JPS63267145A - Predicting device for production proceeding state in workshop - Google Patents

Abstract

PURPOSE:To prevent the occurrence of trouble such as future material depletion, facility load, skill load, and work being impossible of starting or the like by making the prediction of output fitted to the data of delivery and of loss in a production line possible in a multiple and less production system. CONSTITUTION:A control unit 3 functioning as a retrieving means and a computing means for predetermined work completion time composed of central process control devices has ROM 4 and RAM 5, and is moreover connected with an external memory device 6 to store input data issued from an input device 7 and various data which the control unit 3 arithmetically processes to draw up and compile. The retrieving means retrieves a work which a worker can start next on the basis of work data stored in the memory means 6, skill data possessed by the above-mentioned worker, and function data possessed by an idle working machine after the worker completes his assigned work. The computing means for predetermined work completion time reads time data corresponding to the retrieved work from the memory means 6 to compute the predetermined work completion time. Thus the control means 6 repeats the above- mentioned process.

Description

DETAILED DESCRIPTION OF THE INVENTION (Industrial Application Field) The present invention relates to production progress prediction vt'I3 in a factory.

(Conventional technology) Conventionally, in a factory with a high-mix, low-volume production system, it is difficult to predict production volume in line with delivery dates, losses within the production line, etc.; It was difficult to predict the occurrence of problems such as running out of materials, equipment overload, skill overload, and the occurrence of work that could not be started.

(Problems to be Solved by the Invention) Therefore, in actual machining operations, there are limits to the measures that can be taken to prevent the occurrence of the above-mentioned troubles.

(Purpose) This invention was made in order to solve the above-mentioned conventional problems, and it is possible to predict production volume in accordance with delivery dates, losses in the production line, etc., and also to predict troubles in the future. The purpose of the present invention is to provide a production progress prediction device in a factory.

(Means for Solving the Problems) The present invention stores skill data possessed by workers who carry out various tasks performed in a factory, and stores skill data possessed by a working machine operated by the worker, Storage means for storing work data that is given a start N priority of the work to be executed, has mind-keeping skill data and possessed function data required for each work, and time data required to perform each work; Each time the worker completes a task, the worker performs the next task based on the work data stored in the storage means, the skill data of the worker, and the function data of the working machine in the idle state. a search means for searching for a work that can be started; a scheduled end time calculation means for reading time data corresponding to the searched work from the storage means and calculating a scheduled end time of the work; When making a prediction, a time setting means for setting the predicted time in advance, and processing by the search means and end time calculation means until the calculated scheduled end time reaches the time set by the time setting means. The gist thereof is to include a control means for repeating m repetitions, and a display means for displaying the production status of the processed product at the designated time in relation to the arrival of the scheduled end time at the designated time.

(Operation) With the above configuration, the retrieval means retrieves the work data stored in the storage means, the skill data possessed by the worker, and the possessed functions of the working machine in the state IJ every time the worker completes the work. Based on the data, a job that the worker can start next is searched. The scheduled end time calculation means reads time data corresponding to the retrieved work from the storage means and calculates the scheduled end time of the work. The repetition control means repeats the processing by the search means and the end time calculation means until the calculated scheduled end time reaches the time set by the time setting means. The display means displays the production status of the processed product at the designated time in relation to the arrival of the scheduled end time at the designated time.

(Example) Hereinafter, an example in which the present invention is embodied in a work command system of the aTyJ factory will be described with reference to FIGS. 1 to 9.

A wide variety of sewing machines (not shown) are installed in the sewing factory, and each sewing machine is assigned a machine number and is also equipped with a terminal 2.

Each terminal device 2 is connected to a control unit 3, and each terminal device 2 has an end switch and a liquid crystal display device (
(both not shown) are each iQWed. Furthermore, the terminal device 2 has a central processing control unit and a buffer for the terminal device, and the buffer is designed to store data from the control unit I-3. When an end signal is output to the central processing control unit by turning on the end switch, the data in the buffer in the terminal is visually displayed on the liquid crystal display device. The central processing control unit is configured such that the sewing machine in which the terminal unit 2 is installed starts a predetermined &l production work and outputs a work instruction request signal before the scheduled time when the work is finished.

