JPH08137959A - Process organizing device - Google Patents

Abstract

PURPOSE: To simply and quickly prepare highly accurate and optimum process organization. CONSTITUTION: The similarity of respective facilities to be applied to the processing of respective parts is found out by a similar pattern sorting means 5 and respective parts are divided into respective patterns obtained by combining them in accordance with the similarity. Then respective facilities to be applied in each pattern is found out by a common facility/object parts setting means 6 respective facilities to be applied to respective patterns in common are judged and the processing order of each part in a facility is found out from respective facilities in each pattern to determine a line.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION The present invention is suitable for, for example, the process of high-mix low-volume production, and incorporates the TP (total productivity: stockless production process organization) concept to automatically install each facility. The present invention relates to a process knitting device that arranges and performs process knitting.

[0002]

2. Description of the Related Art When a process is organized in the production of a product, first, a PQ analysis table (relationship between the number of types / production amount) and a process analysis table are prepared in order to grasp the actual condition of the process. Using these PQ analysis tables, a check such as “A job shop with a small amount of a large variety of products or a flow line with a large amount of a small variety of products ...” is performed.

Furthermore, in order to improve the flow of goods, a check is made such as "whether it is a one-piece synchronized production, is there idle time, is it more labor-saving?" Process flow analysis).

Furthermore, "Is there a way to shorten the process?
"..." is checked to create a machining route analysis table. After this, check the line formation efficiency to find the line formation table efficiency, create a family table to further reduce the number of people, create a new process layout diagram, and predict the effect etc. , And comprehensively judge these and organize the process.

However, such a process organization is P
Q analysis table, flow chart, processing route analysis table, etc.
Since the process is organized based on a comprehensive judgment by the skilled worker and the unskilled worker, there is a difference in the process obtained due to the difference in these capabilities.

[0006] Even for a skilled worker, if the number of equipment increases or high-mix low-volume production is performed, it becomes difficult to organize the process, and it becomes difficult to perform proper process organization. In other words, (a) PQ analysis, flow charts, and other individual analyzes and evaluations are carried out, but the overall judgment and process organization is that the optimal process organization that is mathematically integrated as a whole is very manual. Difficult and nearly impossible. (b) Due to human labor, individual abilities differ. Unless you have a TP idea, it is very difficult to organize the proper process. (c) If the knitting conditions become complicated due to human labor, such as high-mix low-volume production, it becomes very difficult to perform highly accurate process knitting, that is, stockless, lead time reduction, and operation rate improvement.

[0007]

As described above, in the process organization, since the PQ analysis table and the like must be comprehensively judged, there is a difference in ability between the skilled person and the unskilled person. Even for a skilled person, it becomes difficult to organize the process in the case of high-mix low-volume production. Therefore, it is an object of the present invention to provide a process knitting apparatus capable of performing highly accurate and optimum process knitting easily in a short time.

[0008]

According to a first aspect of the present invention, based on data obtained by allocating a plurality of parts to at least a plurality of pieces of equipment, the degree of similarity of each piece of equipment applied to the processing of each part is calculated. Obtained for each part, the similar pattern dividing means for dividing each component into each pattern according to this similarity degree, and the equipment to be applied for each pattern obtained by this similar pattern dividing means, Of these, common equipment / target component setting means that determines each equipment commonly applied to each group, and equipment for each part from each equipment for each group obtained by this common equipment / target component determination means Lines that determine the processing order for and determine the line for each group according to this processing order.
And a shop setting means, which is a process knitting apparatus for achieving the above object.

According to a second aspect of the present invention, the similar pattern dividing means determines the number of similar equipments with respect to the total number of equipments for each component based on data indicating a plurality of components assigned to at least a plurality of equipments. It has a function of obtaining the degree of similarity shown and dividing each part into each pattern for each number of parts according to this degree of similarity. According to the third aspect, there is a function of obtaining the operating rate of the line determined for each group and correcting the line balance based on the operating rate.

[0010]

According to the first aspect, the similarity of each facility applied to the processing of each component is obtained for each component based on the data obtained by assigning each component to each facility, and the similarity is calculated. According to, divide each part into each combined pattern. Next, each equipment to be applied for each of these patterns is obtained, and among these equipment, each equipment to be commonly applied to each group is determined. Then, the processing order for the equipment for each part is obtained from the equipment for each group, and the line for each group is determined according to this processing order.

According to the second aspect, when the patterns are divided into similar patterns, the degree of similarity, which is the number of similar facilities / the total number of facilities, is calculated for each component based on the data in which each component is assigned to each facility. Each part is divided into each pattern according to the number of parts according to the degree of similarity. According to the third aspect, the operating rate of the line determined for each group is obtained, and the line balance is corrected.

