JP7141487B2 - Production lead time analysis method and production lead time analysis system - Google Patents

Description

The present invention relates to a production lead time analysis method and production lead time analysis system for analyzing the production lead time of a product.

In commercial transactions, as customer needs diversify and competition among companies intensifies, it is necessary for manufacturing companies to meet the production lead times required by customers. Even if the price and quality of the product are ideal at the ordering stage, if the delivery takes a long time, the order may flow to a competitor. In order to shorten the production lead time, companies use various IT technologies to collect the production lead time at that point in time, but the utilization of data is not yet sufficient. Since it mainly uses human experience and knowledge, it lacks reliability and versatility.

Patent Literature 1 describes that in order to manufacture and mount a circuit, a plurality of processes are sequentially performed, and specific equipment is used in each process. In general equipment, the product production lead time varies depending on process differences, the number of products processed per unit time, processing speed, and work time. Waiting time between processes should also be taken into account. In order to comply with the production plan, it is necessary to accurately measure the target lead time of the production lot, which is a single unit that is put into the production line. In response to the problem, Patent Document 1 describes a method of measuring the target lead time for semiconductor and IC manufacturers. In addition to calculating the utilization rate, use the utilization rate of each process facility to calculate the waiting time in each process. Finally, add the total value of each process waiting time and the theoretical work time of the product to obtain the target lead time. is configured to calculate

Chinese Patent Application Publication No. 101727098

However, lot production and production line production methods and equipment such as semiconductor and IC manufacturers according to Patent Document 1 are only techniques applied to production lines and lack versatility. Moreover, in Patent Document 1, the production plan is optimized by accurately measuring the target lead time, and the production lead time is shortened. It is not possible to know at what stage within the lead time the waiting occurred, so it is not possible to shorten the production lead time by pinpointing improvements at the production site.

The present invention has been made to solve the above technical problems, and is a production lead time analysis that analyzes the production lead time of one or more products , which is executed by a production lead time analysis system that is a computer having a display interface. A method is provided, wherein the product is processed through one or more steps by one or more semi-finished products, the semi-finished product is processed and formed through one or more steps, and the production lead time is The analysis method is characterized by including the following steps. That is, the work result information collecting step of collecting the work result information of each related process for each product by the work result information collecting unit, wherein the work result information includes the work start time and work end time of the process. and a process work time calculation step of calculating a process work time based on the work performance information for each process of each product by a process work time calculation unit, wherein the process work time is the time of the process. A step that is the time difference between the work start time and the work end time, a process standard work time acquisition step that acquires the corresponding process standard work time for each process of the product by the process standard work time acquisition unit, and a process delay . a process delay time calculation step of calculating the delay time of the process work time with respect to the corresponding process standard work time in the process for each process of the product by the time calculation unit, and setting it as the process delay time of the process ; By the process stagnation time calculation unit, for each process excluding the slowest process among the processes used for the processing and forming of each semi-finished product and the slowest process for the product, the process stagnation time of the process is calculated. and a step of calculating a product production lead time for each of the products by a product production lead time calculation unit based on the work performance information, wherein the product production lead time is calculated according to the Product production lead time calculation step and product standard production lead time acquisition, which is the time difference between the work start time of the earliest process and the work end time of the latest process collected in the work result information collection step a product standard production lead time acquisition step of acquiring a product standard production lead time corresponding to the product by a product delay time calculation unit; a product delay time calculation step of calculating the delay time of the production lead time and setting it as the product delay time of the product; and calculating the semi-finished product production lead time, wherein the semi-finished product production lead time is calculated from the work start time of the earliest step and the work end time of the latest step among the processes used for the processing and forming of the semi-finished product. A semi-finished product production lead time calculation step and a semi-finished product standard production lead time acquisition unit acquire the corresponding semi-finished product standard production lead time for various semi-finished products of the product a semi-finished product standard production lead time obtaining step; and a delay time of the semi-finished product production lead time relative to the corresponding semi-finished product standard production lead time for each semi-finished product of each of the semi-finished products by the semi-finished product delay time calculation unit. is calculated as the semi-finished product delay time of the semi-finished product, and the semi-finished product stagnation time calculation unit calculates the semi-finished product of the semi-finished product for each of the plurality of semi-finished products used for mutual assembly by the semi-finished product delay time calculation unit. In the step of calculating a stagnation time, the semi-finished product stagnation time is calculated by combining the work finish time of the latest step among the steps used for the processing and forming of the semi-finished product and the earliest step among the steps related to the mutual assembly. It is a time difference from the work start time of the semi-finished product stagnation time calculation step, and the abnormality determination unit determines that the process in which the process delay time exceeds a preset process delay threshold is an abnormal delay process, and the process A process whose stagnation time exceeds a preset process stagnation threshold is determined to be an abnormal stagnation process, a product whose product delay time exceeds a preset product delay threshold is determined to be an abnormally delayed product, and a half-finished product. A semi-finished product whose delay time exceeds a preset semi-finished product delay threshold is determined to be an abnormally delayed semi-finished product, and a semi-finished product whose stagnation time exceeds a preset semi-finished product stagnation threshold is determined as an abnormally stagnant semi-finished product. An abnormality determination step for determining that

The above production lead time analysis method may also be configured as follows. That is, the process stagnation time is the time difference between the work end time of the relevant process and the work start time of the process next to the relevant process.

The above production lead time analysis method may also be configured as follows. That is, the method further includes displaying at least one of the process working time of each process, the standard process working time of various processes, and process abnormality information on a display unit.

In order to shorten the production lead time of the product, it intelligently, visually and quickly identifies the problem process that prolongs the production lead time, and takes pinpoint measures to avoid unnecessary waiting time, It is possible to shorten the production lead time.

