JPH0584373A - Production control system for sewing factory and device therefor - Google Patents

Abstract

PURPOSE:To automatically prepare the production plan data meeting the actual production capability by accumulating the actual data for individual sections and individual varieties in a sewing factory. CONSTITUTION:Terminal devices 6 are installed at cutting, sewing, integrating, finishing, and shipping sections 1-5 in a sewing factory, the data of the number of completed works and the required work time for individual varieties at these sections 1-5 are transmitted to a main control device 7, the data are accumulated in the main control device 7 as actual data, the work time per sheet is calculated for individual sections and individual varieties based on the accumulated data when the item number is completed, and it is converted into the man-hour data and stored. The production plan data for the same variety next time are automatically prepared based on these man-hour data and transmitted to terminal devices of individual sections.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a production management system for a sewn product production line including a plurality of departments such as cutting, sewing, grouping, finishing, and shipping in a sewing factory, and a production management apparatus for realizing the production management system.

[0002]

2. Description of the Related Art The production of sewing products is a human-intensive industry, and even if a production plan is made at a sewing factory, it will not proceed as planned due to the absence of workers, lateness, early departure, or physical condition of the day. Often. In addition, in order to make high-mix low-volume production, it will be difficult to set a target because the production of the next type will be started when the skill of the work is mastered.

Therefore, in order to make a production plan suitable for the actual production capacity, the actual results for each process and each worker in each department (mainly, a sewing department which uses many sewing machines and has the largest number of workers). The number of sheets and their working time are measured, and a terminal device is installed for each worker, and each process time is grasped by the host computer to manage the production status. It is also considered to be used for creation. As described above, the production management in the conventional sewing factory is mainly performed in the unit of work in the sewing process or the unit of worker.

[0004]

However, in the case of obtaining such performance data for each process or worker, there is a considerable difference in the data before and after the worker is proficient, and therefore, a certain point before and after the proficiency is set. However, it is difficult to collect data at such an appropriate time. In addition, there is a problem that the worker himself / herself has a difference in working time between the time of measurement and the other time.

Furthermore, the production of sewn products in an actual sewage factory is carried out through respective work departments (also simply referred to as "sectors") such as cutting, sewing, gathering, finishing and shipping. The actual progress and achievement rate of the production with respect to the production target depends more on the progress of the work as a whole in each department than on the efficiency of the individual worker. It also differs depending on the type of product produced. The present invention has been made in view of the above problems, and accumulates actual data for each department and product type in a sewing factory, and uses the data to produce production plan data suitable for actual production capacity. The purpose is to be able to create automatically.

[0006]

SUMMARY OF THE INVENTION In order to achieve the above object, the present invention provides cutting, sewing, grouping,
The number of completed works and the time required for the work are accumulated as actual data for each department such as finishing and shipping, and for each product type to be produced, and the work time per piece for each department and product type is based on the accumulated data. A production management method for a sewing factory is provided, which calculates and stores, and creates production plan data for the same type of products from the next time on the basis of the stored data.

Further, in order to realize the above production control system, a production control including terminal devices installed in each department in a sewing factory and a main control device which is connected to each terminal device and transmits and receives data. Equipment is also provided. Each terminal device receives and stores the production plan data transmitted from the main management device, displays the production plan data, and measures a time from the time when the production plan data is received. And means for inputting the number of completed works when the work corresponding to the displayed production plan data is completed, and means for storing the number of works input by the means and the time measured by the clock until the input time as actual data. , And means for transmitting the performance data to the main management apparatus.

On the other hand, the main management device collects the result data by receiving the result data from each terminal device and storing the result data for each department, and the result data stored for each part when the work for the current day is completed. A means for storing the data, a means for calculating the required work time per sheet for each department when the work of the same type is completed, and a means for storing the calculation result by converting it into man-hour data for each department and type. , A means for inputting work instruction data on the day, and an instruction for inputting a product type and the number of products to be produced and production plan data creation by the means,
A means for automatically creating production plan data using the stored man-hour data for each department and product type, and a means for transmitting the produced production plan data to each terminal installed in each department. I have it.

