JPS63264093A - Work indicating system - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

DETAILED DESCRIPTION OF THE INVENTION [Industrial Application Field] The present invention relates to a work instruction system for instructing work steps to workers who operate work machines installed in a factory in order to carry out division of labor production.

[Prior Art] Conventionally, this type of work instruction system includes a storage means for storing all the work steps necessary for the divisional production of a product, and a search means for searching the storage means for the work steps to be handled by a worker. A device is known that includes a display device that displays to the worker the work steps retrieved by the search device.

[Problems to be Solved by the Invention] In the above-mentioned conventional work instruction system, the work process retrieved from the first storage means is based on matching of the skills possessed by the worker with the skills necessary to execute the work process. It is assumed that you must do so. Therefore, the storage means stores required skill information for each work process and possessed skill information for each worker. The search means searches for a work process that requires a skill matching the possessed skill for each worker, and the display means displays the searched work process to the worker. The worker only has to perform the displayed work process by operating the work machine. This work instruction system is suitable for sewing factories that produce clothes, shoes, etc. by sewing processed cloth. in general,
In order to produce sewn products, various work processes are required, and each work process (cutting, various sewing tasks, etc.) has a different level of difficulty. There are some workers who cannot do this. In this way, since the abilities (skills possessed) of individual workers differ, it is impossible to allocate work processes while ignoring the abilities of workers, and it is impossible to achieve efficient production. be. The work instruction system is adopted to solve this problem.

However, despite the adoption of the work instruction system, new problems have arisen. In other words, workers have the skills to perform a specific work process within a standard time due to changes in their physical condition or injuries. remembered)
Nevertheless, even if the specific work process is instructed, it may not be acceptable to the worker, or the work time must be significantly extended when carrying out this specific work process,
It is impossible to deal with cases where the progress of other work processes is affected. Furthermore, since the work process is unilaterally instructed to the worker, there is a problem that the work instructions cannot be given in a way that reflects the worker's will.

[Purpose of the invention] This invention was made to solve the above-mentioned problems, and its purpose is to change the work process as instructed due to circumstances on the worker's side, once the work process has been instructed. The objective is to provide a work instruction system that allows for

[Means for Solving the Problems] The present invention provides a storage means for storing all work processes necessary for division of labor production of a product by operating a plurality of working machines by a plurality of workers, and a storage means for the storage means. In a work instruction system that includes a search means for searching for a work process that a worker should be in charge of, and a display means for displaying the work process retrieved by the search means, the work process displayed on the display means is A switch is provided that is operated when the switch is not permissible, and the retrieval means excludes the work process displayed on the display means and searches for a new work process from the storage means when the switch is operated. The technical feature is that

[Operation] After the retrieval means retrieves the work process from the storage means and the display means displays the retrieved work process to the worker, when the worker operates a switch, the retrieval means retrieves the work displayed on the display means. A new work process is searched from the storage means by excluding the process.

[Embodiment] An embodiment in which the present invention is embodied in a work instruction system for a garment factory will be described below with reference to FIGS. 1 to 8.

A wide variety of sewing machines (not shown) are installed in the sewing factory, and each sewing machine is assigned a machine number and a terminal 2 is installed. Each terminal device 2 is connected to a control unit 3, and each terminal device 2 has an end switch (not shown), a liquid crystal display device 2a as a display means, and a work instruction change request key 2b operated by the worker. Each is provided. Then, when the end switch is pressed down, the terminal device 2
It is designed to output a termination signal for. Furthermore,
The terminal device 2 includes a central processing control unit and a buffer for the terminal device, and the buffer is adapted to store data from the control unit 3.

Then, when the termination switch is turned on and a termination signal is output to the central processing control unit, the terminal I! The data in the buffer in 2 is visually displayed on a liquid crystal display device 22a. The central processing control unit is the terminal device 2.
The sewing machine in which the sewing machine is installed starts a predetermined sewing work and outputs a work instruction request signal a predetermined time before the scheduled time when the work is finished. This is to ensure that the next work instruction is given immediately after the work is completed.

A control unit (hereinafter referred to as CPU) 3 as a retrieval means consisting of a central processing control unit is a read-only memory (hereinafter referred to as ROM) that stores various control programs.
4, and a readable/writable memory (hereinafter referred to as RAM) 5 for storing the results of calculations from time to time. An external storage device W6 is connected as a storage means for storing information. The external storage device 6 includes a worker data memory section, a group memory section, a machine data memory section, a manufacturing priority memory section,
It is equipped with various memory sections such as a processing procedure memory section for each manufacturing item and a work data memory section.

