JP4978833B2 - Work record analysis apparatus, work record analysis method, program, and recording medium - Google Patents

Description

  The present invention relates to a work record analysis apparatus that analyzes a work record of work performed on a production line or the like, and notifies a work record deficiency or the like.

  Conventionally, when work that stops the production line, such as repair of manufacturing equipment, has been performed on the production line, after the on-site worker completes the work, the work content is entered in a work record of paper and electronic data. It was.

  However, in a production line where troubles and failures occur frequently, restoration work may continue without a break, or multiple restoration works may occur simultaneously. In such a field, it is difficult for workers to leave all occurrences in the work record as a result of recovery work. Also, if an attempt is made to leave a work record manually, the record may be forgotten. For this reason, incompleteness such as omission or incorrect entry occurs in the work record, and the cause may not be pursued from the work record when dealing with complaints or improving quality.

  On the other hand, a method or apparatus for collecting stop information (non-operation information) by a collecting means for collecting operation data and storing the cause of the stop input by the input means for the stop information in association with the stop information Etc. have been proposed (see, for example, Patent Document 1, Patent Document 2, and Patent Document 3).

In such a conventional method or apparatus, if there is no cause of stop corresponding to the stop information, it can be determined that an input leak due to the stop has occurred, so it is possible to easily detect an input leak in the work record. it can.
Japanese Patent Laid-Open No. 11-188484 (first page, FIG. 1 etc.) JP 2002-202810 A (first page, FIG. 1 etc.) JP 2004-54701 A (first page, FIG. 1 etc.)

  However, in the above-described conventional technology, it is necessary to collect operation data of production facilities constituting the production line. In order to collect operation information of existing production equipment, it is necessary to modify the equipment or to change the sequence program such as a programmable controller installed in the equipment. This may also require changing the work procedure of the field worker. Therefore, introducing such a method and equipment into an existing production facility is very costly and cumbersome and cannot be easily introduced. For this reason, the conventional technique has a problem in that it is difficult to easily detect and notify a work record deficiency such as input leakage.

  The work record analysis apparatus of the present invention includes a production number information acquisition unit that acquires production number information, which is information obtained by counting the number of products produced on a production line constituted by one or more manufacturing apparatuses, and the production line. Production capacity information, which is information indicating the production capacity of the product, and dead time, which is information on the time required for the intermediate product manufactured by each of the one or more manufacturing apparatuses to become the product and the number of productions is counted A line information storage unit that can store information, a work record reception unit that receives work record information that is information about a work record that is a record related to a work that involves stopping the production line, and the production capacity An estimated production number calculation unit that calculates an estimated production number that is the production number of the product estimated at predetermined time intervals using the information, the dead time information, and the work record information; A reference value storage unit that can store a reference value used to detect deficiencies in work record information received by the work record reception unit, and the number of productions for each predetermined time interval acquired using the production number information A work record deficiency detection unit that detects a deficiency in work record information received by the work record reception unit by comparing a difference between the total production number and the estimated production number with the reference value; and the work record A work record analyzing apparatus comprising: an output unit configured to output a defect notification information for notifying a defect in a work record corresponding to the work record information when the defect detection unit detects a defect in the work record information; is there.

  With this configuration, it is not necessary to change production facilities or the like, and the deficiencies described can be easily and inexpensively detected.

  Further, in the work record analyzing apparatus according to the present invention, in the work record analyzing apparatus, the work record deficiency detecting unit has a value obtained by subtracting the value of the total production number from the value of the estimated production number from the reference value. Is larger than the work record information, it is detected that there is omission of work record information that is incomplete, and the output unit includes information for notifying the omission of work record corresponding to the work record information. It is a work record analysis device that outputs deficiency notification information.

  With such a configuration, it is possible to determine the omission of the work while eliminating the influence of the suspension.

  Further, in the work record analyzing apparatus according to the present invention, in the work record analyzing apparatus, the work record deficiency detecting unit may obtain a value obtained by subtracting the value of the estimated production number from the value of the total production number from the reference value. Is larger than the work record information, it is detected that there is an entry error in the work record information that is incomplete, and the output unit includes information for notifying an entry error in the work record corresponding to the work record information. It is a work record analysis device that outputs deficiency notification information.

  With such a configuration, it is possible to determine an error in the work entry by removing the influence of the suspension.

  Further, in the work record analyzing apparatus of the present invention, in the work record analyzing apparatus, when the work record deficiency detecting unit detects deficiency, a difference between the value of the estimated production number and the value of the total production number is calculated. Then, the value obtained by subtracting the reference value is divided by the value of the production capacity information to calculate a deficiency time that is a deficiency of the work record, and the output unit provides information on the deficiency time. Is a work record analysis device that outputs the deficiency notification information including

  With such a configuration, it is possible to inform the worker of the time when the work record is deficient, and the worker can remember the work contents using this deficiency time as a clue, and assists in correcting the work record deficiency. Can be easily corrected.

  Further, in the work record analyzing apparatus according to the present invention, in the work record analyzing apparatus, the work record deficiency detecting unit detects deficiencies in the work record information for each predetermined time interval, and the work record deficiency detecting unit is deficient. Using the start time and end time of the predetermined time interval in which the detection is detected, and the dead time information, occurrence time range information that is information indicating a time range in which the work record is defective is calculated. An operation time analyzing unit that further includes an occurrence time calculating unit, and wherein the output unit outputs the deficiency notification information including information notifying a time range indicated by the occurrence time range information calculated by the occurrence time calculating unit. .

  With this configuration, the worker can know the time when the work record is deficient, and the worker can easily correct the deficiency using this as a clue.

  Further, in the work record analyzing apparatus according to the present invention, in the work record analyzing apparatus, the occurrence time calculating unit is configured to start the predetermined time interval when the work record deficiency detecting unit detects deficiency from the start time of the predetermined time interval. Subtract the maximum value of the dead time information for all of the manufacturing apparatuses, and useless for all of the one or more manufacturing apparatuses from the end time of the predetermined time interval at which the work record deficiency detection unit detects the deficiency. It is a work record analyzing apparatus that subtracts a minimum value of time information and calculates the occurrence time range information.

  With this configuration, the operator can know the time when the work record deficiency occurred, and using this as a clue, the work record deficiency can be easily corrected.

  Further, in the work record analyzing apparatus according to the present invention, in the work record analyzing apparatus, the occurrence time calculation unit is configured to start from the start time and end time of the predetermined time interval when the work record deficiency detection unit detects deficiency. The work record analyzing apparatus calculates the generation time range information for each of the one or more manufacturing apparatuses by subtracting the dead time information corresponding to the one or more manufacturing apparatuses.

  With this configuration, it is possible to present to the worker the time at which the defect in the work record has occurred for each manufacturing apparatus. Using this as a clue, the worker can easily perform the work performed at each time. It can remind you.

  Further, in the work record analyzing apparatus according to the present invention, in the work record analyzing apparatus, the reference value is a product of a number of occurrences of a pause per predetermined time interval of the production line and an average time of the pause. This is a work record analyzing apparatus which is a value set by using.

  With such a configuration, it is possible to accurately determine a work entry error by removing the influence of the suspension.

  According to the work record analyzing apparatus and the like according to the present invention, it is possible to easily detect and notify the deficiencies in the work record.

  Hereinafter, embodiments of a work record analyzing apparatus and the like will be described with reference to the drawings. In addition, since the component which attached | subjected the same code | symbol in embodiment performs the same operation | movement, description may be abbreviate | omitted again.

(Embodiment)
FIG. 1 is a conceptual diagram showing an outline of the configuration of a production system in the present embodiment. The production system includes a work record analyzing apparatus 10, manufacturing apparatuses D1 to D5, and a production number counting apparatus C. The work record analyzing apparatus 10 and the production number counting apparatus C are connected via a communication line or the like so that they can communicate, for example.