The main management device further includes means for pre-storing time data such as work start and end times and break time,
A clock is provided, and the completion of work for the current day is determined based on the time data by the clock and the time data stored in advance, and the rest time is removed from the work time data when the actual data is compiled, and the production plan is automatically calculated. When creating, it is advisable to obtain data on the actual work time of one day. Furthermore, it is advisable to provide the main control device with means for displaying the automatically produced production planning data and means for correcting the displayed production planning data.

[0010]

The production management system of the sewing factory according to the present invention accumulates as actual data for each department of the sewing factory and for each product type to be produced, and is calculated based on the accumulated data. Since production plan data for the same type of products from the next time onward is automatically created based on the work time data of the above, average performance data for each department is not significantly affected by variations in the proficiency level and physical condition of each worker. Can be obtained for each product type, and based on that, production plan data suitable for the actual production capacity can be automatically created.

Further, in the production management device of the sewing factory according to the present invention, in each terminal device installed in each department, the production plan data transmitted from the main management device is received and stored, and the production plan data is stored. indicate. Then, when the work completion number is input when the work corresponding to the displayed production planning data is completed, the input number and the time measured by the clock up to the input time are stored as actual data, and the actual result is stored. Send the data to the main management unit.

On the other hand, in the main management unit, the actual result data from each terminal unit is received and stored for each department, and when the work for the current day is completed, the actual result data stored for each department is totaled to accumulate the actual result accumulated data. Memorize as. Further, when the work of the same product type is completed, the work required time for each sheet is calculated for each department, and the calculation result is converted into department / product type man-hour data and stored. After that, when the product type and the number of products to be produced are input as the work instruction data for the day and an instruction to create the production plan data is given, the production plan data is automatically created using the stored man-hour data for each department / product type and stored. Send to each terminal device for each department.

Further, if time data such as work start and end times and break time are stored in advance, the work completion for the current day can be judged by the time data by the clock and the time data stored in advance, It is easy to exclude the break time from the work time data when totaling the actual data, and it is not necessary to input the data of the actual work time of one day when the production plan is automatically created. Also, if the automatically created production plan data is displayed so that it can be corrected, the administrator can see the automatically created production plan data and respond to the actual situation such as increase or decrease or change of workers on the day. This is convenient because you can make corrections.

[0014]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT An embodiment of the present invention will be specifically described below with reference to the drawings. FIG. 1 is a system configuration diagram showing an arrangement example of each work department and a production control device in a sewing factory adopting the production control method according to the present invention. The production process in this sewing factory is composed of five working departments, namely, a cutting department 1, a sewing department 2, a merging department 3, a finishing department 4, and a shipping department 5.

The cutting section 1 is a section for cutting parts necessary for each sewn product, which is a production target, from a raw material by hand or by a cutting machine. At that time, parts of the same type and size that have the same size are stacked and cut at a time. Then, out of the parts cut at one time, parts of the same color and the same fabric that overlap each other are attached with the same number (moving lot number) and bundled. Although not shown in this embodiment, an automatic machine section for performing edge sewing (surging) or the like by an automatic machine may be provided to prevent the cut parts from being unraveled.

The sewing department 2 is the largest department with the largest number of workers, and in many cases, a plurality of lines are provided for each sewing type. A plurality of sewing machines are installed in each line, and the parts cut by the cutting department 1 are supplied and sewn together. However, a plurality of workers perform a series of sewing processes of a target sewing product. Each work is shared and the work in progress is moved by a hanger conveyor or the like.

In addition, one sewing product is completed on each sewing line, and one sewing product is shared on each sewing line so that a finished product can be produced on the final line. There is. In addition, in order to reduce the replacement of threads during sewing work, items of the same color should be sewn together.
Summary Department 3 performs work such as sewing buttons and zippers to the sewing completed in sewing department 2 to complete the operation, and thread removal work of sewn products.

The finishing section 4 is a section for performing finishing work such as ironing and folding the completed sewn product. The shipping department 5 is a department that attaches labels indicating colors, sizes, materials, trademarks, etc. to each finished sewn product, wraps and wraps, and then ships. The type refers to the types of sewn products such as blouses, skirts, and trousers. The same item number is assigned to items of the same type ordered at one time.

