WO2012108092A1

WO2012108092A1 - Work instruction document creation system

Info

Publication number: WO2012108092A1
Application number: PCT/JP2011/077591
Authority: WO
Inventors: 英徳上野
Original assignee: 株式会社日立製作所
Priority date: 2011-02-08
Filing date: 2011-11-29
Publication date: 2012-08-16
Also published as: JP2012164213A

Abstract

To provide a work instruction document system with which it is possible to easily carry out a re-creation of a work instruction document if work cannot be carried out according to an initial work sequence due to changes in a manufacturing plan, a lack of attachment components, or for other reasons, a work instruction document creation system, comprising an external storage unit (11), an input unit (12), a display unit (13), and a computation unit (14): receives, from the external storage unit (11), a review of a manufacturing plan and/or inventory information of attachment components, said plan or information updated by an input from the input unit (12); simultaneously, with the computation unit (14), extracts the work which can be engaged in, carries out a creation of a backlog of and a postponement of a workload, and updates the work sequence; creates an assembly diagram and a work description based on the updated work sequence; and displays same on the display unit (13).

Description

Work instruction creation system

The present invention relates to a work instruction creation system for creating a work instruction that instructs a worker on a product manufacturing procedure.

As a background art in this technical field, there is JP-A-2000-90163 (Patent Document 1). In this publication, a work instruction / preparation device prepared in advance by a manufacturer is “providing a work instruction / support device that can be easily customized by adding information tailored to the work site by the user”.

JP 2000-90163 A

作業 Work instructions are prepared before starting production, but it is not always possible to work according to work instructions due to a review of production plans and missing parts. In this case, the work is performed without using the work instruction, and the product quality varies. In addition, there is a problem that the number of man-hours increases when the work instruction is modified in accordance with the change in the production status.

The purpose of the present invention is to create a work instruction that can be easily re-created when the original work procedure cannot be performed due to a production plan change, missing parts, or other reasons. To provide a system.

In order to achieve the above object, for example, the configuration and processing procedure described in the claims are adopted. The present application includes a plurality of means for achieving the above object.For example, in the work instruction creation system that includes a storage unit and a calculation unit and creates a work instruction that instructs work content according to a work procedure, The storage unit includes a parts table database (DB) indicating the configuration of the product, a production plan DB for managing the installation start date for the part of the product, an attachment history DB for managing the attachment history of the part, and the part. Related parts DB indicating work relevance and work contents between parts with respect to constituent parts, mounting order DB for managing the mounting order between the parts, parts stock number, scheduled part warehousing date, and parts inventory for managing the planned number DB and a CAD data file for managing the two-dimensional or three-dimensional model data of the part are stored and held, and the calculation unit includes a memory, and each of the storage units stored and held in the storage unit Information is obtained from the database and the CAD data file, these are stored in the memory, the component order data is generated using the information stored in the memory, and the component order data is generated. To generate the work contents necessary for mounting the parts, and also acquire the parts data already attached from the mounting history data included in the information, and the associated CAD data from the parts data of the mounting parts. A work instruction document creating system is characterized in that data is acquired, an assembly drawing is generated, and the work content and the assembly drawing are combined to generate a work procedure manual.

According to the present invention, when the parts inventory DB table created based on the latest information is used, when the work according to the original work procedure cannot be performed due to a change in the production plan, a missing part of the mounting parts, or other reasons, It is possible to provide a work instruction creation system that can easily recreate an instruction.

1 is a schematic overall configuration diagram of a work instruction creation system according to a first embodiment. FIG. 2 is a configuration diagram of an external storage device of the work instruction creation system shown in FIG. 1. FIG. 3 is an example of a parts table of a parts database recorded and held on the hard disk of the external storage device shown in FIG. 2. It is an example of the table structure of related component DB recorded and hold | maintained at the hard disk of the external storage device shown in FIG. It is an example of the table structure of attachment order DB recorded and hold | maintained at the hard disk of the external storage device shown in FIG. It is an example of a work instruction. It is a block diagram of the arithmetic processing part of the work instruction document preparation system shown in FIG. It is a process flowchart of the work instruction document preparation system shown in FIG. It is an example of the table structure of production plan DB recorded and hold | maintained at the hard disk of the external storage device shown in FIG. It is an image figure of an attachment order. It is an example of a table structure of parts inventory DB recorded and held on the hard disk of the external storage device shown in FIG. It is a figure explaining the postponement date of the start date of an attachment component. It is an example of the table structure of attachment log | history DB recorded and hold | maintained at the hard disk of the external storage device shown in FIG.