The above production lead time analysis method may also be configured as follows. That is, in the abnormality determination step, the abnormality determination unit further determines that a product whose product delay time exceeds a preset product delay threshold is an abnormally delayed product, and in the display step, the display unit At least one of the product production lead time, the product standard production lead time, and product abnormality information for each product is further displayed .

It intelligently, visually and quickly identifies problem products that prolong the production lead time in order to shorten the production lead time of the product, so as to take pinpoint action and avoid unnecessary waiting time. , the product production lead time can be shortened.

The above production lead time analysis method may also be configured as follows. That is, in the abnormality determination step, the abnormality determination unit further determines that a semi-finished product whose delay time exceeds a preset semi-finished product delay threshold is an abnormally delayed semi-finished product, and the semi-finished product stagnation time is determined. semi-finished products exceeding a preset semi-finished product stagnation threshold are determined to be abnormally stagnant semi-finished products, and in the display step, the display unit displays the semi-finished product production lead time of each semi-finished product, the semi-finished product production lead time of each semi-finished product, and the At least one of semi-finished product standard production lead time and semi-finished product abnormality information is further displayed .

It intelligently, visually and quickly identifies problematic semi-finished products that lengthen the production lead time in order to reduce the production lead time of the product, thus avoiding unnecessary waiting time by pinpointing actions. As a result, the product production lead time can be shortened.

The above production lead time analysis method may also be configured as follows. That is, in the process standard work time acquisition step, the process standard work time acquisition unit removes abnormal values from the process work time of each process of the product for each process of the product, and obtains the process standard work time. Calculate working hours.

Thereby, the process standard work time can be obtained more accurately.

The present invention further provides a production lead time analysis system that is a computer having a display interface, the production lead time analysis system for analyzing production lead times for one or more products, the products comprising one or more A plurality of semi-finished products are processed through one or more steps, the semi-finished products are processed and formed through one or more steps, and the production lead time analysis system includes the following. That is, for each product, a work performance information collecting unit for collecting work performance information of each related process, wherein the work performance information includes the work start time and work end time of the process; A process work time calculation unit for calculating a process work time based on the work performance information for each process of the above, wherein the process work time is the time difference between the work start time and the work end time of the process , a process standard work time acquisition unit that acquires the corresponding standard work time for each process of the product; a process delay time calculation unit that calculates a delay time and sets it as the process delay time of the process; A process stagnation time calculation unit that calculates the process stagnation time for each process except wherein the product production lead time is the time difference between the work start time of the earliest process and the work end time of the latest process among the individual processes collected by the work performance information collection unit. a calculation unit, a product standard production lead time acquisition unit for acquiring a product standard production lead time corresponding to the product, and a delay time of the product production lead time relative to the product standard production lead time for each product. and a product delay time calculation unit that calculates the product delay time of the product; wherein the semi-finished product production lead time is the time difference between the work start time of the earliest step and the work finish time of the latest step among the steps used for the processing and forming of the semi-finished product. a lead time calculation unit; a semi-finished product standard production lead time acquisition unit that acquires the corresponding semi-finished product standard production lead time for various semi-finished products of the product; A semi-finished product delay time calculation unit that calculates the delay time of the semi-finished product production lead time with respect to the corresponding semi-finished product standard production lead time and sets it as the semi-finished product delay time of the semi-finished product; a semi-finished product stagnation time calculation unit for calculating the semi-finished product stagnation time for each semi-finished product, The product stagnation time is the time difference between the work finish time of the latest process among the processes used for the processing and forming of the semi-finished product and the work start time of the earliest process among the processes related to the mutual assembly. a stagnation time calculating unit for determining a process in which the process delay time exceeds a preset process delay threshold as an abnormally delayed process, and determining a process in which the process stagnation time exceeds the preset process stagnation threshold as an abnormally stagnant process; A product whose product delay time exceeds a preset product delay threshold is determined to be an abnormal delayed product, and a semi-finished product whose semi-finished product delay time exceeds a preset semi-finished product delay threshold is determined to be abnormal An abnormality determination unit that determines that the semi-finished product is delayed and determines that the semi-finished product whose stagnation time exceeds a preset semi-finished product stagnation threshold value is an abnormally stagnant semi-finished product .

The production lead time analysis system may also be configured as follows. That is, the process stagnation time further includes the time difference between the work end time of the process and the work start time of the process next to the process.

The production lead time analysis system may also be configured as follows. That is, it further includes a display for displaying at least one of the process working time of each process , the standard process working time of each process, and process abnormality information.

It intelligently, visually and quickly identifies problem processes that prolong the production lead time in order to shorten the production lead time of the product, so as to take pinpoint action and avoid unnecessary waiting time. , the product production lead time can be shortened.

The production lead time analysis system may also be configured as follows. That is, the abnormality determination unit further determines that a product whose product delay time exceeds a preset product delay threshold is an abnormally delayed product, and the display unit displays the product production lead time of each product, the product At least one of standard production lead time and product defect information is further displayed .

It intelligently, visually and quickly identifies problem products that prolong the production lead time in order to shorten the production lead time of the product, so as to take pinpoint action and avoid unnecessary waiting time. , the product production lead time can be shortened.

The production lead time analysis system may also be configured as follows. Namely
The abnormality determination unit further determines that a semi-finished product whose delay time exceeds a preset semi-finished product delay threshold is an abnormally delayed semi-finished product, and the semi-finished product stagnation time is a preset semi-finished product stagnation threshold. is determined to be an abnormally stagnant semi-finished product, and the display unit further displays the semi-finished product production lead time for each semi-finished product, the semi-finished product standard production lead time for each semi-finished product, and semi-finished product abnormality information display at least one of

It intelligently, visually and quickly identifies problematic semi-finished products that lengthen the production lead time in order to reduce the production lead time of the product, thus avoiding unnecessary waiting time by pinpointing actions. As a result, the product production lead time can be shortened.