  Manufacturing apparatus D1-D5 is an apparatus which produces an electric equipment, a machine, other products, parts, etc., The structure and the articles | goods manufactured are not ask | required. Here, the manufacturing apparatuses D1 to D5 and the production number counting apparatus C constitute a production line 20 for manufacturing a predetermined product. The manufacturing apparatuses D1 to D5 are connected by a conveyance path such as a belt conveyor, for example, and perform processing such as processing and assembly on parts and semi-finished products conveyed on the conveyance path in a predetermined procedure. Here, for convenience of explanation, a product manufactured by the manufacturing apparatus D5 and counted by the production number counting apparatus C is referred to as a product, and a part or a semi-finished product before becoming a product is referred to as an intermediate product. Therefore, the product referred to here is not limited to the final finished product, but also includes intermediate products. In the case of an intermediate product, further processing and assembly are performed in the subsequent process of this production system, and the final product is obtained. Usually, the manufacturing speed of each of the manufacturing apparatuses D1 to D5 is controlled and the tact balance of the production line 20 is maintained so that a state of waiting for an intermediate product conveyed from the preceding manufacturing apparatus does not occur. The contents of the processing performed by the manufacturing apparatuses D1 to D5 can be set by an instruction received by a receiving unit (not shown). For example, by changing processing conditions such as bending, pressure, and temperature, it is possible to change product quality such as product shape and operating characteristics. The quality described here is a concept including product characteristics and the like. Each of the manufacturing apparatuses D1 to D5 is usually a different apparatus that performs a different process, but each of the manufacturing apparatuses D1 to D5 may perform the same process or the same apparatus. In addition, although the case where the number of manufacturing apparatuses is five is described here, the number of manufacturing apparatuses is not limited as long as the number is one or more. In addition, here, a process for manufacturing products is performed in the order of the manufacturing apparatus D1, the manufacturing apparatus D3, the manufacturing apparatus D4, and the manufacturing apparatus D5, and the final product is carried out from the manufacturing apparatus D5. However, the order of arrangement of each manufacturing apparatus is appropriately set depending on the product to be manufactured.

  The production number counting device C counts (counts) the number of products produced. Here, the number of products produced by the production line, specifically, the number of products produced and carried out by the production apparatus D5 is counted. The production number counting device C uses, for example, a sensor such as an infrared sensor to count the number of products that have passed a position that can be detected by the sensor. In addition, about the structure which counts a production number, the various structures of the production number counting apparatus utilized for counting the number of production in a general production line can be utilized. The production number counting device C normally increments a count value indicating the production number by one each time one product is counted, and constitutes production number information which is information including the count value indicating the production number. The production number information preferably includes information on the time of counting. For example, the production number counting device C obtains the time information when the product is counted from, for example, a clock (not shown), and configures the production number information in association with the production number count value. The production number counting apparatus C transmits the work record analyzing apparatus 10 configured. There is no limitation on the timing or trigger at which the production number counting device C transmits production number information to the work record analyzing device 10. The production number counting device C may transmit the production number information every time it constitutes the production number information, or sequentially stores the production number information in a recording medium (not shown) and outputs an instruction to output the production number information. If accepted, the production number information may be transmitted. Instead of transmitting the production number information, the production number information may be sequentially stored on a removable recording medium or the like. The production number counting device C has the same configuration as the counting device used for counting the number of productions in a normal production line or the like, and therefore a detailed description thereof is omitted here.

  FIG. 2 is a block diagram showing a configuration of the work record analyzing apparatus 10.

  The work record analysis apparatus 10 includes a production number information acquisition unit 101, a line information storage unit 102, a work record reception unit 103, an estimated production number calculation unit 104, a reference value storage unit 105, a work record defect detection unit 106, and an occurrence time calculation unit. 107 and an output unit 108.

  The production number information acquisition unit 101 acquires production number information, which is information obtained by counting the number of products produced on the production line 20 constituted by the plurality of manufacturing apparatuses D1 to D5 and the production number counting apparatus C. The production number information acquisition unit 101 acquires production number information directly or indirectly from the production number counter C of the production line 20. There is no limitation on the method by which the production number information acquisition unit 101 acquires the production number information. The production number information acquisition unit 101 may receive production number information from the production number counting device C of the production line 20 or read production number information recorded on a recording medium such as a removable memory or disk. Also good. Here, as an example, a case where the production number information acquisition unit 101 acquires the production number information transmitted from the production number counter C will be described. The production number information acquisition unit 101 temporarily stores the acquired production number information and the like in a recording medium such as a memory (not shown). Further, when the production number information is transmitted from the production number counting device C every time counting is performed, the production number information acquisition unit 101 does not include the time information at which the production number information is counted. The time information when the production number information is received and the production number information may be stored in association with each other. The production number information acquisition unit 101 can be usually realized by an MPU, a memory, or the like. In addition, the production number information acquisition unit 101 may include a communication unit for receiving. The processing procedure of the production number information acquisition unit 101 is usually realized by software, and the software is recorded on a recording medium such as a ROM. However, it may be realized by hardware (dedicated circuit).

  In the line information storage unit 102, the production capacity information, which is information indicating the production capacity of the production line 20, and intermediate products manufactured by each of the plurality of manufacturing apparatuses D1 to D5 become products, and the number of production is counted. The dead time information which is information indicating the dead time which is the required time until is stored. Specifically, the production capacity is the number of production per predetermined time of the production line 20, and the production capacity information is information indicating the number of production per predetermined time. For example, the production capacity is represented by 35 (pieces / minute). Production capacity information is usually called line tact. The dead time is the time required for the intermediate product produced by each of the production apparatuses D1 to D5 to become a final product and be counted by the production number counting device C, and the dead time information is wasted. It is information indicating time. For example, the dead time for the manufacturing apparatus 3 is a time until an intermediate product manufactured by the manufacturing apparatus D3 becomes a product through the manufacturing apparatus D4 and the manufacturing apparatus D5 and is counted by the production number counting apparatus C. Normally, in a production line where tact balance is maintained, when one manufacturing device stops, the other manufacturing devices also stop. However, in order to reduce production loss of products, about the manufacturing devices downstream from the stopped manufacturing device Each of the intermediate products manufactured before the stop by the stopped manufacturing apparatus is stopped after the processing is completed. That is, all of the intermediate products manufactured before the stop by the stopped manufacturing apparatus, in other words, all the intermediate products on the transport path after the stopped manufacturing apparatus are processed by the manufacturing apparatus subsequent to the stopped manufacturing apparatus. Thus, the production line 20 as a whole is not stopped until it is counted by the production number counting device C. Therefore, in other words, the above-described dead time is the time from when each of the manufacturing apparatuses D1 to D5 stops until the production line 20 stops. The line information storage unit 102 stores dead time information corresponding to each of the manufacturing apparatuses D1 to D5. Specifically, manufacturing apparatus identification information, which is information for identifying each of the manufacturing apparatuses D1 to D5, and dead time information corresponding to each of the manufacturing apparatuses D1 to D5 are stored as a pair. The manufacturing device identification information is a name of a manufacturing device, a manufacturing number, or the like. In the line information storage unit 102, production capacity information and dead time information may be stored in advance at the time of factory shipment or the like, and information received by a receiving unit (not shown) or the like may be accumulated. The production capacity information and dead time information may be obtained by an experiment using the production line 20 or may be obtained by calculation from a design value of the production line. The line information storage unit 102 is preferably a non-volatile recording medium, but can also be realized by a volatile recording medium. It may be a non-volatile recording medium or a volatile recording medium. Note that the line information storage unit 102 may be configured by a plurality of physically different recording media and the like, and the production capacity information and the dead time information may be stored in different recording media.

  The work record accepting unit 103 accepts work record information, which is information about a work record that is a record related to a work that involves stopping the production line 20 with respect to the production line 20. The “operation that involves stopping the production line 20 with respect to the production line 20” is specifically an operation that requires one of the manufacturing apparatuses D1 to D5 that constitute the production line 20 to be stopped. By stopping each of the manufacturing apparatuses D1 to D5, as described above, the entire production line 20 is stopped as a result after the time when the dead time for the stopped manufacturing apparatus is added to the stopped time. The work record is, specifically, a record entered by the worker or the like regarding the work performed, for example, a record of the work start time, the work time, the manufacturing apparatus to be worked on, the worker name, the work content, etc. It is. The work record information is information indicating such a work record. Specifically, the work record information is information that can specify the start time and the work time of the work accompanied by the stop of the production line 20 performed on the production line 20. And manufacturing apparatus identification information of the manufacturing apparatus to be worked. As long as the manufacturing apparatus can be identified as a result, the manufacturing apparatus identification information may be, for example, information on a place where the manufacturing apparatus is arranged. Moreover, it is preferable that the work record information includes work content information. The information that can specify the start time and the work time may be, for example, information obtained by combining the start time information and the end time information, or the start time or end time information and the work time information. It may be information. The work content is a name of work performed on the manufacturing apparatus such as repair, replacement, and adjustment. The work record accepting unit 103 may accept work record information in any way. For example, work record information may be received from an input screen or the like that receives work records. In addition, work record information stored in a memory or the like as electronic data such as text information may be read and accepted in advance by an application for managing work management information, a word processor, or the like. Further, work record information recorded by an operator on work record paper or the like may be read out by OCR or the like. The work record information input means may be anything such as a numeric keypad, a keyboard, a mouse, or a menu screen. The work record receiving unit 103 can be realized by a device driver for input means such as a numeric keypad or a keyboard, control software for a menu screen, and the like.