The worker data memory section stores worker data representing worker names and skills possessed by each worker, as shown in the memory map of FIG. The skills possessed by the worker are assigned a level according to the proficiency level of the skill, and the smaller the number, the higher the proficiency level. For example, “
In the case of ``A1'' and ``A2,''``A1'' has a higher level of proficiency.

As shown in the memory map in Figure 3, the machine data memory section stores data representing the machine number, the functions possessed by each sewing machine, the in-use sign indicating the usage status of the sewing machine, the name of the group to which the machine belongs, and the name of the group to which the machine belongs. It is designed to remember the type of thread (for example, color, thickness, etc.) that is attached.

The above-mentioned group is a group of machines that are installed near each other, and in this embodiment, each group has information about other groups that are closer to each other than the other group. The letters are assigned according to the alphabetical order of the Greek letters. That is, α and β,
β and γ are close to each other, and α represents a group that is closer to β than γ.

As shown in the memory map in Figure 4, in the group memory section, in order to limit the movement range of each worker, the movable range (that is, the machine that the worker is responsible for) is set as position data, and the set movement A plurality of workers within the range are stored in groups.

Therefore, when a worker belonging to a certain group uses a machine (sewing machine) used by a worker belonging to another group, the distance traveled will be longer than when using a machine within the group to which the worker belongs. become.

As shown in the memory map in Figure 5, the manufacturing priority memory section is divided into manufacturing items such as shirts and other clothing and shoes, manufacturing priorities (delivery dates) determined for each item, and each item. Data representing lot numbers of parts is stored.

As shown in the memory map in Figure 6, the processing procedure memory section for each manufacturing item stores the name of the processing work (work process name) required to manufacture each of the above-mentioned manufacturing items such as shirts, the normal start order for that work, and its It has become possible to memorize data representing the necessary skills needed to perform the work, the necessary functions of the machine, the group name of the workers who will perform the work, and the thread number used to perform the processing work. There is.

As shown in the memory map of FIG. 7, the work data memory section stores the manufacturing item, the lot number, the work name, and whether or not the work can be started.

The terminal 2 sends data representing a pre-work completed sign indicating that the work has been completed, a processing sign indicating whether the work is being carried out, and a processed sign indicating whether the work has already been completed.
The data is stored based on the data sent from the .

The input device 7 as an input means consisting of a keyboard is a CP.
It is connected to U3, and data such as a work name is stored in each memory section of the external storage device 6 by inputting the provided keys. In addition, the human-powered device 7 is equipped with a key for several switching devices, and by inputting the key, the number of switching devices (hereinafter referred to as the number of switching) can be arbitrarily set, and the input number of switching is stored in the external memory. It is stored in a predetermined storage area of the device 6. In addition, the number of changes is the work unit of a group when a group of multiple fabrics flowing in a production line (in this example, 20 pieces is in principle one unit, hereinafter referred to as a bundle) - 10 = The maximum number of work units that can be smoothly distributed within a production line is set to compare with the number of bundles currently flowing within the production line, and production is performed based on this number of changeovers. This is to control the number of work in progress (number of bundles) flowing within the line. Further, the lot is composed of a plurality of bundles. Communication device 9
is adapted to transmit data output from the CPU 3 to each terminal 2.

The CPU 3 reads the data stored in the manufacturing priority order memory section and the processing procedure memory section for each manufacturing item, and stores the work name and lot number in the work data memory section according to the work order of the manufacturing item to be manufactured with priority. Make me remember. At this time, the previous work completed sign is stored in the work completed sign area corresponding to the work name of the first rank among the work names performed for each lot number of each manufacturing item.

Further, the CPU 3 detects the worker name of the worker who is to start the work via the input device 7, and selects the possessed skills stored in the worker data memory unit corresponding to the worker name. It is configured to read and store. Further, the CPU 3 searches the work data memory section for the work being processed by the worker, reads out one work name that can be the next work after that work, in accordance with the read priority order, and selects the work name corresponding to the read work name. Necessary skills and functions are read out from the manufacturing item-specific processing procedure memory and stored.

The CPU 3 is configured to determine whether or not the necessary skill is included in the stored skills possessed by the worker, and if it is not included, to read the name of the next ranked work from the work data memory section. Furthermore, the CPU 3 reads out the unused functions of the sewing machine from the machine data memory section in order of machine number, sequentially determines whether or not the stored necessary functions are included, and selects them. It is configured to read out the work name of the rank.