The production lead time analysis system may also be configured as follows. That is, the process standard work time acquisition unit calculates the process standard work time for each process of the product by removing an abnormal value from the process work time of the process of each product.

Thereby, the process standard work time can be obtained more accurately.

According to the present invention, in order to shorten the product production lead time, it intelligently, visually and quickly identifies the problems that prolong the production lead time, and takes pinpoint measures to eliminate unnecessary waiting time. can be avoided, and the product production lead time can be shortened.

1 is a block diagram showing the configuration of a production lead time analysis system 100 of Example 1; FIG. (a) shows an example of the work performance information collected by the work performance information collection unit 101, and (b) shows semi-finished products SM00001 to SM00004 assembled to the product PRD01 with the product serial number P0000001, The horizontal axis shows a Gantt chart against time, and (c) shows a Gantt chart against time for four processes for forming a semi-finished product with the semi-finished product serial number BD9AD01 in the semi-finished product SM00002. 5 is a graph showing analysis results of the process analysis unit 103 displayed on the display unit 105 in Example 1. FIG. FIG. 11 is a block diagram showing the configuration of a production lead time analysis system 200 of Example 2; 10 is a graph showing the analysis result of the product analysis unit 201 displayed on the display unit 105 in Example 2. FIG. FIG. 11 is a block diagram showing the configuration of a production lead time analysis system 300 of Example 3; 10 is a graph illustrating the production lead time situation of four semi-finished products of Example 3. FIG. 10 is a graph showing the analysis result of the half-finished product analysis unit 301 displayed on the display unit 105 in Example 3. FIG. FIG. 11 is a flowchart showing a production lead time analysis method of Example 4; It is a graph for demonstrating the principle which a stagnation time generate|occur|produces between two processes which a process process follows. 5 is a graph for explaining the principle of stagnation time between semi-finished products assembled into the same product. 5 is a graph for explaining a comparison between the actual working time of a process and the standard working time of the process;

EMBODIMENT OF THE INVENTION Hereinafter, the form for implementing this invention is demonstrated. In the field of manufacturing, including manual manufacturing and machine manufacturing, the time required from ordering a product to delivering it typically includes processing operation time, transportation time, and hold-up time. Of these, the time when the ratio is the highest and the reduction is most realizable is the stagnation time. There are two main reasons why stagnation occurs. First, there is no seamless connection between sequentially executed steps. For example, as shown in FIG. 10, when the horizontal direction of the paper is taken as the time axis, there is a time difference between the work end time of the previous process and the work start time of the subsequent process in two sequentially executed processes. In such cases, unnecessary stagnation time occurs.

Secondly, semi-finished products assembled into the same product are not produced simultaneously. For example, as shown in FIG. 11, when the horizontal direction of the paper is the time axis, it is assumed that a certain product is formed by assembling three semi-finished products, and that the three semi-finished products are assembled after the production is completed. If this is the case, the half-finished products 1 and 2 will have unnecessary downtime because the manufacturing completion times of the three semi-finished products shown in the figure are not the same.

In order to eliminate the above stagnation time as much as possible, it is necessary to clarify which process or which semi-finished product is where the stagnation occurs. It is not possible to realize the shortening effect of

Furthermore, shortening of processing operation time and transportation time is considered. In processes centered on manual work, the standardization of work is often insufficient, so the time required varies even if the same process is performed or the same product or semi-finished product is produced. In this regard, by establishing standard work, it is possible to achieve pinpoint improvements in process work, product production, and semi-finished product production. For example, as shown in FIG. 12, a process standard work time is set for a certain process, and the time difference between the actual work time of the process and the process standard work time is set as the process delay time. A process with a long Δ is recognized as a process requiring improvement (for example, it may be determined by setting a process delay threshold). As a result, the production lead time for all products can be shortened more reliably.

Based on the above technical idea, in order to shorten the production lead time of products in the manufacturing industry, the present invention is a production method that analyzes the production lead time of one or more products using process work performance information collected on site. A lead time analysis method and system are provided.

Next, the production lead time analysis method and system of the present invention will be described with reference to specific examples.

In the production lead time analysis system of this embodiment, the production lead time of a certain product PRD01 is analyzed. It is processed and formed through a plurality of processes.

The configuration of the production lead time analysis system 100 includes, as shown in FIG.

Here, the work performance information collection unit 101 collects work performance information of each related process for each of the products PRD01. The work performance information includes the work start time and work end time of each process, for example, as shown in FIG. may be Each of the products PRD01 is processed by assembling semi-finished products SM00001 to SM00010, and each semi-finished product is processed and formed through a plurality of processes. DDL-04 is formed by four steps. As an example, FIG. 2(b) shows an explanatory diagram of the semi-finished products SM00001 to SM00004 assembled to the product PRD01 with the product serial number P0000001 with respect to time, and FIG. 2(c) shows the semi-finished products FIG. 10 shows a Gantt chart versus time for four steps for forming a semi-finished product with serial number BD9AD01 in SM00002.

The storage unit 102 stores the work performance information collected by the work performance information collection unit 101, and the storage format of the work performance information in the storage unit 102 is not limited to FIG. can be in the form

The process analysis unit 103 is used to analyze the work time of each process, and includes a process work time calculation unit 106, a process standard work time acquisition unit 107, a process delay time calculation unit 108, and a process stagnation time calculation unit 109.

Here, the process work time calculation unit 106 calculates the process work time for each process of the product PRD01 based on the work performance information shown in FIG. The work time means the time difference between the work start time and the work end time of the process, that is, the processing time for completing the process. As a result, the corresponding process working time is stored for each process of the product PRD01.

