JPH1043998A - Time totalizing method in production process equipment and operation rate totalizing method using this totalizing method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a time totalizing method and a time operation rate totalizing method in a production process by which production control is smoothed by enabling the production control even if producing products are different from each other. SOLUTION: When production time planned with every different product is denoted by TAsec/piece, TBsec/piece... and working time offered to production per unit time is denoted by (t) second, to signals inputted with every actually produced product, its totalized value S is calculated as [S=ΣTA+ΣTB +...], and on the basis of this, a time operation rate % is also calculated as [W=(S/t)×100= (ΣTA+ΣTB+...)/t}×100], and a time frame is taken as the axis of ordinate, and a time operation rate W% is taken as the axis of abscissa, and these are displayed by a bar graph.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION The present invention relates to a method of evaluating production efficiency information required for formulating a production plan and managing a production situation by using a numerical value called a time operation rate.
The present invention relates to a time totaling method capable of accurately grasping the state of a production process at that time and an operation rate totaling method using the totalizing method.

[0002]

2. Description of the Related Art When formulating a production plan, it is necessary to accurately know the production efficiency of target production process equipment.
Conventionally, a production time per product (hereinafter simply referred to as “cycle time”) in a target production process facility is applied as information for knowing production efficiency.

[0003] However, in the conventional method of applying the cycle time as information, since individual production process equipment may be inoperative due to various factors, the planned cycle time is directly applied to the actual production process equipment. Can not do it. For this reason, in the past, in practice, a numerical value obtained by multiplying a planned cycle time by a safety factor (margin factor) was applied as an actual cycle time.

[0004]

However, when the conventional cycle time multiplied by the safety factor is applied, even if the planned numerical value is 100% load (a working state without waste), the actual production In the process equipment, there is a case where the work is performed with a margin. This does not mean that the employee time is being used effectively, which increases labor costs and eventually raises product costs.

[0005] In addition, with respect to the power cost, there is a cost even during the time when the production such as the idling operation is not performed, and this is passed on to the product cost. Such an increase in the product cost based on various factors leads to a reduction in profits when the selling price of the product is determined.

[0006] Further, in general production process equipment, there are cases where many types of products having different cycle times are produced. However, in reality, the production is switched to different products at any time. is there. At the time of such a product changeover, the work of totalizing production information is complicated.
Further, non-production work is concentrated, for example, when switching products to be produced, such as setting up for that purpose. Therefore, in the past, such non-production work was often treated as an exceptional time from the viewpoint of production management, and was often excluded from the management target. However, if all such non-production operations are excluded from the management targets, it becomes impossible to accurately grasp the production status. Therefore, non-production work must also be manifested as a production impediment factor and treated as a management target.

Accordingly, an object of the present invention is to improve the drawbacks of the above-described conventional cycle time formulating method.
The time to be used for production has a cycle time with respect to the time to be used for production per unit time (hereinafter simply referred to as “working time”), and the ratio between the working time and the cycle time is managed as data. A method for totaling time in a production process equipment in which production control is possible even if products to be produced are different from each other, thereby facilitating production management, and an operation rate totaling using the totaling method. There is a way to provide.

[0008]

The feature of the present invention lies in the following constitution. In the time counting method in the production process equipment, the cycle time for production planned for different products (A, B,...) Is defined as CTA (seconds / piece), C
TB (seconds / piece),..., A production completion signal for each different product (A, B,...) Is actually detected from the production process equipment, and the total value S per unit time is detected.
(Seconds) as S = ΔCTA + ΔCTB +...

Another feature of the present invention is as follows. In the method of summing up the hourly operation rates in the production process equipment, the cycle time for production planned for different products (A, B,...) Is defined as CTA (seconds / piece), C
TB (seconds / piece),..., A production completion signal for each different product (A, B,...) Is actually detected from the production process equipment, and the total value S per unit time is detected.
(Seconds) is S = ΔCTA + ΔCTB +... And the working hours to be used for production per unit time is t (seconds).
Using the total value S, the time operation rate W (%) is calculated as W = {S / t} × 100. Next, the time frame is set on the vertical axis, and the time operation rate W (%) is set on the horizontal axis. A time operation totaling method in a production process equipment, characterized by displaying a bar graph that takes the time.

Another feature of the present invention resides in the following configuration. 3. The method according to claim 2, wherein the calculation of the time operation rate W (%) and the display by the bar graph are continuously performed for each unit time.

[0011]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS A preferred embodiment of the present invention will be described below with reference to FIG. Information on the working time and cycle time of the production process equipment 1 to be production controlled is input to the analyzer 2. Analyzer 2 is input unit 2
A, calculation unit 2B, clock unit 2C display unit 2D, and storage unit 2E
Consists of Here, the production process equipment 1 is an entire production line, but is not limited thereto, and may be a part of the production line.