  The estimated production number calculation unit 104 calculates an estimated production number, which is a production number of products estimated at predetermined time intervals, using the production capacity information, dead time information, and work record information. The estimated production number calculation unit 104 calculates the total stop time of the production line 20 for each predetermined time interval from the dead time information stored in the line information storage unit 102 and the work record information received by the work record reception unit 103. And the production time per predetermined time interval is calculated by subtracting this stop time from the predetermined time interval. Then, by multiplying the calculated production time by the production capacity information stored in the line information storage unit 102, the production number of products estimated to be produced at predetermined time intervals is calculated. The predetermined time interval may be a fixed predetermined time interval or an indefinite predetermined time interval. Specific processing in which the estimated production number calculation unit 104 calculates the estimated production number will be described later. The estimated production number calculation unit 104 can be usually realized by an MPU, a memory, or the like. The processing procedure of the estimated production number calculation unit 104 is usually realized by software, and the software is recorded in a recording medium such as a ROM. However, it may be realized by hardware (dedicated circuit).

  The reference value storage unit 105 stores a reference value that is used to detect deficiencies in work record information received by the work record reception unit 103. The reference value is, for example, a difference between the estimated production number calculated for each predetermined time interval calculated using the work record information and the product production number for each predetermined time interval due to incomplete work records. It is a value used to determine whether or not there is. For example, in a production line, there may be several pauses in the production line of about 1 minute that are not recorded in the work record due to product clogging or the like. Even if the work record is accurately recorded, There is a possibility that the counted production number of the product is reduced from the estimated production amount by the amount of the stoppage. For this reason, by setting the number of products considered to have not been produced due to such a temporary stop per predetermined time interval as the reference value, the difference between the estimated production number and the production number information of the product becomes the reference value. If it is within the range, it can be determined that there is no defect in the work record. As a specific example, the product of the number of occurrences of pauses per predetermined time interval of the production line 20 and the average time required for the pauses is calculated, set as a reference value, and the reference value storage unit 105 Store it in. At this time, a desired value may be added or multiplied to increase or decrease the deficiency detection accuracy with respect to the product of the number of occurrences and the average time. Note that the number of occurrences of pauses, the average duration of pauses, etc. may be obtained using information actually measured using the production line 20, etc., or calculated from the design values of the production line, etc. Also good. Further, an average value of the total of actually measured values of the pause times generated per predetermined time interval of the production line 20 may be set as the reference value. Such reference values received from a not-shown receiving unit or the like may be accumulated in the reference value storage unit 105 or stored in advance in the reference value storage unit 105 at the time of factory shipment or the like. Also good. This reference value is set corresponding to a predetermined time interval. The reference value storage unit 105 is preferably a non-volatile recording medium, but can also be realized by a volatile recording medium. It may be a non-volatile recording medium or a volatile recording medium.

  The work record deficiency detection unit 106 uses the production number information acquired by the production number information acquisition unit 101 and the total production number that is the production number for each predetermined time interval, and the estimated production number calculation unit 104 calculates. The difference between the number of productions and the reference value stored in the reference value storage unit 105 are compared to detect a defect in the work record information received by the work record receiving unit 103. The deficiency of work record information is specifically omission of work record information or wrong entry of work record information. The deficiency of work record information is substantially a deficiency of work records corresponding to the work record information. The total production number is a value obtained by totaling the number of products manufactured within a predetermined time interval or a value corresponding thereto. Here, the work record defect detection unit 106 calculates the total production number using the production number information acquired by the production number information acquisition unit 101. However, as a result, if the total production number can be acquired, it does not matter how the work record deficiency detection unit 106 acquires the total production number using the production number information. For example, by using the time information included in the production number information, the production number information included in each predetermined time interval can be detected. Among the production number information stored in, the number of production number information for each predetermined time interval may be counted, and the value obtained by this counting may be used as the total production number. In addition, by using the time information included in the production number information, the production number information obtained immediately before and after each predetermined time interval is started from the start time of each predetermined time interval. Since it can be detected, the total production number may be obtained by calculating the value of the counted production number of the production number information. For example, a value obtained by subtracting the value of the counted production number immediately before the start of the predetermined time interval from the value of the counted production number immediately before the end of one predetermined time interval is used as the total production number. Also good. Specifically, the total production number is a value of the number of products produced at predetermined time intervals. As a specific example, the work record deficiency detection unit 106 subtracts the value of the total production number acquired by the work record deficiency detection unit 106 from the value of the estimated production number calculated by the estimated production number calculation unit 104. When it is larger than the reference value stored in the reference value storage unit 105, it is detected that there is an omission in the work record information, which is an incomplete work record information. The omissions that can be detected by the work record deficiency detection unit 106 are, for example, that the work record is not filled in at all, or that the work time entered in the work record is shorter than actual. And information about the time at which the work was performed has not been entered. Further, the work record defect detection unit 106 subtracts the estimated production number value calculated by the estimated production number calculation unit 104 from the acquired total production number value, and a reference stored in the reference value storage unit 105. When the value is larger than the value, it is detected that there has been a mistake in entering the work record, which is an incomplete work record. The omissions that can be detected by the work record deficiency detection unit 106 include, for example, that a record of work that is not actually performed is entered in the work record, and that the work time entered in the work record is greater than the actual time. It has been written for a long time. Note that the work record defect detection unit 106 may detect both omissions and errors, or may detect only one of them. Further, the work record deficiency detection unit 106 may output a detection result indicating whether the work record information deficiency is a missing entry or a wrong entry, or simply detects whether a missing entry or a wrong entry is detected. In this case, a detection result indicating that the work record is incomplete may be output. In addition, when the work record deficiency detection unit 106 detects deficiency, the reference stored in the reference value storage unit 105 is obtained from the difference between the estimated production number and the total production number for a predetermined time interval at which deficiency is detected. The value obtained by subtracting the value is divided by the value of the production capacity information stored in the line information storage unit 102 to calculate the deficiency time that is the time when the deficiency of work records occurs. May be. The difference here may be an absolute value of the difference between the two. The work record defect detection unit 106 can be usually realized by an MPU, a memory, or the like. The processing procedure of the work record defect detection unit 106 is usually realized by software, and the software is recorded in a recording medium such as a ROM. However, it may be realized by hardware (dedicated circuit).

  The occurrence time calculation unit 107 uses the start time and end time of a predetermined time interval at which the work record deficiency detection unit 106 detects deficiency and the dead time information stored in the line information storage unit 102 to record the work record. Occurrence time range information, which is information indicating a time range in which a defect occurs in the information, is calculated. For example, the occurrence time calculation unit 107 subtracts the maximum value of the dead time information for all of the plurality of manufacturing apparatuses D1 to D5 from the start time of a predetermined time interval when the work record deficiency detection unit 106 detects deficiency. Thus, information on the start time is obtained for the range of time when the deficiency occurs. Further, the deficiency occurs by subtracting the minimum value of the dead time information for all of the plurality of manufacturing apparatuses D1 to D5 from the end time of the predetermined time interval at which the work record deficiency detection unit 106 detects the deficiency. Get end time information for a range of times. The information on the start time and the information on the end time obtained in this way are used as the generation time range information. Moreover, you may calculate generation | occurrence | production time range information for every manufacturing apparatus D1-D5 as follows. That is, the occurrence time calculation unit 107 subtracts the dead time information corresponding to each of the plurality of manufacturing apparatuses D1 to D5 from the start time of the predetermined time interval when the work record deficiency detection unit 106 detects deficiency, The information of the start time is obtained for each manufacturing apparatus D1 to D5 with respect to the time range where the deficiency occurs. Further, the dead time information corresponding to each of the plurality of manufacturing apparatuses D1 to D5 is subtracted from the end time of the predetermined time interval when the work record deficiency detection unit 106 detects the deficiency, and each of the manufacturing apparatuses D1 to D5 is subtracted. The information of the end time is obtained for the time range where the deficiency occurs. The information on the start time and the information on the end time obtained in this way may be used as the generation time range information of each of the manufacturing apparatuses D1 to D5. The occurrence time calculation unit 107 can be usually realized by an MPU, a memory, or the like. The processing procedure of the generation time calculation unit 107 is usually realized by software, and the software is recorded in a recording medium such as a ROM. However, it may be realized by hardware (dedicated circuit).