The CPU 3 sends the stored work name and the corresponding manufacturing item and loft number to the terminal 2 via the communication device 9.
The selected machine number is visually displayed on the liquid crystal display device 2a of the terminal device 2, and the selected machine number is visually displayed on the liquid crystal display device 2a of the terminal device 2. Further, the CPU 3 stores an in-use sign corresponding to the machine number in the machine data memory section, and stores a machining in-progress sign corresponding to the work name in the work data memory section. In this way, the job title and the sewing machine to be used are assigned to the worker, and the sewing job is started.

Also, the CPU 3 returns the terminal 2 after completing the 10 tasks.
Wait until a termination signal is generated from the terminal 2, and when that signal is generated, erase the in-use sign in the machine data memory section corresponding to the machine number of the sewing machine in which the terminal 2 is installed. At the same time, the machine data memory section is configured to store the thread number used in the working process in a location corresponding to the working machine number. That is, in the machine data memory section 1
3. The general thread setting number is rewritten from time to time to the thread number used when the machine is used for work.

Furthermore, the CPU 3 erases the corresponding processing in progress sign in the work data memory section, stores the processed sign, and simultaneously stores the previous work sign corresponding to the work name of the next rank, and performs the above-mentioned allocation work. It is configured as follows, and
The CPU 3 adds up the number of sewing results (number of bundles) produced based on the end signal input from each terminal 2 from time to time, and stores the calculation result in a predetermined storage area of the external storage device 6. ing.

Thereafter, each time the work instruction request signal is generated from each terminal 2, the CPU 3 inputs the work name, the machine number to be used, and the lot number to the terminal 2 from which the work instruction request signal has been generated. The machine number is visually displayed on the liquid crystal display device 2a of the terminal 2 of the sewing machine to which the machine number is attached.

The operation of the work instruction system configured as above is described in the eighth section.
The explanation will be given according to the flowchart shown in the figure.

Now, by operating the input device 7 in advance, the worker's name and possessed skills are stored in the worker data memory section of the external storage device 6, and the memory number and its possessed skills are stored in the machine data memory section.
Group data and the first installed yarn number are stored.

Further, the worker group memory section stores worker names for each group, and the manufacturing priority memory section stores data representing manufacturing items such as shirts and lot numbers of parts divided for each item. The processing procedure memory section for each manufacturing item contains the work base necessary to manufacture the above manufacturing item such as a shirt, the processing order in which to perform that work, the necessary skills necessary to perform that work, and the machine requirements. Data representing the function, the work group that performs the processing work, and the yarn number used for the processing work are recorded. Further, the number of switching operations is stored in a predetermined storage area of the external storage device 7 by the operation of the switching device 7.

Then, when the system starts operating, the CPU 3 first creates a start priority table for all manufacturing items in the work data memory section based on the data stored in the manufacturing order memory section and the processing procedure memory section for each manufacturing item. (Step 1, hereinafter the step will be denoted by S). Next, at 82, terminal 2
Waits for a work instruction request signal to be inputted from , and when the work instruction request signal is input, in S3, the CPU 3 makes the worker of the terminal 2 from which the inputted work instruction request signal was issued work. The external storage device 6
The work processes that can be started are picked up from a predetermined storage area of .

Next, in S4, it is determined whether or not the work group of the worker who performs the picked up work is suitable based on the data stored in the group memory section.If it is determined that the worker is suitable in S4, in S5, the work group It is determined whether the skill level of the worker is appropriate or not based on the skill data to which the skill level data is attached. That is, the determination is made so that workers with high proficiency and possessed skills are selected preferentially. Therefore, if there is no highly skilled worker in S5, the determination is No.

If the check results are not suitable in S4 and S5, the check results are stored in a predetermined storage area of RAM5, the start priority of the work process is incremented in S20, and S3 is performed again.
Return to Returning to S3, going through S4, and then going back to S5, if there is no highly skilled worker, a less skilled worker is selected, and YES is determined.

If it is determined in S5 that the work place is suitable, the optimum work place is checked in 86 to S8.

In S6, the CPU 3 selects the thread number to be used in the picked up work process that can be started by referring to the contents of the processing procedure memory section for each manufacturing item, and determines whether there is a sewing machine equipped with the same type of thread as the selected thread number to be used. (In other words, whether or not there is a sewing machine that does not require thread change among empty sewing machines belonging to the same work group) is recorded in the installed thread number and in-use sign of the applicable machine (sewing machine) in the machine data memory section. Search based on.

If the result of the search is No in S6, then in 87 it is determined whether or not the worker can work on the current sewing machine where the worker is currently located, that is, if the thread is changed, the worker can work on the sewing machine where the worker is currently located. Determine whether it is possible.