[0012]

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 of a process organization device. An input unit 2, a memory 3, and a display device 4 are connected to the main control unit 1. Of these, the input unit 2 receives data obtained by allocating a plurality of parts to a plurality of facilities (including workers) from an external process designing device or the like.

Further, the main control section 1 has a function of issuing a command to process the similar pattern classifying means 5, common equipment / target part setting means 6, line / shop setting means 7, and line balance correction means 8. ing.

The similar pattern dividing means 5 calculates the similarity of each facility applied to the processing of each component based on the data indicating the plurality of components allocated to the plurality of facilities and workers. , And has a function of dividing each part into each combined pattern according to this similarity.

Specifically, the similar pattern dividing means 5 has the respective functions of the similarity portion 5a and the pattern dividing portion 5b. The similarity unit 5a, based on data indicating a plurality of parts allocated to a plurality of equipments and workers, a similarity degree (number of similar equipments / number of similar equipments / total number of equipments for each part). It has a function to calculate the total number of facilities).

The pattern dividing section 5b has a function of dividing each component into patterns corresponding to the number of components (for example, 1 to 4) according to the degree of similarity. The common facility / target component setting means 6 obtains each facility and worker to be applied to the processing of the component for each pattern obtained by the similar pattern dividing means 5, and for each group among these facilities and workers. It has a function to judge each equipment and workers that are commonly applied.

The line / shop setting means 7 is a facility (worker) for each part from each facility and worker for each group obtained by the common facility / target part determination means 6.
It has a function of obtaining a processing order for each group, and determining a line consisting of the arrangement of each facility for each group according to this processing order.

The line balance correction means 8 has a function of obtaining the lead time LT of the line determined for each group and correcting the line balance based on this lead time LT.

Next, the operation of the apparatus configured as described above will be described. As for process organization, when a product order is received as shown in FIG. 2, product design / production design is performed based on this order, then process design is performed, and then process organization is performed.

This process organization is performed according to the process procedure of the process organization of FIG. That is, this processing procedure # 1 to #
Among the 11, processing procedures # 2 to # 10 are processed in the process organization.

In this process organization, as shown in FIG. 4, the process organization process is executed according to each data of the parts group, the equipment group and the people group. When this process is organized, (2) similar allocation (parts, equipment) pattern, (3) line / shop setting, (4)
The processing of line balance setting, (5) continuous operation equipment setting (parts, equipment, time zone), and (6) adjustment cycle setting are performed.

When load of allocated parts and setting of equipment (shape, accuracy) are performed in process design, and data obtained by allocating each part to each equipment is input to the input unit 2, this data becomes It is stored in the memory 3 by the main control unit 1.

This data is obtained by each processing of the leveling period and the scheduling period as shown in FIG. 5, and shows a plurality of parts (objects) P1 to P7 assigned to a plurality of facilities D1 to D6. There is.

For example, the part P1 is processed in each of the facilities D1 to D3, and the part P3 is treated in each of the facilities D1 and D3.
2, it is shown that it is processed in D4. Next, in the processing procedure # 3, the similarity degree unit 5a of the similar pattern dividing means 5 installs the respective equipments P7 to P7 based on the data of the respective parts P7 to P7 assigned to the respective equipments D1 to D6. The degree of similarity indicating the number of similar facilities with respect to the total number is obtained.

That is, this degree of similarity is obtained by the number of similar facilities / the total number of facilities. For example, the total number of facilities is “6” because each of the facilities is D1 to D6. Further, since the equipments applied to the parts P1 and P2 are the equipments D1 to D3 in the part P1 and the equipments D1 to D3 in the part P2, the number of common equipments, that is, the similar equipments is “6”. is there. Therefore, the degree of similarity is "6/6".

Since the equipments applied to the parts P3 and P4 are the equipments D1, D2 and D4 in the part P3 and the equipments D4 to D6 in the part P4, the number of common equipments, that is, the number of similar equipments is It is "2". Therefore,
The similarity is “2/6”.

In this way, the mutual similarity of the parts P1 to P7 is obtained. As shown in FIG. 5, these similarities are “6/6”, “4/6”, and “0” among the parts P1 to P7.
/ 6 ”or the like.

Next, the pattern dividing section 5b divides each component into each pattern for each number of components according to the degree of similarity. That is, the degree of similarity between the parts P1 to P7 is “6/6”.
Of “4/6”, “2/6”, and “0/6”, the similarity “6 /
6 ”is the parts P1 and P2 and the parts P4 and P5, and the similarity“ 4/6 ”is the parts P3 and P7.

Next, the pattern dividing section 5b divides each of the parts P1 to P7 into each pattern for each number of parts based on each part of each similarity. That is, as shown in FIG. 5, grouping (G conversion) is performed in the order of the same similarity and the similarities 1, 2, and 3.
Then, the grouping is divided into a plurality of patterns.

