JPH10244447A - Production control system - Google Patents

Abstract

PROBLEM TO BE SOLVED: To efficiently give input/carrying-out indication of works to respective work processes for operators so that deadlock is not caused by arranging a means to perform an operation on the work input/carrying-out timing and work allocation for the operators in the respective work processes from specific data. SOLUTION: On operators, operators arranged on that day are discriminated and inputted by preregistered operator names of an operator control part 34. Scheduling such as the work input/carrying-out timing and work allocation for the operators in respective work processes is performed by a scheduling part 35 from a production plan stored in a production control part 32, lead time data of respective work stations controlled by a data equipment control part 33 of respective half-finishing product warehouses, the operators which are stored in an operator control part 34 and are arranged on that day and standard work time data of the respective operators.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a work management system, and more particularly, to a job shop type comprising a plurality of processing steps and an in-process warehouse in which a processing step involves input and unloading of a work by an operator. The present invention relates to a work management system for efficiently instructing a worker to input and unload a work into each work process in a work system.

[0002]

2. Description of the Related Art Conventionally, in a job shop type processing system composed of a plurality of processing steps, when a work is manually input and output, a worker is usually required to make effective use of human resources. In addition, the number of processing steps is smaller than the number of processing steps that require manual work loading and unloading.

Therefore, the timing of loading and unloading the work is determined based on a time chart or the like before the start of the processing system, and the minimum required number of workers is determined from the time chart. However, in practice, due to variations in the working time of each worker and short stops in each machining process, etc.
In some cases, the initially planned time chart and the progress of the actual processing system may not be consistent. These inconsistencies have been adjusted and dealt with by skilled workers according to the situation, taking into account the lead time in each machining process, the operating status of each machining process, and the number of workers arranged.

However, when the number of processing steps is large, finally, a timing that requires more workers than those initially arranged in a plurality of processing steps at the same time, that is, a dead time caused by a work input timing. Locks are more likely to occur. This deadlock is difficult to predict even for a skilled worker, and there is a problem that the operating rate in each processing step is reduced. Alternatively, there is a problem that human resources cannot be effectively used, such as disposing workers more than necessary to cope with the deadlock.

[0005]

SUMMARY OF THE INVENTION The present invention has been made in view of the above-mentioned circumstances, and comprises a plurality of processing steps and an in-process warehouse in which a worker inputs and unloads a work in a processing step. The present invention relates to a work management system that efficiently instructs a worker to input and unload a work into each processing step so that the deadlock does not occur.

[0006]

According to the present invention, there is provided a job shop type processing system comprising a plurality of processing steps and an in-process warehouse in which a worker inputs and unloads a work in a processing step. Means for inputting production plan data, means for inputting production plan data, means for inputting production result data, means for managing the production plan data / production result data, operation state monitoring means for monitoring the operation state of each step, and each step Means for entering lead time data for
Means for managing the operation status data / lead time data, means for inputting data relating to workers arranged in the processing system, means for inputting work status data of the workers, data / work status data relating to the workers Means for managing each process from the production plan data of each process, the operation status data of each process, the lead time data of each process, the data on the workers arranged in the processing system, and the work status data. The present invention is characterized in that it comprises means for calculating work input / output timing and work assignment of a worker in a process, and means for outputting the calculation result.

According to a second aspect of the present invention, in the first aspect of the present invention, workers to be arranged in the machining system are individually identified, a standard working time is managed for each worker, and a specific worker is input / outputted. It is characterized in that it is assigned to unloading work.

According to a third aspect of the present invention, in the first aspect of the present invention, in the means for calculating the work input / output timing and the worker assignment in each of the processing steps, when the worker assignment is performed, the work that can be assigned is performed. The present invention is characterized in that workers are assigned while leveling the workload between workers.

According to a fourth aspect of the present invention, in the first aspect of the present invention, the standard work time for each worker is corrected from the history information of the work time for each worker, and the work input / output timing in each of the machining steps is corrected. And a task assignment operation of the operator is performed.

According to a fifth aspect of the present invention, in the first aspect of the present invention, the work input / output timing and the worker's timing in each of the machining steps are reduced by a temporary stop due to a failure or the like in each machining step or an increase or decrease in the number of workers. It is characterized by performing a work assignment operation.

According to a seventh aspect of the present invention, in the first aspect of the present invention, the operation status of each processing step, the work status of the operator, the work input / output timing and the work assignment calculation result of the operator in each of the processing steps are determined. The method is characterized in that successive comparisons are performed, and when an error equal to or more than a set value occurs, a work input / output timing and a work assignment calculation of an operator in each of the machining steps are performed.

The invention of claim 8 is the invention of claim 4 or 5 or 6.
Alternatively, a warning is displayed when the overlapping assignment of the workers cannot be avoided during the work input / unload timing and the work assignment of the workers in the machining process described in 7.