A terminal device 6 is installed near each exit (final process position) of each department 1 to 5, and each terminal device 6 is mainly managed via a local area network (LAN) 8 which is a communication line. The production control device is configured to be connected to the device (host computer) 7 so that data can be mutually transmitted and received.

According to this embodiment, at the start of work, the main management unit 7 transmits the production plan data of the day to the terminal units 6 installed in each department 1 to 5, and each terminal unit 6 transmits the production plan data. When it is received, it is displayed on the display, and each worker is notified to start the work. At that time, in a department such as a sewing department 2 in which a large number of workers have different work contents depending on each process, a display for instructing the work contents for each worker or each process is arranged, and the display is arranged on the terminal device. It is advisable to connect to No. 6 so that the work content and the production plan data concerning the work are displayed.

After that, every time the work corresponding to the production plan data (lot unit, day unit, etc.) instructed in each department is completed, the product number and the number of completed works are input to the terminal device 6 installed there. Then, the terminal device 6 transmits the data to the main management device as actual data together with the time required for the work.

The main control unit 7 accumulates the actual result data, and every time the work of the same product number is completed, the accumulated data is totaled, and the man-hour data for each department / product type (corresponding to the work time per piece) ) Is calculated and stored. When subsequently producing sewn products of the same type, it is possible to automatically create production plan data based on the stored man-hour data for each department and type and send it to each terminal device 6. it can.

FIG. 2 is a functional block diagram showing a configuration example of the terminal device 6 and the main management device 7 of the production management device. The terminal device 6 includes a control unit 10, a clock 11, a display unit 12, a target data memory 13, a performance data memory 14, and a performance input unit 15.

The control unit 10 is composed of a microcomputer including a CPU, a ROM, a RAM and the like, a communication interface for communicating with the main management unit 7, etc., and the terminal unit 6
Control. Although communication with the main management apparatus 7 is performed via the LAN 8 as shown in FIG. 1, the LAN 8 is not shown here for the sake of clarity, and the terminal device 6 and the main management apparatus 7 are not shown. Directly connected.

When the production plan data is transmitted from the main management unit 7, the control unit 10 receives it, stores it in the target data memory 13, stores it, and displays it on the display unit 12 such as an LCD display. Further, the time measurement by the clock 11 is started when the production plan data is received. Then, when the work of the department in which the terminal device 6 is installed is started and the work corresponding to the production plan data (lot unit, day unit, etc.) displayed on the display unit 12 is completed, management of the department is performed. Person or the person in charge near the terminal device 6 determines the number of completed works, the lot number and the color,
Enter while referring to data such as size.

This is carried out from the result input unit 15 having a plurality of operation keys. If the result data to be input is the same as the target data displayed on the display unit 12, it is confirmed and the work is completed. All you have to do is press a key. Thereby, the control unit 10 stores the data such as the lot number, the color, and the target number of sheets for each size stored in the target data memory,
The time measured by the clock 11 up to that point is stored and stored in the actual data memory 14 as actual data.

When the target data displayed on the display unit 12 differs from the number of actually completed sheets or lot number, the display is corrected by key operation from the result input unit 15 and the work completion key is pressed. For example, the control unit 10 stores the data such as the corrected number of completed works and the time measured by the clock 11 as the actual data in the actual data memory 14.
Then, the control unit 10 transmits the performance data stored in the performance data memory 14 to the main management device 7.

Although RAMs are used for the target data memory 13 and the actual data memory 14, each area may be secured in one RAM instead of being provided independently. You may make it also use RAM.

The main management unit 7 includes a control unit 20, a clock 21,
Time data memory 22, work instruction data input unit 23, actual result data memory 24, actual result accumulated data memory 25, department / product-specific man-hour data memory 26, plan data memory 2
7, a display unit 28, and a correction plan data input unit 29. The control unit 20 includes a computer system including a CPU, a ROM, a RAM, and a communication interface for communicating with each terminal device 6, and controls the main management device 7 in an integrated manner.