Hereinafter, embodiments of the present invention will be described with reference to the drawings.

The first embodiment will be described with reference to FIGS. FIG. 1 is a schematic overall configuration diagram of a work instruction creation system according to the present embodiment.

The work instruction creation system 1 includes an external storage unit 11, an input unit 12, a display 13, and a calculation unit 14, as shown in FIG. The input unit 12 includes, for example, a device such as a keyboard and a mouse, receives a creation instruction for a work instruction sheet, and sends the creation instruction to the calculation unit 14. The calculation unit 14 takes in information related to a work instruction creation target from the external storage unit 11 to the internal memory as necessary. The calculation unit 14 creates a work instruction sheet, displays the creation result on the display 13, and simultaneously outputs the work instruction sheet file to the external storage unit 11.

As shown in FIG. 2, the external storage unit 11 includes a parts table database 111 (the database is hereinafter referred to as DB), a production plan DB 112, an installation history DB 113, a related parts DB 114, an attachment order DB 115, and a work instruction file. 117, a parts inventory DB 118, and a CAD data file 116. These DBs are recorded and held on the hard disk.

The parts table DB 111 manages a tree structure 301 composed of block codes, part codes, and part codes as shown in FIG. Here, the block code, the part code, and the component code are unique codes. The table configuration of the parts table DB 111 is a table a 302 and a table b 303. The table a 302 represents the parent-child hierarchy of the tree, and the table b 303 includes a name that can be determined by human eyes and a CAD model name for each code.

As shown in FIG. 9, the production plan DB 112 manages the installation start date for each part code.

The attachment history DB 113 is composed of a part code, a component code, and a flag as shown in FIG. When the attachment has already been completed, “2” indicating that the attachment has been completed is entered in the flag column. In addition, the flag column is “0” for parts that are not yet installed. When there is a plan to attach, “1” is set.

As shown in FIG. 4, the related parts DB 114 includes a table 401 for “parts”, “related parts”, and “work codes”, and a table 402 for “work codes”, “work contents”, and “work hours”. The related parts DB is intended to manage work contents such as fastening between parts.

The attachment order DB 115 is a set of work priorities for the component parts. FIG. 5 shows the configuration of the attachment order DB 115. The attachment order DB 115 is managed by three fields, “first” 51, “rear” 52, and “continuous” 53. For parts that have an order relationship, the part code that is attached first is managed as “first” 51, and the part code that is attached later is managed as “back” 52. “Continuous” 53 is “1” when continuous, and “0” when there is no need for continuous execution.

The work instruction file 117 is for explaining the work to the worker. For example, the work instruction file 117 is composed of an assembly drawing 61 and work contents 62 as shown in FIG.
The parts inventory DB 118 manages the number of stocks and the planned number of future receipts for each part. This parts inventory DB is updated daily by input from the input unit.
The CAD data file 116 has two-dimensional or three-dimensional shape data of the product.

The calculation unit 14 is composed of a control program that represents pre-registered operation procedures and the like, a processor that processes these programs, and controls the external storage unit 11, the input unit 12, the display 13, and the like, and a memory. Is done. Prior to processing in the arithmetic processing unit (arithmetic unit) 14, information managed by the external storage unit 11 is expanded on the memory. In this memory, information related to the calculation process and calculation results in the calculation unit 14 is stored. As shown in FIG. 7, the processor includes a component attachment order generation unit 701, a work content acquisition unit 702, an assembly drawing generation unit 703, and a work instruction form generation unit 704.

