WO2018199731A1 - Interactive system for improving work productivity in manufacturing processes - Google Patents

Interactive system for improving work productivity in manufacturing processes Download PDF

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Publication number
WO2018199731A1
WO2018199731A1 PCT/MX2017/000050 MX2017000050W WO2018199731A1 WO 2018199731 A1 WO2018199731 A1 WO 2018199731A1 MX 2017000050 W MX2017000050 W MX 2017000050W WO 2018199731 A1 WO2018199731 A1 WO 2018199731A1
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Prior art keywords
production
clause
parameters
interactive system
productivity
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PCT/MX2017/000050
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Spanish (es)
French (fr)
Inventor
Fernando MIJARES GARCÍA
Original Assignee
Mijares Garcia Fernando
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Priority to PCT/MX2017/000050 priority Critical patent/WO2018199731A1/en
Publication of WO2018199731A1 publication Critical patent/WO2018199731A1/en

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    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B19/00—Programme-control systems
    • G05B19/02—Programme-control systems electric
    • G05B19/418—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM]
    • G—PHYSICS
    • G06—COMPUTING; CALCULATING OR COUNTING
    • G06Q—INFORMATION AND COMMUNICATION TECHNOLOGY [ICT] SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES; SYSTEMS OR METHODS SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES, NOT OTHERWISE PROVIDED FOR
    • G06Q10/00—Administration; Management
    • G06Q10/06—Resources, workflows, human or project management; Enterprise or organisation planning; Enterprise or organisation modelling
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
    • Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
    • Y02P90/80—Management or planning

Definitions

  • the present invention applies to manufacturing processes and work activities where the real-time measurement of the efficiency of available labor is a relevant factor to meet the production objectives, or, in the measurement of the productive efficiency of Semi-automatic machinery of fully automated production lines.
  • Some examples of inventions related to monitoring and improving labor productivity are:
  • a monitoring system comprising computer terminals at each workstation for data exchange, a monitoring center that communicates with the terminals; a server that collects, processes and analyzes the data collected from the terminals.
  • V Data transmission wirelessly using a certain frequency band
  • Vf The method of implementing the monitoring system, which considers the installation of terminals, the capture of information, data transmission, data processing and calculation of salaries based on the productivity data collected from each terminal.
  • the system proposed in this patent is limited to exchange data and process the production of each worker for the purpose of calculating the payment of wages based on individual productivity.
  • the main limitations with respect to our invention is that said system suggests the possible capabilities of this monitoring system to monitor production, but without clearly stating the embodiment to obtain said system capabilities, which still leaves the problem unresolved. in the background that represents the uncertainty of the multiple individual decisions of workers that can result in the capture of erroneous information.
  • a hierarchical method is mainly drafted to determine the causal relationship of a production system and provide a comprehensive productivity analysis for that system. The method considers the following steps:
  • the method proposed by this patent although it helps to diagnose manufacturing processes and propose efficient systems, does not solve the need to correct the inefficiencies of a productive process in a timely manner at the moment when the progress of production is being negatively offset Regarding the production plan. Nor does it resolve the identification of the individual labor behaviors or deficiencies of the workers at each work station.
  • the system we propose is novel because it focuses on integrating a system and at least one method with different characteristics, focused on detecting and immediately addressing negative gaps that affect compliance with the plans of production, and identify needs to improve individual labor skills for each production process required for each specific production plan.
  • Figure 1 shows the general diagram of the system that shows the sequence to establish the different parameters (i) that allow to configure the programming of the production plan (le) according to the production parameters (la) and the parameters of workers and their competences (Ib).
  • Figure 2 shows the configuration flow of the production program (le) in the console from a work order (2) subdMad in wagons (2a) and the decision processes according to the recovery time (le) and the deviations of productivity (Id) presented by the work stations (2b) and the parts produced.
  • Figure 3 shows the configuration of parameters by competences (Ib) of the workforce assignable to the production of a specific work order (2), with the decision takers based on the certifications of each worker.
  • Figure 4 shows the typical configuration flow of a tablet (4a) for its connection with the sensors of a production line, the sending of data to the console (4b) and synchronization with the server (4c).
  • Figure 5 shows the flow to display the projected production parameters (la) corresponding to a workstation (2b) on a tablet (4a).
  • Figure 6 shows a diagram of the general flow of an example of assignment of a work order (2) in wagons (2a) and how they are assigned to a tablet (4a) in a workstation (2b) so that it can be consulted by the worker assigned to said workstation (2b).
  • Figure 7 represents the interaction of the workers with the system through the tablets (4a) in the work stations (2b) to carry out the production corresponding to a wagon (2a).
  • Figure 8 Represents the way in which the system interacts with the sensors (8a) installed in a production line to automatically feed the production progress, analysis of production data and shutdowns.
  • Figure 9 shows a diagram of the workforce allocation flow within the system according to the needs of a production plan, shifts, overtime and required skills.
  • the interactive system to improve the productivity that we propose here, integrates a sequence of processes specially designed to, on a first piano, analyze and direct the planned production of productive activities in manufacturing environments.
  • production is projected based on quantities and times taking into account a wide variety of factors such as availability of available productive hours, breaks, scheduled and unscheduled stoppages, efficiencies and capacity to the teams and tools, labor competencies and individual behaviors of each worker, to elaborate a realistic production plan.
  • this system directs the production plan guiding those involved and showing in an interactive way what must be happening at each moment in each of the work areas where the production is carried out.
  • this system receives real-time information from the production area, yielding the result of production progress at the moment the process is taking place.
  • the system has elements to analyze the information received from the production area and calculate variables and yields, permanently compared to the production plan, providing feedback to each worker with real-time information on their productivity, compared to the program. of production and offering the possible actions to align your productivity with the production plan and the available time of the day.
  • the human factor in terms of individual skills is one of the most significant variables that can improve or impair productivity.
  • the system proposed here has a human resources module that integrates competencies, skills, training and certifications for each person monitored through the system. This module is integrated into the productive system and validates if the workers in the productive area have the necessary skills and knowledge to be able to properly execute the required work in a timely manner, sending immediate feedback on inefidends detected in the productive system, due to staff with lack of skills and / or knowledge.
  • the system can issue an alert, including the configuration so that the system blocks the assignment of non-competent workers to workstations.
  • the system calculates performance values of each worker for each day of production, generating a database in which, through statistical processing of said data, a reasonably reliable value of the performance and productive capacity of each worker is obtained.
  • this system as it is implemented in different manufacturing companies located in the same area or region, delimited in some way by the availability and mobility of the same labor supply, allows feeding a centralized database of All workers who have interacted with the system from different companies or production centers, generating an individual history of each of these workers, about their productive efficiency, technical skills, quality and fulfillment of their individual production goals, favoring access To this information the process of selecting the best available workforce in the area or region where the system has been implemented.
  • the system has a module in which not so obvious changes in the behavior of the equipment are monitored, such as energy consumption, temperature, air flows, water, oil, etc., to have a historical comparison of production output against energy inputs or equipment behavior and to be able to detect if under the same parameters the behavior changes, activating said system module by means of alerts and signals predicting a possible future failure, to anticipate it and avoid it with pre-ovo or preventive maintenance.
  • the system stores the information of each maintenance generating a historical record of said maintenance.
  • This type of device is ideally an electronic tablet (4a) with a touch screen mounted on a support located in a place inside the workstation (2b), where ergonomically and visually it does not make it difficult for the worker to interact with said device, thereby interrupting The production process.
