JPH07129683A - One-man product production schedule control optimization supporting system - Google Patents

Abstract

PURPOSE:To provide a one-man product production schedule control optimization supporting system of a mount land system, etc., for inserting manually electronic parts into a printed board. CONSTITUTION:This one-man product production schedule control optimization supporting system is provided with a plan supporting block 1 for generating a separate individual allocation of a worker, based on planning data 5, decides a load factor and productivity by evaluating the separate individual allocation, based on work data 4 such as a standard time, the degree of skillness of the worker, a manual insertion machine kind name, a substrate name, etc., summing up the separate individual allocation and executes its evaluation, a set-up supporting block 2 for generating set-up, based in this separate individual temporary allocation, and an actual result supporting block 3 for comparing set-up instruction data and actual result instruction data instruction data and executing the separate individual actual result evaluation. The difference between acheduled productivity and actual result productivity being a result of actual result evaluation obtained by the actual result supporting block 3 is fed back to a planning data base 5 as planning data of the following day, and plan delay is outputted as a business from and informed timely to a manager.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION The present invention optimizes and assists in planning, setup and grasping results in the one-mand duct system such as a manual insertion process (mount land) of electronic parts during manufacturing of a printed circuit board, a retrofitting bench, a board adjusting bench, etc. The present invention relates to a one-man products production process management optimization support system.

[0002]

2. Description of the Related Art Although the process of mounting electronic components on a printed circuit board is becoming more automated, most electronic components are automatically mounted, but some electronic components are not always suitable for automation. When mounting such an electronic component on a printed circuit board, a manual insertion process by an operator is required. In the manual insertion process of printed circuit board electronic parts that are not familiar with automation, the prepared electronic parts are sorted according to standard work instructions based on the parts list necessary for the manual insertion work on the printed circuit board, and then the electronic parts are printed on the printed circuit board. Is manually inserted, and then soldered and then transferred to the next step.

Conventionally, there are three types of manual insertion work processes, such as a mount land system, a straight conveyor system, and a round conveyor system, depending on the mode of parts sorting and manual insertion work. Among the above methods, the Mountland method is a typical method of one-man products.

As high-mix low-volume production has progressed, continuous production by a large number of people such as a straight conveyor system has become impossible. This is because the production volume is low to medium and there are many varieties. In case of straight conveyor system or round conveyor system,
When multiple parts are needed at the same time in the next process, or it is difficult to immediately ship in response to a user's request. In other words, as shown in the figure, three kinds of printed circuit boards are produced in process A, process B, and process C, and three types of printed circuit boards are completed in 3 days and ready for shipment.

Therefore, in order to produce the required number of sheets, one person produces several types of printed circuit boards in steps A to C in one day like one-man products. There is no choice but to produce dozens of pieces. In other words, one-manpto ducts becomes a production system capable of coping with the production of a large variety of products and the simultaneous start-up by simultaneously performing the one-man work, which is the minimum unit of production, simultaneously.

FIG. 12 shows a process of a mount land system which is one of the one-man products system. Unlike the continuous production method, this mount land method is characterized by performing manual insertion by a single worker, and thus performing manual insertion for each product type. The process of mounting the land will be described below with reference to FIG.

In the process shown in FIG. 12, the component sorting setup 24 sorts the product types based on the created mount land process chart and puts the components in the boxes. In the manual insertion work step 25, the manual insertion work program is loaded on the mount land device whose mount land width is adjusted in advance,
Next, the origin is set to align the printed circuit board. When the shape and polarity of the component are instructed on the printed board by the laser beam instruction based on the program, the operator takes out the component and performs the manual insertion work based on the process chart. After the manual insertion work is completed, a check is performed and the printed circuit board is transferred to the next step.

By the way, in the above-mentioned three manual insertion methods, at the manufacturing site level, it is general to manually make a plan and grasp the results just before work. In particular, in the one-man products method such as the mount land method, the worker often performs the work and the work preparation alone, and even if the plan is very ambiguous, the work is often done in a dull manner. . For this reason, other urgent tasks (line stoppages and troubles) tend to be prioritized, and the management tends to be absent.

