JP6853764B2 - Work man-hour estimation device and work instruction system - Google Patents

Description

The present invention relates to a technique of a work man-hour estimation device and a work instruction system.

Patent Document 1 describes the relationship between the product name of a part and the standard man-hour group of working hours required for assembling the part as a system for promptly calculating the estimated work man-hour of the product in the assembly operation without variation. Is described in advance in the form of a table, and the work standard man-hour data is automatically assigned to the corresponding parts by referring to the table for the input items.

Japanese Unexamined Patent Publication No. 2000-117568

In the technique described in Patent Document 1, a method is proposed in which data of standard work elements constituting each work and data including variations of standard work elements depending on workers are prepared in a production apparatus to predict work man-hours. ing. However, it is premised that the data construction of this standard work element is done manually, and in a large-scale factory or a factory that produces a wide variety of products, the preparatory man-hours are often large. In addition, especially when predicting the work man-hours for setup work, the necessary work elements may change depending on the product and work content of the previous work in the target production equipment, and a highly accurate production plan is made. It's difficult.

An object of the present invention is to provide a work man-hour estimation device for making a more accurate production plan.

The present application includes a plurality of means for solving at least a part of the above problems, and examples thereof are as follows. In order to solve the above problems, the work manpower estimation device according to one aspect of the present invention is a storage unit that stores product design information, production process design information, and actual result information for each production process of the product. , The inter-product similarity calculation unit that calculates the similarity between the products, the inter-production process similarity calculation unit that calculates the similarity between the production processes, and the similarity between the products and the production process. Prediction accuracy is calculated using the pre-work dependency estimation unit that creates a regression equation for the setup time of the performance information and creates the work dependency estimation coefficient using the similarity as an explanatory variable, and the work dependency estimation coefficient. It is characterized in that it is provided with a work manpower estimation unit.

According to the present invention, it is possible to provide a work man-hour estimation device for making a more accurate production plan. Issues, configurations and effects other than those described above will be clarified by the description of the following embodiments.

It is a figure which shows the configuration example of the work instruction system. It is a figure which shows the configuration example of the work man-hour estimation apparatus. It is a figure which shows the example of the data structure stored in the production record table. It is a figure which shows the example of the data structure stored in the consumables exchange record table. It is a figure which shows the example of the data structure stored in the design information table. It is a figure which shows the example of the data structure stored in the process design information table. It is a figure which shows the example of the data structure stored in the consumable material exchange time table. It is a figure which shows the example of the data structure stored in the correction setup result table. It is a figure which shows the example of the data structure stored in the setup time table. It is a figure which shows the example of the data structure stored in the information table for each worker. It is a figure which shows the hardware configuration example of the work man-hour estimation apparatus. It is a flowchart which shows the processing example of the work man-hour estimation part. It is a flowchart which shows the processing example of the pre-work dependency estimation part. It is a flowchart which shows the processing example of the worker dependency estimation part. It is the schematic of the output screen which is an example of the output generated by the work man-hour estimation unit. It is a figure which shows the configuration example which concerns on another embodiment of the work man-hour estimation apparatus. It is a figure which shows the example of the data structure stored in the production plan information table. It is a figure which shows the example of the data structure stored in the production amount forecast information table.

[First Embodiment] Hereinafter, the first embodiment according to the present invention will be described with reference to the drawings. In addition, in all the drawings for explaining the embodiment, in principle, the same members are designated by the same reference numerals, and the repeated description thereof may be omitted. Further, in the following embodiments, the components (including element steps and the like) are not necessarily essential unless otherwise specified or clearly considered to be essential in principle. Needless to say. In addition, when saying "consisting of A", "consisting of A", "having A", and "including A", other elements are excluded unless it is clearly stated that it is only that element. It goes without saying that it is not something to do. Similarly, in the following embodiments, when referring to the shape, positional relationship, etc. of a component or the like, the shape is substantially the same unless otherwise specified or when it is considered that it is not apparent in principle. Etc., etc. shall be included.

FIG. 1 is a diagram showing a configuration example of a work instruction system according to the first embodiment of the present invention. The work instruction system 10 includes a work manpower estimation device 100, a production record management device 190, an equipment information management device 160, a process (production process) information management device 170, and a design information management device 180, which are networks. Information can be transmitted and received to and from each other via 199.

The work effort estimation device 100 estimates the work effort based on the information acquired from the production record management device 190, the equipment information management device 160, the process information management device 170, and the design information management device 180. The work man-hour estimation device 100 will be described in detail later.

The production performance management device 190 transmits log information regarding production to the work man-hour estimation device 100 at a predetermined time or in response to a request from the work man-hour estimation device 100. The production record management device 190 is not only a form in which one unit manages work record information of all manufacturing sites, but also a form in which as many production sites as the number of manufacturing sites are installed and the work record information is managed separately for each manufacturing site. It may be.