A control unit (as a search means, scheduled end time calculation means, and repetition control means) consisting of a central processing control unit (
The CPU 3 (hereinafter referred to as CPU) includes a read-only memory (hereinafter referred to as ROM) 4 that stores various control programs, and a continuously writable memory (hereinafter referred to as RAM) 5 that stores the results of the respective calculations. Furthermore, an external storage device 6 is connected as a storage means for storing input data from the human-powered device 7 and each data created and edited by the CPU 3. The first two external storage devices 6 include a worker data memory section, a group memory section,
It is equipped with various memory sections such as a machine data memory section, a manufacturing priority order memory section, a manufactured item processing procedure memory section, 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. As shown in the memory map of FIG. 3, the machine data memory section stores the machine number, the functions possessed by each sewing machine, and data indicating the usage state of the sewing machine and the line in use.

As shown in the memory map in Figure 4, in the group memory section, the movable range is set to limit the movable range of each worker (naturally, the machine that the worker can be in charge of).
Group t1! multiple workers within the set movement range! It is designed to memorize each position. As shown in the memory map in Figure 5, the manufacturing priority memory section stores data representing manufacturing items such as shirts, the manufacturing priority determined for each item, and the loft number of the parts divided by the item IU. It is designed to memorize.

As shown in the memory map in Figure 6, the processing procedure memory section for each manufacturing item stores the processing workers required to manufacture the %U m items such as shirts, the normal starting order for the work, and the order in which the work is performed. It is designed to store data representing the required skills and required functions of the machine, as well as standard time data required to perform the work.

As shown in the memory map of FIG. 7, the work data memory section stores the manufactured item, the lot number, the worker, a pre-work completed sign indicating whether or not the work can be started, and information about the work being performed. Based on the data transmitted from the terminal device 2, data representing a processing sign indicating whether the work is being completed and a processed sign indicating whether the work has already been completed are stored.

An input device 7 consisting of a keyboard and serving as time setting means is connected to the CPtJ 3, and data on the worker, etc. is stored in each memory section of the external storage device 6 by inputting the provided keys.

The doujin device 7 also includes a simulation mode setting key for setting a simulation mode, and an expected end time setting key for inputting data for setting a simulation end time when performing a simulation (both not shown). When the simulation mode setting key is pressed, the simulation mode is set, and when the simulation mode setting key is not pressed, the actual work mode is set. Communication device 9
is adapted to transmit data output from the CPU 3 to each terminal device 2. Display device as display means'
8 is connected to the CPtJ3, and displays various display data output from the CPU3. Further, the printer 10 is connected to the CPU 3 and prints out various print data output from the CPU 3.

The CI) U 3 reads the data stored in the manufacturing priority order memory section and the manufacturing item process procedure memory section, and assigns the workers and lot numbers to the work according to the work order of the manufacturing item to be manufactured with priority. Store it in the data memory section. At this time, the previous work completion sign is stored in the work completion sign area corresponding to the first-rank worker among the workers who carry out the work for each lot number of each manufacturing item.

Further, the CPU 3 detects the worker name of the worker who is to perform the work via the input device 1ff7, and detects the possessed skills stored in the worker data memory unit corresponding to the worker name. It is configured to read and store. Further, C'1) U3 searches the work data memory section for the work being processed by the worker, and stores the next work candidate memory in accordance with the read priority of the worker who will be the next work after that work. Necessary skills and functions corresponding to the read worker are read from the manufacturing item 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 out the worker of the next rank from the next work candidate memory section. . Further, the C'P U 3 reads out the functions possessed by the sewing machine which are not used in the order of machine number from the machine data memory section, sequentially determines and selects whether or not the stored necessary functions are included. If the worker is not available, the next worker is read out.

The CPU 3 sends the stored workers, corresponding manufacturing items, and lot numbers to the terminal 2 via the communication device 9.
The selected machine number is visually displayed on the display device of the terminal device 2, and the selected machine number is visually displayed on the display ¥Ft position of the terminal device 2. Further, the CPU 3 is configured to store an in-use sign corresponding to the machine number in the machine data memory section, and to store a machining in-progress sign corresponding to the worker in the work data memory section. In this way, the worker and the sewing machine to be used are photographed by the worker, and the sewing work is started.

