JP5929370B2 - Priority determination system and priority determination method - Google Patents

Description

  The present invention relates to a priority determination system and a priority determination method.

  At the manufacturing site, a production line that performs assembly work while transporting products is operated in order to improve manufacturing efficiency. Such a production line may have a function of stopping the production line at a fixed position when a work delay or trouble occurs. In order to suppress the stop of the production line, it is required to determine the priority order of support by the support worker.

  Patent Document 1 discloses quality control in a production line having a plurality of processes. Patent Document 2 discloses a technique for warning when a predetermined time has elapsed since the occurrence of an alarm. Patent Literature 3 discloses a technique for changing a time zone from the opening of a store to the opening time and a processing amount in the subsequent time zone.

JP 2001-67109 A JP-A-10-91234 Japanese Patent Laid-Open No. 3-102496

  However, in the techniques of Patent Documents 1 to 3, the priority order for suppressing the stop of the production line is not determined.

  The present invention has been made in view of the above problems, and an object thereof is to provide a priority determination system and a priority determination method capable of determining a priority for suppressing a stop of a production line.

  In order to solve the above-described problem, the priority determination system disclosed in the specification includes an alarm notification unit provided in each process in which a process time is set and a start time is set at the same time, and the alarm notification unit Priority order creating means for creating a priority order for the process for which an alarm is notified based on the notification, and the priority order creating means receives a notification from the alarm notification means from the start time of each process to a predetermined time. Priorities of the respective processes are created in the order received, and the priorities of the processes having the longer remaining process time are set higher than those of the shorter processes for the processes that have received the alarm notification after the predetermined time has passed.

  In order to solve the above problems, the priority order determination method disclosed in the specification is based on a notification from an alarm notification means provided in each process in which a process time is set and a start time is set at the same time. Including a priority order creating step for creating a priority order for the process notified of, in the priority order creating step, the priority order of each process in the order received from the alarm notification means from the start time of each process to a predetermined time. For each process for which an alarm notification has been received after the predetermined time has been exceeded, the priority of the process having the long remaining process time is set higher than that of the short process.

  According to the priority determination system and the priority determination method disclosed in the specification, it is possible to determine the priority for suppressing the stop of the production line.

(A) is the schematic of a production line, (b) is a figure for demonstrating the relationship between tact time and process time, (c) is a figure for demonstrating a judgment line. 1 is a block diagram for explaining an overall configuration of a priority order determination system according to Embodiment 1. FIG. It is an apparatus block diagram of a priority determination system. (A) is a common format that the work trouble range priority table, work delay range priority table, and instruction priority table have, and (b) is the format of the CT order data store. It is a flowchart showing an example of a priority table creation process. It is a flowchart showing an example of the detail of work trouble range processing. (A) and (b) are examples of priorities. It is a flowchart showing an example of the detail of work delay range processing. (A) and (b) are examples of priorities. It is an example of priority. It is an example of priority. (A) is a flowchart showing an example of the process of an instruction | indication means, (b) is an example of an indicator lamp. It is a figure for demonstrating the specific example when an alarm generate | occur | produces in the work trouble range. It is a figure for demonstrating the specific example when an alarm generate | occur | produces in the work trouble range. It is a figure for demonstrating the specific example in case the alarm which generate | occur | produced in the work trouble range continues to a work delay range. It is a figure for demonstrating the specific example when an alarm generate | occur | produces in the work delay range. It is a figure for demonstrating the specific example when an alarm generate | occur | produces in the work delay range. It is an example of the time chart for demonstrating the relationship between lighting of the indicator lamp of each process, and support work.

  Prior to the description of the embodiments, the outline of the principle of each embodiment will be described. FIG. 1A is a schematic diagram of a production line. In the production line, the workpiece 10 is placed on the belt conveyor 20. The workpiece 10 is an unfinished product and is a work target of each process worker. The workpiece 10 is sequentially conveyed to each process by the belt conveyor 20. Each process has a process worker. The first step is referred to as step 1 and the nth step is referred to as step n.