For example, when the number of groups (number of G) is "4",
Each pattern P1-P2, P4-P5, P3-P7, P6
Becomes Further, when the number of groups is "3", each pattern P1-
It becomes P2-P3, P4-P5-P7, and P6.

Next, in the processing procedure # 4, the common equipment / target part setting means 6 applies the respective equipments D1 to D applied from the similar pattern dividing means 5 to each group according to the degree of similarity.
6 is obtained, and each pattern P1 among these facilities D1 to D6
-Each equipment D1 to D6 commonly applied to P2, P4-P5, ... Is judged.

That is, as shown in FIG. 6, each pattern P1-P2, P divided for each group number "4" to "1".
When the respective equipments D1 to D6 to be applied to each of the 4-P5, ...
2 is each equipment D1 to D3, and the pattern P4-P
5 is each equipment D4 to D6, and the pattern P3-P
7 are the facilities D1, D2, D4, and D6.

In this way, each pattern P1-P2, P4-
When the equipment to be applied is calculated for each P5, ...
1 is shared by each pattern P1-P2 and P3-P7, equipment D2 is similarly shared by each pattern P1-P2 and P3-P7, and equipment D4 is each pattern P4-P5 and P3-P.
You can see that it is shared with 7.

The common facility / target part setting means 6 finds each facility D1 to D6 to be applied to each of the remaining groups "3" to "1", and selects each pattern P1 from these facilities D1 to D6. -P2-P3, ... Determines each of the facilities D1 to D6 commonly applied.

Next, in the processing procedure # 5, the line / shop setting means 7 determines the respective equipments as shown in FIG. 7 based on the respective equipments shared by each pattern obtained by the common equipment / target component judging means 6. Equipment D1 for each of the parts P1 to P7
Obtain the processing order for D6.

For example, the processing order of the parts P1 is as follows:
1-D3-D2. Further, the processing order of the part P2 is each equipment D1-D3-D2, the processing order of the part P3 is each equipment D1-D4-D2, and the processing order of the part P4 is each equipment D4-D6-D5.

When the processing order of the equipment is obtained in this way, the line shop setting means 7 sets the patterns P1-P2, P according to the data common to the processing order and the equipment.
A line is determined for each 4-P5, ....

For example, in the pattern P1-P2, the arrangement order of the respective facilities is a serial arrangement of D1-D3-D2. It should be noted that in FIG. 7, equipment having the same allocation order and arrangement order of a plurality of parts is given "0", and different equipment is given "1".

In the patterns P4 to P5, each equipment D
Since 4 and D6 are provided with "1" indicating different equipment, the arrangement order of each equipment is such that D4 and D6 are connected in parallel, and equipment D5 is connected in series to these equipment D4 / D6.

In the arrangement of each equipment D1-D3-D2, when the processing of the equipment D1 is added, for example, the equipment D
If there are two or more units 1, each facility D1-D as shown in FIG.
The arrangement is 3-D2-D1.

In the arrangement of the facilities D1-D3-D2, for example, when there are two or more facilities D1, the process of returning to the facility D1 again with the arrangement of the facilities D1-D3-D2 as shown in FIG. Become.

Next, in the processing procedure # 6, the line balance correction means 8 executes the simulation for the determined line to execute each pattern P1-P2, P4-P.
Lead time L in the line determined for every 5 ...
T is calculated, and the line balance is corrected based on this lead time LT.

For example, in the pattern P1-P2, as shown in FIG. 10, for example, each equipment P1, P2 for each equipment D1,
The waiting time for D3 and D2 is calculated, and the lead time LT for each component P1 and P2 is calculated from these waiting times.
Then, the operating rate is obtained based on these lead times LT.

If these average operating rates do not reach the initially planned operating rates, look at the G numbers shown in FIG. 5, select the G numbers one step lower, and perform the equipment arrangement in the same manner as before, Calculate and set the lead time LT and average operating rate (within "[]").

Normally, the relationship as shown in FIG.
Since it is between the number and the target parts, the equipment arrangement, and the operating rate and the average LT, it is possible to select a more appropriate equipment arrangement of G number suitable for the manufacturing environment.

When the number of parts in each pattern is large, as shown in FIG. 11, the parts are ordered by similar parts to balance the load, and then the average lead time LT and the operating rate are calculated. Must be set. By these methods, more appropriate line / shop settings can be set.

Next, in processing procedure # 7, the main controller 1
Searches for equipment D1 to D6 capable of continuous operation, for example, a tool damage automatic detector in the case of machining and parts to be machined by the equipment, in descending order of load, and in processing procedure # 8, the processing time is large. Therefore, the time zones for nighttime continuous operation, lunch break operation, etc. are set. This is subject to automatic scheduling.

Next, the main control unit 1 sets a multi-process waiting range based on the sum of the setup / operation time of each of the equipments D1 to D6, the sum of the parts supply time, and the worker's ability (operating time) in processing procedure # 9. .