The equipment information management device 160 manages information on the production equipment at the manufacturing site, and transmits information on the production equipment to the work man-hour estimation device 100 at a predetermined time or in response to a request from the work man-hour estimation device 100.

The process information management device 170 manages the process design information in the manufacturing of the product, and transmits the process design information to the work man-hour estimation device 100 at a predetermined time or in response to a request from the work man-hour estimation device 100.

The design information management device 180 manages the design information of the product, and transmits the design information to the work man-hour estimation device 100 at a predetermined time or in response to a request from the work man-hour estimation device 100.

The work effort estimation device 100, the production record management device 190, the equipment information management device 160, the process information management device 170, and the design information management device 180 are MES (Manufacturing Executing System) that manages the target manufacturing site. The production record information data, process route information data, production equipment information data, process design information data, etc. obtained from the above are extracted and transmitted to the control unit 120 (see FIG. 2) of the work manpower estimation device 100 via the network 199. It is also possible to take the form of

FIG. 2 is a diagram showing a configuration example of the work man-hour estimation device 100. As shown in the figure, the work man-hour estimation device 100 includes a storage unit 110, a control unit 120, an input unit 130, an output unit 140, and a communication unit 150.

The storage unit 110 includes a production record storage area 111, a consumable replacement record storage area 112, a design information storage area 113, a process design information storage area 114, a correction setup record storage area 115, and a setup time storage area 116. , And an information storage area 117 for each worker.

In the production record storage area 111, for each part, the work (process), the time when the work (process) is started, the time when the work (process) is completed, the work (processed) production apparatus, and the work (process) are stored. Information that identifies the worker is stored.

FIG. 3 is a diagram showing an example of a data structure stored in the production record table stored in the production record storage area 111. The production record table 111a stores information input from the production record management device 190.

The production record table 111a includes a product ID column 111b, a product name column 111c, a number of members column 111d, a process name column 111e, a process No. column 111f, a start time column 111g, an end time column 111h, and equipment. It has an ID column 111i and a worker ID column 111k. Product ID column 111b, product name column 111c, number column 111d, process name column 111e, process No. column 111f, start time column 111g, end time column 111h, equipment ID column 111i, and work. The person ID column 111k is associated with each other.

In the product ID column 111b, information for identifying a product ID, which is identification information capable of uniquely identifying each product (sometimes referred to as a product) or a product such as a part, is stored. ..

In the product name column 111c, information for specifying the name of the product specified in the product ID column 111b is stored.

In the member number column 111d, information for specifying the quantity of the product specified in the product ID column 111b is stored.

In the process name column 111e, information for specifying the process name for identifying the process for processing the product specified in the product ID column 111b is stored.

The process No. column 111f stores information for specifying the number of the process in the process name column 111e for the product specified in the product ID column 111b, counting from the process start process.

The start time column 111g stores information for specifying the time when the process of the production process specified in the process name column 111e is started for the product specified in the product ID column 111b.

The end time column 111h stores information for specifying the time when the process of the production process specified in the process name column 111e is completed for the product specified in the product ID column 111b.

In the equipment ID column 111i, the product specified in the product ID column 111b is stored in the process name column during the period from the start time specified in the start time column 111g to the end time specified in the end time column 111h. Information for specifying the equipment ID in charge of processing in the production process specified by 111e is stored.

In the worker ID column 111k, the product specified in the product ID column 111b is subjected to a process name in the period from the start time specified in the start time column 111g to the end time specified in the end time column 111h. Information for identifying the worker ID in charge of processing in the production process specified in the column 111e is stored.

Returning to the description of FIG. The consumables replacement record storage area 112 stores the consumables replacement record.

FIG. 4 is a diagram showing an example of a data structure stored in the consumables replacement record table. Information is input to the consumables replacement record table 112a from the production record management device 190.

The consumables replacement record table 112a has an equipment ID column 112b, a consumables name column 112c, a type column 112d, a worker in charge column 112e, a work start time column 112f, and a work end time column 112g. The equipment ID column 112b, the consumables name column 112c, the type column 112d, the person in charge worker column 112e, the work start time column 112f, and the work end time column 112g are associated with each other.

The equipment ID column 112b stores information for identifying the equipment ID, which is identification information that can uniquely identify the equipment existing at the manufacturing site.

In the consumables name column 112c, information for identifying the consumables that have been replaced or replenished in the equipment specified in the equipment ID column 112b is stored.

In the type column 112d, information for specifying the replenishment method of the consumables specified in the consumables name column 112c in the equipment specified in the equipment ID column 112b is stored.

In the worker column 112e in charge, the consumables specified in the consumable name column 112c are used in the equipment specified in the equipment ID column 112b, and the worker in charge of compensation specified in the type column 112d is specified. Information is stored.

In the work start time column 112f, information on the time when the equipment specified in the equipment ID column 112b uses the consumables specified in the consumable name column 112c and the compensation specified in the type column 112d is started is stored. Will be done.

In the work end time column 112g, information on the time when the replenishment specified in the type column 112d is completed by using the consumables specified in the consumable name column 112c in the equipment specified in the equipment ID column 112b is stored. Will be done.