  Moreover, the alarm switch 30 and the indicator lamp 40 are arrange | positioned at each process. The alarm switch 30 is a switch for requesting support from the support worker when each process worker has some trouble. The indicator lamp 40 is an indicator lamp for notifying an alarm. When the alarm switch 30 is pressed, the indicator lamp 40 in the same process is turned on. When the indicator lamp 40 is turned on, the support worker can grasp a process that needs support. Thereafter, the support worker supports the process.

  FIG. 1B is a diagram for explaining the relationship between tact time and process time (CT: cycle time). The tact time is a process work time determined in order to achieve an equal timing of each process. When the tact time elapses after the workpiece 10 is transferred to each step, the workpiece 10 is transferred to the next step. Therefore, the start time of each process is set at the same time. In the example of FIG. 1B, the tact time common to each process is set to 60 seconds.

  The cycle time is a work time required for work in each process and is determined in advance. In the example of FIG. 1B, the cycle time of step 1 is 55 seconds, the cycle time of step 2 is 60 seconds, and the cycle time of step 3 is 50 seconds. If trouble, delay, etc. do not occur, a hand waiting time of 5 seconds will occur in step 1, and a hand waiting time of 10 seconds will occur in step 3.

  When trouble occurs in a process with a long cycle time, there is a possibility that the stop time of the production line becomes longer. Therefore, the priority order of support can be calculated in the order of longer cycle time. In this case, however, a divergence may occur between the priority order based on the cause of the trouble and the calculated priority order. Thereby, the stop time of the production line may be lengthened. In order to suppress this divergence, it is conceivable that the process worker specifies an alarm factor by a plurality of types of notification means. However, in this case, the process operator has to determine the cause of the alarm, which complicates the work and increases the possibility of human error.

  Here, the alarm factor that the process worker requests for support is roughly classified into two categories: “work trouble” and “work delay”. “Work trouble” is an alarm when an immediate support request is required, such as a missing part. Since work cannot be continued in a process where work trouble has occurred, support is required regardless of the length of the cycle time. Therefore, when “work trouble” occurs in a plurality of processes, it is preferable to support a process for which support is requested earlier in time. On the other hand, “work delay” is an alarm when the work is delayed in the latter half of the work. In the process where the work delay has occurred, the work is not stopped. Therefore, when a “work delay” occurs in a plurality of processes, it is preferable to support a process with a long cycle time. This is because the expected waiting time is long in a process with a short cycle time.

  Therefore, an index is provided for discriminating between “work trouble” and “work delay”. “Work hindrance” tends to occur in the first half of the tact time because it is caused by missing parts. Since “work delay” is a work delay, it tends to occur in the latter half of the tact time. From the above, referring to FIG. 1C, a judgment line can be provided in the middle of the tact time. The judgment line is a reference time for discriminating between “work trouble” and “work delay”. Therefore, when the alarm switch 30 is pressed before the determination line, it can be determined that work trouble has occurred in the process. When the alarm switch 30 is pressed after the determination line, it can be determined that a work delay has occurred in the process. According to such a determination method, the stop of the production line can be suppressed.

  Specific examples will be described below.

  FIG. 2 is a block diagram for explaining the overall configuration of the priority order determination system 100 according to the first embodiment. Referring to FIG. 2, the priority determination system 100 includes an alarm switch 30 provided for each process, an indicator lamp 40 provided for each process, a timer 50, a priority generation means 60, an instruction. Means 70 and the like. The priority order determination system 100 includes a CT order data store 80a, a work trouble range priority order table 80b, a work delay range priority order table 80c, and an instruction priority order table 80d.

  When operated by a process worker, the alarm switch 30 notifies the priority generation means 60 of an alarm. The timer 50 transmits the elapsed time at each tact time to the priority order creating means 60. Upon receiving an alarm notification after the decision line, the priority order creating means 60 reads CT order data from the CT order data store. The priority generation means 60 writes the priority data to the work trouble range priority table 80b or the work delay range priority table 80c according to the CT order data and the elapsed time. Alternatively, the priority generation means 60 reads priority data from the work trouble range priority table 80b or the work delay range priority table 80c. Thereafter, the priority order creating means 60 writes the priority order data in the instruction priority order table 80d. The instruction means 70 reads priority order data from the instruction priority order table 80d and instructs the indicator lamp 40 to turn on. Details of each process will be described later.