First, a description will be given of the operation rate and the aggregation processing of the present invention. Number of products to be produced in unit time K
(Pcs) is the cycle time CT (seconds / piece) and the working time is t
(Seconds), it is expressed by the following equation. K (pieces) = t (seconds) / CT (seconds / piece) Expression (1) The time operation rate W (%) is the number k of products actually produced.
Since it is expressed as a percentage of the number of products K (pieces) to be produced with respect to (pieces), it is expressed by the following equation. W (%) = {k (pieces) / K (pieces)} × 100 Expression (2) Here, Expression (1) is substituted into Expression (2). W (%) = [k (piece) × {CT (sec / piece) / t (sec)}] × 100 · Equation (3)

The cycle time CT (seconds / piece) is a fixed numerical value set for each product, and the working time t (seconds) is also calculated in a unit time (for example, every hour,
Alternatively, it is a fixed value (such as 8 hours of working hours per day), and the variable at any given time is only the number k (actually) of products actually produced. For this reason, as shown in equation (3), the method of summing the hourly operation rate W (%) is a production signal of an actually produced product (transmitted every time one or one production is performed). It can be seen that the cycle time CT (second / piece) should be added each time a signal (signal) is input. That is, the total value S (second) obtained by adding the cycle time CT (second / number) is as follows: S (second) = ΣCT (second) Expression (4) Therefore, equation (3) is transformed into the following equation and expressed. W (%) = {CT (second) / t (second)} × 100 Expression (5)

Further, products having different cycle times CT (seconds / piece) (in the following example, CTA (seconds /
), CTB (seconds / piece) for product B, etc.)
Even when the production is performed while switching to the above, the total can be calculated by using the modification of Expression (4). The following equation illustrates this. That is, the total value S (seconds) of the cycle times of different products is expressed as S = ΔCTA + ΔCTB +... Equation (3) is transformed as follows by equation (6). W (%) = {({CTA + {CTB +...) / T} × 100} (7)

The operation of causing the apparatus of FIG. 1 to perform the above-described totaling operation will be described below with reference to the flow of FIG. A working time (base time) tn for each time is input to the input unit 2A in advance, and this is stored in the storage unit 2E.
In addition, a cycle time (CT) is input for several different products in accordance with each target production process equipment 1,
This is stored and stored in the storage unit 2E, and is selected when actual production is performed, and measurement is started using this as CT (seconds / piece).

In the production facility process 1, a production signal (for example, a pulse signal or the like) is input to the input section 2A once each time a product is produced one or one time. And the timer 2C
, The current time is input to the input unit 2A, and a memory address (AD) for a time that is specified in advance, for example, in units of one hour, is calculated. On the basis of this, the cycle time CT
(Seconds / pieces) are added. Further, the working time (base time) tn (second) indicated by the time is read out from the working time for each hour stored in the storage unit 2E, and the time operation rate is calculated using the above formula (5) or (7). The processing of W (%) is performed. The processed data is further processed by the calculation unit 2B and displayed on the display unit 2D as, for example, a time operation rate W (%) for each time in a bar graph shown in FIG.

FIG. 3 also shows the number of products produced at each time. That is, in this figure, the production starts at 8:00 am and stops at 5:00 in the evening. During this time, the number of products produced every hour is counted and displayed.

[0018]

According to the present invention constructed and operated as described above, the following effects can be obtained. For different products, the aggregate value of the cycle time can be quantified. Since the time operation rate for each time is obtained as numerical data, production management can be easily performed.
Further, when a plurality of products are switched and produced, a time operation rate can be easily obtained. Further, non-production work time when switching products can be easily managed. Furthermore, since the data processing is performed online and immediately, the data can be examined at any time as needed.

[Brief description of the drawings]

FIG. 1 is a block diagram of an apparatus in which the method of the present invention is implemented.

FIG. 2 is a diagram showing an example of a data processing flow according to the present invention.

FIG. 3 is a diagram showing a bar graph of analysis data and the number of products produced for each time according to an embodiment of the present invention.

[Explanation of symbols]

 1 Production Equipment Process 2 Analyzer 2A Input Unit 2B Timekeeping Unit 2C Operation Unit 2D Display Unit 2E Storage Unit

Claims (3)

[Claims] 1. A method for counting time in a production process equipment, comprising: setting a cycle time for production planned for each of different products (A, B,...) To CTA (seconds / piece) and CTB (seconds / piece).
), ... and actually different products (A,
B,...) Is detected from the production process equipment, and a total value S (seconds) per unit time thereof is expressed as S = ΣCTA + ΣCTB +. Aggregation method. 2. A method for counting time in a production process equipment, comprising: setting a cycle time for production planned for each of different products (A, B,...) To CTA (seconds / piece) and CTB (seconds / piece).
), ... and actually different products (A,
B,...) Are detected from the production process equipment, and the total value S (seconds) per unit time is set as S = ΣCTA + ΣCTB +. To t (seconds)
The time operation rate W (%) is calculated as W = {S / t} × 100 using the total value S. Next, a time frame is set on the vertical axis, and the time operation rate W is set on the horizontal axis.
A method of totaling time utilization rates in production process equipment, which is displayed as a bar graph taking (%). 3. The method according to claim 2, wherein the calculation of the hourly operation rate W (%) and the display by a bar graph are continuously performed for each unit time. .