JP5451166B2 - Production improvement support system - Google Patents

Description

  The present invention relates to a production improvement support system that can sequentially grasp the operation status of people and facilities in a production line that performs production by people and facilities, such as multi-product small-quantity production, and can lead to improvement.

Conventionally, improvement activities in production lines have been to carefully observe the current situation from the perspective of time measurement and work research, twist ideas for improvement, apply them, and then evaluate the application results thoroughly. The PDCA (Plan Do Check Action) cycle was established.
In recent years, the conventional mass production line has been changed to medium-medium-quantity production and multi-variety small-quantity production, and the product life cycle has been shortened.
Due to this environmental change, the conventional improvement method has a disadvantage that it takes too much time to follow the change in the production form, and it takes too much time and it is difficult to apply the improvement plan.
As a result, it was difficult to improve productivity and reduce costs in the field production line, and improvement activities were slow.
As an attempt to improve conventional productivity, Patent Document 1 discloses identification information for identifying a product, a detection signal for detecting the arrival and completion of a product for each process, and a time added thereto. The information is used to calculate the working time.
Further, Patent Document 2 describes what equipment operation information is transmitted from an equipment controller to an information aggregation analysis device according to a predetermined time interval and preset conditions, and is analyzed and displayed there. Yes.
Patent Document 3 describes a technique for optimizing parameters necessary for production of processing machines, jigs, personnel, and the like by simulation.

Japanese Patent Laid-Open No. 7-152835 (pages 2 and 3, FIG. 1) Japanese Patent Laid-Open No. 9-85591 (page 3, FIG. 1) Japanese Unexamined Patent Publication No. 2000-112504 (pages 3-4, FIG. 1)

The thing of patent document 1 had the problem that grasping | ascertaining of the waiting time between arrival and completion, and the working time in the work form of the multi-car holding which one person works using many equipment cannot be grasped.
Moreover, in the thing of the patent document 2, although the operating condition of an installation was able to be confirmed, it was not able to grasp | ascertain the operation of an installation and a movement of a person in association.
Moreover, the thing of patent document 3 had the problem that variation factors, such as trouble occurrence on the spot, cannot be considered.

  The present invention has been made to solve the above-described problems, and provides a production improvement support system that can grasp the operation status of equipment and the work status of workers even when there are multiple units. The purpose is to get.

The production improvement support system according to the present invention is a production improvement support system for supporting the improvement of the production state of a production line in which a single operator operates a plurality of facilities to produce workpieces. A server having a database pre-stored with a worker registration table that associates workers who operate the machine, a stock sensor that detects the presence or absence of work in the equipment, a presence sensor that detects the presence of the worker for each equipment, and equipment It is configured to control, and the output of the presence sensor and the presence sensor is input, and the operation information of the equipment including the input of the input presence sensor and the worker information including the output of the presence sensor are transmitted to the server. Connect to the controller and server to be stored in the database, acquire the operation information and worker information of the equipment stored in the database, and register the worker. Referring to the table, those having a client terminal to display a working coalition status tables conjointly working situation and operational status of a plurality of equipment in charge of the worker of the worker along the time axis.

As described above, the present invention is a production improvement support system for supporting the improvement of the production state of a production line in which a single operator operates a plurality of facilities to produce workpieces. A server with a database that stores in advance a worker registration table that associates workers to be operated, a stock sensor that detects the presence or absence of workpieces in equipment, a presence sensor that detects the presence of workers for each equipment, and controls equipment The output of the presence sensor and the presence sensor is input, and the operation information of the equipment including the input of the input presence sensor and the worker information including the output of the presence sensor are transmitted to the server. , Controller to be stored in the database, connected to the server, obtain equipment operation information and worker information stored in the database, refer to the worker registration table Te, because with a client terminal to display the work Union situation table that was Union the work situation and operating status of the plurality of equipment which is in charge of the workers of the worker along the time axis, of the equipment even in the case of multi-platform retention It is possible to grasp the operation status and the work status of the worker in association.