Then, if the determination in S7 is No, it is determined whether or not the work can be performed in the same work group (that is, sewing machines located in the same work group) if the same thread change is performed in the same work group. . If the first determination is NO in S8, the process moves to S21 and the work group name is expanded. That is, the name of the next positionally adjacent work group is set, and the process of S6 is performed based on the set work group to search for a machine (work place) that can similarly perform the work. Then, even in the expanded work group, the judgments in S6 and S7 are NO.
If the second determination is No in S8, the process moves to S20.

If the determination in each of steps 86 to S8 is YES, S
The process moves to step 9 to determine the optimal work location. Then, the CPU 3 searches in S6 to S8 and stores the result obtained as YES in a predetermined storage area of the RAM-5 as a work instruction candidate (SIO). Next, in 311, it is determined whether or not all the startable processes picked up in S3 have been checked, and if they have not been checked, the process moves to S20 and the loop from 83 to S10 is repeated.

If all available processes picked up in Sll are checked, the judgment in 811 becomes YES, and C is selected in S12.
PU3 compares the number of bundles flowing in the production line at the present time (number of work-in-progress) with the number of changeovers set in advance, and if the number of bundles flowing in the production line is greater than the number of changeovers, returns YES. After making a determination, the process moves to 313. 313
In S14, the CPU 3 determines the one with the earliest start order (ie, delivery date) as the highest priority, and determines the optimal work instruction. Further, if the number of bundles flowing through the production line is smaller than the number of switches at 312, the determination is No and the process moves to S22. In S22, the CPU 3 gives top priority to the one with the smallest work location (ie, moving distance), that is, the work instruction without moving the work location or the work instruction without thread change, and proceeds to S14. Through the process of S22, the work instruction giving priority to efficiency is selected.

Then, the CPU 3 transfers the optimal work instruction selected in S13 and S22 to the terminal 2 that issued the work instruction request signal via the communication device 9 (S15). The terminal device 2 stores the transferred work instructions in its buffer, and then when the worker presses the end switch, the work instructions stored in the buffer are displayed on the liquid crystal display device 2a.
The worker looks at the work instruction and turns on the work instruction change key 2b if he or she determines that it is inappropriate based on his or her skill level (S16). When the CPU 3 inputs a change signal based on the ON operation of the work instruction change key, S1
In step 7, the same work instruction requested for change is excluded from the work instruction candidate list and the process returns to SIO. Further, if the work instruction change request key 2b is not pressed, the process returns to S2.

In this embodiment, -20 is stored in the worker data memory section.
− The possessed skill data given to the worker is set to a higher technical level than usual, and the selected optimal work instruction is selected based on that data, so the optimal work instruction given to the worker is For workers, there may be cases where the level of skill they possess does not actually match. In such a case, or when the user voluntarily does not want to perform the instructed work, in this embodiment, the work instruction can be changed by inputting the work instruction request change key. By doing so, it is possible to obtain work instructions that are appropriate to the actual skill level of the worker or reflect the worker's intentions, and in this case, the balance within the production line can be maintained, so that production It is possible to improve the efficiency of the line.

Note that this invention is not limited to the above embodiments,
Any changes may be made without departing from the spirit of the invention.

[Effects of the Invention] As detailed above, in this invention, when the worker is unable to perform the instructed work process due to personal reasons such as changes in the worker's physical condition or injury, or when the instructed work process is If the instructed work is unacceptable, such as when the work time has to be significantly extended and the progress of other work processes is adversely affected, the instructed work process may be stopped once. It is possible to change to other work steps. Further, there is an advantage that the intention of the worker can be reflected without unilaterally giving work instructions as in the conventional case.

[Brief explanation of drawings]

FIG. 1 is an electrical block diagram of an embodiment embodying the present invention, FIG. 2 is an operator data memory map diagram, FIG. 3 is a machine data memory map diagram, FIG. 4 is a group memory map diagram, and FIG. The figure is a processing procedure memory map diagram for each manufacturing item. In Figure 6, manufacturing priority 2 is a terminal, 2a is a liquid crystal display device as a display means, 2b is a work instruction change request key, and 3 is a control unit (CPU) as a search means. ), 4 is ROM,
5 is a RAM, 6 is an external storage device as a storage means, 7 is an input device as an input means, and 9 is a communication device.

Claims (1)

[Scope of Claims] 1. A storage means for storing all the work processes necessary for the divisional production of a product by operating a plurality of working machines by a plurality of workers; In a work instruction system comprising a search means (3) for searching for a work process, and a display means (2a) for displaying the work process retrieved by the search means, the work process displayed on the display means is the work process. The search means includes a switch (2b) that is operated when the operator does not accept the work process, and when the switch is operated, the search means excludes the work process displayed on the display means and searches for a new work process. A work instruction system characterized by searching from a storage means.