The part attachment order generation unit 701 has a function of determining an attachment procedure for a component at a part for which an attachment instruction has been issued. The work content acquisition unit 702 has a function of acquiring, from a memory, work contents to be executed according to the component mounting order. The assembly drawing generation unit 703 has a function of generating an assembly drawing from the already attached parts and the parts to be attached. The attached parts are acquired from the attachment history DB 113. In the assembly drawing generation unit 703, with respect to the CAD data of the entire product, the attached parts are set to “display”, and the parts not yet attached are set to “non-display”. The parts to be attached are highlighted and colored differently from other parts to generate an assembly drawing. The work instruction form generation unit 704 generates a work instruction form from the work contents and the assembly drawing.
Next, the operation of the work instruction creation system according to the present embodiment will be described with reference to the flowchart of FIG.
S1: Acquire external information.
The installation start date for each part is acquired from the production plan DB 112 and stored in the memory of the calculation unit 14 shown in FIG. In the production plan information fetched into the calculation unit 14, the work start date is associated with the part code as shown in FIG.
When a request for creating a work instruction is received by the input unit 12, this is used as a trigger, and each data of the parts table, the mounting order, and the mounting history in the external storage unit 11 is acquired. The parts table data is acquired from the parts table DB 111, the mounting order data is acquired from the mounting order DB 115, and the mounting history data is acquired from the mounting history DB 113.
Next, the process proceeds to S2.
S2: Temporarily determine the mounting order of components.
Here, the attachment order of the components constituting the part for which the attachment instruction has been given is determined. FIG. 10 shows the structure of the attachment order data and the work ordering result. The mounting priority order of the parts is determined using the mounting order data.
The order in which components are attached takes into account not only the priority among the components of the part, but also the priority between the parts and the priority between the blocks. That is, the order of attachment may be set between parts or blocks.
Next, the process proceeds to S3.
S3: Obtain parts inventory and receipt schedule.
Get inventory of component parts and receipt schedule for the part where the trigger for starting work starts. In the parts inventory DB 118, as shown in FIG. 11, the inventory quantity 1101 for each part as of the work start date and the future inventory quantity 1102 are managed. It should be noted that whether the number described in the warehousing number column is the inventory number 1101 or the future warehousing number 1102 can be determined by referring to the date column. Further, the parts inventory DB 118 is updated daily by input from the input unit 12, and the latest information is used.
Next, the process proceeds to S4.
S4: The date when the component can be started.
The date on which parts can be started to be installed is determined based on the parts inventory and the order of parts installation. If there is no parts in stock on the installation start date, the start date is postponed until the warehousing date. Also, if there are parts that should be started after the parts that have been put back, they are put back together.

The process will be described with reference to FIG.
Here, it is assumed that the parts A-1-1 to the parts A-1-6 have an attachment order relationship as shown in the (1) part attachment order diagram. Arrows indicate the order. (2) The figure of implementation of back-to-back with a delay in parts receipt shows that only component A-1-4 is out of stock and is delayed with respect to the installation start date of part A-1. ing. In this case, the date on which the part A-1-4 can start until the day when the part is received is postponed. Further, since the part A-1-6 is a part to be mounted after the part A-1-4, the part A-1-6 is interlocked with the backward tilting of the A-1-4, and this is also backwardly tilted. As a result, the mounting order is as shown in the figure of (3) component mounting order (after correction).
Here, in this process, the work load is set to 0 for each attachment work. The mounting order at this stage is provisional because it does not consider the workload. The yyyymmdd = M described next to S4 in FIG. 8 is the provisional attachment start date, N indicates the attachment order, M is set as the provisional start date, N = 1, and the process proceeds to S5.
S5: Extract the work contents and work time for the attachment parts.
This extraction is performed according to the following procedure.
(1) In the calculation part 14 of FIG. 1, the attachment components which can be started on the Mth day are acquired.
(2) The related parts DB 114 is searched for all the parts in the Mth day for the Nth part in the mounting order. The related part is a part that causes some work for the mounting part. For example, it is a fastening destination part or a part that becomes a base point when determining dimensions.
(3) The attachment history data 113 is searched using related parts as a key, and attached parts are extracted.
(4) For the selected part code, obtain the work contents and work time that occur with the attached parts.
(5) The Nth component is registered as a mounted component on the memory of the calculation unit 14, and the process proceeds to S6.
S6: The work time obtained in S5 is set as the work load, and the load is piled up on the day when it can be started.
The work load is piled up (accumulation of the installation work time of each part) by the following procedure.
(1) For a mounting part, find the working time that occurs with all the mounted parts among the related parts. Here, the work time generated between the attached part and the already-attached part is acquired from the related part information in FIG. 4, and the work time generated on the same day is piled up.
(2) The parts subjected to the stacking process are temporarily registered in the arithmetic unit memory as attached parts.
(3) Judgment of presence / absence of parts that can be installed on the Mth day
Thereafter, the presence / absence of a part to be attached on the Mth day is determined. If there is, the process returns to S5 to repeat the process. If not, the process proceeds to S7.
S7: A part to be moved backward is determined.
Here, in the case where there are parts that can be mounted on the Mth day in the determination of (3) of S3, when the accumulated work time exceeds one day's working hours (for example, 10 hours including overtime), For any of the parts, the installation start date will be postponed. In this case, if there are parts in the order of attachment shown in FIG. 5, they are separated so as not to fall backward. If continuity of work is required between A-1-2 and A-1-3, A-1-5 is moved backwards. The work time is checked again with the postponement process, and the postponement work is repeated until it is within the work time of the day. With this process, the mounting order and the mounting start date are determined. Here, it is assumed that the excess of the work time is resolved by moving the part A-1-5 backward. As a result, it is assumed that the mounting order is determined in the order of A-1-1, A-1-2, A-1-3, A-1-5, A-1-4, A-1-6.