Therefore, even though the one-man products production form is suitable for high-mix low-volume production, there are the following problems. (1) It is difficult to consider load balance and productivity in the production plan. That is, ambiguous allocation is made. (2) Setup schedules are hardly considered. (3) Since the work is done by one person, it is carried out in an individual play, and the variation in productivity tends to increase. (4) Since the progress status is left to the operator, the progress status is made after the work is completed, and thus it is difficult to timely provide the work progress confirmation feedback.

Hereinafter, in order to clarify the significance of the present invention,
The background of the problems will be described in more detail. Even in the one-man products system, there are generally three support blocks, that is, plan support, setup support, and performance support. The above problems also occur due to the problems existing in each of these support blocks. Therefore, the problems of the support blocks will be described.

Looking first at the current state of the plan support block, FIG. 11 shows a conventional plan making procedure. This conventional planning procedure consists of model names, board names, lots, lot sizes, standard time for manual insertion, basic numbers such as the number of work and manual insertion points, time for switching manual insertion model change, skill level of workers, work order. In consideration of the above, I finally planned for the next day with intuition and experience, and created a personalized plan list by handwriting all items. For this reason, it is difficult to consider load balance and productivity in the production plan, and vague allocation is often made.

Next, looking at the problems with the setup support, if the plan is vague and the actual results are not thoroughly managed, it is difficult to accurately grasp and predict the switching timing of the model change, and all the switching is required. It was difficult to advance the preparation such as arranging jigs and tools in advance. For this reason, the work is stopped each time switching is performed, which is a factor that significantly reduces efficiency.

Next, regarding the problem of performance support, especially grasping of performance, as described above, the manual insertion work is performed by an individual, and there are large variations. The biggest drawback of the one-man products method is that the progress of workers varies.
Compared with general tact operation (line work),
The actual difference (performance) against the plan, which is the actual difference, tends to increase. The main reason for this is that there is no forced tact and the like, and that there is a tendency for a large amount of non-regular work such as assisting manual insertion workers in setting up, supplementing parts, and preparing jigs and tools.

Further, in this performance support block, feedback for confirming the progress of work is not timely. In the case of the one-man products method, it is very difficult to keep track of the progress. This is because it is difficult to grasp the progress because each of them switches multiple times a day to support high-mix low-volume production. There is. For this reason, it was in a state of post-management to confirm by the daily man-hour report submitted at the end of the work.

As for a method for solving such a problem, there has been no algorithm for obtaining an optimum solution in a plan until now, and a method for obtaining an approximate solution by artificial intelligence or a genetic algorithm is generally used, but the cost is high. I had to become.

[0016]

SUMMARY OF THE INVENTION In view of the above problems, the present invention is a one-man product production process for optimizing and supporting a production plan, setup, and achievement grasp in a one-man product type printed circuit board production process with a simple algorithm. The point is to provide a management optimization support system.

[0017]

According to the present invention, in a one-man products production process management optimization support system, a step of creating an individual worker allocation based on plan data and the individual worker allocation based on the work data. A planning support block consisting of a step of evaluating each of the above and a step of performing a total allocation and an evaluation of individual allocations by workers, and a setup support for creating a setup based on the provisional plan created by the planning support block. A block and a performance support block that performs performance evaluation by comparing the setup instruction data created by the setup support block with the performance data, and feeds back the evaluation result obtained by the performance support block to the plan database. . The finally created personalized allocation results and the like are output as a form and distributed to each worker.

In the support system, the individual worker allocation is determined based on the individual worker work results, the individual worker planning delay, the short-term schedule, and the switching overlap data, and the individual worker allocation is evaluated. Judgment is made based on individual worker load factor and productivity. As a result of the evaluation of the total allocation that aggregates the individual worker allocation, it is determined whether the total unloaded is 1 or more. If the total unloaded is 1 or more, it is registered from the unloaded worker list database registered in advance. When the assigned work units are larger than the unloaded maximum of the individual workers as a result of the work assignment, the individual assignment priority is determined for each worker as the unloaded load in order, and the work assignment is performed. Reallocation is performed based on the upper limit load factor obtained from the individual priority database.