The process standard work time acquisition unit 107 acquires the corresponding process standard work time for each process of the product PRD01 and stores it in the storage unit 102 . The concept of process standard work time here is for determining the corresponding process delay time by comparing with the process work time of each relevant process of the product PRD01, as shown in FIG. In the examination of the process standard working time acquisition method, for example, for the process standard working time of the process with the process code L1-ASM-01, among the work performance information stored in the storage unit 102, each process L1-ASM of the product PRD01 For the process work time of -01, remove abnormal values from it using the Smirnov-Grubbs test and take the average of the remaining data, and use the average value as the process standard work time of process L1-ASM-01 good. As a result, each process of the product PRD01 is associated with the process standard work time.

The process delay time calculation unit 108 calculates, for each process of the product PRD01, the delay time of the process work time with respect to the corresponding process standard work time in the process, and stores it in the storage unit 102 as the process delay time of the process. do. As a result, the process delay time is stored correspondingly for each process of the product PRD01.

The process stagnation time calculation unit 109 calculates and stores the process stagnation time of each process, excluding the slowest process, among the processes used for processing and forming the product PRD01 and the semi-finished products SM00001 to SM00010. Stored in unit 102 . That is, the process stagnation time calculation unit 109 calculates the process stagnation time calculation unit 109 for each process except for the slowest process among the processes used for processing and forming each semi-finished product and the slowest process for all products in each of the products PRD01. The stagnation time is calculated and stored in the storage unit 102, and the process stagnation time here is the time difference between the work end time of the process and the work start time of the process next to the process.

Here, first, since the slowest process in the product is the last one in the first place, the process stagnation time is not calculated. Furthermore, the "steps used for processing and forming a semi-finished product" mean each step for forming the semi-finished product. "The slowest process among the processes used for processing and forming" of the relevant semi-finished product means the assembling process of assembling these separate semi-finished products together (when there are multiple assembling processes, the slowest one). assembly process). If the semi-finished product is completed by assembling a plurality of other semi-finished products and then undergoing some further processing, or if the semi-finished product is not completed by assembling a plurality of other semi-finished products, the semi-finished product "The slowest process among the processes used for processing and forming" of a product means the last one process among a plurality of processes for producing the semi-finished product. As a result, for each of the products PRD01, the corresponding process stagnation time is stored for each process except for the slowest process for processing and forming the semi-finished product and the slowest process for the product.

The abnormality determination unit 104 determines the process delay time and the process stagnation time of each process using preset threshold values stored in the storage unit 102 . Specifically, the abnormality determination unit 104 determines that a process in which the process delay time exceeds a preset process delay threshold among the processes of the product PRD01 is an abnormal delay process. , the process whose process stagnation time exceeds a preset process stagnation threshold value is determined to be an abnormally stagnant process.

The display unit 105 displays the analysis result of the process analysis unit 103 in the production lead time analysis system 100 of this embodiment to the outside. As shown in FIG. 3, the abnormal delay rate and abnormal stagnation rate of each process in a plurality of products PRD01 produced in a certain period may be displayed in graph format. The abnormal delay rate and abnormal stagnation rate of the process are respectively calculated as process abnormality information based on the data of each term by a calculation unit (not shown) and stored in the storage unit 102, and the user can also display the graph on the computer display interface. By clicking on various parts of the , the process standard work time of each process, the process work time of a certain process, and other process abnormal information (such as process delay time of each process, process stagnation time of each process, abnormal delay A process code and other identification information determined to be a process, a process code and other identification information determined to be an abnormally stagnant process, etc.) can also be obtained. Although the analysis result of the process analysis unit 103 is exemplified in FIG. 3, the form of illustration is not limited to this.

In this way, according to this embodiment, in order to shorten the production lead time of a product, pinpoint measures can be taken by intelligently, visually and quickly identifying the position of the problem process that prolongs the production lead time. can be taken to avoid unnecessary waiting time and shorten the product production lead time.

As shown in FIG. 4, the configuration of the production lead time analysis system 200 of this embodiment is the same as that of the production lead time analysis system 100 of the first embodiment, and further includes a product analysis unit 201, which includes the production of each product. It is used for lead time analysis and includes a product production lead time calculation unit 202 , a product standard production lead time acquisition unit 203 and a product delay time calculation unit 204 .

Here, the product production lead time calculation unit 202 calculates and stores the product production lead time for each of the products PRD01 (that is, products with the same product number but different product serial numbers) based on the above-described work performance information. The product production lead time stored in the storage unit 102 is the work start time of the earliest process and the work start time of the latest process among the processes collected by the work performance information collection unit 101, which are stored in the storage unit 102. It means the processing time for producing the product, which is the time difference from the finish time. As a result, each product PRD01 is stored with a corresponding product production lead time.

The product standard production lead time acquisition unit 203 acquires the product standard production lead time corresponding to the product PRD01 and stores it in the storage unit 102 . The definition of product standard production lead time here is similar to the process standard work time described above, and is used to determine the corresponding product delay time compared with each product production lead time of product PRD01. The method of obtaining the product standard production lead time is also similar to the process standard work time. The data may be averaged, and the average value may be used as the product standard production lead time for the product PRD01. As a result, the product standard production lead time is stored in the storage unit 102 for the product PRD01.

The product delay time calculation unit calculates the delay time of the product production lead time of the product with respect to the product standard production lead time for each of the products PRD01, and stores it in the storage unit 102 as the product delay time of the product. Thereby, each of the products PRD01 has correspondingly stored product delay times.

In this embodiment, the abnormality determination unit 104 also uses a preset threshold value stored in the storage unit 102 to determine the product delay time of each product PRD01. Specifically, the abnormality determination unit 104 determines that a product whose product delay time exceeds a preset product delay threshold among the products PRD01 is an abnormally delayed product.