Next, on the (M + 1) th day, it is determined whether there are any parts that can be attached and started. If there are any, M = M + 1 is set, and the process proceeds to S5.
Repeat the above process until there are no parts that can be attached. Thereby, the attachment order P1, P2, P3,. For the parts already attached in the calculation unit 14, the attached state is released before the process proceeds to S8. However, the parts already attached in the attachment history DB 113 of the external storage unit 11 are left in the attached state.
If there is no part that can be mounted on the (M + 1) th day, the process proceeds to S8.
S8: Create an assembly drawing.
Assembly drawings are created according to the following procedure.
(1) A set of CAD data files 116 in the external storage unit 11 shown in FIG.
(2) The part 14 with the mounting order P1 is acquired by the calculation unit 14 in FIG.
(3) The calculation unit 14 acquires the CAD model name for the component code stored in the memory. The CAD model name corresponding to the part code can be acquired from the information in the table b in FIG.
(4) The calculation unit 14 acquires the part code of the mounted part from the mounting history information stored in the memory.
(5) The computing unit 14 acquires the CAD model name of the mounted part stored in the memory.
(6) Display the attached parts, highlight the attached part's CAD data to distinguish it from the attached parts, set the other parts to non-display, and use the assembly drawing for the attached parts.
(7) Register the mounted parts in the mounting history data on the memory.
(8) N = N + 1, and it is determined whether there is a part with the mounting order PN. If yes, return to S2 (2). The processes from (2) in S8 to (7) in S8 are repeated until there are no attached parts, and as many assembly drawings as the number of attached parts are created. The process ends at the stage when there are no attachment parts, and the process proceeds to S9.
S9: Creation of work instructions
In accordance with the parts mounting order, the work contents corresponding to the mounting parts and the assembly drawing are synthesized to obtain a work procedure manual.
The work instruction is completed by the above processing. The work instruction sheet is displayed on the display 13 and is output to the external storage unit 11 as a work instruction sheet file.

By operating this work instruction creation system, the work start date of the production plan DB 112, the flag column of the installation history DB 113, and the work instruction file 117 of the database stored in the external storage unit 11 are updated. Is done. The parts table DB 111, the related parts DB 114, the mounting order DB 115, etc. are basically not changed.

When the above work instruction creation system is applied to plant production including exhaust ducts, even if there is a change in production plan or missing parts, the installation order is changed and the installation order is adapted to the actual work. I was able to create instructions. In addition, the number of man-hours for creating work instructions can be reduced by automatic generation.

As described above, according to the present embodiment, by including the storage unit having the initially created related parts DB table and the mounting order DB table, and the latest parts inventory DB table, the production plan can be changed, the mounting parts can be missing, For this reason, it is possible to provide a work instruction creation system that can easily recreate a work instruction when the work according to the original work procedure cannot be performed. In addition, by automatically generating work instructions, the number of steps for creating work instructions can be reduced.

In addition, this invention is not limited to the above-mentioned Example, Various modifications are included. For example, the above-described embodiments have been described in detail for easy understanding of the present invention, and are not necessarily limited to those having all the configurations described. The external storage unit can be incorporated in the calculation unit depending on the size of the storage capacity.

DESCRIPTION OF SYMBOLS 11 ... External memory | storage part, 12 ... Input part, 13 ... Display, 14 ... Calculation part, 51 ... Previous attachment part in attachment order DB, 52 ... Later attachment part in attachment order DB, 53 ... Continuous attachment in attachment order DB Parts, 61 ... Assembly drawing, 62 ... Work content, 111 ... Parts table DB, 112 ... Production plan DB, 113 ... Installation history DB, 114 ... Related parts DB, 115 ... Installation order DB, 116 ... CAD data file, 117 ... Work instruction file 118, parts inventory DB, 301 ... tree structure of parts table DB, 302 ... table a of parts table DB, 303 ... table b of parts table DB, 401 ... table of related parts DB, 402 ... related parts DB table, 701... Component mounting order generation unit, 702 .. work content acquisition unit, 703... Assembly drawing generation unit, 704. 01 ... the number of inventory, 1102 ... the number of receipts in the future.