The clock 21 measures time, and the time data memory 22 stores in advance the work start time and work end time of the sewing factory and the time data such as start time and end time of each break time such as lunch break. Keep it. The work instruction data input unit 23 has a plurality of operation keys for instructing the data such as the product number of the product type to be produced and the number of produced products and the production plan data before starting the work on the day. It is an operation unit that has.

The actual data memory 24, the actual accumulated data memory 25, the department / product type man-hour data memory 26, and the plan data memory 27 respectively include actual data, actual accumulated data, department / product man-hour data, and created production. A time data memory 2 which is a memory for storing plan data.
Although the RAM is used together with 2, the areas may be secured in one RAM without separately providing these areas, or the RAM of the control unit 20 may be used also.

The display unit 28 is a display device such as an LCD display for displaying the production planning data stored in the planning data memory 27. The correction plan data input unit 29 is an operation unit having a plurality of operation keys for correcting the displayed production plan data, a transmission instruction key, and the like, and is also formed integrally with or integrally with the work instruction data input unit 23. May be.

Next, the operation of this main control unit will be described with reference to the flow chart shown in FIG. When this main management device starts operation and the work instruction data (including the production plan data creation instruction) data of the day is input from the work instruction data input unit 23, it is determined whether or not it is the production planning data creation instruction. If YES, the man-hour data for each department / product type is read out from the man-hour data memory 26 for each department / product type, and the production plan data for each department is created based on the data and the input product number and the number of production. , Plan data memory 27
And is displayed on the display unit 28.

Then, it is judged whether or not there is a change in the plan data from the correction plan data input unit 29, and if there is, the produced production plan data is corrected and changed according to the input from the correction plan data input unit 29. If there is not, it waits for the transmission instruction key to be pressed as it is, and when there is a transmission instruction, the production planning data stored in the planning data memory 27 is transmitted to each terminal device as work instruction data, and thereafter the actual data is received. wait.

On the other hand, when the production plan data is not instructed, the terminal device waits for the actual data to be transmitted, and when the actual data is transmitted, the actual data is received and the actual number of sheets is transferred. And the actual time is the actual data memory 2
Stored in section 4 for each department. At that time, the time data memory 2
When it is determined that the actual time includes the rest time by referring to the rest time data of No. 2 and the time data of the clock 21, the rest time is subtracted to obtain the actual time.

Then, by referring to the work end time data of the time data memory 22 and the time data of the clock 21, it is judged whether or not the work of the day is completed, and if it is not completed, it is added to the work instruction of the day. It is judged whether there is any change, and if there is no change, it waits for the actual data to be transmitted. If there are additions or changes to the work instructions for the day (work instruction data input section 2
3), data is input again from the work instruction data input unit 23, and production planning data is automatically created.

When it is judged that the work of the day is completed,
The actual result data for the current day stored in the actual result data memory 24 is totaled for each department and product type, stored in the actual result accumulated data memory 25, and the processing is ended. However, when the work of the part number is completed, the work required time per piece of sewn product is calculated for each department and product type based on the result accumulation data stored in the result accumulation data memory 25, and the calculated work required time is calculated. The man-hour data for each type / product is converted and stored in the man-hour data memory 26 for each department / product, and the process ends.

In the above-mentioned embodiment, the case where the production plan data is created before the start of work on the day has been described. However, after the work on the previous day is completed, the data stored in the man-hour data memory 26 by department / product type is used. Automatically create production planning data for the next day, modify it if necessary and modify the planning data memory 2
7, the production plan data may be immediately transmitted to the terminal device 6 of each department in the morning of the day.

According to this embodiment, the actual result data is grasped not for each worker or for each fine process but for the whole department, that is, how many people complete each work in what day (hour). Since the required time per piece is calculated by totaling each product type, the average actual time actual data for each department is not significantly affected by variations in the proficiency level of each worker and physical condition. Can be obtained, and based on that, a production plan suitable for the actual production capacity can be automatically created.