  • the tablet (4a) is wirelessly linked to sensors (8a) that detect the flow of a produced or assembled part by the worker, automatically capturing in the tablet program (4a) each piece produced or assembled and the moment in which said process occurs. Or, manually the worker can have access to a button, which every time he presses it sends a signal to the tablet (4a) to count a piece produced or assembled each time that button is pressed.
  • This arrangement of electronic tablets (4a) can be configured for a production line or for all areas of a manufacturing company where there is a production process that can be counted as sub processes or sub assemblies made by the workers as part of compliance with the production plan (le). Once all the electronic tablets (4a) necessary to monitor and interact with the workers of a manufacturing line or center are installed, each of said tablets is linked (4a) to a central console (4b) specially designed for this interactive system.
  • Said central console (4b) receives and concentrates the information of each tablet (4a) installed in the line or manufacturing center and in turn connects with a production management computer (4c), from where the specific parameters are configured ( 1), according to the production plan (le), the available workforce (Ib) and the capacity of the equipment and the logistics of supply of Insumes, transport of parts in process, work schedules, among other variables that allow measure the efficiency of each production plan (le).
  • the production management computer (4c) is in turn linked to a master server (4d), which is a remote server where the computer platform that allows each production management computer (4c) is installed. , with permissions to link to the system, access the functionalities required for the configuration of production parameters (la), activate and deactivate access to electronic tablets (4a) at workstations (2b), register and lowers individual users of electronic tablets (4a), as well as access to results and statistics processed with the data collected by each electronic tablet (4a), related to the activity of each active worker in the system.
  • master server (4d) which is a remote server where the computer platform that allows each production management computer (4c) is installed.
  • the general configuration comprises three main aspects, the production parameters (the), the equipment maintenance parameters (Id) and the labor competency parameters (Ib).
  • the production parameters (la) are configured by giving values to each production variable that contemplates the production plan (le).
  • the main variables in a common manufacturing process are: number of parts to be produced, number of sub processes or sub assemblies, total time, available workers, effective man-hours, parts to be produced per unit of time, duration, number of scheduled shutdowns and of unscheduled stoppages, among others, that the person responsible for the production plan (le) determines based on their experience and knowledge about the manufacturing process to be carried out.
  • the values that determine the equipment maintenance parameters (Id) are established. These parameters are defined for preventive and predictive maintenance that will allow in the system programming to determine the indicated time and carry out stoppages for maintenance of the equipment before it presents failures or its work efficiency falls below the parameters linked to the efficiency requirements to achieve the production goal. To achieve this early detection of future failures in the equipment, the system issues alerts when deviations occur in the efficiency parameters of any equipment that is part of a production line monitored by the system.
  • the labor competency parameters (Ib) are established, to ensure that each worker available in the production process has the knowledge and skills necessary to achieve the efficiency and quality required in the plan of production.
  • the labor competency parameters (Ib) begin with the reference given by the profiles of each position specified by the human resources area (see Fig. 9). With the reference of the profiles, a breakdown or matrix of technical and labor competencies aligned to training, training and evaluation programs is performed to certify each worker in the competences achieved. The competences are defined in turn by the technical production requirements of the parts, pieces or assemblies established in each work order (2).
  • the next step in the process is to program these parameters so that each of the devices that make up the system performs the corresponding functionality according to said programming.
  • the first indispensable programming is the production plan (le), which in real practice begins with a work order (2), in which the production programmer demands a certain number of pieces and a required delivery date.
  • the design of the production plan (le) in the system considers the available resources and the definition of the values of the parameters of each slope of the system to estimate the effective man-hours of work in relation to the installed capacity and clearances to achieve total production of the work order (2) within the required period.
  • the work order (2) or the demand that starts the process is divided into sub orders or production wagons (2a).
  • These wagons (2a) allow disaggregating the total order and distributing it according to the available labor resources and the production capacity of the equipment involved in the production plan (le).
  • the amount of effective production hours necessary to complete each car (2a) is calculated. This calculation is based on the variables "standard cycle” and “recovery time”, generating multiples of said calculations according to the number of wagons (2a) or sub-orders in which the entire order was divided.
  • each wagon (2a) generating a waiting queue of wagons (2a) that according to the pre-established parameters, will allow to project and compare, within shorter periods, the real advance against the advance programmed in the system to meet the production plan (le) determined for each work order (2).
  • the monitoring by the system on the progress of production compared to the projected productivity, identifies at all times the productivity deviations (2d) that may occur by work station or by manufactured part.
  • the detection of productivity deviations (2d) is measured by assigning the wagons (2a) in the waiting queue to the available work stations (2b) and according to the production progress presented by each work station (2b).
  • a wagon (2a) of the waiting queue is assigned to a workstation (2b)
  • the information collected by the electronic tablets (4a) is sent in real time to the central console (4b) and processed said information on the master server (4d), to first detect recovery times (2c) per workstation and per part.
  • recovery times do not occur in a workstation (2b), the system applies recovery times of the parts.
  • the system applies recovery times from the workstation (2b). If both the work stage (2b) and the parties have recovery times (2c), the system offers the person in charge of the production plan the option of choosing one of the two recovery times or performing a combination of both, to achieve A more realistic projection. This process is continuously carried out by the system to detect active productivity deviations (2d) at the moment they occur.
  • a car (2a) can be assigned to the work stage (2b), said car (2a) being placed at the end of the waiting queue of said work station (2b).
  • the calculation of recovery times and active deviations allows the system to estimate the effective hours and the corresponding work volumes that this car (2a) will take to be produced, indicating in the system the start time and end time for the production of each car (2a), and the person in charge of the production plan can assign and reallocate wagons (2a) to the waiting positions and the work stations (2b) that best suits to meet the total production in the required period.
  • the system updates the production balances and the projection of hours based on the production since the last update of the system or that modifications have been made to the initial parameters (1) .
  • the system After each update of the production balance, the system identifies the occurrence of new productivity deviations in the wagons (2a) assigned to each work stage (2b) so that they can be ratified in the production line or at the specific station where deviation occurs (2d).
  • the person responsible for the production plan may decide to make unscheduled shutdowns, for maintenance, staff rest or other circumstances. These stops can be carried out for the entire production process or for a specific station (2b).
  • the system When performing the production plan (le) related to a work order (2), the system allows the person in charge of the production plan to efficiently assign the necessary workers to comply in time with the delivery of the order (2).
  • This assignment includes the identification of the workforce available for both ordinary work shifts and overtime that must be worked to achieve the production plan (le).
  • the available workforce is fed into the system under the parameters of competencies and individual productivity (Ib) when registering the certifications of each worker as well as their productivity and efficiency, measured by the statistical results of the individual performance that the system registers and accumulates Each worker

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Abstract

The invention relates to an interactive system for improving labour efficiency in manufacturing processes that involves defining production parameters, working skills and equipment maintenance; a central console that links to electronic devices installed in work stations and that processes databases of work productivity and sensors for counting production on production lines monitored by the system in real time during the production process, detecting deviations in the implementation of the production plan.

Description

SISTEMA INTERACTIVO PARA LA MEJORA DE LA PRODUCTIVIDAD LABORAL EN PROCESOS DE MANUFACTURA  INTERACTIVE SYSTEM FOR THE IMPROVEMENT OF LABOR PRODUCTIVITY IN MANUFACTURE PROCESSES
APLICACIÓN DE LA INVENCIÓN APPLICATION OF THE INVENTION
La presente invención aplica a los procesos de manufactura y actividades laborales donde la medición en tiempo real de la eficiencia de la mano de obra disponible es un factor relevante para cumplir con los objetivos de producción, o bien, en la medición de la eficiencia productiva de maquinaria semi automática de líneas de producción totalmente automatizadas. The present invention applies to manufacturing processes and work activities where the real-time measurement of the efficiency of available labor is a relevant factor to meet the production objectives, or, in the measurement of the productive efficiency of Semi-automatic machinery of fully automated production lines.