  FIG. 3 is a device configuration diagram of the priority order determination system 100. Referring to FIG. 3, the priority order determination system 100 includes a CPU 101, a RAM 102, a storage device 103, an interface 104, and the like. Each of these devices is connected by a bus or the like. A CPU (Central Processing Unit) 101 is a central processing unit. The CPU 101 includes one or more cores. A RAM (Random Access Memory) 102 is a volatile memory that temporarily stores a priority determination program executed by the CPU 101, data processed by the CPU 101, and the like. The storage device 103 is a nonvolatile storage device. As the storage device 103, for example, a ROM (Read Only Memory), a solid state drive (SSD) such as a flash memory, a hard disk driven by a hard disk drive, or the like can be used. By executing the priority determination program, the timer 50, priority generation means 60, instruction means 70, CT order data store 80a, work trouble range priority table 80b, work delay range priority table 80c, and instruction priority table 80d. Is realized.

(Priority creation process)
Next, priority order creation processing will be described. FIG. 4A shows a common format that the work trouble range priority table 80b, the work delay range priority table 80c, and the instruction priority table 80d have. Referring to FIG. 4A, the process in which the alarm has occurred is associated with the priority order. As an example, in the example of FIG. 4A, the priority order 1 of the process 1 is set to 1 and the priority order of the process 3 is set to 2. Since the work trouble range priority table 80b, the work delay range priority table 80c, and the instruction priority table 80d are independent from each other, the priorities in the tables may be different.

  FIG. 4B shows the format of the CT order data store 80a. With reference to FIG.4 (b), each process and CT order are linked | related. The CT order is an order in which the cycle time of each process is long. In the example of FIG. 4B, the cycle time of step 1 is the longest. Since the cycle time of each process is determined in advance, the rank of the CT order data store 80a is a fixed value.

  FIG. 5 is a flowchart showing an example of a priority table creation process. The flowchart of FIG. 5 is executed with the start of each tact time. Referring to FIG. 5, priority order creating means 60 determines whether or not it is before the decision line has passed (step S1). When it is determined as “Yes” in step S1, the priority level creation means 60 performs work trouble range processing (step S2).

  FIG. 6 is a flowchart showing an example of details of the work trouble range processing. Referring to FIG. 6, priority order creating means 60 determines whether any alarm switch 30 is newly pressed (step S11). When it is determined as “Yes” in step S11, the priority order creating means 60 records the process number of the alarm switch 30 in the work trouble range priority order table 80b (step S12). Referring to FIG. 7A, when the alarm switch 30 of step 1 is newly pressed, the priority order creating means 60 associates step 1 with the priority order “1”. If an alarm has already occurred in step 1 and the alarm switch 30 in step 3 is newly pressed, the priority order creating means 60 associates step 3 with the priority order “2”.

  When it is determined as “No” in step S11 or after execution of step S12, the priority generation means 60 determines whether any of the alarm switches 30 has been released (step S13). When it is determined as “Yes” in Step S13, the priority order creating means 60 deletes the process from the work trouble range priority order table 80b and raises the priority order after the corresponding process (Step S14). In the example of FIG. 7B, when an alarm is generated in step 1 and step 3, the alarm in step 1 is canceled and the priority of step 3 is increased. When it is determined as “No” in step S13 or after execution of step S14, the flowchart of FIG. 6 ends.

  Referring to FIG. 5 again, after executing step S2, priority creating means 60 copies the data in work trouble range priority table 80b to instruction priority table 80d (step S3). After execution of step S3, step S1 is executed again. When it is determined as “No” in Step S1, the priority order creating means 60 determines whether or not the tact time has ended (Step S4). When it is determined as “No” in step S4, the priority order creating means 60 executes work delay range processing (step S5).