The display unit 105 displays the analysis result of the product analysis unit 201 in the production lead time analysis system 200 of this embodiment to the outside. When analyzing each of a plurality of products PRD01 to PRD10 produced in a certain period using the production lead time analysis system 200 of this embodiment, as shown in FIG. The number of days may be displayed in graphical form. The abnormal delay rate and the average number of delay days of the product are respectively calculated as product abnormality information by a calculation unit (not shown) based on the data of the above items and stored in the storage unit 102, and the user can also display the graph on the computer display interface. By clicking on various parts of the product, you can see the product standard production lead time of each product, the product production lead time of a certain product, and other product abnormality information (such as the product delay time of each product, and the abnormally delayed product) product number and serial number) can also be obtained. Although the analysis result of the product analysis unit 201 is exemplarily shown in FIG. 5, the form of illustration is not limited to this.

Therefore, according to this embodiment, in order to shorten the production lead time of the product, it is possible to intelligently, visually and quickly identify the problem products that prolong the production lead time, and take pinpoint measures. It is possible to avoid unnecessary waiting time and shorten the product production lead time.

The configuration of the production lead time analysis system 300 of this embodiment, as shown in FIG. Used to analyze the production lead time of semi-finished products, it includes a semi-finished product production lead time calculation unit 302 , a semi-finished product standard production lead time acquisition unit 303 , a semi-finished product delay time calculation unit 304 and a semi-finished product stagnation time calculation unit 305 .

Here, the semi-finished product production lead time calculation unit 302 calculates the semi-finished product production lead time for each semi-finished product of the product PRD01 based on the work performance information described above, stores the semi-finished product production lead time in the storage unit 102, and calculates the semi-finished product production lead time. The product production lead time is the time difference between the work start time of the earliest process and the work finish time of the latest process among the processes used for processing and forming the semi-finished product stored in the storage unit 102. It means the processing time for forming the product. As a result, each half-finished product is associated with the semi-finished product production lead time.

The semi-finished product standard production lead time acquisition unit 303 acquires the corresponding semi-finished product standard production lead time for each semi-finished product of the product PRD01 and stores it in the storage unit 102 . The definition of semi-finished product standard production lead time here is similar to the process standard work time described above, and is compared with the semi-finished product production lead time of each semi-finished product of product PRD01 to determine the corresponding semi-finished product delay time. used to The method of acquiring the semi-finished product standard production lead time is also similar to the process standard work time. may be used to remove abnormal values and average the remaining data, and the average value may be used as the semi-manufactured standard production lead time of the semi-manufactured product PRD01. As a result, the semi-finished product standard production lead time for the semi-finished product of product PRD01 is stored in storage unit 102 .

The semi-finished product delay time calculation unit 304 calculates the delay time of the semi-finished product production lead time for each semi-finished product PRD01 with respect to the corresponding semi-finished product standard production lead time. It is stored in the storage unit 102 as the product delay time. As a result, the corresponding semi-finished product delay time is stored for each semi-finished product of the product PRD01.

A semi-finished product stagnation time calculation unit 305 calculates the semi-finished product stagnation time for each of a plurality of semi-finished products to be assembled into the same semi-finished product. It is the time difference between the work end time of the latest process among the processes used for formation and the work start time of the earliest process among the processes related to the mutual assembly.

Regarding "mutual assembly" here, semi-finished product C, for example, is processed after assembly of semi-finished products A and semi-finished products B, and the final product is formed by assembling semi-finished products C and semi-finished products D. Then, semi-finished products A and semi-finished products B are "two semi-finished products used for mutual assembly", and semi-finished products C and semi-finished products D are "two semi-finished products used for mutual assembly".

In order to simplify the explanation, FIG. 7 shows the situation of the production lead time of the above four semi-finished products. The production of the semi-finished product A starts at time t0, the production is completed at time t1, and the production of the semi-finished product B is completed at time t2. Between times t2 and t3, both semi-finished products A and B are stagnant. From t3 to t4 is the process of assembling the semi-finished product A and the semi-finished product B, that is, "the process related to the mutual assembly of the semi-finished product A and the semi-finished product B". However, at time t4, the assembling process ends and the assembling is completed. After that, the production of the semi-finished product C is completed at time t6 through the processing process for a certain period of time (from time t4 to time t6). Production of semi-finished product D is completed at time t5, and both semi-finished products C and D are stagnant between times t6 and t7. From t7 to t8 is the process of assembling the semi-finished product C and the semi-finished product D, that is, "the process related to the mutual assembly of the semi-finished product C and the semi-finished product D". is completed and the product is obtained. In this example, as can be seen from the above definitions, the semi-finished product stagnation time for semi-finished product A is (t3-t1), the semi-finished product stagnation time for semi-finished product B is (t3-t2), and the semi-finished product stagnation time for semi-finished product C is (t7-t6), and the semi-finished product stagnation time of the semi-finished product D is (t7-t5).

Thereby, each half-finished product in each of the products PRD01 is stored with the corresponding half-finished product stagnation time.

In this embodiment, the abnormality determination unit 104 also uses a preset threshold value stored in the storage unit 102 to determine the semi-finished product delay time of each semi-finished product of the product PRD01. Specifically, the abnormality determination unit 104 determines that a semi-finished product whose semi-finished product delay time exceeds a preset semi-finished product delay threshold for each of the products PRD01 is an abnormally delayed semi-finished product. A semi-finished product whose product stagnation time exceeds a preset semi-finished product stagnation threshold is determined to be an abnormally stagnant semi-finished product.