[0019]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS A one-man products production process optimization management support system of the present invention generates an initial plan by a simple algorithm such as a difference between actual and actual, urgency, and overlap of switching,
The plan data is evaluated individually or as a set to improve the degree of completion, thereby making a plan.

First, the entire one-man product production process management optimization support system of the present invention will be described. FIG. 1 shows a system flow of the support system of the present invention. In FIG. 1, the system has a system flow composed of three blocks: a planning support block 1, a setup support block 2, and a performance support block 3.

The information used in this system is processed by using various databases as computer information. As the computer information, a model name, a board name, a lot, a lot size, a switching time, the number of works, a standard time, a production schedule and the like are taken into a system from a network (for example, a LAN system). In addition, the skill level and work order of the operator are prepared as a dedicated database for this system.

First, the outline of the flow of the plan making support block 1 will be described. <Step 1> An individual assignment for each worker is automatically created based on the plan data reflecting the past performance data. <Step 2> Individual allocation is evaluated based on necessary data 4 described later. <Steps 3 and 4> The load factor and productivity of each worker are judged based on the individual allocation evaluation, and it is checked whether the judgment of all the workers is completed.

<Step 5> The individual allocation is aggregated, and the overall allocation and its evaluation are performed to adjust the allocation. <Step 6> The overall load factor and productivity are judged based on the overall evaluation. <Step 7> The result of Step 6 is output. For example, a form is printed to create an individual allocation list 6 and an overall load factor list 7. The above is the flow of the planning support block 1.

Next, the setup support block 2 following the plan support block 1 generates a setup instruction based on the form created in step 7 of the <step 8> plan support block. <Step 9> The result of the setup instruction generation is output as a form to create the setup instruction document 8.

Next, the performance support block 3 following the setup support block 2 carries out <step 10> performance evaluation based on each performance data 10 based on the setup instruction document 8. <Step 11> Judgment of the actual difference (the difference between the planned productivity and the actual productivity) is made from the result evaluation. If there is no actual difference, the actual result evaluation is stored in the actual result database 9.

<Step 12> If there is a difference between the actual and actual values by looking at the result of the actual / real difference determination, the planned delay is fed back to the plan database 5, and the process returns to step 10 to perform the actual result evaluation again and the corrected actual result data is taken as the actual result. Give feedback to the database 10. Further, in step 12, if the difference between the actual and actual is negative, the result (plan delay) is notified to the manager as an alarm.

The above is the outline of the flow of the whole one-man product production process management optimization support system of the present invention. The flow based on the above steps will be described in detail below. FIG. 2 shows a flow of creating and evaluating an individual assignment in step 1 and step 2 of the flow. This individual assignment is created based on the production schedule, work order, actual / actual difference results, short-term schedule, and plan data 5 of switching overlap.

The point of creating the personalized layout is to determine the work order. The algorithm for determining the work order is whether the work record up to immediately before (step 13), the plan delay due to the actual difference (step 14), the short-term schedule (step 15), or the switching overlap (step 1).
Determine from 6). The administrator will judge the new models that have no work record.

The overlapping of the switching operations in step 16 means that when a plurality of workers change the model of the board to be produced during their own work at almost the same time, the switching personnel perform the setup table and the replacement of parts at almost the same time. However, at this time, the work switching times of a plurality of workers overlap. At this time, if the switching work performed by the switching personnel is not carried out all at once, the switching time will vary depending on the switching order.

When the creation of the individual allocation is completed, the individual allocation is evaluated from the temporarily determined order (step 2 in FIG. 1), and a predetermined reference value (database 4) for the load factor and the productivity is obtained. The comparison is made (step 3 in FIG. 1), and if it is less than that, the work order is automatically reallocated. The plan is provisionally completed by repeating the above (step 4 in FIG. 1).

When the individual assignment is temporarily completed, the overall assignment and its evaluation (step 5 in FIG. 1) are performed to adjust the assignment of all the workers. FIG. 3 shows a flow for automatically correcting the individual allocation when performing the overall evaluation. At the time when the individual assignment is temporarily completed, it is judged whether or not there is a whole number of man-hours of 1 or more (total unloaded one or more) (step 20), and if there is a member registered in the unloaded list database. Each plan is automatically unloaded (step 21), and the individual plans are automatically corrected.

