JPH07191735A - Neck process finding device - Google Patents

Abstract

PURPOSE:To provide a neck process finding device capable of finding a process to be a neck by exactly grasping a manufacturing result in a whole shop. CONSTITUTION:At each line, a fault stop time recording function part 26 records a fault stop record, a waiting monitor function part 28 monitors a waiting time, a line tact measuring function part 30 measures a line tact and the manufacturing result and a control function part 32 sets a recess time, etc. Then, a neck process calculation function part 34 calculates separate manufacturing capacity based on data measured and recorded by the respective function parts so as to find the process to be the neck.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an apparatus for finding a neck process for analyzing a working condition of a line in a production factory and finding a process that becomes a neck.

[0002]

2. Description of the Related Art Conventionally, in a line of a production factory, an operator records a stop record indicating the stop time of a line stop occurring for each line and the cause of the stop, and the average tact value / Workpiece number)
The operation status was analyzed based on this average tact value. Then, this stop record was handwritten on a predetermined sheet.

[0003]

However, in the above-described conventional operating status analysis method for a line, the average tact value (operating time / operating time / operating time / The number of works) is only calculated. In addition, since the stop record is manually written by the operator, there is a case where the operator forgets to record a so-called chocolate stop, which is a temporary interruption.

Therefore, there is a problem that it is difficult to grasp the production record of the entire shop, and it is impossible to determine which line is the cause of the decrease in the production record. There is also a problem that it may be difficult to grasp accurate operation data because recording may be omitted.

The present invention has been made in order to reduce such a conventional problem, and provides a neck process finding apparatus capable of finding a process that becomes a neck by grasping an accurate production record in the entire shop. The purpose is to provide.

[0006]

SUMMARY OF THE INVENTION The present invention for achieving the above object is an apparatus for monitoring the operating status of each line in a shop consisting of a plurality of lines to find a bottleneck process, Failure stop recording means for recording the failure stop status in the line, waiting wait monitoring means for monitoring the waiting stop time in each line, line tact measuring means for measuring the line operation time in each line, and operation information in each line Managing means, a failure stop record recorded by the failure stop recording means, a hand waiting time monitored by the hand waiting monitoring means, a line tact measured by the line tact measuring means, and the managing means The net production capacity for each line is calculated based on the operation information managed by Characterized in that from the process calculation means constituted neck process discovery device.

[0007]

The present invention thus constructed operates as follows.

The failure stop recording means measures and records the time from the line stop due to the failure to the line restart as the line failure stop time based on the operation information of each line and the failure stop information.

The hand-held monitoring means measures and records the hand-hold stop time by using the hand-hold judgment logic.

The line tact measuring means measures and records as a line tact from the first equipment start to the last equipment stop, and counts the production record.

The management means sets a break time and the like.
Based on the rest time set here, the actual failure stop time and hand wait time excluding the rest time from the failure stop time recorded by the failure stop recording means and the hand wait time recorded by the hand wait monitoring means. To calculate.

In the neck process calculation means, the stand-alone production is carried out based on the failure stop time measured by the failure stop recording means, the hand waiting time measured by the hand waiting monitoring means, the line tact measured by the line tact measuring means, and the production record. Calculate ability.

This independent production capacity indicates how much production was possible if there was no hand waiting time. Independent production capacity = (total line tact + cumulative failure stop time + hand waiting time). It is derived from the formula: (cumulative total) / (cumulative line tact + cumulative failure downtime) x production record.

The operation status is analyzed by comparing the individual production capacities for each line. Therefore, it is possible to grasp the accurate production record in the entire shop and find the process that becomes a bottleneck.

[0015]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of the present invention will be described below with reference to the drawings. FIG. 1 is a block diagram showing a schematic configuration of a neck process finding apparatus according to the present invention, and shows only a portion related to the gist of the present invention.

A vehicle body assembly shop 10 will be described as an example of a shop including a plurality of lines.

The vehicle body assembly shop 10 includes a front floor line 12, a rear floor line 14, an engine compartment (encon) line 16, a floor main line 18, a body main line 20, and a struck line 22.
Of each line.

Although the neck process finding device 24 according to the present invention is connected to each of the above-mentioned lines, the neck process finding device 24 connected to the floor main line 18 will be described in the embodiment shown in FIG. .

The neck process finding device 24 includes a failure stop recording function unit 26, a waiting waiting monitoring function unit 28, a line tact measurement function unit 30, and each of these function units, which are connected to the floor main line 18, respectively. Independent management function unit 32, failure stop recording function unit 26, waiting waiting monitoring function unit 2
8, a line tact measurement function unit 30, and a neck process calculation function unit 34 connected to the management function unit 32. The failure stop recording function unit 26 described above functions as a failure stop recording unit, the hand wait monitoring function unit 28 functions as a hand wait monitoring unit, the line tact measurement function unit 30 functions as a line tact measurement unit, and the management function unit. 32 functions as a management means, and the neck process calculation function part 34 functions as a neck process calculation means.

As shown in FIG. 2, the fault stop recording function unit 26 measures the time from the line stop due to the fault occurrence to the line restart based on the line fault timing signal. In the example shown in FIG. 2, when a failure occurs in the equipment 1, the line failure stop is performed from the rising of the failure signal to the rising of the line operation signal due to restart of the line stopped due to the failure. It is measured and recorded as time.

The hand-held monitoring means measures and records the hand-hold stop time by using the hand-hold judgment logic. This waiting logic will be described with reference to FIG.

In the waiting determination process, it is first determined whether or not the drop lifter is ready to be received (S
1) If the acceptance preparation is completed, the monitoring timer is started (S2).