  When the work record deficiency detection unit 106 detects a deficiency in the work record information, the output unit 108 configures and outputs deficiency notification information for notifying a work record deficiency corresponding to the work record information. The output unit 108 may output according to the content of the work record information deficiency, or may output a notification indicating only deficiency. For example, when the work record deficiency detection unit 106 detects a work record entry failure, the output unit 108 configures and outputs deficiency notification information including information for notifying the work record entry failure. Further, for example, when the work record deficiency detection unit 106 detects an entry error in the work record, the output unit 108 outputs deficiency notification information including information for notifying the entry error in the work record. In addition, when the work record deficiency detection unit 106 calculates deficiency information, in addition to the work record deficiency, deficiency notification information including this deficiency information may be configured and output. Further, the output unit 108 configures and outputs deficiency notification information including information notifying the time range indicated by the occurrence time range information calculated by the occurrence time calculation unit 107 in addition to the notification of the deficiency of the work record. Also good. The deficiency notification information configured by the output unit 108 may be numbers, text information, image information, charts, graphs, and the like as long as it can notify deficiencies in work records. The information may be included. In particular, the output unit 108 uses a symbol such as an arrow or a line to indicate the time range indicated by the occurrence time range information when the time when the defect occurs is represented by a chart, graph, or table with the horizontal axis set to time. The range may be displayed, or the range may be displayed by changing the background color, the background pattern, or the like. The output described here is a concept including display on a display, printing on paper by a printer, sound output, transmission to an external device, and the like. The output unit 108 may or may not include an output device such as a display or a printer. The output unit 108 can be realized by output device driver software, or output device driver software and an output device. Further, the output unit 108 may include an MPU, a memory, and the like for configuring the defect notification information.

  Next, the operation of the production system of this embodiment will be described.

  First, the operation of the production line 20 will be described. In the production line 20, each of the manufacturing apparatuses D1 to D5 sequentially performs the manufacturing using the intermediate product, and the production number counting apparatus C counts the number of manufactured products, and the result of the counting and the time of the counting Measurement production number information including information is sequentially constructed. Then, the configured production number information is transmitted to the work record analyzing apparatus 10. In addition, when any of the manufacturing apparatuses D1 to D5 is stopped, the subsequent manufacturing apparatus of the stopped manufacturing apparatus processes each of all intermediate products manufactured by the stopped manufacturing apparatus before the stop. After stopping, it stops sequentially.

  Next, the operation of the work record analysis apparatus 10 will be described using the flowchart of FIG. Here, it is assumed that a plurality of production number information output from the production line 20 is acquired in advance by the production number information acquisition unit 101 and recorded in a memory or the like.

  (Step S301) The work record accepting unit 103 accepts work record information.

  (Step S302) The estimated production number calculation unit 104 acquires the dead time corresponding to the work record information received in step S301 from the dead time information stored in the line information storage unit 102. As a specific example, the estimated production quantity calculation unit 104 uses, as a search key, manufacturing apparatus identification information that identifies a manufacturing apparatus that is a work target included in each work record information. The associated dead time is retrieved from the dead time information and acquired.

  (Step S303) The estimated production number calculation unit 104 calculates a loss time using the work record information received in step S301 and the dead time information read in step S302. The loss time is a time, for example, a start time, that can be used to specify a period that is estimated that the production number counting device C has not counted the product, which is calculated using the work record information. For example, since the time when the production number counting device C did not count is usually the same as the time required for the work performed on the desired manufacturing device, the work record information is intended for the desired manufacturing device. As the loss time, only the start time estimated that the production number counting device C did not count the product is calculated as the loss time. . Specifically, after each manufacturing apparatus is stopped by work, the product count of the production number counter C is stopped from the time delayed by the dead time corresponding to the stopped manufacturing apparatus. For this reason, for example, by subtracting the dead time obtained by the search in step S302 from the work start time included in the record corresponding to the manufacturing apparatus identification information used for the search among the records of the work record information, Get the loss time.

  (Step S304) The estimated production number calculation unit 104 uses the loss time acquired in step S303 to calculate the total loss time included in each predetermined time interval during the period in which the production line 20 produced. The production time for each predetermined time interval is calculated by calculating and subtracting from the predetermined time interval. Total loss time is the time that a product was not manufactured. Here, the total loss time is calculated as the sum of the loss time, which is the time during which the production number counting device C has not been counted due to the stop of the manufacturing apparatus accompanying the work, for each predetermined time interval. For example, if the time determined by a predetermined time interval is from 13:00 to 14:00, and the loss time is from 13:45 to 14:10, the total time from 13:00 to 14:00 The loss time is 15 minutes from 13:45 to 14:00, and the production time is 45 minutes.

  (Step S305) The estimated production number calculation unit 104 acquires the production capacity information stored in the line information storage unit 102, and uses this production capacity information and the production time acquired in step S304 to set a predetermined time interval. Calculate the estimated number of production for each. Specifically, the estimated production quantity is calculated by multiplying the production time by a value indicating the production quantity per predetermined time indicated by the production capacity information.

  (Step S306) The work record defect detection unit 106 uses the production number information acquired by the production number information acquisition unit 101 to acquire a total production number that is the number of products produced at each predetermined time interval. As a specific example, from the count value included in the production number information acquired immediately before the end of each predetermined time interval, the total number included in the production number information acquired immediately before the start of each predetermined time interval. By subtracting the numerical value, the total production number for each predetermined time interval is acquired. Further, the total production number may be acquired by counting the number of production number information included in each predetermined time interval. The acquired total production number is temporarily stored in a memory (not shown), for example.

  (Step S307) The work record defect detection unit 106 substitutes 1 for the counter K.

  (Step S308) The work record deficiency detection unit 106 determines whether or not the Kth predetermined time interval exists within the period for which work record information is to be entered. For example, if the time period for which the work record is to be recorded, specifically, the worker's working time is the time from 8:00 to 20:00, and the predetermined time interval is 1 hour, K = 1. The first predetermined time interval is the time from “8:00 to 9:00”, and K = 2 the second predetermined time interval is the time from “9:00 to 10:00”. Become. When it exists, it progresses to step S309, and when it does not exist, it progresses to step S317.

  (Step S309) The work record deficiency detection unit 106 calculates the estimated production number for the Kth predetermined time interval from the estimated production number acquired in Step S305 and the total production number acquired in Step S306. Get production number and.

  (Step S310) The work record defect detection unit 106 subtracts the total production number acquired in Step S309 from the estimated production number acquired in Step S309.

  (Step S311) The work record defect detection unit 106 acquires the reference value from the reference value storage unit 105, and determines whether or not the difference obtained as a result of the subtraction in step S310 is larger than the reference value. If so, the process proceeds to step S312, and if not, the process proceeds to step S318.

  (Step S312) The work record deficiency detection unit 106 detects that the work record is not filled in the Kth predetermined time interval.

  (Step S313) The work record defect detection unit 106 reads the production capacity information stored in the line information storage unit 102, and subtracts the total production number acquired in step S309 from the estimated production number acquired in step S309. The value obtained in this manner is divided by the value indicated by the read production capacity information to calculate the deficiency time within the Kth predetermined time interval.

  (Step S314) The occurrence time calculation unit 107 uses the start time and end time of the Kth predetermined time interval in which the deficiency is detected in Step S312 and the dead time information stored in the line information storage unit 102. Then, at least one of the generation time range information indicating the time range in which the deficiency occurs for the entire production line 20 or the generation time range information for each of the manufacturing apparatuses D1 to D5 is calculated.

  (Step S315) The work record defect detection unit 106 associates the detection result of the omission with the generation time range information calculated by the generation time calculation unit 107, and accumulates it in a memory or the like (not shown).

  (Step S316) The work record defect detection unit 106 increments the counter K by one. Then, the process returns to step S308.