Returning to the description of FIG. Design information for each product is stored in the design information storage area 113.

FIG. 5 is a diagram showing an example of a data structure stored in the design information table.

Information is input to the design information table 113a from the design information management device 180.

The design information table 113a has a product name column 113b and a design information column 113c. The product name column 113b and the design information column 113c are associated with each other.

Information that identifies the name of the product is stored in the product name column 113b.

The design information column 113c stores the design information of the product specified in the product name column 113b. Quantitative data and qualitative data are mixed depending on the target product and the items stored in the design information. For example, materials are qualitative data, and size and weight are quantitative data. The design information column 113c also includes various design information items.

Returning to the description of FIG. The process design information storage area 114 stores process design information for each production process.

FIG. 6 is a diagram showing an example of a data structure stored in the process design information table. Information is input to the process design information table 114a from the process information management device 170.

The process design information table 114a has a product name column 114b, a process name column 114c, a process No. column 114d, and a process design information column 114e. The product name column 114b, the process name column 114c, the process No. column 114d, and the process design information column 114e are associated with each other.

Information for specifying the name of the product is stored in the product name column 114b.

The process name column 114c stores information that identifies a process required for manufacturing the product specified in the product name column 114b.

In the process No. column 114d, information for specifying the number of the production process specified in the process name column 114c from the first process in the product specified in the product name column 114b is stored. To.

The process design information column e includes the process name column 114c and the design information of the production process specified in the process No. 114d for the product specified in the product name column 114b. Quantitative data and qualitative data will be mixed in the items and their numbers stored in the design information depending on the target product.

Returning to the description of FIG. The correction setup record storage area 115 stores a statistical value of the consumables replacement time and information on the correction setup record, which is the setup time excluding the replacement of consumables.

FIG. 7 is a diagram showing an example of a data structure stored in the consumable material replacement time table. Information is input to the consumables replacement time table 115a from the work man-hour estimation device 100.

The consumables replacement time table 115a has an equipment ID column 115b, a consumables name column 115c, a type column 115d, and a working time estimation value column 115e. The equipment ID column 115b, the consumables name column 115c, the type column 115d, and the working time estimation value column 115e are associated with each other.

The equipment ID column 115b stores information for identifying the equipment ID, which is identification information that can uniquely identify the equipment existing at the manufacturing site.

In the consumable name column 115c, information for identifying the consumable to be replaced or replenished in the equipment specified in the equipment ID column 115b is stored.

In the type column 115d, information specifying the usage method of the consumable specified in the consumable name column 115c in the equipment specified in the equipment ID column 115b is stored.

In the work time estimation value column 115e, a type column calculated by using the consumables specified in the consumable name column 115c in the equipment specified by the equipment ID column 115b calculated by the work man-hour estimation device 100. The work time statistical value of the work specified by 115d is stored.

FIG. 8 is a diagram showing an outline of the correction setup result table 115f stored in the correction setup result storage area 115. The correction setup result table 115f is input from the work man-hour estimation device 100.

The correction setup result table 115f includes a product ID column 115g, a product name column 115h, a number of members column 115i, a process name column 115k, a process No. column 115m, a setup time column 115n, and a consumables replacement time column 115p. It also has a correction setup time column 115r, an equipment ID column 115s, and a worker ID column 115t. Product ID column 115g, product name column 115h, number of members column 115i, process name column 115k, process No. column 115m, setup time column 115n, consumables replacement time column 115p, correction setup time column 115r The equipment ID column 115s and the worker ID column 115t are associated with each other.

In the product ID column 115g, information for identifying a product ID, which is identification information capable of uniquely identifying a product such as each product or part, is stored.

In the product name column 115h, information for specifying the name of the product specified in the product ID column 115g is stored.

In the member number column 115i, information for specifying the quantity of the product contained in the product specified in the product ID column 115g is stored.

In the process name column 115k, information for specifying the process name for identifying the process for processing the product specified in the product ID column 115g is stored.

In the process No. column 115m, information for specifying the number of the production process in the process name column 115k for the product specified in the product ID column 115g from the process start process is stored.

The setup time column 115n stores information for specifying the setup time of the production process specified in the process name column 115k and the process No. column 115m for the product specified in the product ID column 115g.

In the consumables replacement time column 115p, an estimated value of the time required for consumables replacement in the production process specified in the process name column 115k and the process No. column 115m for the product specified in the product ID column 115g is stored. Will be done.

In the correction setup time column 115r, the setup time is estimated excluding the time required for the replacement of consumables in the production process specified in the process name column 115k and the process No. column 115m for the product specified in the product ID column 115g. The value is stored.

In the equipment ID column 115s, information for specifying the equipment ID in charge of processing the production process specified in the process name column 115k and the process No. column 115m for the product specified in the product ID column 115g is stored. ..