ANTECEDENTES DE LA INVENCIÓN BACKGROUND OF THE INVENTION
Uno de los principales problemas que enfrentan las industrias para cumplir a tiempo sus planes de producción sin menoscabo en su rentabilidad, es la dificultad para medir y corregir a tiempo las inefidendas relacionadas con la productividad de la mano de obra y de la pérdida de eficiencia por desgaste o fatiga de maquinaria y materiales. One of the main problems faced by industries to meet their production plans in time without compromising their profitability, is the difficulty to measure and correct in time the inefficiencies related to labor productivity and the loss of efficiency due to wear or fatigue of machinery and materials.
Independientemente de los programas de capad tadón, entrenamiento, selección de personal, medición de competendas, inventivos económicos y otras herramientas de desarrollo laboral que pueda proporcionar cada empresa a su personal, en el piso de trabajo ocurren infinidad de variables ligadas a la conducta individual de cada trabajador, que en su conjunto afectan la productividad. Estas variables son extremadamente difíciles de controlar, limitándose las soluciones actualmente conoddas a resolver en base a la recolección de datos estadísticos e identificadón de tendendas, una vez que ya transcurrió tiempo valioso para el cumplimiento del plan de producción, o con un alto costo de supervisión en el piso de producdón para lograr, mediante la presenda permanente de supervisores, detectar y corregir las conductas individuales que afectan la productividad, en el momento en que ocurren. Regardless of the training programs, training, personnel selection, competency measurement, economic inventories and other work development tools that each company can provide to its personnel, in the work floor there are countless variables linked to the individual behavior of Each worker, which as a whole affects productivity. These variables are extremely difficult to control, limiting the solutions currently agreed to be resolved based on the collection of statistical data and identification of trends, once valuable time has elapsed for the fulfillment of the production plan, or with a high cost of supervision on the production floor to achieve, through permanent supervision of supervisors, detect and correct individual behaviors that affect productivity, at the time they occur.
Algunos ejemplos de invenciones relacionadas con el monitoreo y mejora a la productividad laboral son: Some examples of inventions related to monitoring and improving labor productivity are:
/. "WO 2014/056003 Λ2".- Publicación de solicitud internacional de patente que reclama la invención de un sistema para administrar la productividad laboral en tiempo real, utilizando tecnologías de transferencia inalámbrica de datos. /. "WO 2014/056003 Λ2" .- International patent application publication claiming the invention of a system for managing labor productivity in real time, using wireless data transfer technologies.
En esta solicitud de patente se reclama, principalmente: This patent application mainly claims:
Í. Un sistema de monitoreo que comprende terminales de computadora en cada estación de trabajo para el intercambio de datos, una central de monitoreo que se comunica con las terminales; un servidor que colecta, procesa y analiza ios datos recolectados de las terminales.  Í. A monitoring system comprising computer terminals at each workstation for data exchange, a monitoring center that communicates with the terminals; a server that collects, processes and analyzes the data collected from the terminals.
La captura en cada estación de trabajo de una secuencia de procesos referendada a un periodo predeterminado;  The capture at each workstation of a sequence of processes referred to a predetermined period;
iii. La transmisión y el procesamiento de los datos capturados en las estaciones de trabajo;  iii. The transmission and processing of data captured at work stations;
Repetidores de señal para los casos en que el servidor y la central de monitoreo se encuentren distantes;  Signal repeaters for cases where the server and the monitoring center are distant;
V. La transmisión de datos de manera alámbrica inalámbrica utilizando determinada banda frecuencia;  V. Data transmission wirelessly using a certain frequency band;
Vf. El método de implementadón del sistema de monitoreo, que considera la instalación de terminales, la captura de información, transmisión de datos, procesamiento de los datos y cálculo de salarios en bases a los datos de productividad recolectados de cada terminal. Vf. The method of implementing the monitoring system, which considers the installation of terminals, the capture of information, data transmission, data processing and calculation of salaries based on the productivity data collected from each terminal.
El sistema propuesto en esta patente se limita a intercambiar datos y procesar la producción de cada trabajador para efectos de calcular el pago de salarios en base a la productividad individual. Las principales limitaciones con respecto a nuestra invención, es que dicho sistema sugiere las posibles capacidades de este sistema de monitoreo para monitorear la producción, pero sin plantear claramente la forma de realización para obtener dichas capacidades del sistema, lo cual sigue dejando sin resolver el problema de fondo que representa la incertidumbre de las múltiples decisiones individuales de los trabajadores que puede traducirse en captura de información errónea. The system proposed in this patent is limited to exchange data and process the production of each worker for the purpose of calculating the payment of wages based on individual productivity. The main limitations with respect to our invention, is that said system suggests the possible capabilities of this monitoring system to monitor production, but without clearly stating the embodiment to obtain said system capabilities, which still leaves the problem unresolved. in the background that represents the uncertainty of the multiple individual decisions of workers that can result in the capture of erroneous information.
2. "WO 2014/042508 A1".- Solicitud de patente internacional relativa a un sistema inalámbrico para monitoreo remoto de líneas de producción en empresas de manufactura. Este sistema basa su funcionamiento principalmente en el uso de tarjetas de radiofrecuencia y lectores de dichas tarjetas. 2. "WO 2014/042508 A1" .- International patent application for a wireless system for remote monitoring of production lines in manufacturing companies. This system bases its operation mainly on the use of radio frequency cards and readers of said cards.
Reclama como elementos novedosos la ubicación de módulos de detección y captura de datos situados en las líneas de producción a monitorear. Estos datos se capturan en forma de señales eléctricas y se transmiten en forma de señales electromagnéticas para ser procesados en un módulo de administración central. Señala como principal problema a resolver la rigidez de los sistemas de monitoreo que requieren de Instalación de cableado en líneas y celdas de producción, enfocándose en redamar la novedad del sistema por la configuración de sus distintos componentes tecnológicos, sin señalar a detalle utilidad o aplicación relacionada con la interacción entre el sistema y las personas, a excepción de la supervisión remota, descrita esta de manera muy general. It claims as novel elements the location of data detection and capture modules located in the production lines to be monitored. This data is captured in the form of electrical signals and transmitted in the form of electromagnetic signals to be processed in a central administration module. It indicates as the main problem to solve the rigidity of the monitoring systems that require installation of wiring in production lines and cells, focusing on drafting the novelty of the system by the configuration of its different technological components, without pointing out in detail utility or related application with the interaction between the system and people, except for remote supervision, this is described in a very general way.
3. "US2004/0034555 A1 ".- Documento de patente estadounidense que reclama la invención de una metodología jerárquica para medir la productividad y mejorar sistemas complejos de producción. 3. "US2004 / 0034555 A1" .- US patent document that claims the invention of a hierarchical methodology to measure productivity and improve complex production systems.