  (Step S317) The output unit 108 forms deficiency notification information using the detection result of omissions stored in a memory or the like, occurrence time range information, and the like, and outputs it to an output device such as a display. Then, the process ends. If no defect is detected in the work record, an output indicating that there is no defect may be output, or no output may be performed.

  (Step S318) The work record deficiency detection unit 106 subtracts the estimated production number acquired in Step S309 from the total production number acquired in Step S309.

  (Step S319) The work record defect detection unit 106 acquires the reference value from the reference value storage unit 105, and determines whether or not the difference obtained as a result of the subtraction in step S318 is larger than the reference value. If so, the process proceeds to step S320, and if not, the process proceeds to step S316.

  (Step S320) The work record deficiency detection unit 106 detects that there is a mistake in entering the work record within the Kth predetermined time interval.

  (Step S321) The work record defect detection unit 106 reads the production capacity information stored in the line information storage unit 102, and subtracts the estimated production number acquired in step S309 from the total production number acquired in step S309. The difference obtained in this manner is divided by the value indicated by the read production capacity information to calculate the deficient time within the Kth predetermined time interval.

  (Step S322) The occurrence time calculation unit 107 uses the start time and end time of the Kth predetermined time interval in which the deficiency is detected in Step S320, and the dead time information stored in the line information storage unit 102. Then, at least one of the generation time range information indicating the time range in which the deficiency occurs for the entire production line 20 or the generation time range information for each of the manufacturing apparatuses D1 to D5 is calculated.

  (Step S323) The work record deficiency detection unit 106 associates the detection result of the entry error with the generation time range information calculated by the generation time calculation unit 107, and stores it in a memory or the like (not shown). Then, the process proceeds to step S316.

  In the flowchart of FIG. 3, the process ends when the power is turned off or the process is terminated.

  Hereinafter, a specific operation of the work record analysis apparatus according to the present embodiment will be described. A conceptual diagram of the work record analyzing apparatus is shown in FIG.

  In the production line 20 such as the automatic assembly process as shown in FIG. 1, the manufacturing apparatuses D1 to D5 are connected by a conveyance path such as a belt conveyor. Further, in this process, the processing speed for processing the product is controlled by a control device (not shown), and the tact balance is maintained in each of the manufacturing apparatuses D1 to D5 so that no waiting state occurs. .

  When a plurality of products are produced by the production line 20, the production number counting device C sequentially counts the number of products produced, and the production number information configured using the count result is the work record analyzing device 10. Sent to. Then, the transmitted production number information is received by the production number information acquisition unit 101 and stored in a memory, a hard disk, or the like.

  FIG. 4 is a diagram showing a production number information management table for managing the production number information acquired by the production number information acquisition unit 101. The production number information management table has information of “production number” and “time”. “Production number” is a count value of the production number counter C, and is usually a continuous value. Further, “time” is the time when the production number counting device C performs counting. Each row in the production number information management table is one piece of production number information constituted by one count.

  Next, when the work record information recorded by the user in handwriting on a form or the like is input to the work record analyzing apparatus 10 using an input terminal, a keyboard, or the like, the work record receiving unit 103 receives the work record information. The received work record information is stored in a memory (not shown) or the like.

  FIG. 5 is a diagram illustrating the work record information received by the work record receiving unit 103. The work record information includes “work time”, “work start time”, “work time”, “work location”, and “work content” of work performed within the “work time”. . “Attendance time” is the working hours of the worker. “Work start time” is the time when the work is started. “Working time” is the time required for the work. As described above, the work here is a work that involves stopping the manufacturing apparatus. Here, the “work place” is a manufacturing apparatus that is a work target, and the name of the apparatus that is the manufacturing apparatus identification information is input. Here, it is assumed that the names of the manufacturing apparatuses D1 to D5 are the names of the facilities 1 to 5, respectively. “Work content” is information indicating the content of the work.

  Note that the work record information is automatically input from the database in which the work record information is stored when there is a work record device or the like that stores the work record input using a keyboard or the like in a database or the like. Alternatively, as described above, a person may read a handwritten form of a work record and directly input it using an input terminal.

  FIG. 6 is a diagram showing a management table for managing dead time information and production capacity information stored in the line information storage unit 102. The dead time information has attributes of “device name” and “dead time”. “Device name” is the name of the manufacturing device D1 to D5. “Waste time” is the time required from the time when the manufacturing apparatus is stopped until the counting of products is stopped. Here, the production capacity information (line tact) is a production amount per minute of the production line 20. For the dead time and the production capacity information, the line design value of the production line 20 may be used. Alternatively, a line experiment may be performed using the production line 20, and the experimental result may be obtained in advance by statistical processing.

  Next, the estimated production number calculation unit 104 performs processing for estimating the number of products produced at predetermined time intervals using the work record information, dead time information, and production capacity information.

  Specifically, the estimated production number calculation unit 104 is a manufacturing device that is manufacturing device identification information of the “work place” attribute included in the record for one record of the work record information as shown in FIG. 6 is used as a search key, and a record having a device name that matches the search key in the “device name” attribute is searched in the dead time information shown in FIG. 6, and the dead time included in the searched record is obtained. To do. Then, the lost time corresponding to the work record information is calculated by subtracting the dead time obtained by the search from the attribute value of “work start time” of the record of the work record information. This process is repeated for each record of work record information as shown in FIG. The acquired loss time information is stored in a memory or the like (not shown).

  FIG. 7 is a loss time management table for managing the upper part of the loss time calculated by the estimated production number calculation unit 104. The loss time management table describes “time attendance”, “loss time”, “loss time”, “dead time”, and “work content”. As the “time attendance” and “work content”, the “time attendance” and “work content” of the work record information shown in FIG. 5 are used as they are. The loss time is a loss time corresponding to each piece of work record information calculated by the estimated production number calculation unit 104. The “loss time” is a loss time indicating a period during which the production number counter C corresponding to each work record information is not counting, and the value of the “work time” of the work record information shown in FIG. It is used. The “dead time” is the dead time used when calculating the loss time.

  Next, the estimated production number calculation unit 104 divides the information on the loss time at an arbitrary predetermined time interval, and obtains the production time for each predetermined time interval. First, the loss time included in the time from “8:00 to 9:00” carved at a predetermined time interval is detected from the loss time management table shown in FIG. Here, there is no loss time included in this time zone. Accordingly, the loss time is not detected in this time zone, and the production time is set to 60 minutes. The production time is similarly set to 60 minutes for the time zone “9:00 to 10:00”. On the other hand, in the time zone “10:00 to 11:00”, the loss time is detected in 25 minutes from “10:05” and 8 minutes from “10:53”. Therefore, 25 (minutes) +7 (minutes) = 32 (minutes), which is the total loss time in this time zone, is subtracted from the predetermined time interval of 60 minutes, and the production time is 60 (minutes) −32 (minutes). ) = 28 (minutes). In addition, in “11:00 to 12:00”, since there is a loss time carried over from “10:53” for one minute, the production time is 60 (minutes) −1 (minutes) = 59 (minutes). In this way, the same calculation is performed in the time zone after 12:00. FIG. 8 is a table showing the production time for each predetermined time interval calculated in this way, and a time chart showing the production time with the horizontal axis representing time. In FIG. 8, “Time” indicates each predetermined time interval, and here, the start time of each predetermined time interval is displayed.

  As for the predetermined time interval, increasing the time interval makes it less susceptible to errors such as temporary stoppage such as product clogging, and reduces false detection of incomplete entry such as omission of work record information. , The estimation accuracy of the time when the incompleteness of entry has occurred becomes worse.

  On the other hand, if the time interval of the predetermined time interval is reduced, it is more susceptible to errors such as pause, and erroneous detection of incomplete entry is increased, but the estimation accuracy of the time when the incompleteness is improved is improved. is there. Therefore, when setting the predetermined time interval, it is desirable to consider the average value and the number of occurrences of the suspension time of the temporary stop. Note that the predetermined time intervals are not necessarily all constant.

  Next, the estimated production number calculation unit 104 uses the production time for each predetermined time interval as shown in FIG. 8 and the production capacity information stored in the line information storage unit 102 to determine the predetermined time interval. Calculate the estimated number of production for each. As a calculation method, as described in Japanese Patent Application Laid-Open No. 2006-146876 and the like, if the tact balance is maintained, it can be obtained by the following equation.