In the worker ID column 115t, there is information for identifying the worker ID in charge of processing the product specified in the product ID column 115g in the production process specified in the process name column 115k and the process No. column 115m. It is stored.

Returning to the description of FIG. The setup time storage area 116 stores information used for estimating the setup time.

FIG. 9 is a diagram showing an example of a data structure stored in the setup time table. Information is input to the setup time table 116a from the work man-hour estimation device 100.

The setup time table 116a includes an equipment ID column 116b, a product name column 116c, a process name column 116d, a process No column 116e, a basic setup time column 116f, a product similarity coefficient column 116g, and a process similarity. It has a coefficient column 116h and. The equipment ID column 116b, the product name column 116c, the process name column 116d, the process No. column 116e, the basic setup time column 116f, the product similarity coefficient column 116g, and the process similarity coefficient column 116h are Each is associated.

The equipment ID column 116b stores information for identifying the equipment ID, which is identification information that can uniquely identify the equipment existing at the manufacturing site.

The product name column 116c stores information that identifies the name of the product processed by the equipment specified in the equipment ID column 116b.

The process name column 116d stores information that identifies the process required to manufacture the product specified in the product name column 116c in the equipment specified in the equipment ID column 116b.

In the process No. column 116e, the production process specified in the process name column 116d for the product specified in the product name column 116c in the equipment specified in the equipment ID column 116b is described from the first step. Information that identifies the number of the process is stored.

The basic setup time column 116f is specified in the process name column 116d and the process No. 116e for the product specified in the product name column 116c in the equipment specified in the equipment ID column 116b. An estimated value of the setup time required for processing is stored.

The product similarity coefficient column 116g is specified in the process name column 116d and the process No. 116e for the product specified in the product name column 116c in the equipment specified in the equipment ID column 116b. In the process, a coefficient for correcting the setup time according to the degree of similarity with the target product in the process performed in the equipment specified in the equipment ID column 116b immediately before is stored. This coefficient is calculated using, for example, product design information such as the material, size, weight, and product-specific design value shown in the design information table 113a.

The process similarity coefficient column 116h is specified in the process name column 116d and the process No. 116e for the product specified in the product name column 116c in the equipment specified in the equipment ID column 116b. In the process, a coefficient for correcting the setup time according to the degree of similarity with the process targeted in the process performed in the equipment specified in the equipment ID column 116b immediately before is stored. This coefficient is calculated using, for example, process design information such as a program ID shown in the process design information table, a jig, and a process design value which is a setting value peculiar to the process.

Returning to the description of FIG. The worker-specific information storage area 117 stores information used for correction for each worker in the estimation of the setup time.

FIG. 10 is a diagram showing an example of a data structure stored in the worker-specific information table. Information is input to the worker-specific information table 117a from the work man-hour estimation device 100.

The worker-specific information table 117a includes an equipment ID column 117b, a product name column 117c, a process name column 117d, a process No. column 117e, a worker column 117f, a setup time column 117g, and a correction value column 117h. , Have. The equipment ID column 117b, the product name column 117c, the process name column 117d, the process No. column 117e, the worker column 117f, the setup time column 117g, and the correction value column 117h are associated with each other.

The equipment ID column 117b stores information for identifying the equipment ID, which is identification information that can uniquely identify the equipment existing at the manufacturing site.

The product name column 117c stores information that identifies the name of the product processed by the equipment specified in the equipment ID column 117b.

The process name column 117d stores information that identifies the process required to manufacture the product specified in the product name column 117c in the equipment specified in the equipment ID column 117b.

In the process No. column 117e, the production process specified in the process name column 117d for the product specified in the product name column 116c in the equipment specified in the equipment ID column 117b is described from the first step. Information that identifies the number of the process is stored.

In the worker column 117f, in the equipment specified in the equipment ID column 117b, the process specified in the process name column 117d and the process No. 117e for the product specified in the product name column 117c is performed. Information that identifies the worker who performed the work is stored.

In the setup time column 117g, the equipment specified in the equipment ID column 117b is used for the process specified in the process name column 117d and the process No. 117e for the product specified in the product name column 117c. Therefore, the estimated value of the setup time when the worker specified in the worker column 117f performs the process is stored.

In the correction value column 117h, in the equipment specified in the equipment ID column 117b, the process specified in the process name column 117d and the process No. 117e for the product specified in the product name column 117c. Therefore, a coefficient for correcting the setup time when the worker specified in the worker column 117f performs the process from the reference setup time is stored.

Returning to the description of FIG. The control unit 120 of the work man-hour estimation device 100 includes a performance collection unit 121, a work man-hour estimation unit 122, a consumable replacement time estimation unit 123, a similarity calculation unit 124, a pre-work dependency estimation unit 125, and work. A person-dependent estimation unit 126 is provided.

The performance collection unit 121 acquires information to be stored in the production performance table 111a and the consumables replacement performance table 112a from the production performance management device 190 when it is predetermined (for example, every day) or when it is specified. Further, the information stored in the design information table 113a is acquired from the design information management device 180, and the information stored in the process design information table 114a is acquired from the process information management device 170 and the equipment information management device 160. Then, the production record table 111a, the consumables replacement record table 112a, the design information table 113a, and the process design information table 114a are updated.