The display unit 105 displays the analysis result of the semi-finished product analysis unit 301 in the production lead time analysis system 300 of this embodiment to the outside. As shown in FIG. 8, the abnormal delay rate and abnormal stagnation rate of each semi-finished product in a plurality of products PRD01 produced in a certain period may be displayed in a graph format. The abnormal delay rate and the abnormal stagnation rate of semi-finished products are respectively calculated as semi-finished product abnormal information based on the data of the above items by a calculating unit (not shown) and stored in the storage unit 102. The user can also, on the computer display interface, By clicking on various parts of the graph, you can see the standard production lead time of each semi-finished product, the semi-finished product production lead time of a certain semi-finished product, and other semi-finished product abnormal information (such as the delay of each semi-finished product). time, semi-finished product stagnation time of each semi-finished product, semi-finished product number and sequence number determined to be abnormally delayed semi-finished product, semi-finished product number and sequence number determined to be abnormally stagnant semi-finished product, etc.) be able to. Although the analysis result of the semi-finished product analysis unit 301 is exemplarily shown in FIG. 8, the form of illustration is not limited to this.

Therefore, according to this embodiment, in order to shorten the production lead time of the product, it is possible to intelligently, visually and quickly identify the problem semi-finished products that prolong the production lead time, and take pinpoint measures. This makes it possible to avoid unnecessary waiting time and shorten the product production lead time.

This embodiment relates to a production lead time analysis method, and a flow chart of the production lead time analysis method is shown in FIG.

The production lead time analysis method analyzes the production lead time of a certain product PRD01. Each of the products PRD01 is processed through a plurality of processes using a plurality of semi-finished products. It is processed and formed through processes.

First, in step S901, for each of the products PRD01, the work performance information of each related process is collected, and the work performance information includes the work start time and work end time of the process. 1, the description thereof is omitted.

Next, in step S902, for each process of the product PRD01, the process work time is calculated based on the work record information, and the process work time is the time difference between the work start time and the work end time of the process. means.

Next, in step S903, for each process of the product PRD01, the corresponding process standard work time is acquired. Since the definition of the process standard work time is the same as in the first embodiment, the explanation thereof is omitted.

Next, in step S904, for each process of the product PRD01, the delay time of the process work time of the process with respect to the corresponding process standard work time is calculated and set as the process delay time of the process. Since the specific definition of the process delay time is the same as that of the first embodiment, the explanation thereof will be omitted.

Next, in step S905, for each of the products PRD01, for each step excluding the slowest step among the steps used for processing and forming each semi-finished product and the slowest step in the product, the process stagnation time of the process is The calculated process stagnation time is the time difference between the work end time of the process and the work start time of the process next to the process. Since the specific definition of the process stagnation time is the same as in Example 1, the explanation thereof will be omitted.

Next, in step S906, for each of the products PRD01, the product production lead time is calculated based on the work performance information. It is the time difference between the work start time of the earliest process and the work end time of the latest process.

Next, in step S907, the product standard production lead time corresponding to the product PRD01 is obtained. Since the definition of the product standard production lead time is the same as in the second embodiment, the explanation thereof will be omitted.

Next, in step S908, for each of the products PRD01, the delay time of the product production lead time of the product with respect to the product standard production lead time is calculated and set as the product delay time of the product. A specific definition of the product delay time is the same as that of the second embodiment, so the explanation thereof is omitted.

Next, in step S909, for each semi-finished product of the product PRD01, the semi-finished product production lead time is calculated based on the work performance information. It is the time difference between the work start time of the earliest process and the work end time of the latest process. Since the "steps used for processing and forming" are the same as in the first embodiment, the description thereof will be omitted.

Next, in step S910, for each semi-finished product of product PRD01, the corresponding semi-finished product standard production lead time is acquired. The definition of the semi-manufactured standard production lead time is the same as in the third embodiment, so the explanation thereof is omitted.

Next, in step S911, for each semi-finished product of product PRD01, the delay time of the semi-finished product production lead time for the semi-finished product relative to the corresponding semi-finished product standard production lead time is calculated, and the semi-finished product delay for the semi-finished product is calculated. Time. A specific definition of the semi-finished product delay time is the same as that of the third embodiment, so the explanation thereof is omitted.

Next, in step S912, for each of the plurality of semi-finished products used for mutual assembly, the semi-finished product stagnation time of the semi-finished product is calculated. It is the time difference between the work end time of the latest process and the work start time of the earliest process among the processes related to mutual assembly. A specific definition of the semi-finished product stagnation time is the same as that of the third embodiment, so the explanation thereof is omitted.

Next, in step S913, an abnormality determination is performed. A process exceeding the stagnation threshold is determined to be an abnormal stagnation process, a product whose product delay time exceeds a preset product delay threshold is determined to be an abnormally delayed product, and a semi-finished product whose delay time is preset A semi-finished product exceeding the delay threshold is determined to be an abnormally delayed semi-finished product, and a semi-finished product having a semi-finished product stagnation time exceeding a preset semi-finished product stagnation threshold is determined to be an abnormally stagnant semi-finished product.

Next, in step S914, display is performed. Specifically, analysis results related to processes, analysis results related to products, and analysis results related to semi-finished products are displayed. Since the specific display contents are the same as those in the first to third embodiments, the description thereof is omitted. Here the flow ends.

Therefore, according to this embodiment, in order to shorten the production lead time of the product, it is possible to intelligently, visually and quickly identify the problems that prolong the production lead time, and take pinpoint measures. It is possible to avoid unnecessary waiting time and shorten the product production lead time.
<Modification>

Although embodiments of the present invention have been illustrated and described above, it will be apparent to those skilled in the art that the present invention is not necessarily limited to each embodiment having all of the configurations described. The configuration of another embodiment can be added to the configuration of one embodiment without departing from the technical idea of the invention, and the addition, deletion, or replacement of a part of the configuration of each embodiment with another configuration. It can be performed. Such modifications will be described below.