Claims

In a work instruction creation system that includes a storage unit and a calculation unit, and creates a work instruction that instructs work content according to work procedures.
The storage unit configures the parts table database indicating the configuration of the product, the production plan database that manages the installation start date for the part of the product, the mounting history database that manages the mounting history of the part, and the part A related parts database indicating work relevance between parts and work contents with respect to parts; an attachment order database for managing the order of attachment between the parts; A CAD data file for managing the two-dimensional or three-dimensional model data of the part,
The calculation unit includes a memory, acquires information from each of the database and the CAD data file stored and held in the storage unit, stores these on the memory,
Using the information stored on the memory, generating the mounting order data of the parts, generating the work content necessary when mounting the parts from the mounting order data of the parts,
At the same time, the part data already attached is acquired from the mounting history data included in the information, the CAD data related to these parts data is acquired from these parts data, and the assembly drawing is generated.
A work instruction creation system characterized in that the work content and the assembly drawing are combined to generate a work procedure manual.
In the work instruction creation system according to claim 1,
The calculation unit further generates a mounting order temporarily according to the mounting order data,
A work instruction creation system characterized in that the provisional order is temporarily changed based on the provisionally generated attachment order and the parts inventory data and warehousing schedule data included in the information.
In the work instruction creation system according to claim 2,
The calculation unit further obtains work time data included in the information for the re-created installation order based on the parts inventory data, implements a pile of work times, and determines the installation start date. If the working time exceeds the set time, the work instruction creation system is configured to postpone the installation start date of the part that exceeds the working time.
In the work instruction creation system according to claim 3,
Further, the calculation unit further inverts the installation start date of the immediately preceding component together when the installation of the component that performs the backward operation is continuous with the installation of the immediately preceding component in the re-created mounting order. A work order creation system characterized by that.
In the work instruction creation system according to claim 1,
In addition to the already attached component data, the arithmetic unit further acquires component data to be attached from now, and draws these two types of components using CAD data. Work order creation system.
In the work instruction creation system according to claim 1,
The arithmetic unit further updates the work history data at the same time as the generation of the work content and the assembly drawing according to the mounting order data, and repeats the same process for the next component to be mounted. A work order creation system characterized by being.
In a work instruction creation system having a calculation unit connected to an external storage unit, an input unit, and a display,
The computing unit is
A component mounting order generation unit;
Work content acquisition unit for acquiring work content using the component mounting order generated by the component mounting order generation unit;
An assembly drawing generation unit that generates an assembly drawing using the component attachment order generated in the component attachment order generation;
A work instruction generating unit that generates a work instruction using the work content acquired by the work content acquiring unit and the assembly drawing generated by the assembly drawing generating unit;
A work instruction creation system characterized by comprising:
In the work instruction preparation system according to claim 7,
The external storage unit includes a parts table database including parts constituting the product,
A production plan database for managing the installation start date for the product part;
An attachment history database for managing the attachment history of the part;
A related part database indicating work relevance between parts and work contents with respect to the parts constituting the part;
A mounting order database for managing the order of mounting between the parts, a parts inventory database for managing the number of parts in stock, the scheduled date of goods receipt, and the planned number;
A CAD data file for managing 2D or 3D model data of the part;
Remember and
The operation unit includes a memory, acquires information from each of the databases and CAD data files stored and held in the external storage unit, and stores the information in the memory. Instruction creation system.
In the work instruction creation system according to claim 8,
The component mounting order generation unit has a function of determining the mounting order for the component parts of the parts for which mounting instructions are issued,
The work content acquisition unit is included in the information, and has a function of acquiring the work content to be performed according to the mounting order of the components from the memory,
The assembly drawing generation unit has a function of generating an assembly drawing from the mounting order of the component parts, a mounted part included in the information, and a part to be mounted in the future. system.
In the work instruction creation system according to claim 8,
The work instruction creation system, wherein the input unit is used for updating contents of the parts inventory database.
In the work instruction preparation system according to claim 7,
The work instruction creation system according to claim 1, wherein the display highlights a part to be attached when the assembly drawing is displayed.