Se redama principalmente un método jerárquico para determinar la relación causal de un sistema de producción y proveer un análisis integral de productividad para dicho sistema. El método considera tos siguientes pasos: A hierarchical method is mainly drafted to determine the causal relationship of a production system and provide a comprehensive productivity analysis for that system. The method considers the following steps:
1. Identificar un arreglo de operaciones de producción;  1. Identify an array of production operations;
2. Modelar el sistema como un arreglo de procesos unitarios de producción interconectados;  2. Model the system as an arrangement of interconnected unit production processes;
3. Aplicar al menos una configuración de procesos unitarios de producción interconectados, para factorizarla en subsistemas de manufactura para su descripción y análisis;  3. Apply at least one configuration of interconnected production unit processes, to factor it into manufacturing subsystems for description and analysis;
4. Evaluar cada proceso unitario de producción y cada subsistema de manufactura para calcular al menos una métrica de productividad para cada uno de ellos;  4. Evaluate each unit production process and each manufacturing subsystem to calculate at least one productivity metric for each of them;
5. Determinar y describir la secuencia de procesos y flujo de materiales para cada subsistema de producción;  5. Determine and describe the sequence of processes and flow of materials for each production subsystem;
6. Determinar entrada de insumos, salida de productos y productos defectuosos, para un tiempo total del simulador; 7. Determinar cada secuencia operativa de ios subsistemas de manufactura y la eficacia total del equipo para cada proceso unitario de producción; 6. Determine input of inputs, output of defective products and products, for a total time of the simulator; 7. Determine each operational sequence of the manufacturing subsystems and the total efficiency of the equipment for each unit production process;
8. Determinar el rendimiento de cada proceso unitario de producción;  8. Determine the performance of each unit production process;
9. Determinar la eficacia total del rendimiento de los subsistemas; 9. Determine the total efficiency of subsystem performance;
10. Recolectar todos los costos del sistema de manufactura; 10. Collect all costs of the manufacturing system;
11. Definir todas las actividades directas de manufactura;  11. Define all direct manufacturing activities;
12. Asignar tos costos directos por categorías;  12. Assign direct costs by categories;
13. Obtener el valor monetario de tos costos directos de cada actividad;  13. Obtain the monetary value of the direct costs of each activity;
14. Asignar costos por grupo de actividades;  14. Assign costs by group of activities;
15. Determinar el costo directo unitario de manufactura por cada tipo de producto;  15. Determine the direct unit cost of manufacturing for each type of product;
16. Determinar costos unitarios de manufactura promedio en determinado periodo.  16. Determine average manufacturing costs in a given period.
El método que propone esta patente, si bien ayuda a diagnosticar procesos de manufactura y a proponer sistemas eficientes, no resuelve la necesidad de corregir de manera oportuna las ineficiendas de un proceso productivo en el momento mismo en que el avance de la producción se está desfasando negativamente con respecto al plan de producción. Tampoco resuelve la identificación de las conductas o deficiencias laborales individuales de los trabajadores en cada estación de trabajo. The method proposed by this patent, although it helps to diagnose manufacturing processes and propose efficient systems, does not solve the need to correct the inefficiencies of a productive process in a timely manner at the moment when the progress of production is being negatively offset Regarding the production plan. Nor does it resolve the identification of the individual labor behaviors or deficiencies of the workers at each work station.
A partir de estas consideraciones, el sistema que nosotros proponemos es novedoso porque se enfoca en integrar un sistema y al menos un método con características diferentes, enfocado a detectar y atender de manera inmediata desfases negativos que afectan cumplir con los planes de producción, y a identificar necesidades de mejorar las competencias laborales individuales para cada proceso de producción requerido para cada plan de producción determinado. Based on these considerations, the system we propose is novel because it focuses on integrating a system and at least one method with different characteristics, focused on detecting and immediately addressing negative gaps that affect compliance with the plans of production, and identify needs to improve individual labor skills for each production process required for each specific production plan.
FIGURAS FIGURES
La Figura 1 muestra el diagrama general del sistema que muestra la secuencia para establecer los diferentes parámetros (i) que permiten configurar la programación del plan de producción (le) conforme a ios parámetros de producción (la) y a los parámetros de trabajadores y sus competencias (Ib).  Figure 1 shows the general diagram of the system that shows the sequence to establish the different parameters (i) that allow to configure the programming of the production plan (le) according to the production parameters (la) and the parameters of workers and their competences (Ib).
La Figura 2 muestra el flujo de configuración del programa de producción (le) en la consola a partir de una orden de trabajo (2) subdMdida en vagones (2a) y los procesos de decisión conforme al tiempo de recuperación (le) y a las desviaciones de productividad (Id) que presenten las estaciones de trabajo (2b) y las partes producidas. Figure 2 shows the configuration flow of the production program (le) in the console from a work order (2) subdMad in wagons (2a) and the decision processes according to the recovery time (le) and the deviations of productivity (Id) presented by the work stations (2b) and the parts produced.
La Figura 3 muestra la configuración de parámetros por competencias (Ib) de la mano de obra asignable a la producción de determinada orden de trabajo (2), con los tactores de decisión en base a las certificaciones de cada trabajador. Figure 3 shows the configuration of parameters by competences (Ib) of the workforce assignable to the production of a specific work order (2), with the decision takers based on the certifications of each worker.
La Figura 4 muestra el flujo de configuración típica de una tableta (4a) para su enlace con ios sensores de una línea de producción, el envío de datos a la consola (4b) y sincronización con el servidor (4c). Figure 4 shows the typical configuration flow of a tablet (4a) for its connection with the sensors of a production line, the sending of data to the console (4b) and synchronization with the server (4c).
La Figura 5 muestra el flujo para desplegar en una tableta (4a) los parámetros de la producción (la) proyectada correspondiente a una estación de trabajo (2b). La Figura 6 muestra un diagrama del flujo general de un ejemplo de asignación de una orden de trabajo (2) en vagones (2a) y como se asignan estos a una tableta (4a) en una estación de trabajo (2b) para que pueda ser consultada por el trabajador asignado a dicha estación de trabajo (2b). Figure 5 shows the flow to display the projected production parameters (la) corresponding to a workstation (2b) on a tablet (4a). Figure 6 shows a diagram of the general flow of an example of assignment of a work order (2) in wagons (2a) and how they are assigned to a tablet (4a) in a workstation (2b) so that it can be consulted by the worker assigned to said workstation (2b).
La Figura 7 representa la interacción de los trabajadores con el sistema a través de las tabletas (4a) en las estaciones de trabajo (2b) para realizar la producción correspondiente a un vagón (2a). Figure 7 represents the interaction of the workers with the system through the tablets (4a) in the work stations (2b) to carry out the production corresponding to a wagon (2a).
La Figura 8 Representa la forma como el sistema interactúa con los sensores (8a) instalados en una línea de producción para alimentar automáticamente el avance de producción, análisis de los ddos de producción y paros. Figure 8 Represents the way in which the system interacts with the sensors (8a) installed in a production line to automatically feed the production progress, analysis of production data and shutdowns.
La Figura 9 muestra un diagrama dei flujo de asignación de trabajadores dentro del sistema conforme a las necesidades de un plan de producción, los turnos, horas extras y competencias requeridas. Figure 9 shows a diagram of the workforce allocation flow within the system according to the needs of a production plan, shifts, overtime and required skills.