The work manpower estimation unit 122 sets the production record table 111a, the consumables replacement record table 112a, the design information table 113a, and the process design information table 114a when predetermined (for example, every day) or when specified. And, according to a predetermined process described later, the information stored in the correction setup result table 115f, the setup time table 116a, and the information stored in the worker-specific information table 117a are generated, and the correction setup result table 115f is generated. Then, the setup time table 116a and the worker-specific information table 117a are updated. Further, the work man-hour estimation unit 122 edits and outputs the result in the format shown on the output screen 500 described later.

The consumables replacement time estimation unit 123 is in charge of internal processing of the work man-hour estimation unit 122. Specifically, the consumables replacement time estimation unit 123 acquires the information stored in the production record table 111a and the consumables replacement record table 112a, performs a predetermined process, and updates the correction setup record table 115f.

The similarity calculation unit 124 is in charge of internal processing of the work man-hour estimation unit 122. Specifically, the similarity calculation unit 124 calculates the similarity between the two products and the similarity between the two processes from the design information table 113a and the information stored in the process design information table 114a. .. Here, there are various methods for calculating the degree of similarity, but the degree of similarity between the two products and between the two processes is stored in the design information table 113a and the process design information table 114a. Any embodiment thereof may be used as long as it is quantified based on the information of a plurality of items. For example, since the information stored in the design information table 113a and the process design information table 114a is a mixture of qualitative data and quantitative data, for example, the qualitative data is converted into quantitative data based on the quantification theory. Later, a method of calculating the similarity based on the Mahalanobis distance can be considered.

The pre-work dependency estimation unit 125 is in charge of internal processing of the work man-hour estimation unit 122. Specifically, the pre-work dependency estimation unit 125 acquires the design information table 113a, the process design information table 114a, and the information stored in the correction setup result table 115f, performs a predetermined process, and sets up the setup time. The information to be stored in the table 116a is generated, and the setup time table 116a is updated.

The worker dependence estimation unit 126 is in charge of internal processing of the work man-hour estimation unit 122. Specifically, the worker dependency estimation unit 126 acquires the information stored in the design information table 113a, the process design information table 114a, and the correction setup result table 115f, and according to a predetermined process, the information for each worker. The information to be stored in the table 117a is generated, and the worker-specific information table 117a is updated.

The input unit 130 receives the input of information. The output unit 140 outputs information. The communication unit 150 transmits / receives information via the network 199.

FIG. 11 is a diagram showing a hardware configuration example of the work man-hour estimation device. The work effort estimation device 100 includes a central processing unit (CPU) 901, a memory 902, an external storage device 903 such as a hard disk device (Hard Disk Drive: HDD), and a CD (Computer Disk) or DVD (Digital). A reader 905 that reads and writes information to and from a portable storage medium 904 such as a Versail Disk), an input device 906 such as a keyboard, mouse, and bar code reader, an output device 907 such as a display, and communication such as the Internet. This can be realized by a general computer 900 provided with a communication device 908 that communicates with another computer via a network, or a network system including a plurality of the computers 900.

For example, the control unit 120 can be realized by loading a predetermined program stored in the external storage device 903 into the memory 902 and executing the program in the CPU 901, and the input unit 130 uses the input device 906 by the CPU 901. The output unit 140 can be realized by using the output device 907 by the CPU 901, and the communication unit 150 can be realized by using the communication device 908 by the CPU 901. Can be realized by the CPU 901 using the memory 902 or the external storage device 903.

This predetermined program is downloaded from the storage medium 904 via the reader 905 or from the network via the communication device 908 to the external storage device 903, then loaded onto the memory 902 and executed by the CPU 901. You may do so.

Further, it may be directly loaded onto the memory 902 from the storage medium 904 via the reading device 905 or from the network via the communication device 908 and executed by the CPU 901.

The production record management device 190, the equipment information management device 160, the process information management device 170, and the design information management device 180 can also be realized by a general computer 900 as shown in FIG.

FIG. 12 is a flowchart showing a processing example of the work man-hour estimation unit. First, the work man-hour estimation unit 122 acquires the production record for the designated period from the production record storage area 111 and the replenishment / replacement record of consumables from the consumable replacement record storage area 112 for the target equipment (step). S10). Depending on the designated period, a plurality of production records and consumables replacement record storage areas 112 are acquired.

Next, the consumables replacement time estimation unit 123 estimates the consumables replenishment / replacement work time according to the following procedure (step S20). In the following, the processing result of this step S20 may be shown as (1). First, the consumables replacement time estimation unit 123 acquires the consumables replacement / replenishment record of the target equipment from the consumables replacement record storage area 112 and links it to the production record at the same time.

Next, the consumables replacement time estimation unit 123 groups the production results on two axes, one for each product and one for each process, and sets this group as group 1.