For example, the production lead time analysis system may include the product analysis unit 201 of Example 2 and the semi-finished product analysis unit 301 of Example 3 at the same time. 2 or only the half-finished product analysis unit 301 of the third embodiment may be included.

Furthermore, in the process analysis unit 103 of the first embodiment, only the process delay time can be calculated without including the process stagnation time calculation unit 109. Similarly, in the semi-finished product analysis unit 301 of the third embodiment, It is also possible to calculate only the semi-finished product delay time without including the stagnation time calculation unit 305 .

Furthermore, in each of the above examples, analysis of a plurality of products PRD01 that are processed from a plurality of semi-finished products is described, but the product may be processed from only one semi-finished product. Since there is no mutual assembly between products, "the slowest process among the processes used for processing and forming" of the semi-finished product is the slowest process in all products. Furthermore, each semi-finished product may be processed and formed through only one type of process, and only one certain product may be analyzed.

Further, in each of the above examples, the standard process operation time for a process was calculated by averaging multiple process operation times for each product for that process using the Smirnov-Grubbs test after removing outliers. However, the calculation method is not limited to this, and may be another data processing method other than the Smirnov-Grubbs test. In addition, the process standard work time may be obtained by calculation based on existing data, or may be artificially set in advance. For example, the process work time using an industry standard may be used. For the same reason as above, the product standard production lead time and semi-finished product standard production lead time may also be obtained or preset by another calculation method.

Furthermore, the production lead time analysis method of the fourth embodiment includes steps S902 to S905 related to process analysis, steps S906 to S908 related to product analysis, and steps S909 to S912 related to half-finished product analysis. The order is not limited to the above, and may be executed sequentially or concurrently in a different order of execution. In addition, the production lead time analysis method may include only steps related to process analysis, only steps related to product analysis, or only steps related to half-finished product analysis. In this case, step S913 and the display step of step S914, only the corresponding target is determined and displayed.

Claims (12)