[0014]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS FIG. 1 is a schematic diagram showing a main part of an embodiment of the present invention.
Based on the processing instruction data stored in the processing instruction data storage devices 6 to 10 provided in the respective processing stations, predetermined processing conditions are set and processing is performed. Also, equipment operation status monitoring devices 11 to 1 provided at each processing station.
5 monitors the operation status of each processing station. The information input devices 16 to 20 are provided for giving instructions such as inputting a type of a workpiece to be processed in each processing station and starting processing, and serve as a trigger for starting processing in the processing station. The processing instruction data storage device, the equipment operation status monitoring device, and the information input device are connected to a control device 22 via a line 21.

The in-process warehouses 23 to 26 are buffers for temporarily storing the work processed in each processing station, and the work processed in the processing station 1 is stored in the in-process warehouse 23 in the processing station 2. Are processed and stored in the in-process warehouse 24, respectively. The work flows from the processing station 1 to the in-process warehouse 2
3. The order is from the in-process warehouse 23 to the processing station 2, from the in-process warehouse 2 to the in-process warehouse 24, and finally passes through the processing station 5 to become a finished product.

The information input devices 27 to 30 are provided for inputting work entry / exit information in each in-process warehouse, and are connected to the control device 22 via the line 21. Although not shown here, the information input device 31 inputs the storage information of the finished product. Here, it is assumed that a worker enters the work, such as loading of the work into the processing station and unloading of the work from the processing station to the in-process warehouse. In addition, it is assumed that the unloading of the work processed at the processing station must be performed within a certain fixed time.

The control unit 22 includes a production management unit 32 having a production performance and a production plan management function, an equipment management unit 33 having a function of managing the operation performance of each equipment and the lead time of each equipment, the number of workers and A worker management unit 34 for managing information on each worker, a scheduling unit 35 for scheduling work input / output timing and work assignment of each worker in each processing step, and the production management unit 32 and the equipment management unit 33 , An operator management unit 34 and a control unit 36 for controlling the scheduling 35. The information input device 37 and the work instruction data output device 38 are the control device 2
2, a production plan, the number of workers, information about each worker, a lead time for each processing station, and the like are input from an information input device 37, and a work instruction data output device 38 outputs a work instruction to the worker. Instruct the loading and unloading work.

The production plan of the day and the workers arranged on the day inputted from the information input device 37 are stored in the production management section 32 and the worker management section 34, respectively. With respect to the worker, the worker to be arranged on the day is identified and input based on the worker name registered in the worker management unit 34 in advance. Then, the production plan stored in the production management unit 32, the lead time data of each processing station managed by the data equipment management unit 33 of each in-process warehouse, and the work arranged on the same day stored in the worker management unit 34 Based on the standard work time data of each worker and each worker, the scheduling unit 35 performs scheduling of work input / output timing and work assignment of each worker in each processing step.

FIG. 2 is a diagram showing a data structure in the scheduling unit 35.
A work input plan table 39 (FIG. 2A), a work-in-process table 40 (FIG. 2B), and a work station lead time table 41 (FIG. 2).
(C)) and an operator management table 42 (FIG. 2D). In the work input plan table 39, there is a problem that the input of the work to each processing station in the unit of minute causes a decrease in the operation rate in each processing step. Alternatively, there is a problem that human resources cannot be effectively used, such as disposing workers more than necessary to cope with the deadlock.

[0005]

In the present invention, the above-described plan and the assignment of workers are managed.

In this embodiment, five processing stations 1
Since there are ５5, a storage table for input assignment to five processing stations is generated. The work-in-progress table 40 stores the number of work in progress in each of the work-in-progress warehouses 23 to 26 by reading from the production management unit 32. In the processing station lead time table 41,
The lead time data at each processing station is read from the equipment management unit 33 and stored. In the worker management table 42, the standard work time data of the pre-setup including the work input work and the post-setup including the work unloading work in each processing station for each worker to be arranged is read out from the worker management unit 34 on the day. Has been remembered. When the workers A and B are arranged, a storage table as shown in the figure is generated.

FIG. 3 is a diagram for explaining the operation of the scheduling section 35. First, the in-process table 40 (FIG.
Referring to (B)), when there is a work to be input to the next processing station, the input of the work to the next processing station is sequentially assigned. That is, when the number of in-process s1 to s4 in each in-process warehouse is 0 or more,
As long as the assignment of the operator is allowed, the input assignment of the work to each processing station is performed. For example, when performing the input allocation of the work in the in-process warehouse 26 in the in-process table 40, first, the next processing station 5
The lead table 41 (FIG. 3)
(C)), and standard work times ta51 and t for the setup of the worker A that can be assigned at that time.
a52 is read out from the worker management table 42 (FIG. 3D), and they are combined to form one work cell 43 (FIG. 3D).
(E)). Then, this is assigned to the work input plan table 39 (FIG. 3A). When a plurality of workers can be assigned in the assignment of the workers, the assignment is performed so that the total is equalized to the work time of each worker.