Next, the consumables replacement time estimation unit 123 further subdivides the group 1 into a production record without consumables replacement / replenishment and a production record with consumables replacement / replenishment (by consumables) into group 2.

Next, the consumables replacement time estimation unit 123 calculates statistical values (mean value, median value, variance, etc.) of actual working hours for each group of group 2.

Next, the consumables replacement time estimation unit 123 calculates the time required for each consumables replacement / replenishment based on the difference between the representative values (mean value / median value) of group 2, and stores it in the correction setup actual storage area 115. ..

Next, the correction setup time is calculated for each group of group 1 by the formula shown in Equation 1, and stored in the correction setup actual storage area 115.

<Equation 1> (Correction setup time) = (Setup time)-(Estimated value of consumable replacement time)

Next, the pre-work dependency estimation unit 125 estimates the pre-work dependency (step S30). In the following, the processing result of this step S30 may be shown as (2).

FIG. 13 is a flowchart showing a processing example of the pre-work dependency estimation unit. The process of the pre-work dependency estimation unit is started in step S30.

The pre-work dependency estimation unit 125 acquires design information from the design information storage area 113 and process design information from the process design information storage area 114 for all production results (step S310).

Then, the pre-work dependency estimation unit 125 calculates the product similarity with the previous work by the similarity calculation unit 124 from the design information of the manufacturing log of the immediately preceding work for all the production results (step S320).

Next, the pre-work dependency estimation unit 125 calculates the process design similarity with the pre-work from the process design information of the production log of the immediately preceding work for all the production results (step S330).

Next, the pre-work dependency estimation unit 125 creates a regression equation for the correction setup time for each group 1 using the product similarity and the process similarity as explanatory variables. Then, the pre-work dependency estimation unit 125 stores the regression coefficient in the setup time storage area 116 (step S340).

Next, the worker dependence estimation unit 126 estimates the worker dependence (step S40). In the following, the processing result of this step S40 may be shown as (3).

FIG. 14 is a flowchart showing a processing example of the worker dependency estimation unit. The process of the worker dependence estimation unit is started in step S40.

The worker dependency estimation unit 126 acquires the worker information in charge from the production record storage area 111 for all the production results (step S410).

Next, the worker dependence estimation unit 126 subdivides the group by worker (group 3) (step S420).

The worker dependence estimation unit 126 calculates statistical values (mean value, median value, variance, etc.) of the correction setup time for each group of group 3 and stores them in the information storage area 117 for each worker (step S430).

Next, the work man-hour estimation unit 122 calculates the prediction accuracy by the combination of (1) + (2), (1) + (3), (1) + (2) + (3) (step S50). .. That is, the work man-hour estimation unit 122 has the prediction accuracy using the estimated time of the replenishment / replacement work of consumables and the coefficient of determination of the pre-work dependence, and the estimated time and worker dependence of the replenishment / replacement work of consumables. The prediction accuracy using the coefficient of determination of, and the estimation accuracy of the replenishment / replacement work of consumables, the estimation coefficient of pre-work dependence, and the estimation coefficient of worker dependence are calculated respectively.

Here, the prediction accuracy is, for example, a statistical value of the setup time calculated by dividing the actual data into training data and test data, the predicted value of the setup time performed using the training data is P, and the test data is used. When (average value or median value) is A, it is calculated by the formula shown in Equation 2 below.

<Numerical value 2> Prediction accuracy = (A- | AP |) / A

The above is the processing flow of the work man-hour estimation unit 122. According to the processing of the work man-hour estimation unit 122, it depends on the time required for replacement of consumables for each equipment, the similarity between the previous process and the subsequent process, and the similarity between the product targeted for the pre-work and the product targeted for the post-work. Since the fluctuation of the time required for the setup work can be taken into consideration, it is possible to provide a work man-hour estimation device for making a more accurate production plan.

FIG. 15 is a schematic view of an output screen which is an example of the output generated by the work man-hour estimation unit. The output screen 500 includes an equipment ID selection area 500a, a learning data acquisition start date selection area 500b, a learning data acquisition end date selection area 500c, an evaluation instruction receiving means 500d, an evaluation data acquisition start date selection area 500e, and evaluation. It has a data acquisition end date selection area 500f, a result graph display area 500g, and a result display area 500h.

The output screen 500 is displayed by the output unit 140. The equipment ID selection area 500a, the training data acquisition start date selection area 500b, the training data acquisition end date selection area 500c, the evaluation data acquisition start date selection area 500e, and the evaluation data acquisition end date selection via the input unit 130. Inputs are received in the area 500f and the evaluation instruction receiving means 500d. Upon receiving the input to the evaluation instruction receiving means 500d, the work man-hour estimation unit 122 outputs the correction setup time information matching the selected equipment ID from the worker-specific information table 117a to the result graph display area 500 g, and the quantity. The evaluation result of the prediction accuracy by the combination of the dependency estimation and the worker dependency estimation is output to the result display area 500h.