Then, it is judged whether or not the work has arrived at the drop lifter (S3). Here, when the work does not arrive at the drop lifter, it is determined whether the value of the monitoring timer exceeds the set value (S4), and when the value of the monitoring timer exceeds the set value, it is determined that waiting for work has occurred. Then (S
5), regarding the value of the monitoring timer as the waiting time for hand (S6),
The process returns to the work arrival determination process (S3). On the other hand, when the value of the monitoring timer does not exceed the set value, it is determined that the waiting time is normal, and the process returns to the work arrival determination process (S3).

Further, the work arrival determination process (S3).
When the work arrives at the drop lifter, the monitoring timer value determined to be the hand waiting time in each of the above-described processes (S4, S5, S6) is recorded as the hand waiting time (S7), and the process is performed. Return to the beginning (S8).

The line tact measurement function unit 30 measures and records the line tact from the start of the first equipment to the stop of the last equipment.
Count production results.

The measurement of this line tact will be described with reference to FIG. As shown in FIG. 4, the line tact is calculated as the sum of the T / F transport time (A), the location pin return time and the clamp return time (B), and the robot tact (C) in each process.

The management means sets a break time and the like.
The break time set here is to eliminate the time overlapping with the break time from the failure stop time measured by the above-mentioned failure stop recording unit and the hand waiting time measured by the hand waiting monitoring function unit 28. To use. By performing such processing, it is possible to grasp the actual failure stop time and the actual waiting time.

In the neck process calculation function section 34, the failure stop time measured by the failure stop recording function section 26, the hand waiting time measured by the hand waiting monitoring function section 28, and the line tact measured by the line tact measuring function section 30. And the independent production capacity is calculated based on the production results. This stand-alone production capacity indicates how much production was possible, for example, how many cars could be produced if there was no waiting time on a line. It is derived by the formula: (total line tact + total failure downtime + total waiting time for hands) / (total line tact + total failure downtime) x production results.

The necking process can be found by obtaining and comparing the above-mentioned independent production capacity for each line.

In the neck process found in this way, when the measured line tact may exceed the target value or when the line tact is larger than the past line tact, teaching of the robot is performed. It can be determined that the production capacity of the process is reduced due to a defect or a worker's work delay. Therefore, it is possible to improve the production capacity in the neck process by improving the teaching of the robot or instructing the operator.

The neck process finding device 24 according to the present invention can calculate the failure rate.

This failure rate is derived from the equation: failure rate (%) = (total failure stop time) / (total line tact + total failure stop time + total waiting time for hand) × 100.

The failure rate calculated in this manner is compared with the shift staff, and if the failure rate is higher than the shift staff, it is determined that the production capacity is lowered due to the frequent occurrence of failures. can do.

Further, in the neck process finding device 24 according to the present invention, the total stop time is calculated for each failure phenomenon at the time of the immediate end. The logic for calculating the cumulative stop time for each failure phenomenon will be described with reference to FIG.

In the process of calculating the total stop time for each failure phenomenon, first, the failure data is read, and the failure stop time and the failure phenomenon signal are fetched (S9).

Then, access the failure database,
A failure phenomenon similar to the read failure data is searched (S10). Here, if there is data related to the same phenomenon as the read failure data in the failure database, the cumulative stop time is added and recorded in the failure database (S12). The failure data search process described above (S1
0, S11) is performed for all the read failure data.

The data of the cumulative stop time for each failure phenomenon calculated in this way is sorted in order of the total stop time for each failure phenomenon, so that the failure record data is examined in the order of the failure causes that are significantly involved in the failure stop. be able to.

Based on the above processing, a neck process is found, and the neck process is improved by performing processing such as improvement of robot teaching, instruction of a worker, and removal of a cause of failure for the neck process. .

[0039]

As described above, according to the present invention, the failure stop time recording means records the failure stop record for each line, the hand waiting monitoring means monitors the hand waiting time, and the line tact measuring means. The line tact and the production performance are measured by and the break time is set by the management means. Then, the neck process calculating means calculates the individual production capacity based on the data measured and recorded by each of the above means, and finds the process that becomes the neck.

Therefore, it is possible to accurately grasp the production capacity in the shop and easily analyze in which line the production capacity is decreasing. Further, the production efficiency can be improved by improving the discovered neck process.

[Brief description of drawings]

FIG. 1 is a block diagram showing a schematic configuration of a neck process finding device according to the present invention.

FIG. 2 is a time chart showing a line failure stop timing.

FIG. 3 is a flowchart of a handheld determination logic.

FIG. 4 is an explanatory diagram showing a breakdown within a line tact.

FIG. 5 is a flowchart of a failure phenomenon-specific cumulative time calculation logic.

[Explanation of symbols]

 10 Body Assembly Shop 12 Front Floor Line 14 Rear Floor Line 16 Engine Compartment Line 18 Floor Main Line 20 Body Main Line 22 Overdrive Line 24 Neck Process Detecting Device 26 Failure Stop Recording Function Unit 28 Waiting Monitoring Function Unit 30 Line Tact Measurement Function Part 32 Management function part 34 Neck process calculation function part

Claims (1)

[Claims] 1. A device for monitoring the operating status of each line in a shop consisting of a plurality of lines to find a bottleneck process, and a failure stop recording means for recording the failure stop status of each line, The waiting time monitoring means for monitoring the waiting time in the line, the line takt measuring means for measuring the line operating time in each line, the managing means for managing the operating information in each line, and the failure stop recording means are used for recording. Breakdown record,
The waiting time monitored by the waiting monitoring means,
It has a neck process calculation means for finding a neck process by calculating the independent production capacity in each line based on the line tact measured by the line tact measurement means and the operation information managed by the management means. A neck process finding device characterized in that