DESCRIPCIÓN DE LA INVENCIÓN DESCRIPTION OF THE INVENTION
El sistema interactivo para mejorar la productividad que aquí proponemos, integra una secuencia de procesos diseñados especialmente para, en un primer piano, analizar y dirigir la producción planeada de actividades productivas en ambientes de manufactura. En un segundo plano, una vez analizada la demanda de productividad, se proyecta la producción en base a cantidades y tiempos tomando en cuenta una gran variedad de factores como disponibilidad de horas productivas disponibles, descansos, paros programados y no programados, eficiencias y capacidad de los equipos y herramientas, competencias laborales y comportamientos individuales de cada trabajador, para elaborar ínidalmente un plan realista de producción. En un tercer plano, este sistema dirige el plan de producción guiando a los involucrados y mostrando de una manera interactiva lo que debe de estar pasando en cada momento en cada una de las áreas de trabajo donde se realiza la producción. En un cuarto plano, este sistema recibe información en tiempo real del área de producción, arrojando el resultado del avance en la producción en el momento en que está ocurriendo el proceso. En un quinto plano, el sistema cuenta con elementos para analizar la información percibida del área de producción y calcular variables y rendimientos, comparados permanentemente con el plan de producción, retroaiimentando a cada trabajador con información en tiempo real sobre su productividad, comparada con el programa de producción y ofreciendo las posibles acciones para alinear su productividad con el plan de producción y el tiempo disponible de la jornada. The interactive system to improve the productivity that we propose here, integrates a sequence of processes specially designed to, on a first piano, analyze and direct the planned production of productive activities in manufacturing environments. In the background, once the demand for productivity is analyzed, production is projected based on quantities and times taking into account a wide variety of factors such as availability of available productive hours, breaks, scheduled and unscheduled stoppages, efficiencies and capacity to the teams and tools, labor competencies and individual behaviors of each worker, to elaborate a realistic production plan. In a third level, this system directs the production plan guiding those involved and showing in an interactive way what must be happening at each moment in each of the work areas where the production is carried out. In a fourth plane, this system receives real-time information from the production area, yielding the result of production progress at the moment the process is taking place. On a fifth level, the system has elements to analyze the information received from the production area and calculate variables and yields, permanently compared to the production plan, providing feedback to each worker with real-time information on their productivity, compared to the program. of production and offering the possible actions to align your productivity with the production plan and the available time of the day.
El factor humano en cuanto a habilidades individuales se refiere, es una de las variables más significativas que pueden mejorar o perjudicar la productividad. Para poder tener un mejor control del plan productivo, el sistema aquí propuesto cuenta con un módulo de recursos humanos que integra competencias, habilidades, entrenamiento y certificaciones para cada persona monitoreada mediante el sistema. Este módulo se integra al sistema productivo y valida si los trabajadores que están en el área productiva cuentan con las habilidades y conocimientos necesarios para poder ejecutar apropiadamente el trabajo requerido en tiempo y forma, enviando retroalimentación inmediata sobre inefidendas detectadas en el sistema productivo, debido a personal con carencia de habilidades y/o conocimiento. Cuando un individuo asignado a una estación de trabajo, para participar en la producción de una orden de trabajo determinada, no cuenta con registro de las competencias requeridas para el tipo de producción a realizar, el sistema puede emitir una alerta, incluyendo la configuración para que el sistema bloquee la asignación de trabajadores no competentes a estaciones de trabajo. El sistema calcula valores de rendimiento de cada trabajador para cada jornada de producción, generando una base de datos en la cual, mediante procesamiento estadístico de dichos datos, se obtiene un valor razonablemente confiable del rendimiento y de la capacidad productiva de cada trabajador. The human factor in terms of individual skills is one of the most significant variables that can improve or impair productivity. In order to have a better control of the production plan, the system proposed here has a human resources module that integrates competencies, skills, training and certifications for each person monitored through the system. This module is integrated into the productive system and validates if the workers in the productive area have the necessary skills and knowledge to be able to properly execute the required work in a timely manner, sending immediate feedback on inefidends detected in the productive system, due to staff with lack of skills and / or knowledge. When an individual assigned to a workstation, to participate in the production of a particular work order, does not have a record of the competencies required for the type of production to be performed, the system can issue an alert, including the configuration so that the system blocks the assignment of non-competent workers to workstations. The system calculates performance values of each worker for each day of production, generating a database in which, through statistical processing of said data, a reasonably reliable value of the performance and productive capacity of each worker is obtained.
En un beneficio ulterior, este sistema, conforme se va implementando en diferentes empresas de manufactura localizadas en una misma zona o región, delimitada de alguna manera por la disponibilidad y movilidad de una misma oferta de tuerza laboral, permite alimentar una base de datos centralizada de todos los trabajadores que han interactuado con el sistema desde diferentes empresas o centros de producción, generando un historial individual de cada uno de dichos trabajadores, sobre su eficiencia productiva, competencias técnicas, calidad y cumplimiento de sus metas individuales de producción, favoreciendo con el acceso a esta información el proceso de selección de la mejor mano de obra disponible en la zona o región donde el sistema se ha implementado. In a further benefit, this system, as it is implemented in different manufacturing companies located in the same area or region, delimited in some way by the availability and mobility of the same labor supply, allows feeding a centralized database of All workers who have interacted with the system from different companies or production centers, generating an individual history of each of these workers, about their productive efficiency, technical skills, quality and fulfillment of their individual production goals, favoring access To this information the process of selecting the best available workforce in the area or region where the system has been implemented.
Otro atributo relevante de este sistema es que considera dentro de las variables de productividad que el equipo utilizado en los procesos de manufactura está sujeto a tallas por uso o defectos lo cual normalmente solo es detectado por una falla o por anormalidades perceptibles, en el funcionamiento del mismo equipo. El sistema cuenta con un módulo en el cual se monitorean cambios no tan obvios en el comportamiento de los equipos, como consumo de energía, temperatura, flujos de aire, agua, aceite, etc., para tener una comparación histórica de salida de producción contra insumos energéticos o comportamiento del equipo y poder detectar si bajo los mismos parámetros el comportamiento cambia, activando dicho módulo del sistema mediante alertas y señales pronosticando una posible falla futura, para anticiparla y evitarla con mantenimiento predicovo o preventivo. En este mismo sentido, ei sistema almacena la información de cada mantenimiento generando un registro histórico de dicho mantenimientos. Another relevant attribute of this system is that it considers within the productivity variables that the equipment used in the manufacturing processes is subject to size by use or defects which is normally only detected by a fault or perceptible abnormalities, in the operation of the same team. The system has a module in which not so obvious changes in the behavior of the equipment are monitored, such as energy consumption, temperature, air flows, water, oil, etc., to have a historical comparison of production output against energy inputs or equipment behavior and to be able to detect if under the same parameters the behavior changes, activating said system module by means of alerts and signals predicting a possible future failure, to anticipate it and avoid it with pre-ovo or preventive maintenance. In this same sense, the system stores the information of each maintenance generating a historical record of said maintenance.
En una forma ideal de realización del sistema, se inicia por la instalación de dispositivos de intercambio de datos en las estaciones de trabajo, las cuales permiten que cada trabajador en su puesto de trabajo cuente con uno de estos dispositivos para recibir información y para capturar sus avances de producción. Este tipo de dispositivos idealmente es una tableta electrónica (4a) de pantalla táctil montada sobre un soporte ubicado en un sitio dentro de la estación de trabajo (2b), donde ergonómica y visualmente no dificulte al trabajador ¡nteractuar con dicho dispositivo, interrumpiendo con ello el proceso de producción. In an ideal way of realizing the system, it is initiated by the installation of data exchange devices in the workstations, which allow each worker in their workplace to have one of these devices to receive information and to capture their production advances. This type of device is ideally an electronic tablet (4a) with a touch screen mounted on a support located in a place inside the workstation (2b), where ergonomically and visually it does not make it difficult for the worker to interact with said device, thereby interrupting The production process.