BRIEF DESCRIPTION OF THE DRAWINGS It is a block diagram which shows the production improvement assistance system by Embodiment 1 of this invention. It is a block diagram which shows the client terminal of the production improvement assistance system by Embodiment 1 of this invention. It is a figure which shows the database content of the server of the production improvement assistance system by Embodiment 1 of this invention. It is a figure which shows the example of a display of the man machine chart of the client terminal of the production improvement assistance system by Embodiment 1 of this invention. It is a flowchart which shows the process of the resource calculation means of the client terminal of the production improvement assistance system by Embodiment 1 of this invention.

Embodiment 1 FIG.
FIG. 1 is a block diagram showing a production improvement support system according to Embodiment 1 of the present invention.
In FIG. 1, a production facility 1 is controlled by a sequencer 2 (controller), and a workpiece is placed on a work table 3 and processed. The control status of the sequencer 2 is displayed on the display device 4 as an equipment screen. The work table 3 is provided with a stock sensor 5 for detecting that the work is placed at a predetermined position, and detects the presence or absence of the work. The in-stock sensor 5 is an infrared sensor and is disposed on a jig for fixing the workpiece. A presence sensor 7 for detecting the presence of a person 6 working in the facility 1 is disposed at a position where the person 6 works. The presence sensor 7 includes a pressure sensor that measures the time when the person 6 gets on the mat.
The sequencer 2 is connected to a server 8 having a database via a LAN 9, and the server 8 is connected to a client terminal 10 via the LAN 9. Information from the presence sensor 7 and information from the presence sensor 5 are input to the sequencer 2, and these are stored in the database of the server 8.
The server 8 has a database formed in a storage device, and various information for supporting improvement of work is stored in this database. For example, TS (standard time) data, an operator work situation table shown in FIG. 3 described later, an equipment table, and an operator registration table are included.
The client terminal 10 has a display unit for displaying a display screen, can read and write the database of the server 8, obtains information stored in the database, displays the equipment operation status, and the worker work status. , Display the man-machine chart (work alliance status table) indicating the work status of the person-equipment, and semi-automatic creation of the person / equipment input resource plan.

FIG. 2 is a block diagram showing a client terminal of the production improvement support system according to Embodiment 1 of the present invention.
In FIG. 2, the client terminal 10 acquires work status data from the database of the server 8, and also acquires data acquisition means 12 for acquiring a model-specific production plan from a separately created production plan 11, and the acquired data. Based on the man-machine chart display means 13 for displaying the man-machine chart on the display unit 15, the number of workers and the number of equipment required for each model series and each process are calculated based on the acquired data, and displayed as necessary. Resource calculation means 14 to be displayed on the unit 15.

FIG. 3 is a diagram showing the database contents of the server of the production improvement support system according to Embodiment 1 of the present invention.
FIG. 3A is a diagram showing a worker work status table, which includes a worker ID, work contents indicating presence or absence, start date and time of work contents, and end date and time of work contents. This table may be created for each worker ID.
FIG. 3B is a diagram showing an equipment table, which includes equipment ID, equipment operation status code, start date and time, and end date and time of the code. The equipment operation status code includes, for example, 0000 (normal operation), 0001 (work waiting), 0002 (chuck abnormality), 0003 (coolant liquid shortage), and the like. The equipment table may be created for each equipment.
FIG. 3C is an operator registration table showing correspondence between workers and equipment at each time point, and which operator operates which equipment in which period and which equipment is registered in advance. The associated period is indicated by a start date and time and an end date and time. By specifying the time and equipment from this table, the worker can be specified.
In addition to this, the database has a master table in which the equipment and the designated worker are associated with each other. If the equipment is designated, the designated worker can be listed. It also has a model name table with model names of all manufactured models, and the model series can be distinguished from the model name. In addition, each model has a work cycle time (standard time, TS data).