[Second Embodiment] Next, the work instruction system according to the second embodiment of the present invention will be described. In the second embodiment, the work man-hour estimation device 100 uses the setup time calculated in the same manner as in the first embodiment to make a highly accurate production plan and instruct the work to the manufacturing site. Further, the work instruction system includes a work instruction device 200 (not shown) that assigns equipment and a person in charge according to a production plan and instructs each person in charge of work instructions. The work man-hour estimation device 100 creates a production plan based on the estimated work man-hours, and transmits the production plan to the work instruction device 200.

FIG. 16 is a diagram showing a configuration example according to another embodiment of the work man-hour estimation device. In addition to the first embodiment shown in FIG. 2, the control unit 120 is provided with the production planning unit 127, and the storage unit 110 is provided with the production planning storage area 118. Hereinafter, the differences will be mainly described.

The production planning unit 127 creates a simulation model of the production process in the factory on the desk and creates a production plan. In the simulation model, according to the process path for each product and various dispatch rules for determining the processing priority between products, the progress caused by the manufacturing equipment, the worker, and other products. By reproducing the constraints of the above on a computer, the time transition of the entire production line and production process is simulated, and a progress plan for all the products put into the production line is created. In addition, the production planning unit 127 outputs various statistical values such as by product / product, by process, by process, by manufacturing equipment, and by worker from the progress plan of all the created products as production index information. be able to. Further, when the production planning unit 127 creates a production plan including the setup time according to the prediction accuracy, the production planning unit 127 delivers it to the work instruction device 200.

Differences in the accuracy of the simulation results are expected depending on the actual information and accuracy considered in the simulation model, but in this embodiment, the simulation method of the existing simulator is used without being specified. To do. For example, a discrete event type simulation method is generally used for simulating a production process in a factory, but the simulation is not limited to this.

Further, when creating a simulation model, an input specification peculiar to the present embodiment is provided, and data input by the input specification can be executed in the simulation model.

In the work instruction system according to the second embodiment, the setup time column 117g of the worker-specific information table 117a is used as input data used for the simulation to improve the prediction accuracy of the setup time between each process, and the production planning unit 127 creates a production plan.

The production planning storage area 118 includes information predicted by the production planning unit 127 in the simulation, or information related to the production index obtained from the information predicted by the simulation. For example, in the present embodiment, the production plan information table 118a as shown in FIG. 17 is stored in the production plan storage area 118.

FIG. 17 is a diagram showing an example of a data structure stored in the production planning information table. The production plan information table 118a includes a product ID column 118b, a product name column 118c, a number column 118d, and a process No. A column 118e, a process name column 118f, an equipment name column 118g, a start time column 118h, an end time column 118i, and a previous process end time column 118k are provided.

The product ID column 118b stores information for identifying the product ID, which is identification information that can uniquely identify the ID of each product.

Information for identifying the product type is stored in the product name column 118c.

In the member number column 118d, information for specifying the quantity of the product included in the product ID specified in the product ID column 118b is stored.

Process No. In the column 118e, information for specifying the process No., which is identification information capable of uniquely identifying the manufacturing process of the product, is stored for the product type specified in the product name column 118c.

In the process name column 118f, information for specifying the process name for identifying the process identified in the process No. column 118e is stored for the product type specified in the product name column 118c.

In the equipment name column 118g, information for specifying the name of the equipment used in the production process specified in the process No. column 118e and the process name column 118f is stored for the product type specified in the product name column 118c.

The start time column 118h stores information for specifying the time at which the process of the production process specified in the process name column 118f is started for the product ID specified in the product ID column 118b.

The end time column 118i stores information for specifying the time at which the process of the production process specified in the process name column 118f is finished for the product ID specified in the product ID column 118b.

In the pre-process end time column 118k, information for specifying the time at which the process in the process before the production process specified in the process name column 118f is completed for the product ID specified in the product ID column 118b is stored. Will be done.

Further, the production amount prediction information table 119a as shown in FIG. 18 is stored in the production plan storage area 118.

FIG. 18 is a diagram showing an example of a data structure stored in the production amount prediction information table. The production amount forecast information table 119a includes a production month column 119b, a product name column 119c, and a production number column 119d.

Information for specifying the production month is stored in the production month column 119b.

Information for specifying the product name is stored in the product name column 119c.

In the production number column 119d, information for specifying the production number of the product specified in the product name column 119c is stored in the month specified in the production month column 119b.

As described above, according to the work man-hour estimation device 100 according to the second embodiment, the work man-hour estimation device 100 utilizes the setup time calculated in the same manner as in the first embodiment to obtain a highly accurate production plan. You can stand up and instruct the work to the manufacturing site.

The above-described embodiments have been described in detail in order to explain the present invention in an easy-to-understand manner, and are not necessarily limited to those having all the described configurations. It is possible to replace a part of the configuration of the embodiment with another configuration, and it is also possible to add the configuration of another embodiment to the configuration of the embodiment. It is also possible to delete a part of the configuration of the embodiment.