Based on the individual priority database 11 created in advance for each unloaded manual insertion worker, the skill level (work experience period with model model and predetermined board), experience level (various work experience and period) ), Productivity in the past work (worker efficiency) and quality status in the past work (number of defects, tendency,
The work is allocated to each worker while considering the data (for example, all defects) (steps 19 and 20).

Next, it is judged whether or not all are allocated (step 21), and when the size of the business unit to be allocated exceeds the maximum of the individual unloaded, the individual priority database 1
The recalculation is performed based on the upper limit load factor based on the data of No. 1 (step 22), the reallocation is executed, and if the allocation is still not made (step 23), the manager makes a judgment such as work lot division or replacement with work schedule. Yes (Step 2
4).

The individual assignment list 6 and the overall load factor list 7 created through the above steps are printed on a form or output to a display (step 7 in FIG. 1). In Figure 4,
An example of the output of the individual allocation list 6 is shown. In the allocation list 6, each numerical value is calculated and displayed in the order of work. In the allocation list 6, especially the work start / end time must be managed so that the work is performed according to this. The work record is displayed as a record item.
Furthermore, the final load factor and productivity are, for example, 12
Is displayed as 99 (%) and the productivity 13 is displayed as 53.7 (%).

The numerical calculation formulas and units in the allocation list 6 are as follows. Working hours are H per hour
The standard time is minutes and the switching time is minutes. Direct / indirect ratio γ = direct man-hours / total man-hours P / F (%) = operator's ability (performance) required time (H) = switching time + additional time + insertion start-
End time Workmanship (H) = Standard time x Number of products produced Load factor (%) = Σ Required time / (Working time-Excluded time)
Excluded time is meeting time, machine stop time, etc. Productivity (%) = ΣProduction man-hours / Working hours × γ

FIG. 5 shows an output example of the allocation evaluation list 6 which is the adjusted individual allocation list. This allocation evaluation list 6 is output by display, printing, etc. after the allocation adjustment is completed (step 7 in FIG. 1). Then, in the allocation evaluation list 6, the actual load rate 14, the total load rate 15, the productivity 16, and the overall allocation evaluation 17 are displayed. In the overall allocation evaluation 17, the name of the worker adjusted to the load 0 and the name of the corresponding worker when the total unloaded amount is less than one are displayed.

The calculation formula in the allocation evaluation list 6 is as follows. Registered working hours (H) = Fixed working hours Real working hours (H) = 0 when the load is 0 P / F (%) = Worker capacity Actual load rate (%) = Load only by the load target Rate Total load rate (%) = Load rate for the number of man-hours Productivity (%) = (Σ standard time × Σ number of products ÷ Σ actual working time) × γ Direct indirect ratio γ = Direct man-hours / Total man-hours

Next, after the individual plans in the plan support block are fixed, the total switching frequency is calculated, and the setup plan is displayed or printed on the display or the like (step 9 in FIG. 1). FIG. 6 shows an example of a set-up plan list for a predetermined line. In this setup plan list, the switching time 18 and the switching content 19 are displayed for each setup staff 17 on the line in charge. As a result, one-day setup work is systematically carried out. There are various forms of switching, and the time may vary depending on the content. Therefore, in this system, the parts replenishment time is divided into the switching time (switching of work contents etc.) and the parts replenishment time (simultaneous parts replenishment etc. in continuous production of the same model).
A mark 20 or the like is attached to distinguish them.

Next, the performance support block will be described. Regarding the work base, the point is how the performance support block grasps the work performance and status in real time, and promptly takes measures based on the actual difference from the plan. That is,
This is based on the recognition that there is no variation because the workers are at their own pace, and that problems occur because there is no management according to the situation.

Therefore, in this system, in order to inform the manager of the problem (prediction difference) in real time and prompt the improvement, the line-by-line difference shown in FIG. 7 and the individual-by-person difference shown in FIG. 8 are displayed. Is displayed or printed, and when the actual difference is negative, an alarm is issued to alert the administrator (step 12 in FIG. 1). Further, the negative data fixed for one day is fed back to the plan database 5 (FIG. 1) for the purpose of creating a plan for the next day.