  FIG. 8 is a flowchart illustrating an example of details of the work delay range process. Referring to FIG. 8, priority creating means 60 determines whether any alarm switch 30 is newly pressed or not (step S21). If “Yes” is determined in step S21, the priority order creating means 60 records the corresponding process number in the work delay range priority table 80c, and the work delay range priority table 80c is stored in the CT order data store 80a. Are sorted in the order of CT (step S22). FIG. 9A shows a case where the alarm switch 30 in step 3 is newly pressed when an alarm has already occurred in step 1. When the cycle time of the process 3 is longer than the cycle time of the process 1, the priority creating means 60 rearranges the priorities, sets the priority of the process 3 to “1”, and sets the priority of the process 1 to “2”. "

  When it is determined as “No” in step S21 or after execution of step S22, the priority generation means 60 determines whether any of the alarm switches 30 has been released (step S23). If it is determined as “Yes” in step S23, the priority order creating means 60 deletes the corresponding process from the work delay range priority order table 80c, and raises the priority order after the corresponding process (step S24). In the example of FIG. 9B, when an alarm is generated in step 1 and step 3, the alarm in step 3 is canceled and the priority order of step 1 is advanced. When it is determined “No” in step S23 or after execution of step S24, the flowchart of FIG. 8 ends.

Referring to FIG. 5 again, after step S5 is executed, priority generation means 60 determines whether or not data remains in work trouble range priority table 80b (step S6). If it is determined as “Yes” in step S6, the priority level creating means 60 executes step S3 after executing steps S13 to S14 of FIG . For example, with reference to FIG. 10, it is assumed that different data is stored in work trouble range priority table 80b and work delay range priority table 80c. In this case, the work trouble range priority order table 80b is copied to the instruction priority order table 80d by executing step S3. In other words, the priority order is maintained for the process in which the alarm notification is not canceled even if the decision line is exceeded.

  When it is determined as “No” in Step S6, the priority order creating means 60 copies the work delay range priority order table 80c to the instruction priority order table 80d (Step S7). For example, with reference to FIG. 11, it is assumed that no data remains in the work trouble range priority order table 80b. In this case, by executing step S7, the work delay range priority table 80c is copied to the instruction priority table 80d. After execution of step S7, step S1 is executed again.

If it is determined as “Yes” in step S4, the priority generation means 60 determines whether or not one or more alarm switches remain (is not released) (step S8). If it is determined as “No” in step S8, the flowchart of FIG. 5 ends. If it is determined “Yes” in step S8, a signal related to the line stop is output. As a result, the production line stops.

  Next, an example of processing of the instruction unit 70 will be described. FIG. 12A is a flowchart illustrating an example of processing of the instruction unit 70. The flowchart of FIG. 12A is periodically executed within each tact time. The instruction means 70 lights “red” on the indicator lamp 40 of the process with the highest priority in the instruction priority table 80d, and lights “yellow” on the indicator lamp 40 of the other process in which the alarm is generated. The indicator lamp 40 in the process where no alarm is generated is turned off. For example, referring to FIG. 12B, when the priority of process 1 is “1” and the priority of process 3 is “2”, the instruction unit 70 displays “red” on the indicator lamp of process 1. Is turned on, “yellow” is turned on for the indicator lamp 40 in step 3, and the remaining indicator lights 40 are turned off.

  FIG. 13 and FIG. 14 are diagrams for explaining a specific example when an alarm is generated in the work trouble range. It is assumed that the alarm switch 30 is pressed first in step 1 and the alarm switch 30 is pressed next in step 3 in the work trouble range. In this case, since step S11 and step S12 of FIG. 6 are executed, the priority order is created in the order in which the alarm switch 30 is pressed in the work trouble range. Therefore, referring to FIG. 13, the indicator lamp 40 in step 1 is lit in “red”, and the indicator lamp 40 in step 3 is lit in “yellow”. In Step 2, since the alarm switch 30 is not pressed, the indicator light 40 in Step 2 is turned off.

  When the alarm switch 30 of the process 1 is released, the process 1 is deleted from the work trouble range priority order table 80b by executing steps S13 and S14 of FIG. Thereby, with reference to FIG. 14, the indicator lamp 40 of the process 1 goes out. In this case, since the priority order of the other process in which the alarm is generated is advanced, the indicator lamp 40 in the process 3 is lit in “red”.

  FIG. 15 is a diagram for explaining a specific example in the case where an alarm generated in the work trouble range continues to the work delay range. In the work trouble range, it is assumed that the alarm switch 30 is pushed first in step 1 and the alarm switch 30 is pushed next in step 3 so that both alarms continue to the work delay range. When the alarm generated in the work trouble range continues to the work delay range, the work trouble range priority order table 80b is maintained by executing steps S6 and S3 in FIG. Thereby, referring to FIG. 15, “red” of the indicator lamp 40 in step 1 is maintained, and “yellow” of the indicator lamp 40 in step 3 is maintained.