Also, each time an assignment is made, it is checked whether or not each operator assigns to a plurality of processing stations at the same time, that is, whether or not deadlock occurs due to the work input timing. For example,
In FIG. 4, the input of the work cell 44 overlaps with the work unloading work of the worker A at the processing station 3, so that the assignment of the work cell 44 is shifted. While performing these checks, work cells are allocated until the production plan of the day is achieved, and the work input plan table 39 is produced.

The work input / unload timing and the work assignment information of each worker at each processing station generated by the scheduling section 35 are transmitted to a specific worker by a work instruction data output device 38. , The work is input to the designated processing station. At the time of loading, the worker carries out the raw material of the work from the in-process warehouse or the warehouse (not shown here) and loads it into the processing station. Then, after the input is completed, the information input devices 16 to 20 notify the controller 36 of the completion of the input operation. The control unit 36 monitors the information input devices 16 to 20 and, upon receiving the notification of the completion of the input operation, notifies a predetermined processing station of the start of processing. In addition, the time from the work instruction to the start of the processing is stored in the worker management unit 34 as a history of the work time of the setup of the worker.

Then, the end of processing at a predetermined processing station is detected by the equipment operation status monitoring means 11 to 15 and is notified to the control unit 36. The control unit 36 refers to the work input plan table 39 and notifies the specific worker of the unloading of the work from the predetermined processing station by the work instruction data output device 38. Further, the processing from the processing start notification to the processing end notification is stored in the equipment management unit 33 as the history of the lead time data of the processing station.

An operator unloads the work from the processing station and stores it in the in-process warehouses 23 to 26 or a work unloading warehouse (not shown). And
After the work is completed, the information input devices 27 to 31 notify the completion of the carry-out work. The control unit 36 stores the time from the unloading work instruction to the completion of the work in the worker management unit 34 as a history of the post-setup work time.

In accordance with the above-described procedure, each worker is instructed to input or unload a work. The control unit 36 checks the consistency between the work input plan table 39 and the actual progress time in real time. It is carried out. With the exception of the processing station lead time and the work time by the operator,
If a time lag that is longer than the preset value occurs, the cover history data is read from the facility management unit 33 and the worker management unit 34, respectively, and the lead time data of each processing station and the standard work time for each worker are calculated. Then, the scheduling unit 35 performs rescheduling. Also, when a short stop or the like occurs at the processing station, or when an instruction to increase or decrease the number of workers is given, the scheduling unit 35 performs rescheduling.

Since the rescheduling is performed at the stage when the machining has already been performed, deadlock may not be avoided in the assignment of the worker even by controlling the work input timing. In that case, a warning display is performed by the work instruction data output device 38.

[0028]

According to the first aspect of the present invention, there is provided a job shop type processing system comprising a plurality of processing steps and an in-process warehouse in which a worker inputs and unloads a work in a processing step. Means for inputting production plan data, means for inputting production result data, means for managing the production plan / production result data, operation status monitoring means for monitoring the operation status of each process, and lead time data for each process. Means for inputting, means for managing the operation state data, the means for managing the lead time data, means for inputting data relating to workers arranged in the processing system, means for inputting work state data of the workers, Means for managing data, work status data, production plan data for each process, operating status data for each process, and resource Means for calculating the work input / output timing and the work assignment of the worker in each processing step from the dead time data, data relating to the workers arranged in the processing system, and work status data, and means for outputting the calculation results. In a job shop type processing system consisting of a plurality of processing steps and work-in-progress warehouses that involve the loading and unloading of workpieces by workers in the processing steps, It is possible to construct a mechanism for efficiently instructing the loading and unloading of the work.

According to a second aspect of the present invention, in the first aspect of the present invention, the workers to be arranged in the machining system are individually identified, the standard work time is managed for each worker, and a specific worker is input / outputted. It is characterized in that it is assigned to unloading work, and it is possible to reduce the error between the work input / output timing and the work allocation result of the worker and the actual progress time in the machining process due to the variation of the working time for each worker. is there.

According to a third aspect of the present invention, in the first aspect of the present invention, the means for calculating the work input / output timing and the work assignment of the operator in each of the machining steps includes:
When allocating the workers, the work load is leveled among the assignable workers, and the workers are allocated. The work load is leveled among the workers arranged in the machining system. Can be achieved.

According to a fourth aspect of the present invention, in the first aspect of the present invention, in the work management system, the standard work time for each worker is corrected based on history information of the work time for each worker.
It is characterized in that the work input / unload timing and the work assignment of the operator in each of the processing steps are calculated, and the accuracy of the result of the work input / output timing and the work assignment of the operator in each of the processing steps can be improved. It is.