In the initial stage, it may be necessary to correct the automatically created production planning data to the extent of setting conditions, but as the actual data is accumulated, the planning accuracy improves and It is possible to move to full automation by omitting settings.

Further, the daily totaling and the cumulative totaling after the production of the same product number are started, the learning tendency is calculated from the daily totaling result at the completion of the work, the average real time is corrected, and the accumulated results are accumulated. By doing so, the performance data considering the proficiency level can be obtained. Also, in addition to the actual time data, if the data of the personnel composition of each department, the model used, the attachments, etc. are stored and used as a feedback target, it can be used as a facility planning material for future production work.

[0042]

As described above, according to the present invention, the actual data for each working department and each product in the sewing factory is accumulated, and the production data is utilized to make a production plan suitable for the actual production capacity. Data can be created automatically.

[Brief description of drawings]

FIG. 1 is a system configuration diagram showing an arrangement example of each work department and a production control device in a sewing factory which is an embodiment of the present invention.

FIG. 2 is a functional block diagram showing a configuration example of a terminal device and a main management device which constitute the production management device in FIG.

FIG. 3 is a flowchart of processing by a main management device 7 in FIG.

[Explanation of symbols] 1 Cutting section 2 Sewing section 3 Summary section 4 Finishing section 5 Shipping section 10 Control section 11 Clock
12 display unit 13 target data memory 14 actual result data memory 15 actual result input unit 20 control unit 21
Clock 22 Time data memory 23 Work instruction data input unit 24 Actual data memory 25 Actual accumulated data memory 26 Man-hour data memory by department / product type 27 Plan data memory 28 Display unit 29 Revised plan data input unit

Front page continuation (72) Inventor Chieko Mukai, 8-2 Kokuryo-cho, Chofu City, Tokyo 1 Juki Co., Ltd. (72) Inventor Tomo Suzuki 1-2 Kokuryo-cho, Chofu-shi, Tokyo 1 Juki Co. In the company

Claims (4)

[Claims] 1. Cutting, sewing, grouping in a sewing factory,
The number of completed works and the time required for the work are accumulated as actual data for each department such as finishing, shipping, etc., and for each product type to be produced, and the work per piece for each department and product type is based on the accumulated data. A production management system for a sewing factory, which calculates and stores time, and creates production plan data for the same product type from the next time onward based on the stored data. 2. A sewing factory for cutting, sewing, collecting,
A production management apparatus comprising a terminal device installed in each department such as finishing and shipping, and a main management device connected to each terminal device for transmitting and receiving data, wherein each terminal device is the main management device. A means for receiving and storing the production planning data transmitted from the device, a means for displaying the production planning data, a clock for measuring the time from the time when the production planning data is received, and the displayed production planning data. A means for inputting the number of completed works when the work corresponding to the data is completed, a means for storing the number of sheets input by the means and the time measured by the clock until the time of the input as actual data, and the actual data And a means for transmitting to the main management device, the main management device receives the result data from each of the terminal devices and stores it by department, and when the work for the day is completed The means for totaling the result data stored for each department and storing it as the result accumulated data, the means for calculating the work required time per sheet for each department when the work of the same type is completed, and the calculation result A means for converting and storing the man-hour data for each department / product, a means for inputting work instruction data for the day, and a command for inputting the product type and the number of products and production plan data creation by the means, the department It is provided with means for automatically creating production planning data using the man-hour data for each type and type, and means for transmitting the created production planning data for each department to a terminal device installed in each department. Production control equipment for a sewing factory. 3. The production management apparatus for a sewing factory according to claim 2, wherein the main management apparatus is provided with a means for previously storing time data such as work start and end times and break time, and a clock. By the time data and the stored time data according to, to determine the work completion for the current day,
A production management device for a sewing factory, which is characterized by removing rest time from the work time data when collecting the actual data, and obtaining data of the actual work time of one day when automatically creating a production plan. 4. The production management device for a sewing factory according to claim 2, further comprising: a means for displaying the automatically created production plan data on the main management device, and a means for correcting the displayed production plan data. A production management device for a sewing factory, which is characterized by the provision of.