In the actual work mode, the CPLJ3 waits until the 10 tasks are completed and a termination signal is generated from the terminal device 2, and then sends the terminal device 2 to the station where the signal is generated.
The in-use sign in the machine data memory section is erased in accordance with the machine number of the sewing machine in which the sewing machine is installed. On the other hand, in the simulation mode, when the expected working time of the work has elapsed, the in-use sign in the machine data memory section is erased corresponding to the machine number of the sewing machine in which the terminal device 2 is installed. It is configured. Furthermore, in both modes, the CPU 3 erases the corresponding in-processing number in the work data memory section, stores the processed sign, and at the same time stores the previous work sign corresponding to the next-ranked worker. Configured to perform allocation work.

Thereafter, in the actual work mode, the CPLJ 3 informs the terminal device 2 of the worker, machine number and lot number to be used each time the work instruction request signal is generated from each terminal device 2.
The information is visually displayed on the display devices of the terminal 2 where the work instruction request signal was generated and the terminal 2 of the sewing machine to which the machine number is attached.

The operation when performing a simulation in the work command system configured as described above will be explained with reference to the flow chart shown in FIG.

Now, by operating the input device 7 in advance, the worker's name and skills possessed are stored in the worker data memory section of the external storage device 6, and the machine number and its possessed functions are stored in the machine data memory section. Furthermore, the worker group memory section stores worker names for each group, and the production priority memory section stores manufacturing items such as clothing such as shirts,
Data representing the manufacturing priority determined for each item and the lot number of parts divided for each item are stored, and the processing procedure memory section for each manufacturing item stores the manufacturing items such as clothing such as shirts. Data representing the workers required to perform the work, the processing order in which the work will be performed, the necessary skills necessary to perform the work, and the necessary functions of the machine are stored.

When the simulator mode setting key of the input device 7 is turned on, the CPLJ 3 is set to the simulation mode 7 (step 1, hereinafter the step will be referred to as S). Next 8
At step 2, the correction factor for the standard time required for each task is input using the numeric keypad of the input device 7 (S2). Note that the correction factor is used to provide a margin for the standard time required for each task. Then, the CPU 3 multiplies the standard time required for each task by the correction factor based on the input correction factor (S3), and sends the calculated result to the RA.
It is stored in a predetermined storage area of M5. Next, when the end time setting key of the input device 7 is operated and the set end time is input, the CPU 3 stores the end time data in a predetermined storage area of the RAM 5 (S4). In S5, the CPLJ3 searches the worker name (operator) data and various data stored in the machine data memory section to see if there is any work that cannot be started for all operators, and if there is no work that can be started. The work candidates are stored in a predetermined storage area of the RAM 5, and the process moves to S6. If there are work candidates, in S51, the workers who cannot start work because there are no workers are converted into display data, and then the data is displayed on the display device 8. ], visual display and printing are performed, and the process moves to step 86.

In S6, the CPU 3 picks up the work that can be started from a predetermined storage area of the RAM 5 according to the start priority assigned to select the work that can be started on which the worker should work, and then selects the work that can be started on the work picked up in S7. It is determined whether or not the work group of the worker is suitable for the work to be performed based on the data stored in the group memory section. If it is determined that the work group is suitable in S7, it is determined in S8 that the skill level of the worker in the work group is suitable. Determine whether or not. Further, if it is not suitable in S7 and S8, the check result is stored in a predetermined storage area of the RAM 5, the priority is incremented in 318, and the process returns to S6 again.

If it is determined in S8 that the worker is suitable, CPtJ3 performs a screening process of 8% of the worker's skill load based on the check results performed in S7 and S8 (S9). That is, each skill item that the worker is unable to perform at that time is accumulated, and the accumulated skill load data is converted into display data and print data, and then outputted to the display device 8 and printer 10 for visual display and printing. and moves to 811.

In S11, when the current work is finished and the next work is to be carried out, the optimum work place is checked.

What is the optimal work place? When a worker finishes a certain work after the expected work time (= standard time x correction factor for that work), the next work step that he is instructed to do is in the same place (that is, on the same sewing machine). If it is not possible to work in the same place, the sewing machine in the same group to which the worker belongs is determined. It becomes the best place to work. Then, if there is no optimal work place, the result is stored in a predetermined storage area of the RAM 5, and the process moves to 818. If there is an optimal work place, an integration process is performed to determine whether the equipment (machine) has a certain amount of load based on the processing results stored in a predetermined area of the RAM 5 when checking the optimal work place in S11. S12).

Then, in S13, the integrated equipment load data is converted into display data and print data, and then outputted to the display and printer 10, respectively, for visual display and printing, and then the process moves to 814.