According to a fifth aspect of the present invention, in the first aspect of the present invention, standard lead time data of each processing step is corrected from history information of the operation status of each processing step, and a work is loaded / unloaded in each of the processing steps. The present invention is characterized in that the timing and the work assignment of the operator are calculated, and the accuracy of the work input / output timing and the result of the work assignment of the worker in the machining process can be improved.

According to a sixth aspect of the present invention, in the first aspect of the invention, the work input / output timing and the worker's timing in each of the machining steps are reduced by a temporary stop due to a failure or the like in each of the machining steps or by increasing or decreasing the number of workers. The present invention is characterized in that a work assignment calculation is performed, and it is possible to minimize an error between the work input / output timing and the work assignment result of the operator and the actual progress time in each processing step.

According to a seventh aspect of the present invention, in the first aspect of the present invention, the operation status of each processing step, the operation status of the operator, the work input / output timing in each of the processing steps, and the operation assignment operation result of the operator are calculated. Successively comparing, when an error equal to or more than a set value occurs, a work input / output timing in each of the processing steps and a work assignment calculation of an operator are performed, and a work input / output timing and work in each of the processing steps are characterized. It is possible to reduce the error between the user's work assignment result and the actual progress time.

According to an eighth aspect of the present invention, in the first aspect of the invention, during the calculation of the work input / output timing and the work assignment of the worker in each of the processing steps according to the fourth, fifth, sixth and seventh aspects, the worker In the case where overlapping assignment cannot be avoided, a warning is displayed. In a plurality of machining steps, a timing that requires more workers than the initially arranged worker at the same time, that is, a deadlock caused by a work input timing is previously set. It is possible to detect and reduce the risk due to the deadlock.

[Brief description of the drawings]

FIG. 1 is a main part configuration diagram for explaining an embodiment of the present invention.

FIG. 2 is a diagram illustrating a data structure in a scheduling unit.

FIG. 3 is a diagram illustrating an operation of a scheduling unit.

FIG. 4 is a diagram for explaining work cell assignment.

[Explanation of symbols]

1-5: Processing station, 6-10: Processing instruction data storage device, 11-15: Equipment operation status monitoring device, 16-
20 information input device, 21 line, 22 control device, 2
3 to 26: In-process warehouse, 32: Production management unit, 33: Equipment management unit, 34: Worker management unit, 35: Scheduling unit, 36: Control unit, 37: Information input device, 38: Work instruction data output device , 39 ... Work input plan table, 4
0: Work-in-progress table, 41: Processing station lead time table, 42: Worker management table, 43, 44
... work cell.

Claims (7)

[Claims] 1. An operator inputs a work into a machining process.
In a job shop type processing system composed of a plurality of processing steps including an unloading operation and a work-in-progress warehouse, a production plan input means for inputting production plan data, a means for inputting production result data, the production plan data / production Means for managing performance data, operating status monitoring means for monitoring the operating status of each process, means for inputting lead time data for each process, means for managing the operating status data / lead time data, and the processing system Means for inputting data relating to the disposed worker, means for inputting work status data of the worker, data relating to the worker
Means for managing work status data, production plan data of each process, operation status data of each process, lead time data of each process, data on workers arranged in the processing system, and work status data; A work management system comprising: means for calculating work input / output timing and work assignment of a worker in each processing step; and means for outputting the calculation result. 2. The system according to claim 1, wherein the workers arranged in the processing system are individually identified, a standard work time is managed for each worker, and a specific worker is assigned to work input / output work. Work management system as described. 3. A method for calculating work input / unload timing and worker assignment in each of the machining steps, wherein when assigning workers, the work load among the assignable workers is leveled. 2. The work management system according to claim 1, wherein the work is assigned. 4. The method according to claim 1, wherein the standard work time for each worker is corrected based on the history information of the work time for each worker, and the work input / output timing and the work assignment of the worker in each of the machining steps are calculated. The work management system according to claim 1, wherein 5. From the history information of the operation status of each processing step,
2. The method according to claim 1, wherein the standard lead time data of each processing step is corrected, and a work input / output timing and a work assignment of an operator in each processing step are calculated.
Work management system as described. 6. A work input / output timing and a worker assignment calculation in each processing step are performed by a temporary stop due to a failure or the like in each processing step or an increase / decrease in the number of workers. 1. The work management system according to 1. 7. The operation status of each machining process and the work status of the worker are sequentially compared with the work input / output timing and the work assignment calculation result of the worker in each of the machining processes, and an error greater than a set value occurs. 2. The work management system according to claim 1, wherein a warning is displayed when the overlapping of the respective machining steps cannot be avoided.