FIG. 4 is a diagram showing a display example of a man-machine chart of the client terminal of the production improvement support system according to Embodiment 1 of the present invention.
In FIG. 4, the example of a display in case the worker A works with the equipment a, the equipment b, and the equipment c is shown as an example.
“Attendance” of worker A is the presence time detected by the presence sensor 7, and the absence time is displayed as “addition”. “Equipment maintenance” is caused by a trouble with the equipment “a”, and “lunch” is a predetermined time.
The equipment shows “in operation” and “waiting for work” in a normal state, and in addition to this, “trouble” indicating an abnormal time.

FIG. 5 is a flowchart showing the processing of the resource calculation means of the client terminal in the production improvement support system according to Embodiment 1 of the present invention.

Next, the operation will be described.
FIG. 1 shows a case where a single worker processes a workpiece using three facilities and has multiple units. When the workpiece is placed at a predetermined position on the work table 3 of the equipment 1, processing is performed.
The execution of this processing is based on the TS data stored in the database of the server 8, and the sequencer 2 gives a work start instruction for each work and a completion timing instruction by a timer using the screen of the display device 4 attached to the equipment. Is called.
When the work is placed at a predetermined position on the work table 3, the stock sensor 5 detects the work placement and confirms the start and end of the work. For this reason, the in-stock sensor 5 is arranged, for example, on a mounting jig so as to detect whether or not the workpiece is placed in the facility 1 and is in a position (predetermined position) to be processed.
In addition, the presence sensor 7 detects a work situation including which equipment 1 the worker is involved in. By detecting the work time for each equipment 1 with the presence sensor 7, it is possible to grasp the work contents and the respective times when one person works with a plurality of equipment.
These pieces of information are transmitted to the sequencer 2 and stored in the storage unit of the sequencer. The relationship between the equipment and the worker can be grasped by the worker registration table in FIG.

The sequencer 2 controls equipment processing and collects information detected by the presence sensor 7 and the presence sensor 5. That is, the sequencer 2 uses operation information (stopping, waiting, working, setup change, error) from the equipment, and the movement of the person 6 using the presence sensor 7 is the presence information (when and in which process). Are acquired in real time. In the presence sensor 7, the absence time is defined as “addition”.
Information taken into the sequencer 2 is transmitted to the server 8 in a fixed cycle and is made into a database with the data structure shown in FIG. The database of the server 8 can be read and written from the sequencer 2.

The client terminal 10 can read / write data from / to the database of the server 8, obtain necessary data from the database, display equipment operation status, worker work status, person-equipment work status display, Processes such as semi-automatic creation of human / equipment input resource plans.
That is, equipment information and person movement / location information for a specific period (for example, startup period) are extracted from the database, a man-machine chart is displayed by the man-machine display means 13, and a person and equipment by the resource calculation means 14 are extracted. The calculation process of the input resource is performed.

  The man machine display means 13 displays a man machine chart as shown in FIG. In this man-machine chart, as shown in FIG. 4, detailed movements of both people and facilities are displayed. As a result, the manager can grasp the work status of the person and the operating status of the equipment in an integrated manner. This man-machine chart can be automatically created and displayed.

The resource calculation means 14 evaluates / plans the input resources (people, equipment) based on the result data.
Line productivity from the database of the server 8 through the data acquisition means 12 such as cycle time (the time from when a workpiece is input until the next workpiece is input, which is obtained from TS data), working time, etc. Collect management data automatically.
Based on these data, the minimum necessary number of people and the number of facilities are calculated each time the production situation changes. At this time, based on the result data, the above optimal input resource is calculated in consideration of factors such as the maintenance of the equipment and the time for leaving the person's work table. Thereby, it is possible to formulate a resource plan with a high probability.