  Estimated number of production = Production time per given time interval x Line tact

  Here, as the production capacity information stored in the line information storage unit 102 indicates, since the line tact is 40 pieces / minute, an estimated production number as shown in FIG. 9 is calculated at each predetermined time interval. can do. In FIG. 9, “Time” indicates each predetermined time interval, and here, the start time of each predetermined time interval is displayed.

  Next, the work record defect detection unit 106 is used when the estimated production number calculation unit 104 calculates the estimated production number using the production number information acquired by the production number information acquisition unit 101 stored in a memory or the like. The total production number that is the number of products produced per hour that is the same predetermined time interval as the predetermined time interval is acquired. Here, the count value included in the production number information acquired immediately before the start of each predetermined time interval is calculated from the count value included in the production number information acquired immediately before the end of each predetermined time interval. Subtraction is performed to obtain the total production number for each predetermined time interval.

  FIG. 10 is a diagram illustrating the total number of productions for each predetermined time interval acquired by the work record defect detection unit 106. In FIG. 10, “time” indicates each predetermined time interval, and here, the start time of each predetermined time interval is displayed.

  Next, the work record defect detection unit 106 acquires the estimated production number and the total production number at the first predetermined time interval from the estimated production number shown in FIG. 9 and the total production number shown in FIG. To do. Here, assuming that the predetermined time interval with the earlier time is the first, the estimated production number and the total production number in the time zone from “8:00 to 9:00”, where “time” is “8”, are acquired. To do. Then, the acquired total production number is subtracted from the acquired estimated production number to obtain a difference. Then, the difference is compared with the reference value stored in the reference value storage unit 105, and if the subtraction result is larger than the reference value, the occurrence of omission is detected. Here, if the reference value is “200”, the difference obtained by subtracting the total production number indicated by the total production number from the estimated production number at a predetermined time interval from “8:00 to 9:00” is “16”. Since the reference value is 200 or less, no omission is detected.

  When it is determined that there is no omission, the work record defect detection unit 106 subtracts the estimated production number from the total production number for the same predetermined time interval to obtain a difference, and this difference is stored in the reference value storage unit 105. Compared with the stored reference value, if the subtraction result is larger than the reference value, the occurrence of an entry error is detected. Here, the subtraction result is “−16”, which is equal to or less than the reference value “200”, so that an entry error is not detected. As a result, for the time from “8:00 to 9:00”, incomplete work records are not detected.

  FIG. 11 is a reference diagram showing a value obtained by subtracting the total production number indicated by the total production number from the estimated production number for each predetermined time interval.

  Next, a predetermined time interval from “9:00 to 10:00” that is the second predetermined time interval, and a predetermined time interval from “10:00 to 11:00” that is the third predetermined time interval. The same processing as described above is performed for the predetermined time interval from “11:00 to 12:00”, which is the time interval and the fourth predetermined time interval. Also for each of these predetermined time intervals, as shown in FIG. 11, the difference obtained by subtracting the total production number from the estimated production number is equal to or less than the reference value. Similarly, the estimated production number is calculated from the total production number. Since the difference obtained by subtracting is also less than or equal to the reference value, an incomplete work record is not detected.

  Next, an estimated production number and a total production number for a predetermined time interval from “12:00 to 13:00”, which is a sixth predetermined time interval, are obtained, and the total production number is obtained from this estimated production number. Subtract to find the difference. Then, the difference is compared with the reference value stored in the reference value storage unit 105. The difference obtained by subtracting the total production number from the estimated production number at a predetermined time interval from “12:00 to 13:00” is “368” as shown in FIG. Since it is larger than 200, it is determined that there is an omission. If it is determined that there is an omission, the work record deficiency detection unit 106 calculates a deficiency time that is estimated to be an omission. Specifically, the deficiency time is calculated by the following equation from the difference obtained by subtracting the total production number from the estimated production number.

  Defect time = (difference-reference value) / line tact

  For example, in the time zone from “12:00 to 13:00”, line tact = 40 (pieces / minute), difference = 368 (pieces), and reference value = 200 (pieces), so the deficient time is ( 368−200) /40=4.2 (minutes).

  Next, the occurrence time calculation unit 107 is information on the start time and end time of a predetermined time interval in which the work record deficiency detection unit 106 detects omission of entry, in this case, “12:00” which is information on the start time. Then, the generation time range information for each of the manufacturing apparatuses D1 to D5 and the generation time range information for the entire production line 20 are calculated using “13:00” which is the end time information.

  First, the generation time calculation unit 107 calculates the generation time range information for each of the manufacturing apparatuses D1 to D5 as follows. That is, the generation time range information of the nth manufacturing device (n is an integer of 1 to 5) among the manufacturing devices D1 to D5 is (the start time of the time zone when the work record deficiency detection unit 106 detects omission of entry— It is the time from (the dead time of the nth manufacturing apparatus) to (the end time of the time zone in which the work record deficiency detecting unit 106 detects omission of entry-the dead time of the nth manufacturing apparatus). Thereby, as shown in FIG. 12, the generation | occurrence | production time range information about each manufacturing apparatus D1-D5 is calculated. In FIG. 12, “apparatus” is the name of each of the manufacturing apparatuses D1 to D5, “occurrence time range” is the occurrence time range indicated by the calculated occurrence time range information, and “dead time” is the occurrence time range information. It is a dead time used for each calculation. Moreover, the generation time calculation unit 107 calculates the generation time range information for the entire production line 20 as follows. That is, from (the start time of the time zone in which the work record deficiency detection unit 106 detects omission of entry—the maximum value of the dead time of the manufacturing apparatus), The time until the minimum value of the dead time of the manufacturing apparatus is used as the generation time range information for the entire production line 20. Here, since the maximum value of the dead time of the manufacturing apparatus is 30 minutes for the manufacturing apparatus D1, and the minimum value is 5 minutes for the manufacturing apparatus D5, the generation time range information of the entire production line 20 is “11:30”. -12: 55 ", and it can be seen that entry omission occurs in any of the manufacturing apparatuses D1 to D5 within this period. Then, information indicating that the above-described omission has occurred, deficiency time, and occurrence time range information are associated with each other and stored in a memory or the like.

  Here, if the estimated production number at a predetermined time interval from “12:00” to “13:00” is “2032” and the total production number is “2400”, the total production is calculated from the estimated production number. The difference obtained by subtracting the number is “−368”, which is determined to be equal to or less than the reference value, and it is determined that there is no omission. In order to determine an entry error, a difference obtained by subtracting the estimated production number from the total production number is calculated, and it is determined whether or not this difference is larger than a reference value. In this case, the difference is “368”, which is larger than the reference value “200”, so that it is determined that there is an entry error. Then, as in the case of omission of entry described above, deficiency time and occurrence time information are calculated, and information indicating that there is an entry error and stored in the memory.

  The reference value is the average time required for temporary stop such as product clogging obtained by statistical processing using information measured at the time of actual manufacturing or experiment, and the number of temporary stops that occur within a predetermined time interval. It is preferable to set using the number of occurrences. For example, if there are five average one-minute pauses per hour, the criterion can be calculated by line tact x average pause time x number of pauses. In this case, the reference value Is preferably about 40 (pieces / minute) × 1 (minutes) × 5 (times) = 200 (pieces). When the reference value is set in this way, if frequent pauses occur frequently at a predetermined time interval, it can be detected as a missing entry that frequent pauses have occurred.

  Thereafter, the same processing is repeated for the remaining predetermined time intervals.

  Next, the output unit 108 stores the information stored in the memory or the like indicating that the entry is incomplete, specifically the information indicating that there is an entry failure or the information indicating that there is an entry error, and the like. The deficiency notification information is configured using the corresponding occurrence time information and deficiency time, and the configured deficiency notification information is displayed on a display device such as a monitor.

  FIG. 13 is a diagram illustrating a display example of deficiency notification information output by the output unit 108. Here, the work record information received by the work record receiving unit 103 and deficiency notification information including a time chart created using the work record information are configured and displayed on a monitor (not shown). In this time chart, the range of work time indicated by each work record information is displayed as a straight line with the same number as the work record information. Further, the time range indicated by the occurrence time information of omission of the production line 20 accumulated in the memory or the like, here, the above-mentioned range of “11:30 to 12:55” is drawn with a double arrow line, The deficiency time is displayed above this double arrow line. Further, together with the work record information displayed below the time chart, entry failure occurrence time information 131 for the production line 20 and entry failure occurrence time information 132 for each of the production apparatuses D1 to D5 are included in each production apparatus. The display of the equipment 1-5 corresponding to D1-D5 is attached and displayed.