By the way, the information about the progress of the plan executed based on the plan created by the system is collected by communicating with the LAN system constructed in the process. As shown in FIG. 9, the mount land process 21
A LAN slave station is arranged in each step of the printed circuit board manufacturing process 22 including
Data such as a magazine number, work start time, work end time, switching time, and other time are acquired from the LAN server 23. At this time, by obtaining the magazine number, the model name, substrate name, lot, lot size, manufacturing number, quantity, etc. can be obtained from the database 4 (FIG. 2).

[0042]

According to the present invention, by constructing a system for supporting production allocation and its optimization instruction, switching setup instruction, difference from actual results and correction instruction for the one-man products system, (1) plan It is possible to significantly reduce the creation time. (2) By outputting various forms such as an individual allocation list, it becomes easy for the worker to self-manage and for the manager to grasp work trends. (3) Unloading can be reduced by optimizing the individual allocation plan. (4) Appropriate man-hours for overload can be grasped. (5) The switching setup can be efficiently performed. (6) The difference between the planned productivity and the actual productivity is output in real time, and the feedback to the plan of the next day can be performed, so that an appropriate plan can be created.

[Brief description of drawings]

FIG. 1 is a flowchart of a one-man products management optimization support system of the present invention.

FIG. 2 is a flow chart of creating and allocating individual allocation in the one-man products management optimization support system of the present invention.

FIG. 3 is a flow chart of individual allocation automatic correction in the one-man products management optimization support system of the present invention.

FIG. 4 is a diagram showing an individual allocation list created by the one-man products management optimization support system of the present invention.

FIG. 5 is a diagram showing an allocation evaluation list created by the one-man products management optimization support system of the present invention.

FIG. 6 is a diagram showing a setup plan list created by the one-man products management optimization support system of the present invention.

FIG. 7 is a diagram showing an example of a form output of management for managing the difference between the planned productivity and actual performance productivity by line created by the one-man products management optimization support system of the present invention.

FIG. 8 is a diagram showing an example of a form output of management for managing the difference between the individual planned productivity and the actual performance productivity created by the one-man products management optimization support system of the present invention.

FIG. 9 is a block diagram in which the one-man products management optimization support system of the present invention is constructed in a LAN system.

FIG. 10 is an explanatory diagram of a straight conveyor system and a one-man products system.

FIG. 11 is an explanatory diagram of a conventional plan creation procedure in the one-man products system.

FIG. 12 is a diagram showing a flow of a mount land system.

[Explanation of symbols]

 1 Planning support block 2 Setup support block 3 Actual support block 4 Individual allocation evaluation required database 5 Planning database 6 Individual evaluation list output 7 Overall load factor list output 8 Setup instruction output 9 Actual database

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Claims (4)

[Claims] 1. A one-man product production process management optimization support system, a step of creating an individual worker allocation based on plan data, a step of evaluating the individual worker allocation based on the work data, and an operator. A plan creation support block consisting of steps of total allocation and evaluation of individual assignments, a setup support block for creating a setup based on the provisional plan created by the plan creation support block, and the setup support block One-man product production characterized by comprising a performance support block for performing performance evaluation by comparing the created setup instruction data and performance data, and feeding back the evaluation result obtained in the performance support block to the plan database. Process management optimization support system. 2. The individual worker allocation is determined based on the individual worker's work performance, individual worker's plan delay, short-term schedule, and switching overlap data, and the individual worker allocation is evaluated by the individual worker. The one-man product production process management optimization support system according to claim 1, wherein the determination is made based on a load factor and productivity. 3. As a result of the evaluation of the total allocation in which the individual allocations for the workers are aggregated, it is determined whether or not the unloaded total is one or more, and when the unloaded total is one or more, the unloaded work registered in advance. Workers registered from the person list database are sequentially set as unloaded, the individual priority is judged, work is assigned, and as a result of the work assignment, the size of the work unit assigned from the maximum unloaded individual worker The one-man product production process management optimization support system according to claim 1, wherein the reallocation is performed based on the upper limit load factor obtained from the individual priority database. 4. The one-man product production process management optimization support system according to claim 3, wherein the result of evaluation of the total allocation, which is the total allocation of individual workers, is output as a form.