  16 and 17 are diagrams for explaining a specific example in the case where an alarm is generated in the work delay range. It is assumed that the alarm switch 30 is pressed simultaneously in step 1 and step 3 in the work delay range. In this case, since step S21 and step S22 of FIG. 8 are executed, the priority order is set in the CT order in the work delay range. In the example of FIG. 16 and FIG. 17, the cycle time of process 3 (55 seconds) is longer than the cycle time of process 1 (50 seconds), so the priority of process 3 is higher. Therefore, referring to FIG. 16, the indicator lamp 40 in step 3 is lit in “red”, and the indicator lamp 40 in step 1 is lit in “yellow”. In Step 2, since the alarm switch 30 is not pressed, the indicator light 40 in Step 2 is turned off.

  When the alarm switch 30 in step 3 is released, step 3 is deleted from the work delay range priority table 80c by executing steps S23 and S24 in FIG. Thereby, with reference to FIG. 17, the indicator lamp 40 of the process 3 goes out. In this case, since the priority of the other process in which the alarm is generated is advanced, the indicator lamp 40 of process 1 is lit in “red”.

  FIG. 18 is an example of a time chart for explaining the relationship between the lighting of the indicator lamp 40 in each step and the support work. In the example of FIG. 18, the tact time is set to 60 seconds, and the determination line is set to 40 seconds after the start of the tact time. Further, the cycle time of step 1 is set to 55 seconds, the cycle time of step 2 is set to 60 seconds, and the cycle time of step 3 is set to 50 seconds.

  In the example of FIG. 18, the alarm switch 30 in step 3 is first pressed in the work trouble range. In this case, by the execution of step S2 and step S3 in FIG. 5, the indicator lamp 40 in step 3 is lit red. In this case, the support worker performs support in step 3. If the alarm switch 30 in the process 2 and the process 1 is pushed in this order before the alarm switch 30 in the process 3 is released, the priority of the process 2 is set to 2 and the priority of the process 1 is set to 3 Is done. Thereby, the indicator lamp 40 of process 1 and process 2 lights in "yellow".

  When the support work of process 3 is completed and the alarm switch 30 of process 3 is released, the priority of process 2 is set to 1 and the priority of process 1 is set to 2. Thereby, the indicator light 40 in the step 2 becomes “red”, and the indicator light 40 in the step 1 maintains “yellow”. In this case, the support worker performs support in step 2. When the support work of process 2 is completed and the alarm switch 30 of process 2 is released, the priority order of process 1 is set to the first. As a result, the indicator lamp 40 in step 1 becomes “red”. In this case, the support worker performs support in step 1.

  Next, when the alarm switch 30 of the process 2 is pushed in the state where the alarm switch 30 of the process 1 is not released in the work trouble range, the priority order of the process 2 is set to the second. As a result, the indicator lamp 40 in step 2 is lit in “yellow”. In the example of FIG. 18, even if the alarm switch 30 in step 1 and step 2 enters the work delay range, it is not released, so the indicator light 40 in step 1 remains “red” and the indicator light 40 in step 2 is “yellow”. To maintain.

When the alarm switch 30 in step 3 is pressed after entering the work delay range, if there is an alarm that continues from the work trouble range, the work delay range priority table 80c is not written to the instruction priority table 80d. Next, when the alarm switch 30 in step 1 and step 2 is released, the priority of step 3 is set to the first. As a result, the indicator lamp 40 in step 3 is lit red. In this case, the support worker performs support in step 3.

  Next, in the example of FIG. 18, in the work delay range, the alarm switch 30 of the process 1 and the process 2 is simultaneously pressed without releasing the alarm switch 30 of the process 3. In the example of FIG. 18, the cycle time of step 2 is the longest, the cycle time of step 1 is the second longest, and the cycle time of step 3 is the shortest. Therefore, the priority of process 2 is set to No. 1, the priority of process 1 is set to No. 2, and the priority of process 3 is set to No. 3. As a result, the indicator lamp 40 in step 2 is lit in “red”, and the indicator lamps 40 in step 1 and step 3 are lit in “yellow”. In this case, the support worker supports the process 2 even if the support work of the process 3 is in progress.

