Here, it is assumed that the first voltage V1 is higher than the second voltage V2, the first voltage V1 is turned on, and the second voltage V2 is turned off. Note that on and off may be reversed.
[0034]
The processing of the control device 32 will be described with reference to FIGS.
[0035]
First, the time measurement unit 52 performs time measurement S2 of the current time. In the voltage measuring section 50, a voltage value measurement S4 receiving the voltage signal a from the detecting section 30 is performed, and calculation S6 of signal information indicating whether the voltage value of the voltage signal is on or off is performed. . As a result, the time and signal information are stored in the data storage unit 54. Next, the control unit 56 receives the time and signal information stored in the data storage unit 54, and performs a calculation S8 of the work time 82 and the loss time 84. The work time 82 and the loss time 84 are compared with the target values, respectively, S10. If the actual measurement value is smaller than the target value, the process is continued. On the other hand, if the actual measurement value is larger than the target value, the control unit 56 outputs a warning signal. When the warning signal is output, the working time warning unit 62 or the loss time warning unit 64 issues a warning to the worker using a warning means such as a siren. Here, the target work time is a set value set in advance by the work time setting unit 58, and the target loss time is obtained by subtracting the target work time from the target tact time set in advance by the tact time setting unit 60. Value.
[0036]
The processing of the management computer 34 will be described with reference to FIGS.
[0037]
The management computer 34 receives the time b, the signal information, the target working time, and the target tact time information b from each control device 32 by issuing an instruction request c to each control device 32 through the control unit 76, and The signal is stored in the storage unit 70 in the form of a signal information table 90 and a target value table 92. The values in the target value table 92 are target values 100 of the working time, the loss time, and the tact time for each worker. The data processing unit 72 creates a worker-specific time chart 96, a worker-specific measured value (work time, loss time, tact time) and warning display data from the signal information table 90 and the target value table 92. The warning display data is data indicating the type of the measured value and the worker when the measured value exceeds the target value. These data are processed into display data by the data display unit 74 and displayed through the display 36.
[0038]
As shown in FIG. 8, the operator-specific time chart 96 is displayed as a graph in which the horizontal axis represents time, and the vertical axis represents signal information indicating ON or OFF, and parameters. The measured values for each worker are displayed in the display format of the measured value table 94. Also, based on the warning display data, the color or pattern of the data cell of the worker whose actual measurement value exceeds the target value is changed and a warning is displayed. For example, since the loss time 98 of the third worker exceeds the target value 100, for example, the pattern of the background is changed or displayed by enclosing with a thick frame as shown in FIG.
[0039]
The production manager can grasp the production status in real time by looking at the actual measurement value table 94, and can see the consistency of the line balance in the process by looking at the time chart 96 for each worker. For example, it is assumed that the pallet 28 flows in the order of a first worker, a second worker, and a third worker. FIG. 8A shows a state in which the work time and the loss time of each worker have little variation and the process is balanced. On the other hand, in FIG. 8B, the work time of the second worker and the first worker is long, and the loss time of the third worker is long. At this time, the following occurs between the lines. That is, there is some abnormality in the work performed by the second worker, and the work time is long. For this reason, the first worker sees that the pallet 28 cannot be moved and is apparently working because the post-process is blocked. On the other hand, the third worker waits for work because the pallet 28 does not flow from the second worker, and the loss time becomes longer. Therefore, the production manager can recognize that an abnormality has occurred in the work position of the second worker even from a place such as the production control room even if he is not on the side of the line. , Or go directly to the work position of the second worker, and can judge the situation with his / her own eyes, thereby enabling quick response.
[0040]
As described above, the in-process production status management device 20 according to the present invention can measure the accurate operation status of the production line and accurately grasp the production status.
[0041]
Further, a program for realizing a series of processing sequences in the in-process production status management device of the present invention includes a floppy disk, a hard disk, a magnetic tape, a medium such as a CD-ROM / optical disk / magneto-optical disk, an MD, and a ROM / RAM. The following is stored in a recording medium such as a memory. The program may be supplied from another system to the present system via communication.
[0042]
An example of the stored program content is for managing the in-process production status of a production line in which an operator continuously assembles a work, and has a specific configuration shown in FIG.
[0043]
As a first step, detection means S1 detects whether a pallet flowing on a production line (belt conveyor) is at a work position of an operator for each process, and outputs a detection signal as a voltage signal. Next, in the time information generating means, the measuring means, and the determining means constituting the control means, as a second step, the time information relating to the current time is generated by the time information generating means S2, and the time information outputted from the detecting means is outputted. The voltage signal (detection signal) is received by the measuring means S4, the voltage signal is converted into an information signal and calculated S6, and the working time and the loss time are calculated and output by the measuring means S8 together with the time information. Further, as a third step, a predetermined target work time, a predetermined target tact time, the work time and the loss time are received by the determination means, and a determination S10 is made as to whether or not an abnormality has occurred in each step. The control means outputs the output of the determination signal. Finally, as a fourth step, the work time, the loss time, and the determination signal output from the control means are received by the management computer, and the production status analysis processing S14 is performed, and the production status display S16 is performed. Is executed. Further, when it is determined whether or not an abnormality has occurred in each process, when an abnormality has occurred, the operation of issuing a warning S12 to a worker by a warning unit may be performed.
[0044]
The embodiments described here are not limited to the contents unless the gist of the present invention is changed.
[0045]
【The invention's effect】
As described above, in the in-process production status management device and the recording medium of the present invention, the following effects can be obtained in each claim.
[0046]
In claim 1 and claim 5 of the present invention, the work time and the loss time are always measured for each worker, that is, for each process, and the work time and the takt time are calculated. By performing the comparison, it is determined whether or not an abnormality has occurred in each step. The work time, tact time, and determination result are collected by the management computer, the production status is analyzed, and information such as abnormal locations in the process, work time, and loss time is presented to the production manager. Thus, the production manager can accurately grasp the production status. In addition, when an abnormality occurs, it is possible to specify the cause of whether the operation time is due to excessive working time or excessive loss time, and a quick response can be taken. Further, it is possible to improve the consistency of the line balance between the processes, reduce the loss time, and improve the productivity.
[0047]
According to a second aspect of the present invention, in addition to the operation of the first aspect, a warning can be issued to a worker by using a warning means when an abnormality has occurred. It is possible to call attention to the worker and to cause the worker to take an action immediately. In addition, the line work supervisor can immediately detect the abnormality and take appropriate measures, and judge the consistency of the line balance between processes.
[0048]
The third or fourth aspect of the present invention has the following effects in addition to the effects of the first or second aspect of the invention. The switch is in a first state or on when the pallet is in the work position of each worker, and the switch is in a second state or off when the pallet is removed. For this reason, it can be reliably detected that the pallet is placed and removed. Accordingly, only the passage of the pallet can be accurately measured without being affected by the movement of the operator, and the configuration of the apparatus can be simplified as compared with a detecting unit using an ultrasonic sensor or an optical sensor.
[Brief description of the drawings]
FIG. 1 is a diagram showing a schematic configuration of an embodiment of an in-process production status management device according to the present invention.
FIG. 2 is a diagram showing a schematic configuration and operation of a detection unit according to the present invention.
FIG. 3 is a diagram showing a schematic configuration of a control device according to the present invention.
FIG. 4 is a diagram showing a schematic configuration of a management computer according to the present invention.
FIG. 5 is a diagram illustrating a relationship between a signal output from a detection unit according to the present invention, a work time, a loss time, and a tact time.
FIG. 6 is a flowchart showing a processing flow of a control device according to the present invention.
FIG. 7 is a data flow diagram showing a data flow of a management computer according to the present invention.
FIG. 8 is a diagram showing a time chart for each worker according to the present invention.
FIG. 9 is a diagram showing a schematic processing sequence of an embodiment of the in-process production status management device according to the present invention.
FIG. 10 is a diagram schematically showing a conventional work analyzer.
FIG. 11 is a diagram showing an example of the arrangement of a conventional measuring instrument.
[Explanation of symbols]
Reference Signs List 20 In-process production status management device 24 Belt conveyor 28 Pallet 30 Detection unit 32 Control device 34 Management computer