Como una forma de facilitar la captura de datos, especialmente cuando se trata de una secuencia continua de producción o ensamble de productos, la tableta (4a) se enlaza de manera inalámbrica a sensores (8a) que detectan el flujo de una pieza producida o ensamblada por ei trabajador, capturando automáticamente en el programa de la tableta (4a) cada pieza producida o ensamblada y el momento en que ocurre dicho proceso. O bien, manualmente el trabajador puede tener acceso a un botón, el cual cada vez que lo presiona envía una señal a la tableta (4a) para contabilizar una pieza producida o ensamblada cada vez que se presiona dicho botón. As a way to facilitate data capture, especially when it is a continuous sequence of production or assembly of products, the tablet (4a) is wirelessly linked to sensors (8a) that detect the flow of a produced or assembled part by the worker, automatically capturing in the tablet program (4a) each piece produced or assembled and the moment in which said process occurs. Or, manually the worker can have access to a button, which every time he presses it sends a signal to the tablet (4a) to count a piece produced or assembled each time that button is pressed.
Esta disposición de tabletas electrónicas (4a) puede configurarse para una línea de producción o para todas las áreas de una empresa de manufactura donde exista un proceso de producción que pueda contabilizarse como sub procesos o sub ensambles realizados por ios trabajadores como parte dei cumplimiento del plan de producción (le). Una vez instaladas todas las tabletas electrónicas (4a) necesarias para monitorear e irrteractuar con tos trabajadores de una línea o centro de manufactura, cada una de dichas tabletas es enlazada (4a) a una consola central (4b) diseñada especialmente para este sistema interactivo. Dicha consola central (4b) recibe y concentra la información de cada tableta (4a) instalada en la línea o centro de manufactura y a su vez se conecta con una computadora de administración de la producción (4c), desde donde se configuran los parámetros específicos (1), de acuerdo al plan de producción (le), a la mano de obra disponible (Ib) y a la capacidad del equipo y de la logística de suministro de Insumes, transporte de partes en proceso, horarios laborales, entre otras variables que permiten medir la eficiencia de cada plan de producción (le). This arrangement of electronic tablets (4a) can be configured for a production line or for all areas of a manufacturing company where there is a production process that can be counted as sub processes or sub assemblies made by the workers as part of compliance with the production plan (le). Once all the electronic tablets (4a) necessary to monitor and interact with the workers of a manufacturing line or center are installed, each of said tablets is linked (4a) to a central console (4b) specially designed for this interactive system. Said central console (4b) receives and concentrates the information of each tablet (4a) installed in the line or manufacturing center and in turn connects with a production management computer (4c), from where the specific parameters are configured ( 1), according to the production plan (le), the available workforce (Ib) and the capacity of the equipment and the logistics of supply of Insumes, transport of parts in process, work schedules, among other variables that allow measure the efficiency of each production plan (le).
La computadora de administración de la producción (4c) se encuentra a su vez enlazada a un servidor maestro (4d), el cual es un servidor remoto donde se encuentra instalada la plataforma informática que permite a cada computadora de administración de la producción (4c), con permisos para enlazarse al sistema, acceder a las funcionalidades requeridas para la configuración de parámetros de producción (la), activar y desactivar el acceso a las tabletas electrónicas (4a) en las estaciones de trabajo (2b), dar de alta y de baja a usuarios individuales de las tabletas electrónicas (4a), así como acceso a resultados y estadísticas procesadas con los datos recolectados por cada tableta electrónica (4a), relativos a la actividad de cada trabajador activo en el sistema. En la presente descripción no entramos en detalles específicos sobre las características de las tecnologías de comunicación remota, inalámbrica o similares, que pueden ser utilizadas para la interconexión y comunicación entre los componentes del sistema, dado que tales tecnologías son ampliamente conocidas y disponibles, por lo que esta omisión no constituye un obstáculo para la comprensión sobre la forma de realizar la invención por un técnico con conocimientos medios en la materia. The production management computer (4c) is in turn linked to a master server (4d), which is a remote server where the computer platform that allows each production management computer (4c) is installed. , with permissions to link to the system, access the functionalities required for the configuration of production parameters (la), activate and deactivate access to electronic tablets (4a) at workstations (2b), register and lowers individual users of electronic tablets (4a), as well as access to results and statistics processed with the data collected by each electronic tablet (4a), related to the activity of each active worker in the system. In this description we do not enter into specific details about the characteristics of remote, wireless or similar communication technologies, which can be used for the interconnection and communication between the components of the system, given that such technologies are widely known and available, so this omission does not constitute an obstacle to the understanding of how to carry out the invention by a technician with average knowledge in the field.
A partir de la instalación y conexión de los componentes físicos del sistema, la siguiente etapa es la de configuración de los parámetros (1). La configuración general comprende tres vertientes principales, tos parámetros de producción (la), los parámetros de mantenimiento de equipos (Id) y los parámetros de competencias de la mano de obra (Ib). From the installation and connection of the physical components of the system, the next stage is the configuration of the parameters (1). The general configuration comprises three main aspects, the production parameters (the), the equipment maintenance parameters (Id) and the labor competency parameters (Ib).
Los parámetros de producción (la) se configuran dando valores a cada variable de producción que contempla el pian de producción (le). Las principales variables en un proceso común de manufactura son: número de piezas a producir, número de sub procesos o sub ensambles, tiempo total, trabajadores disponibles, horas-hombre efectivas, piezas a producir por unidad de tiempo, duración, número de paros programados y de paros no programados, entre otros, que ei responsable del pian de producción (le) determine en base a su experiencia y conocimientos sobre el proceso de manufactura a realizar. The production parameters (la) are configured by giving values to each production variable that contemplates the production plan (le). The main variables in a common manufacturing process are: number of parts to be produced, number of sub processes or sub assemblies, total time, available workers, effective man-hours, parts to be produced per unit of time, duration, number of scheduled shutdowns and of unscheduled stoppages, among others, that the person responsible for the production plan (le) determines based on their experience and knowledge about the manufacturing process to be carried out.
En otra vertiente de configuración del sistema, se establecen tos valores que determinan tos parámetros de mantenimiento del equipo (Id). Estos parámetros se definen para mantenimiento preventivo y predictivo que permitirán en la programación del sistema determinar el momento indicado y realizar paros para mantenimiento dei equipo antes de que éste presente fallas o su eficiencia de trabajo caiga por debajo de tos parámetros vinculados a ios requerimientos de eficiencia para lograr la meta de producción. Para lograr esta detección anticipada de faltas futuras en los equipos, el sistema emite alertas en el momento en se presentan desviaciones en tos parámetros de eficiencia de cualquier equipo que forme parte de una línea de producción monitoreada por el sistema. En la tercera vertiente, se establecen los parámetros de competencias de la mano de obra (Ib), para asegurar que cada trabajador disponible en el proceso de producción cuenta con los conocimientos y habilidades necesarios para alcanzar la eficiencia y calidad, requeridos en el plan de producción. Los parámetros de competencias de la mano de obra (Ib) inician con la referencia que arrojan los perfiles de cada puesto especificados por el área de recursos humanos (ver Fig. 9). Con la referencia de los perfiles, se realiza un desglose o matriz de competencias técnicas y laborales alineadas a programas de entrenamiento, capacitación y evaluaciones para certificar a cada trabajador en las competencias alcanzadas. Las competencias se definen a su vez por los requerimientos técnicos de producción de las partes, piezas o ensambles establecidos en cada orden de trabajo (2). In another system configuration aspect, the values that determine the equipment maintenance parameters (Id) are established. These parameters are defined for preventive and predictive maintenance that will allow in the system programming to determine the indicated time and carry out stoppages for maintenance of the equipment before it presents failures or its work efficiency falls below the parameters linked to the efficiency requirements to achieve the production goal. To achieve this early detection of future failures in the equipment, the system issues alerts when deviations occur in the efficiency parameters of any equipment that is part of a production line monitored by the system. In the third aspect, the labor competency parameters (Ib) are established, to ensure that each worker available in the production process has the knowledge and skills necessary to achieve the efficiency and quality required in the plan of production. The labor competency parameters (Ib) begin with the reference given by the profiles of each position specified by the human resources area (see Fig. 9). With the reference of the profiles, a breakdown or matrix of technical and labor competencies aligned to training, training and evaluation programs is performed to certify each worker in the competences achieved. The competences are defined in turn by the technical production requirements of the parts, pieces or assemblies established in each work order (2).