  Here, a display example in the case of omission of entry has been shown, but the same display as in FIG. 13 is possible even when there is an entry error.

  FIG. 14 is a diagram showing a display example when there is an entry error in the work record information. Here, it is the same as FIG. 13 except that the time range in which an entry error has occurred is drawn with a double arrow line and that the entry error occurrence time information for each of the manufacturing apparatuses D1 to D5 is not displayed. is there. In addition, in FIG. 14, it cannot be overemphasized that you may make it display the generation time information of the incorrect entry for every manufacturing apparatus D1-D5.

  The output unit 108 may configure and output any form of abnormality notification information other than the above, and display according to the operation method of the work record at the production site. Is preferred.

  In this embodiment, the total production number is subtracted from the estimated production number to determine omission of entry, and the estimated production number is subtracted from the total production number to determine an entry error. The difference between the estimated production number and the total production number is obtained instead of such a determination, and the comparison result between the absolute value of this difference and the reference value and the sign of the difference Based on the combination, it may be determined whether there is an entry error or omission. For example, if the absolute value of the difference obtained by subtracting the aggregated production number from the estimated production number is greater than the reference value, it is judged that there is omission if the sign of the difference is positive, and it is entered if it is negative You may judge that there is a mistake. Also, find the difference between the estimated production number and the total production number, compare the absolute value of this difference with the reference value, and if the comparison shows that the absolute value of the difference is larger than the reference value, there is an abnormality in the entry You may make it judge only.

  Further, instead of determining whether or not the difference is larger than the reference value, the value of the reference value may be changed to determine whether or not the difference is greater than or equal to the reference value.

  Further, the reference value for determining omission of entry and the reference value for determining entry error may be set to different values.

  Further, in the above specific example, the difference between the estimated production number and the total production number is detected by comparing it with the reference value. However, the same result as that obtained by comparing with the reference value is obtained. If so, it is considered to be compared with the reference value here. For example, if the value obtained by subtracting the reference value from the difference between the estimated production count and the total production count or its absolute value is positive, it is judged that the work record is incomplete, and if it is negative, the work record is incomplete. In this case, it is also considered that the difference between the estimated production number and the total production number is compared with a reference value.

  As described above, according to the present embodiment, since the difference between the estimated number of products obtained from the work record information and the total number of products actually counted is determined, the deficiency of entry is determined. It is not necessary to change the equipment or the like, and the deficiencies described can be detected easily and inexpensively.

  In addition, according to the present embodiment, the difference obtained by subtracting the total production number of the product actually counted from the estimated production number of the product obtained from the work record information can be manufactured in the loss time due to the suspension. The occurrence of omissions is determined when the number of productions is greater than the estimated number of productions, so it is possible to determine omissions in work by removing the effect of temporary suspension.

  Further, according to the present embodiment, the difference obtained by subtracting the estimated production number of the product obtained from the work record information from the total production number of the actually counted product can be manufactured in the loss time due to the suspension. When the number of productions is estimated to be greater than that, the occurrence of an entry error is determined. Therefore, it is possible to accurately determine an operation entry error by removing the influence of the temporary stop.

  Further, according to the present embodiment, it is estimated that the product can be manufactured in the loss time due to the temporary stop from the difference between the estimated number of products obtained from the work record information and the total number of products actually counted. Since the value obtained by subtracting the number of productions is divided by the line tact, that is, the value indicated by the production capacity information, the deficient time when the work record was deficient is calculated. Can be recalled, and correction of deficiencies in work records can be assisted and correction can be facilitated.

  In addition, according to the present embodiment, there is a lack of work recording in the entire production line 20 using the maximum and minimum values of the dead time between the manufacturing apparatuses D1 to D5 and the production number counting apparatus C. Since the occurrence time is estimated, the operator can know the time when the work record deficiency occurs, and this can be used as a clue to easily correct the work record deficiency.

  Moreover, according to this Embodiment, the time when the deficiency of work recording generate | occur | produced for each manufacturing apparatus D1-D5 using the dead time between each manufacturing apparatus D1-D5 and the production number counting apparatus C occurred. As a result, it was possible to present to the worker the time at which the lack of work records occurred for each manufacturing device, and this was used as a clue to the worker at each time. It is possible to remind the work.

  In the above embodiment, the case where the number of manufacturing apparatuses constituting the production line is five has been described. However, the present invention is applicable if the number of manufacturing apparatuses constituting the production line is one or more. Even in such a case, the same effects as those of the above embodiment can be obtained.

  In the above embodiment, each process (each function) may be realized by centralized processing by a single device (system), or by distributed processing by a plurality of devices. May be.

  In the above embodiment, each component may be configured by dedicated hardware, or a component that can be realized by software may be realized by executing a program. For example, each component can be realized by a program execution unit such as a CPU reading and executing a software program recorded on a recording medium such as a hard disk or a semiconductor memory.

  The software that realizes the work record analysis apparatus in the above embodiment is the following program. That is, the program includes a production number information obtaining step for obtaining production number information, which is information obtained by counting the number of productions of products produced by a production line constituted by one or more manufacturing apparatuses, and the production line. And a work record receiving step for receiving work record information that is information about a work record that is a record relating to a work involving a stop of the production line, and information indicating the production capacity of the production line stored in the line information storage unit Production time information, dead time information that is information on the time required for the intermediate product manufactured by each of the one or more manufacturing apparatuses to become the product, and the number of productions is counted, and the work record information An estimated production number calculating step for calculating an estimated production number that is the production number of the product estimated at predetermined time intervals, and the production The work record received by the work record accepting step stored in the reference value storage unit, the difference between the total production number, which is the production number for each predetermined time interval acquired using the information, and the estimated production number Compared with a reference value used for detecting a deficiency in information, a work record deficiency detection step for detecting deficiencies in the work record information received in the work record reception step, and the work record deficiency detection step by the work record deficiency detection step. This is a program for executing an output step of configuring and outputting deficiency notification information for notifying deficiencies in work records corresponding to the work record information when deficiencies are detected in the information.

  In the above program, in a transmission step for transmitting information, a reception step for receiving information, etc., processing performed by hardware, for example, processing performed by a modem or an interface card in the transmission step (only performed by hardware). Not included) is not included.

  Further, this program may be executed by being downloaded from a server or the like, and a program recorded on a predetermined recording medium (for example, an optical disk such as a CD-ROM, a magnetic disk, a semiconductor memory, or the like) is read out. May be executed by

  Further, the computer that executes this program may be singular or plural. That is, centralized processing may be performed, or distributed processing may be performed.

  In the above embodiment, it goes without saying that two or more communication means (such as an information transmission unit) existing in one apparatus may be physically realized by one medium.

  The present invention is not limited to the above-described embodiments, and various modifications are possible, and it goes without saying that these are also included in the scope of the present invention.

  In the above embodiment, the case where the work record analysis apparatus is a stand-alone has been described. However, the work record analysis apparatus may be a stand-alone apparatus or a server apparatus in a server / client system. In the latter case, the output unit or the reception unit receives an input or outputs a screen via a communication line.

  As described above, the work record analyzing apparatus and the like according to the present invention are suitable as apparatuses for analyzing work records, and are useful as apparatuses for detecting deficiencies such as omissions in writing or mistakes in work records.