Finally, the main control unit 1 performs the color display with a delay of n days, for example, red, yellow, and green, for the supply location of the processed part and the part whose processing is delayed in the processing procedure # 10. As described above, in the above-described embodiment, the degree of similarity of each of the equipments D1 to D6 applied to the processing of each of the components P1 to P7 is obtained, and each of the components P1 to P7 is divided into each pattern according to the similarity, Each equipment D1 applied to each of these patterns
D6 is obtained to determine the equipments D1 to D6 commonly applied to each pattern, and the equipments D1 to D6 for each pattern to the equipments D1 to D6 for each part P1 to P7 are determined.
Since the line is determined by obtaining the processing order for, the following effects can be obtained. (a) The process organization based on the concept of TP (total productivity) stockless production can be automated, and the lead time of this process can be shortened, the stock amount can be reduced, and the operating rate can be improved. (b) Even a non-skilled person can easily perform highly accurate process organization. (c) Since the process organization function is modularized, CAD
It is possible to organize the process directly linked to the product design and production plan including. As a result, it can be incorporated into an existing system to promptly switch equipment and improve the efficiency of high-mix low-volume production. (d) When allocating parts with new specifications to equipment (lines / shops), the process organization function has a pattern classification function (a kind of cluster analysis) of similar equipment / parts, which allows existing equipment patterns to be created in a short time. And can be allocated effectively. As a result, the lead time can be shortened, the stock amount can be reduced, and the operation rate can be improved.

Therefore, highly accurate and optimal process organization can be easily performed in a short time, and the optimum process organization that is mathematically integrated as a whole can be performed. The present invention is not limited to the above-mentioned one embodiment and may be modified as follows.

For example, not only processing and assembling steps but also things,
The present invention can be applied to the flow of drawings, slips, people, etc., and all process organization that is organized from the processes of equipment, people, etc. that process it. Specifically, for products, process organization of production processing processes other than machining, process organization of logistics department.

On the object / drawing, the process organization of the equipment / person for the inspection process and design process. On the slip, the process organization of the office processing department. For food, the process organization of the food processing department.

Further, since the comparison main body and the similar main body according to its various attributes (cluster analysis) can be classified by the pattern dividing function of the similar equipment / parts of the process organization function, the classification / similarity of various similar items can be obtained. It is possible to search. As a result, for example, similar graphics can be classified based on the component body and various graphic elements possessed by the component, and similar drawings can be searched.

[0054]

As described above in detail, according to the present invention, it is possible to provide a process knitting apparatus capable of performing highly accurate and optimum process knitting easily in a short time.

[Brief description of drawings]

FIG. 1 is a configuration diagram showing an embodiment of a process organization device according to the present invention.

FIG. 2 is a diagram showing a flow from order reception to process organization.

FIG. 3 is a diagram showing a processing procedure of process organization.

FIG. 4 is a diagram showing an outline of process organization processing.

FIG. 5 is a diagram showing a process of classifying similar patterns.

FIG. 6 is a diagram showing a process of setting common equipment / target parts.

FIG. 7 is a diagram showing a process of setting a line shop.

FIG. 8 is a diagram showing another example of line determination.

FIG. 9 is a diagram showing another example of line determination.

FIG. 10 is a diagram showing a process of line balance correction.

FIG. 11 is a diagram showing a process of line balance correction.

FIG. 12 is a diagram showing a process of line balance correction.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 1 ... Main control part, 2 ... Input part, 3 ... Memory, 5 ... Similar pattern classification means, 6 ... Common equipment / target component setting means, 7 ...
Line shop setting means, 8 ... Line balance correction means.

Claims (3)

[Claims] 1. Based on data obtained by allocating a plurality of parts to at least a plurality of pieces of equipment, the degree of similarity of each piece of equipment that is applied to the processing of the parts is obtained for each of the parts,
Similar pattern dividing means for dividing the respective parts into respective patterns in accordance with the degree of similarity and the respective equipment to be applied for each of the patterns obtained by the similar pattern dividing means are obtained. Common equipment / target parts setting means for judging each equipment commonly applied to a group, and each equipment from each equipment for each group obtained by this common equipment / target parts setting means And a line shop setting means for determining a processing order for the equipment and determining a line for each group according to the processing order. 2. Similarity pattern dividing means, based on data indicating a plurality of parts assigned to at least a plurality of facilities, similarity degree indicating the number of similar facilities with respect to the total number of the facilities for each of the components. The process knitting apparatus according to claim 1, wherein the process knitting device has a function of determining each of the parts and dividing each of the parts into each pattern according to the number of parts. 3. An operation rate for a line determined for each group is calculated, and a line balance correction function is provided based on the operation rate.
The described process organization device.