  When the support work of process 2 is completed and the alarm switch 30 of process 2 is released, the priority order of process 1 is set to the first. As a result, the indicator lamp 40 in step 1 is lit red. In this case, the support worker performs support in step 1. When the support work of the process 1 is completed and the alarm switch 30 of the process 1 is released, the priority order of the process 3 is set to the first. As a result, the indicator lamp 40 in step 3 is lit red. In this case, the support worker performs support in step 3.

  According to the present embodiment, it is possible to determine the work trouble range and the work delay range by providing the judgment line in the tact time. Thereby, the priority for suppressing the stop of a production line can be created. Specifically, since each process is supported in the order in which the alarm switch 30 is pressed in the work trouble range, an increase in work interruption time is suppressed. Thereby, the stop of a production line can be suppressed. In the work delay range, each process is supported in the order in which the cycle time is long, so that an increase in delay time is suppressed. Thereby, the stop of a production line can be suppressed. In addition, the priority set in the work trouble range is maintained for the process in which the alarm is not canceled even if the work trouble range is exceeded. Thereby, the lengthening of the work interruption time is suppressed. Further, according to the present embodiment, it is not necessary for each process worker to determine the cause of the alarm, so there is no need to provide a plurality of alarm switches. Thereby, the work of each process worker is simplified, and human errors can be suppressed.

  In the above example, the types of indicator lights are “red” and “yellow”, but are not limited thereto. There is no particular limitation as long as the priority “No. 1” can be distinguished from other priorities. Each priority order may be displayed for each process. For example, “No. 1” may be displayed on the indicator lamp of the process with the priority “No. 1”, and “n No.” may be displayed on the indicator lamp of the process with the priority “n”. In addition, as a means for notifying the priority order, a notification means such as an audio output device whose sound type changes according to the priority order may be used.

  A recording medium in which a software program for realizing the functions of the priority determination system 100 is recorded may be supplied to the priority determination system 100 and the CPU 101 may execute the program. Examples of the storage medium for supplying the program include a CD-ROM, DVD, Blu-ray, or SD card. Further, a dedicated circuit for realizing each unit in FIG. 2 may be used.

  Although the embodiments of the present invention have been described in detail above, the present invention is not limited to such specific embodiments, and various modifications and changes can be made within the scope of the gist of the present invention described in the claims. It can be changed.

DESCRIPTION OF SYMBOLS 10 Work 20 Belt conveyor 30 Alarm switch 40 Indicator light 50 Timer 60 Priority creation means 70 Instruction means 80a CT order data store 80b Work trouble range priority table 80c Work delay range priority table 80d Instruction priority table 100 Priority judgment system

Claims (5)

Alarm notification means provided for each process in which the process time is determined and the start time is set at the same time;
A priority order creating means for creating a priority order for a process for which an alarm is notified based on a notification from the alarm notification means,
The priority order creating means creates the priority order of each process in the order received from the alarm notification means from the start time of each process to a predetermined time, and receives each alarm notification after exceeding the predetermined time. A priority determination system characterized in that, for a process, the priority of a process having a long remaining process time is set higher than that of a short process. 2. The priority order determination system according to claim 1, wherein the priority order creating means excludes the process for which the alarm by the alarm notification means has been canceled from the priority order. 3. The priority order determination system according to claim 2, wherein if there is a process in which the alarm notification is not canceled even after the predetermined time has elapsed, the priority order creating means maintains the priority order of the process.   The priority determination system according to any one of claims 1 to 3, further comprising an indicator lamp that displays the priority. Priority order that the priority order creating means creates a priority order for the process notified of the alarm based on the notification from the alarm notification means provided in each process whose process time is set and the start time is set at the same time Including creation steps,
In the priority order creating step, the priority order creating means creates the priority order of each process in the order received from the alarm notification means from the start time of each process to a predetermined time, and the alarm is issued after the predetermined time is exceeded. For each process that has received the notification, the priority order creating means sets the priority of the process having the long remaining process time to be higher than that of the short process.

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