Next, the processing of the resource calculation unit 14 will be described in more detail based on the flowchart of FIG.
In step S 1 of FIG. 5, the data acquisition unit 12 acquires a production plan for each manufacturing model (hereinafter simply referred to as a model) from the separately created production plan 11, and also models and processes from the database of the server 8. Every time, work time and equipment operation time are acquired.
Next, in step S2, the model information in the database is referred to, the models are grouped in the same series, and the following data is extracted for each model series and for each process.
As the work time, a net work time (W) per unit and a net non-work time (W_σ) per unit are calculated.
As equipment time, a net operating time variation per unit (O) and a net non-operating time variation per unit (O_σ) are calculated.
Here, the unit indicates the time for one work, and the net work time indicates the work time for which value is recognized. In the present invention, it is the time when the presence sensor detects the presence, which is the presence time in FIG. Further, the net operation time indicates the operation time of the facility whose value is recognized, and in the present invention, it is the operation time in FIG.

Next, the above-mentioned data is allocated to the production plan for each series in the following manner, and the necessary number of facilities and input personnel are calculated for each process.
For this reason, in step S3, the multi-carried coefficient s is calculated by the equation (1).

Multi-hand holding coefficient (s) = Σ (W _k + α * W_σ _k ) / number of workers allocatable per line (1)

  Next, in step S4, the number of workers is calculated by equation (2). In equation (2), i: number of model series, N: number of units produced by model series, and α: work efficiency safety factor.

Number of workers = s * Σ (W _i + α * W_σ _i ) * N _i / day working time (2)

Next, in step S5, the number of facilities is calculated by equation (3).
In equation (3), i: number of model series, N: number of units produced by model series, and β: equipment operation safety factor.

Number of facilities = Σ (O _i + β * O_σ _i ) * N _i / day of operation availability (3)

  In this way, the number of workers and the number of facilities in the case of having multiple units can be calculated, and evaluation of facilities and human resources and planning can be supported based on the actual data.

According to the first embodiment, since the man-machine chart can be displayed on the screen of the client terminal, the operation status of the equipment and the worker's work status can be grasped in association even when there are multiple units.
In addition, since line productivity management data such as cycle time and work time during equipment processing can be automatically collected, improvement activities can be advanced in a short period of time based on this data.
In addition, it is possible to support the evaluation and planning of facilities and human resources based on the actual data.

DESCRIPTION OF SYMBOLS 1 Equipment 2 Sequencer 3 Worktable 4 Display apparatus 5 Inventory sensor 6 Person 7 Existence sensor 8 Server 9 LAN
DESCRIPTION OF SYMBOLS 10 Client terminal 11 Production plan 12 Data acquisition means 13 Man-machine chart display means 14 Resource calculation means 15 Display part

Claims (3)

A production improvement support system for supporting the improvement of the production state of a production line in which one worker operates a plurality of facilities to produce workpieces,
A server having a database that stores in advance a worker registration table that associates the facility with a worker who operates the facility;
A stock sensor that detects the presence or absence of workpieces in the above equipment,
A presence sensor that detects the presence of the worker for each of the above facilities,
It is comprised so that the said equipment may be controlled, The output of the said presence sensor and the said presence sensor is input, The operation information of the installation including the output of this inputted said presence sensor and the output of the said presence sensor are included. A controller that sends worker information to the server and stores it in the database;
Connected to the server, it acquires the operation information and the operator information stored the facilities in the database, with reference to the worker registration table, working conditions and the work of the worker along the time axis A production improvement support system comprising a client terminal for displaying a work alliance status table in which operation statuses of a plurality of the facilities in charge of a person are associated.   2. The production improvement according to claim 1, wherein a standard time for each work is stored in advance in the database of the server, and the controller issues a work instruction to the worker based on the standard time for each work. Support system.   The client terminal uses the facility operation information and the worker information stored in the database of the server to calculate the number of facilities and the number of workers required for each work model and for each process. The production improvement support system according to claim 1 or 2, further comprising means.

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