Schematic diagram of the configuration of the production system in the embodiment Block diagram of the work record analyzer Flow chart for explaining the operation of the work record analyzing apparatus Figure showing the same production number information management table The figure which shows the work record information The figure which shows the management table which manages the same dead time information and production capacity information Figure showing the loss time management table The figure which shows the production time for the same predetermined time interval Figure showing the estimated production number Figure showing the total number of production Figure showing the value obtained by subtracting the total production number from the estimated production number The figure which shows the occurrence time information Figure showing the display example Figure showing the display example

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 Work record analyzer 20 Production line 101 Production number information acquisition part 102 Line information storage part 103 Work record reception part 104 Estimated production number calculation part 105 Reference value storage part 106 Work record defect detection part 107 Occurrence time calculation part 108 Output part 131 Occurrence time information 132 Occurrence time information

Claims (11)

A production number information obtaining unit for obtaining production number information, which is information obtained by counting the number of products produced on a production line constituted by one or more manufacturing apparatuses;
Production capacity information that is information indicating the production capacity of the production line, and waste information that is information on the time required for each manufacturing apparatus from when each manufacturing apparatus constituting the production line stops to when the production line stops A line information storage unit for storing a pair of time information and manufacturing device identification information for identifying each manufacturing device ;
A work record receiving unit that receives work record information that is information about a work record that is a record related to a work involving a stop of one or more manufacturing apparatuses constituting the production line for the production line;
The time when the production line corresponding to the time when the manufacturing device indicated by the work record information is stopped is acquired using the dead time information paired with the manufacturing device identification information of the manufacturing device, Using the time excluding the time at which the production line is stopped and the production capacity information , an estimated production number that is the production number of the product estimated at each predetermined time interval is calculated. An estimated production number calculation unit;
A reference value storage unit that can store a reference value that is the number of products used to detect deficiencies in work record information received by the work record reception unit;
The work record acceptance unit accepts the difference between the total production number, which is the production number for each predetermined time interval acquired using the production number information, and the estimated production number, with the reference value. A work record deficiency detector that detects deficiencies in work record information;
A work record comprising: an output unit configured and configured to output deficiency notification information for notifying a work record deficiency corresponding to the work record information when the work record deficiency detection unit detects a deficiency in the work record information; Analysis device. The work record deficiency detection unit enters work record information that is deficient in the work record information when a value obtained by subtracting the value of the total production number from the value of the estimated production number is greater than the reference value. Detect that there is a leak,
The work record analyzing apparatus according to claim 1, wherein the output unit outputs the deficiency notification information including information for notifying entry failure of a work record corresponding to the work record information. The work record deficiency detection unit fills in work record information that is deficient in the work record information when a value obtained by subtracting the value of the estimated production number from the value of the total production number is larger than the reference value. Detects mistakes and
The work record analysis apparatus according to claim 1, wherein the output unit outputs the deficiency notification information including information for notifying a work record entry error corresponding to the work record information. The work record deficiency detection unit, when deficiency is detected, divides the value obtained by subtracting the reference value from the difference between the estimated production number value and the total production number value by the production capacity information value. And calculating a deficiency time which is a time when the deficiency of the work record occurs,
The work record analyzing apparatus according to claim 1, wherein the output unit outputs the deficiency notification information including the deficiency time information. The work record deficiency detection unit detects deficiencies in work record information for each predetermined time interval,
Information indicating a range of time at which deficiencies occur in the work record using the start time and end time of the predetermined time interval at which the work record deficiency detection unit has detected deficiencies and the dead time information. An occurrence time calculation unit for calculating certain occurrence time range information;
5. The work record analysis apparatus according to claim 1, wherein the output unit outputs the deficiency notification information including information notifying a time range indicated by the occurrence time range information calculated by the occurrence time calculation unit. . The occurrence time calculation unit subtracts the maximum value of the dead time information for all of the one or more manufacturing apparatuses from the start time of the predetermined time interval when the work record deficiency detection unit detects deficiency, The generation time range information is obtained by subtracting a minimum value of dead time information for all of the one or more manufacturing apparatuses from an end time of the predetermined time interval at which the work record deficiency detection unit detects deficiency. The work record analyzing apparatus according to claim 5 for calculating. The occurrence time calculation unit subtracts the maximum value of the dead time information corresponding to the one or more manufacturing apparatuses from the start time of the predetermined time interval when the work record deficiency detection unit detects deficiency. The minimum value of the dead time information corresponding to the one or more manufacturing apparatuses is subtracted from the end time of the predetermined time interval when the work record deficiency detection unit detects the deficiency, The work record analyzing apparatus according to claim 5 or 6, wherein the occurrence time range information for each of the manufacturing apparatuses is calculated. The reference value is set using a product of the number of production per predetermined time of the production line, the number of times of temporary stop per predetermined time interval of the production line, and the average time of the temporary stop. The work record analyzing apparatus according to claim 1, wherein the work record analyzing apparatus is a value. A production number information acquisition unit, a line information storage unit, a work record reception unit, an estimated production number calculation unit,
A work record analysis method performed using a work record analysis device including a reference value storage unit, a work record deficiency detection unit, and an output unit,
The production number information obtaining unit obtains production number information, which is information obtained by counting the production number of products produced on a production line composed of one or more manufacturing apparatuses;
A work record accepting step for accepting work record information, which is information about a work record that is a record relating to a work that involves stopping one or more manufacturing apparatuses constituting the production line, with respect to the production line;
The estimated production number calculation unit configures the production line stored in the line information storage unit with the time when the production line corresponding to the time when the manufacturing apparatus indicated by the work record information is stopped is stopped. The stop is obtained from a pair of dead time information, which is information on the time required for each manufacturing apparatus from when each manufacturing apparatus stops until the production line stops, and manufacturing apparatus identification information for identifying each manufacturing apparatus. It is acquired using the dead time information paired with the manufacturing device identification information of the manufacturing device, and the time excluding the time when the production line is stopped at every predetermined time interval is stored in the line information storage unit. using said capacity information indicating the capacity of the production line to be, the estimated production number calculation step of calculating an estimate of the number produced a number of production the product to be estimated for each of the predetermined time interval
The work record deficiencies detection unit, wherein the number of aggregate production is the production number per said predetermined obtained using the production number information time intervals, the difference between the estimated production number, stored in the reference value storage unit The work for detecting deficiencies in the work record information received in the work record reception step compared to a reference value, which is the number of products used for detecting deficiencies in the work record information received in the work record reception step. Recording defect detection step;
An output step for configuring and outputting deficiency notification information for notifying a deficiency in work records corresponding to the work record information when the output unit detects deficiencies in the work record information in the work record deficiency detection step; A work record analyzing method comprising: On the computer,
A production number information obtaining step for obtaining production number information, which is information obtained by counting the number of products produced on a production line constituted by one or more manufacturing apparatuses;
A work record receiving step for receiving work record information, which is information about a work record that is a record related to a work involving a stop of one or more manufacturing apparatuses constituting the production line, with respect to the production line;
The time when the production line corresponding to the time when the manufacturing apparatus indicated by the work record information is stopped is stopped after each manufacturing apparatus constituting the production line stored in the line information storage unit stops. Manufacturing device identification of the stopped manufacturing device obtained from a pair of dead time information, which is information on the time required for each manufacturing device until the production line stops, and manufacturing device identification information for identifying each manufacturing device Time obtained by using dead time information paired with information and excluding the time when the production line is stopped every predetermined time interval, and the production capacity of the production line stored in the line information storage unit An estimated production number calculating step of calculating an estimated production number that is a production number of the product estimated at each predetermined time interval using production capacity information that is information indicating
The work record receiving step stored in a reference value storage unit accepts a difference between the total production number, which is the production number for each predetermined time interval acquired using the production number information, and the estimated production number. Compared with a reference value that is the number of products used for detecting deficiencies in the work record information, a work record deficiency detection step for detecting deficiencies in the work record information received in the work record reception step,
When the work record deficiency detection step detects a deficiency in the work record information, the deficiency notification information for notifying the work record deficiency corresponding to the work record information is configured and output. program. A production number information obtaining step for obtaining production number information, which is information obtained by counting the number of products produced on a production line constituted by one or more manufacturing apparatuses;
A work record receiving step for receiving work record information, which is information about a work record that is a record related to a work involving a stop of one or more manufacturing apparatuses constituting the production line, with respect to the production line;
The time when the production line corresponding to the time when the manufacturing apparatus indicated by the work record information is stopped is stopped after each manufacturing apparatus constituting the production line stored in the line information storage unit stops. Manufacturing device identification of the stopped manufacturing device obtained from a pair of dead time information, which is information on the time required for each manufacturing device until the production line stops, and manufacturing device identification information for identifying each manufacturing device It is acquired using dead time information paired with information, and the time excluding the time when the production line is stopped every predetermined time, and the production capacity of the production line stored in the line information storage unit An estimated production number calculating step of calculating an estimated production number that is a production number of the product estimated at each predetermined time interval using production capacity information that is information indicating ;
The work record receiving step stored in a reference value storage unit accepts a difference between the total production number, which is the production number for each predetermined time interval acquired using the production number information, and the estimated production number. Compared with a reference value that is the number of products used for detecting deficiencies in the work record information, a work record deficiency detection step for detecting deficiencies in the work record information received in the work record reception step,
When the work record deficiency detection step detects a deficiency in the work record information, the deficiency notification information for notifying the work record deficiency corresponding to the work record information is configured and output. A recording medium on which a program for recording is recorded.

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