Una vez definidos los parámetros de cada vertiente, el siguiente paso en el proceso es programar estos parámetros para que cada uno de los dispositivos que integran el sistema realice la funcionalidad correspondiente de acuerdo a dicha programación. Once the parameters of each slope are defined, the next step in the process is to program these parameters so that each of the devices that make up the system performs the corresponding functionality according to said programming.
La primera programación indispensable es ia del pian de producción (le), que en la práctica real inicia con una orden de trabajo (2), en la cual el programador de producción demanda un número determinado de piezas y una fecha requerida de entrega. Con este par de datos, el diseño del plan de producción (le) en el sistema considera ios recursos disponibles y la definición de los valores de los parámetros de cada vertiente del sistema para estimar las horas-hombre efectivas de trabajo en relación con la capacidad instalada y las holguras para lograr la producción total de la orden de trabajo (2) dentro del plazo requerido. The first indispensable programming is the production plan (le), which in real practice begins with a work order (2), in which the production programmer demands a certain number of pieces and a required delivery date. With this pair of data, the design of the production plan (le) in the system considers the available resources and the definition of the values of the parameters of each slope of the system to estimate the effective man-hours of work in relation to the installed capacity and clearances to achieve total production of the work order (2) within the required period.
Al diseñar el plan de producción (le), la orden de trabajo (2) o la demanda que inicia el proceso, se divide en sub órdenes o vagones de producción (2a). Estos vagones (2a) permiten desagregar la orden total y distribuirla conforme a los recursos de mano de obra disponibles y a la capacidad de producción de los equipos involucrados en el plan de producción (le). A partir de la división de la orden en vagones (2a), se calcula la cantidad de horas efectivas de producción necesarias para completar cada vagón (2a). Este cálculo toma como base las variables "ciclo estándar" y "tiempo de recuperación'', generándose múltiplos de dichos cálculos conforme al número de vagones (2a) o sub-órdenes en que se dividió la orden completa. Enseguida se asigna la secuencia de producción de cada vagón (2a), generando una cola de espera de vagones (2a) que de acuerdo a los parámetros pre-estableddos, permitirán proyectar y comparar, dentro de periodos más cortos, el avance real contra el avance programado en el sistema para cumplir el plan de producción (le) determinado para cada orden de trabajo (2). When designing the production plan (le), the work order (2) or the demand that starts the process, it is divided into sub orders or production wagons (2a). These wagons (2a) allow disaggregating the total order and distributing it according to the available labor resources and the production capacity of the equipment involved in the production plan (le). From the division of the order into wagons (2a), the amount of effective production hours necessary to complete each car (2a) is calculated. This calculation is based on the variables "standard cycle" and "recovery time", generating multiples of said calculations according to the number of wagons (2a) or sub-orders in which the entire order was divided. production of each wagon (2a), generating a waiting queue of wagons (2a) that according to the pre-established parameters, will allow to project and compare, within shorter periods, the real advance against the advance programmed in the system to meet the production plan (le) determined for each work order (2).
El monitoreo por parte del sistema sobre el avance de la producción, comparado con la productividad proyectada identifica en cada momento las desviaciones de productividad (2d) que puedan ocurrir por estación de trabajo o por parte fabricada. La detección de las desviaciones de productividad (2d) se mide al asignar los vagones (2a) en la cola de espera a las estaciones de trabajo (2b) disponibles y de acuerdo al avance de producción que presente cada estación de trabajo (2b). Al asignarse un vagón (2a) de la cola de espera a una estación de trabajo (2b), la información recolectada por las tabletas electrónicas (4a), es enviada en tiempo real a la consola central (4b) y procesada dicha información en el servidor maestro (4d), para detectar primeramente tiempos de recuperación (2c) por estación de trabajo y por parte. Cuando no ocurren tiempos de recuperación en una estación de trabajo (2b), el sistema aplica tiempos de recuperación de las partes. Cuando no ocurren tiempos de recuperación de las partes, el sistema aplica tiempos de recuperación de la estación de trabajo (2b). Si tanto la estadón de trabajo (2b) como las partes presentan tiempos de recuperación (2c), ei sistema le ofrece al responsable del plan de producción la opción de elegir uno de los dos tiempos de recuperación o realizar una combinación de ambos, para lograr una proyección más realista. Este proceso lo realiza continuamente el sistema para detectar desviaciones activas de productividad (2d) en el momento en que ocurren. The monitoring by the system on the progress of production, compared to the projected productivity, identifies at all times the productivity deviations (2d) that may occur by work station or by manufactured part. The detection of productivity deviations (2d) is measured by assigning the wagons (2a) in the waiting queue to the available work stations (2b) and according to the production progress presented by each work station (2b). When a wagon (2a) of the waiting queue is assigned to a workstation (2b), the information collected by the electronic tablets (4a) is sent in real time to the central console (4b) and processed said information on the master server (4d), to first detect recovery times (2c) per workstation and per part. When recovery times do not occur in a workstation (2b), the system applies recovery times of the parts. When part recovery times do not occur, the system applies recovery times from the workstation (2b). If both the work stage (2b) and the parties have recovery times (2c), the system offers the person in charge of the production plan the option of choosing one of the two recovery times or performing a combination of both, to achieve A more realistic projection. This process is continuously carried out by the system to detect active productivity deviations (2d) at the moment they occur.
Cuando no ocurren desviaciones activas en una estación de trabajo (2b), el sistema aplica desviaciones de las partes. Cuando no ocurren desviaciones activas de las partes, el sistema aplica desviaciones de la estadón de trabajo. Si tanto la estación de trabajo como las partes presentan desviaciones activas, el sistema le ofrece al responsable del plan de producción la opción de elegir una de las dos desviaciones activas, o realizar una combinadón de ambas, para lograr una proyección más realista. Una vez estableddos tiempos de recuperación y las desviaciones activas, un vagón (2a) puede ser asignado a la estadón de trabajo (2b), colocándose dicho vagón (2a) al final de la cola de espera de dicha estación de trabajo (2b). El cálculo de los tiempos de recuperación y desviaciones activas permite al sistema estimar las horas efectivas y los tumos de trabajo correspondientes que va a tomar ese vagón (2a) para ser producido, indicándose en ei sistema hora de inicio y hora de término para la producción de cada vagón (2a), pudiendo el responsable del plan de producción asignar y reasignar vagones (2a) a las posiciones de espera y a las estaciones de trabajo (2b) que mejor convenga para cumplir con la producción total en el plazo requerido. When no active deviations occur in a workstation (2b), the system applies deviations of the parts. When there are no active deviations of the parts, the system applies deviations from the work stage. If both the workstation and the parties have active deviations, the system offers the person in charge of the production plan the option of choosing one of the two active deviations, or making a combination of both, to achieve a more realistic projection. Once recovery times and active deviations have been established, a car (2a) can be assigned to the work stage (2b), said car (2a) being placed at the end of the waiting queue of said work station (2b). The calculation of recovery times and active deviations allows the system to estimate the effective hours and the corresponding work volumes that this car (2a) will take to be produced, indicating in the system the start time and end time for the production of each car (2a), and the person in charge of the production plan can assign and reallocate wagons (2a) to the waiting positions and the work stations (2b) that best suits to meet the total production in the required period.