Claims (7)

An in-process production status management device for managing an in-process production status of a production line on which a worker continuously assembles a work,
Detecting means for detecting a work start signal due to arrival of a pallet flowing on the production line for each process and a work end signal due to payout, and outputting a detection signal;
The work start signal, and working time for measuring the end signal measured time measuring unit for outputting time information, the detection means is the output detection signal and the time receiving the time information outputted from the measurement unit working time and A control unit that calculates the loss time , compares the target work time and the target tact time set in advance, and a control unit that includes a target time setting unit that sets and stores the target work time and the target tact time .
A management computer that calculates work time and loss time for each worker based on the signal information, time information, target work time, and target tact time output from the control unit and displays a time chart for each worker. An in-process production status management device characterized by including: 2. The process according to claim 1, wherein the control unit further includes a warning unit configured to warn an operator when the work time or the loss time is longer than the target work time or the target loss time. 3. Production status management device. The detection means is disposed at a work position of each worker on the production line, takes a first state in response to the pallet being placed on the upper part, and responds to the removal of the pallet. The in-process production status management device according to claim 1, further comprising a switch that takes a second state. 4. The in-process production status management device according to claim 3, wherein the detection unit includes a switch that turns on as the first state and turns off as the second state. 2. The in-process production status management apparatus according to claim 1, wherein the management computer displays a warning for each worker when an abnormality further occurs. An in-process production status management method for managing an in-process production status of a production line on which a worker continuously assembles a work,
A first step of detecting a work start signal due to arrival of a pallet flowing on a production line and a work end signal due to payout for each process;
A second step of measuring a work time and a loss time by receiving a detection signal for each worker detected in the first step and time information when the signal is measured;
A third step of comparing the preset target work time and the preset target tact time with the work time and the loss time obtained in the second step;
A fourth step of calculating a work time and a loss time for each worker based on the target work time and the target tact time and displaying a time chart for each worker;
A production status management method in a process, comprising: A recording medium storing a program for realizing the in-process production status management method according to claim 6.

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