At step 814, the CPU 3 then performs processing to total the workload of the workers who are performing the work, and sends the processing results to the RA.
The work amount data for each worker stored in a predetermined storage area of M5 and aggregated in S15 is converted into display data and print data, and then outputted to the display device 8 and printer 10, respectively, for visual display and printing. Then, the process moves to step 316.

In S16, when the work that the worker can start and the optimal work location are determined as described above, the CPU 3 adds up the expected work time of the work that the worker can start from the start of &19J100, and sets the accumulated time as the Simire Receiver end time. It is determined whether or not the limit has been reached, and if the limit has not been reached, the process returns to S6 and picks up work that can be started for the next worker. When it is determined in step 816 that the end time of the simulation control has been reached, the production status of the entire sewing line, that is, the production amount, each worker, is determined based on the various data stored in the predetermined storage area of S17-eRAM5. The display device 8 displays and prints the in-line loss for each line. and the printer 9, respectively.

In the flowchart, for example, as shown in FIG. 9, sewing tasks A1 to A12, etc. are performed for workers a to d, who have been given numbers [001] to [004] in advance, according to the start priority order of FIG. 7. When performing a work simulation, it is assumed that when the loop from S6° to 316 in the flowchart is processed for the first time, workers a to d are instructed to perform works A1 to A4, respectively. Next, CPLJ
3, when performing each process in the second loop from 86 to S16, the next work instruction is given to the work instructed in the first time, starting with the one with the shortest expected work time. From the third time onwards, the expected work time for each task for which each worker has been given instructions is accumulated, and as a result of the accumulation, the next start priority is given to the person with the shortest accumulated expected work time. I will give instructions on the work to be done. Note that if the expected work times calculated by la are the same, work instructions are given to the workers in the order of the number given to them first.

In this way, the work distribution of the workers and the calculation of the work f items are continued until the simulation end time, and the results of each calculation are integrated.

As a result, at the end of the simulation, the production volume of the entire line, the production volume of each worker, the equipment load, the skill load,
It is possible to know in advance the tasks that cannot be done by a skilled worker before the actual work.

Note that the present invention is not limited to the above-mentioned embodiments, and can be arbitrarily modified without departing from the spirit of the present invention.

<Effects of the Invention> As detailed above, this invention makes it possible to predict production volume in line with delivery dates, losses within the production line, etc., and also to prevent material shortages, equipment loads, skill loads, and work that cannot be started in the future. This has an excellent effect of preventing the occurrence of troubles such as the above.

In addition, this device can be used to remove components of clothing such as shirts! In addition to a-manufacturing processing, we also cut the fabric into the shape of the component parts, cut and/or sew the fabric into the shape of the component parts of shoe covers, and bond the soles of shoes. It can also be applied to support work to respond to delivery dates for production Wf pictures of shoes, etc.

[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. Figure 6 is a manufacturing priority memory map diagram, Figure 7 is a work data memory map diagram, Figure 8 is a flowchart diagram, and Figure 9 is a diagram showing the tasks assigned to workers. FIG. 3 is an explanatory diagram for explaining the relationship between the work and the expected work time. 2 is a terminal device; 3 is a control unit (CPLJ) serving as a search means, a repeat control means, and a scheduled end time calculation means; 4
is a ROM, 5 is a RAM, 6 is an external storage device as a storage means, 7 is an input device, 8 is a display device as a display means,
9 is a communication device. ′Patent applicant Brother Industries, Ltd. ASICS Co., Ltd.

Claims (1)

[Scope of Claims] Data on the skills possessed by workers who carry out various tasks performed in a factory are stored, data on the capabilities possessed by working machines operated by the workers are stored, and the starting priority of the tasks to be executed is determined. storage means for storing work data that includes possessed skill data and possessed function data that are assigned and required for each work, and time data required to perform each work; The work data stored in the storage means, the skill data of the worker,
a retrieval means for retrieving a work that the worker can start next based on function data possessed by a work machine in a dormant state; and a retrieval means for retrieving time data corresponding to the retrieved work from the storage means, and retrieving the time data corresponding to the retrieved work, a scheduled end time calculation means for calculating a scheduled end time of the production process; a time setting means for presetting the predicted time when predicting future production progress; and a time setting means for calculating the calculated expected end time from the time setting means. a repetition control means for repeating the processing by the search means and the end time calculation means until a set time is reached; 1. A production progress prediction device in a factory, characterized in that it is provided with display means for displaying.