Further, each of the above-mentioned parts, configurations, functions, processing parts and the like may be realized by hardware by designing a part or all of them by, for example, an integrated circuit. Further, each of the above parts, configurations, functions and the like may be realized by software by interpreting and executing a program in which the processor realizes each function. Information such as programs, tables, and files that realize each function can be stored in a memory, a recording device such as a hard disk, or a recording medium such as an IC card, an SD card, or a DVD.

It should be noted that the control lines and information lines according to the above-described embodiment are shown as necessary for explanation, and not all control lines and information lines are necessarily shown in the product. In practice, it can be considered that almost all configurations are interconnected. The present invention has been described above with a focus on embodiments.

10 ... Work instruction system, 100 ... Work effort estimation device, 110 ... Storage unit, 111 ... Production record storage area, 112 ... Consumables replacement record storage area, 113 ... Design information Storage area, 114 ... Process design information storage area, 115 ... Correction setup result storage area, 116 ... Setup time storage area, 117 ... Worker-specific information storage area, 120 ... Control unit, 121 ... Achievement collection unit, 122 ... Work effort estimation unit, 123 ... Consumables replacement time estimation unit, 124 ... Similarity calculation unit, 125 ... Pre-work dependency estimation unit, 126.・ ・ Worker dependency estimation unit, 130 ・ ・ ・ input unit, 140 ・ ・ ・ output unit, 150 ・ ・ ・ communication unit, 160 ・ ・ ・ equipment information management device, 170 ・ ・ ・ process information management device, 180 ・・ ・ Design information management device, 190 ・ ・ ・ Production record management device, 199 ・ ・ ・ Network.

Claims (6)

A storage unit that stores product design information, production process design information, and performance information for each production process of the product.
An inter-product similarity calculation unit that calculates the inter-product similarity,
The inter-production process similarity calculation unit that calculates the similarity between production processes, and the inter-production process similarity calculation unit.
A pre-work dependency estimation unit that creates a regression equation for the setup time of the actual information and creates a work dependency estimation coefficient using the similarity between the products and the similarity between the production processes as explanatory variables.
A work man-hour estimation unit that calculates prediction accuracy using the coefficient of determination of work dependence,
A work man-hour estimation device characterized by being equipped with. The work man-hour estimation device according to claim 1.
Consumables replacement time estimation unit that estimates the time required for replenishment / replacement of consumables from the above-mentioned actual information,
A work man-hour estimation device characterized by being equipped with. The work man-hour estimation device according to claim 1.
The performance information includes a method of identifying the worker in charge of the process.
It is equipped with a worker dependence estimation unit that estimates the difference in working time between workers from the actual information.
The worker dependence estimation unit creates a regression equation for the setup time of the actual information using the difference in work time depending on the worker, and creates an estimation coefficient of work dependence.
A work man-hour estimation device characterized by this. The work man-hour estimation device according to claim 1.
The performance information includes a method of identifying the worker in charge of the process.
A worker dependency estimation unit that estimates the difference in working time between workers from the actual information,
It is equipped with a consumables replacement time estimation unit that estimates the time required for replenishment / replacement of consumables from the above-mentioned actual information.
The worker dependence estimation unit creates a regression equation for the setup time of the actual information using the difference in work time depending on the worker, and creates an estimation coefficient of work dependence.
A work man-hour estimation device characterized by this. A storage unit that stores product design information, production process design information, and performance information for each production process of the product.
An inter-product similarity calculation unit that calculates the inter-product similarity,
The inter-production process similarity calculation unit that calculates the similarity between production processes, and the inter-production process similarity calculation unit.
A pre-work dependency estimation unit that creates a regression equation for the setup time of the actual information and creates a work dependency estimation coefficient using the similarity between the products and the similarity between the production processes as explanatory variables.
A work man-hour estimation unit that calculates prediction accuracy using the coefficient of determination of work dependence,
The production planning department that delivers the production plan including the setup time according to the prediction accuracy to a predetermined external device,
A work man-hour estimation device characterized by being equipped with. A work instruction system including a work man-hour estimation device for estimating work man-hours and a work instruction device for instructing production work using a production plan calculated using the work man-hours.
The work man-hour estimation device is
A storage unit that stores product design information, production process design information, and performance information for each production process of the product.
An inter-product similarity calculation unit that calculates the inter-product similarity,
The inter-production process similarity calculation unit that calculates the similarity between production processes, and the inter-production process similarity calculation unit.
A pre-work dependency estimation unit that creates a regression equation for the setup time of the actual information and creates a work dependency estimation coefficient using the similarity between the products and the similarity between the production processes as explanatory variables.
A work man-hour estimation unit that calculates prediction accuracy using the coefficient of determination of work dependence,
The production planning department that delivers the production plan including the setup time according to the prediction accuracy to the work instruction device,
A work instruction system characterized by being equipped with.

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