A production lead time analysis method for analyzing the production lead time of one or more products , which is executed by a production lead time analysis system, which is a computer having a display interface , wherein the products are produced by one or more semi-finished products. or processed through a plurality of steps, and the semi-finished product is processed and formed through one or a plurality of steps, in the production lead time analysis method,
A work performance information collecting step of collecting work performance information of each related process for each of the products by the work performance information collecting unit , wherein the work performance information includes the work start time and work end time of the process. When,
a process work time calculation step of calculating, by a process work time calculation unit, a process work time based on the work performance information for each process of each of the products, wherein the process work time is the work start time of the process; a step that is the time difference from the work end time;
a process standard work time acquisition step of acquiring a process standard work time corresponding to each process of the product by a process standard work time acquisition unit ;
A process delay time calculation step of calculating the delay time of the process work time with respect to the corresponding process standard work time in the process for each process of the product by the process delay time calculation unit, and setting the delay time of the process as the process delay time of the process. When,
By the process stagnation time calculation unit, for each process excluding the slowest process among the processes used for the processing and forming of each semi-finished product and the slowest process for the product, the process stagnation time of the process is calculated. A process stagnation time calculation step to be calculated;
a step of calculating a product production lead time for each of the products by a product production lead time calculation unit based on the work performance information, wherein the product production lead time is collected in the work performance information collection step; A product production lead time calculation step, which is the time difference between the work start time of the earliest process and the work end time of the latest process among the processes;
A product standard production lead time acquisition step of acquiring a product standard production lead time corresponding to the product by a product standard production lead time acquisition unit;
a product delay time calculation step of calculating the delay time of the product production lead time with respect to the product standard production lead time for each product, and using the product delay time of the product as the product delay time of the product, by the product delay time calculation unit;
a step of calculating a semi-finished product production lead time based on the work result information for each semi-finished product of each product by a semi-finished product production lead time calculation unit, wherein the semi-finished product production lead time is calculated based on the semi-finished product; A semi-finished product production lead time calculating step, which is the time difference between the work start time of the earliest process and the work end time of the latest process among the processes used for the process formation in the above;
a semi-finished product standard production lead time acquisition step of acquiring a corresponding semi-finished product standard production lead time for various semi-finished products of the product by a semi-finished product standard production lead time acquiring unit;
A semi-finished product delay time calculation unit calculates the delay time of the semi-finished product production lead time with respect to the corresponding semi-finished product standard production lead time for each semi-finished product, and calculates the semi-finished product of the semi-finished product. a semi-finished product delay time calculation step for the delay time;
A step of calculating, by a semi-finished product stagnation time calculation unit, for each of a plurality of semi-finished products used for mutual assembly, the semi-finished product stagnation time of the semi-finished product, wherein the semi-finished product stagnation time is the a semi-finished product stagnation time calculating step, which is the time difference between the work end time of the latest process among the processes used for processing and forming and the work start time of the earliest process among the processes related to the mutual assembly;
The abnormality determination unit determines a process in which the process delay time exceeds a preset process delay threshold as an abnormally delayed process, and determines a process in which the process stagnation time exceeds a preset process stagnation threshold as an abnormally stagnant process. A product whose product delay time exceeds a preset product delay threshold is determined to be an abnormally delayed product, and a semi-finished product whose semi-finished product delay time exceeds a preset semi-finished product delay threshold is abnormally delayed. an abnormality determination step of determining that the semi-finished product is a semi-finished product, and determining that a semi-finished product whose stagnation time exceeds a preset semi-finished product stagnation threshold value is an abnormally stagnant semi-finished product;
A production lead time analysis method, comprising: 2. The production lead time analysis method according to claim 1, wherein said process stagnation time is the time difference between the work end time of said process and the work start time of the process next to said process. a display step of displaying at least one of the process work time of each process, the process standard work time of various processes, and process abnormality information by a display unit;
3. The production lead time analysis method according to claim 2, further comprising: In the abnormality determination step, the abnormality determination unit further determines that a product whose product delay time exceeds a preset product delay threshold is an abnormally delayed product,
In the display step, the display unit further displays at least one of the product production lead time, the product standard production lead time, and product abnormality information for each product.
4. The production lead time analysis method according to claim 3, characterized by: In the abnormality determination step, the abnormality determination unit further determines that the semi-finished product whose delay time exceeds a preset semi-finished product delay threshold is an abnormally delayed semi-finished product, and the semi-finished product stagnation time is preset. Semi-finished products exceeding the set semi-finished product stagnation threshold are determined to be abnormally stagnant semi-finished products,
In the display step, the display unit further displays at least one of the semi-finished product production lead time for each semi-finished product, the semi-finished product standard production lead time for each semi-finished product, and semi-finished product abnormality information.
4. The production lead time analysis method according to claim 3, characterized by: In the process standard work time acquisition step, the process standard work time acquisition unit removes an abnormal value from the process work time of each process of each product to determine the standard process work time for each process of the product. 6. The production lead time analysis method according to any one of claims 1 to 5, wherein the production lead time is calculated. 1. A production lead time analysis system, which is a computer having a display interface, for analyzing production lead time of one or more products, wherein said products are manufactured by one or more semi-finished products. In the production lead time analysis system, wherein the semi-finished product is processed through a plurality of steps and formed through one or a plurality of steps,
a work performance information collection unit for collecting work performance information of each related process for each of the products, wherein the work performance information includes work start time and work end time of the process;
A process work time calculation unit for calculating a process work time for each process of each product based on the work performance information, wherein the process work time is the time difference between the work start time and the work end time of the process. a process work time calculation unit;
a process standard work time acquiring unit that acquires the corresponding process standard work time for each process of the product;
a process delay time calculation unit that calculates the delay time of the process work time with respect to the corresponding process standard work time in the process for each process of the product and sets it as the process delay time of the process;
A process stagnation time calculation unit for calculating the process stagnation time of each process for each process excluding the slowest process among the processes used for the processing and forming of each semi-finished product and the slowest process for the product. When,
a product production lead time calculation unit for calculating a product production lead time for each product based on the work performance information, wherein the product production lead time is calculated for each process collected by the work performance information collection unit; a product production lead time calculation unit, which is the time difference between the work start time of the earliest process and the work end time of the latest process;
a product standard production lead time acquiring unit for acquiring a product standard production lead time corresponding to the product;
a product delay time calculation unit that calculates the delay time of the product production lead time with respect to the product standard production lead time for each product, and determines the product delay time of the product;
A semi-finished product production lead time calculation unit for calculating a semi-finished product production lead time based on the work performance information for each semi-finished product of each of the products, wherein the semi-finished product production lead time is calculated based on the processing of the semi-finished product. A semi-finished product production lead time calculation unit that is the time difference between the work start time of the earliest process and the work end time of the latest process among the processes used for formation;
a semi-finished product standard production lead time acquiring unit for acquiring corresponding semi-finished product standard production lead times for various semi-finished products;
For each semi-finished product of each said semi-finished product, the delay time of said semi-finished product production lead time with respect to the corresponding semi-finished product standard production lead time for said semi-finished product is calculated, and the semi-finished product delay time is taken as the semi-finished product delay time of said semi-finished product. a calculation unit;
A semi-finished product stagnation time calculation unit for calculating a semi-finished product stagnation time for each of a plurality of semi-finished products used for mutual assembly, wherein the semi-finished product stagnation time is calculated according to the processing and forming of the semi-finished product. a semi-finished product stagnation time calculation unit, which is the time difference between the work finish time of the latest process among the processes to be used and the work start time of the earliest process among the processes related to the mutual assembly;
Determining a process in which the process delay time exceeds a preset process delay threshold as an abnormally delayed process, and determining a process in which the process stagnation time exceeds a preset process stagnation threshold as an abnormally stagnant process, A product whose product delay time exceeds a preset product delay threshold is determined to be an abnormally delayed product, and a semi-finished product whose delay time exceeds a preset semi-finished product delay threshold is determined to be an abnormally delayed semi-finished product. an abnormality determination unit that determines and determines that a semi-finished product whose stagnation time exceeds a preset semi-finished product stagnation threshold value is an abnormally stagnant semi-finished product;
A production lead time analysis system comprising: 8. The production lead time analysis system according to claim 7, wherein said process stagnation time is the time difference between the work end time of said process and the work start time of the process next to said process. a display unit that displays at least one of the process working time of each process , the standard process working time of various processes, and process abnormality information;
9. The production lead time analysis system of claim 8, further comprising: The abnormality determination unit further determines that a product whose product delay time exceeds a preset product delay threshold is an abnormally delayed product,
The display unit further displays at least one of the product production lead time, the product standard production lead time, and product abnormality information for each product.
10. The production lead time analysis system according to claim 9, characterized by: The abnormality determination unit further determines that a semi-finished product whose delay time exceeds a preset semi-finished product delay threshold is an abnormally delayed semi-finished product, and the semi-finished product stagnation time is a preset semi-finished product stagnation threshold. semi-finished products exceeding
The display unit further displays at least one of the semi-finished product production lead time of each semi-finished product, the semi-finished product standard production lead time of each semi-finished product, and semi-finished product abnormality information.
10. The production lead time analysis system according to claim 9, characterized by: 8. The process standard work time acquisition unit calculates the process standard work time by removing an abnormal value from the process work time of each process of each product for each process of the product. 12. The production lead time analysis system according to any one of -11.

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