Cuando ocurren asignaciones y/o reasignadones de vagones (2a), el sistema actualiza los balances de producción y la proyección de horas en base a la producción acontecida desde la última actualización del sistema o que se hayan realizado modificaciones a los parámetros iniciales (1). When assignments and / or reallocations of wagons (2a) occur, the system updates the production balances and the projection of hours based on the production since the last update of the system or that modifications have been made to the initial parameters (1) .
Después de cada actualización del balance de producción, el sistema identifica la ocurrencia de nuevas desviaciones de productividad en los vagones (2a) asignados a cada estadón de trabajo (2b) para que puedan ser ratificados en la línea de producción o en la estación específica donde ocurre la desviación (2d). After each update of the production balance, the system identifies the occurrence of new productivity deviations in the wagons (2a) assigned to each work stage (2b) so that they can be ratified in the production line or at the specific station where deviation occurs (2d).
Cuando no ocurren desviaciones de productividad (2d) y el parámetro de holgura lo permite, ei responsable del plan de producción puede deddir realizar paros no programados, para mantenimiento, descanso del personal u otras circunstancias. Estos paros pueden realizarse para todo el proceso de producción o para una estación específica (2b). When productivity deviations (2d) do not occur and the slack parameter allows it, the person responsible for the production plan may decide to make unscheduled shutdowns, for maintenance, staff rest or other circumstances. These stops can be carried out for the entire production process or for a specific station (2b).
Al realizar ei pian de producción (le) relacionado con una orden de trabajo (2), ei sistema permite ai responsable del plan de producción asignar eficientemente a los trabajadores necesarios para cumplir en tiempo con la entrega de la orden (2). Esta asignación comprende la identificación de la mano de obra disponible tanto por turnos de trabajo ordinario como por horas extraordinarias que se tienen que laborar para lograr ei plan de producción (le). La mano de obra disponible se alimenta en el sistema bajo ios parámetros de competencias y productividad individual (Ib) al registrar las certificaciones de cada trabajador así como su productividad y eficiencia, medióle por los resultados estadísticos del rendimiento individual que el sistema registra y acumula de cada trabajador. When performing the production plan (le) related to a work order (2), the system allows the person in charge of the production plan to efficiently assign the necessary workers to comply in time with the delivery of the order (2). This assignment includes the identification of the workforce available for both ordinary work shifts and overtime that must be worked to achieve the production plan (le). The available workforce is fed into the system under the parameters of competencies and individual productivity (Ib) when registering the certifications of each worker as well as their productivity and efficiency, measured by the statistical results of the individual performance that the system registers and accumulates Each worker
Una vez que se asigna una plantilla completa para iniciar con la producción de una orden de trabajo (2), se sincroniza ia hora de inicio y conclusión de cada tumo y por cada trabajador para que el sistema automáticamente establezca la proyección de la producción por estación de trabajo (2b) y el estándar de los ciclos de producción. Cada trabajador puede consultar en la tableta (4a) de su estación de trabajo (2b) la producción proyectada para el turno, el estándar de productividad requerido para cumplir con el número de partes proyectadas en el plan (le), para medir durante todo el turno su nivel de productividad contra la productividad proyectada. Once a complete template is assigned to start with the production of a work order (2), the start and end time of each tumor is synchronized and for each worker so that the system automatically establishes the projection of production by station Working (2b) and the standard of production cycles. Each worker can check on the tablet (4a) of his work station (2b) the projected production for the shift, the productivity standard required to meet the number of parts projected in the plan (le), to measure throughout the entire Turn your productivity level against the projected productivity.

Claims

REIVINDICACIONES
Una vez establecido lo anterior, reclamo de mi exclusiva invención: 1. Un sistema interactivo para la mejora de la productividad laborar en procesos de manufactura, caracterizado porque el sistema cuenta con dispositivos (4a) de intercambio de datos, instalados en estaciones de trabajo (2b) de una línea de producción, para recibir información de producción; sensores de producción (8a) enlazados a los dispositivos (4a) de intercambio de datos; una consola centralOnce the above is established, I claim my exclusive invention: 1. An interactive system for improving productivity working in manufacturing processes, characterized in that the system has data exchange devices (4a), installed in workstations ( 2b) of a production line, to receive production information; production sensors (8a) linked to the data exchange devices (4a); a center console
(4b) de procesamiento de datos con ios dispositivos (4a) instalados en las estaciones de trabajo (2b); una computadora de administración de la producción (4c) para la configuración de parámetros del sistema (1); una consola central (4b) y la computadora de administración de la producción (4c); parámetros de producción (la), parámetros de competencias laborales (Ib); planes de producción (le); parámetros de mantenimiento de equipos (Id); información de órdenes de trabajo (2); información de perfiles de puestos y de competencias técnicas y laborales; datos de tiempos de recuperación (2c) y datos de desviaciones de productividad (2d).(4b) data processing with the devices (4a) installed in the workstations (2b); a production management computer (4c) for the configuration of system parameters (1); a central console (4b) and the production management computer (4c); production parameters (la), labor competency parameters (Ib); production plans (le); equipment maintenance parameters (Id); work order information (2); information on job profiles and technical and labor skills; recovery time data (2c) and productivity deviation data (2d).
2. El sistema interactivo reivindicado en la dáusula 1, caracterizado porque el dispositivo de intercambio de datos (4a) idealmente es una tableta electrónica de pantalla táctil montada sobre un soporte ubicado en un sitio dentro de la estación de trabajo (2b), donde ergonómica y vtsualmente no dificulta al trabajador interactuar con dicha tableta. 2. The interactive system claimed in clause 1, characterized in that the data exchange device (4a) is ideally an electronic touch screen tablet mounted on a support located in a place inside the workstation (2b), where ergonomic and it usually does not make it difficult for the worker to interact with said tablet.
3. El sistema interactivo reivindicado en la dáusula 1, caracterizado porque los sensores (8a) que detectan el flujo de cada pieza producida o ensamblada por cada trabajador, se capturan automáticamente en el programa de la tableta (4a) en el momento en que ocurre dicho proceso. 3. The interactive system claimed in clause 1, characterized in that the sensors (8a) that detect the flow of each piece produced or assembled by each worker, are captured automatically in the tablet program (4a) at the time that process occurs.
4. El sistema interactivo reivindicado en ia cláusula 1, caracterizado porque la consola centra! (4b) recibe y concentra ia información de cada tableta (4a) instalada en la línea o centro de manufactura y a su vez se conecta con la computadora de administración de ia producción (4c).  4. The interactive system claimed in clause 1, characterized in that the console centers! (4b) receives and concentrates the information of each tablet (4a) installed in the line or manufacturing center and in turn connects with the production management computer (4c).
5. El sistema interactivo reivindicado en la cláusula 1, caracterizado porque la configuración de los parámetros del sistema (1) se realiza de acuerdo al plan de producción (le), a la mano de obra disponible 5. The interactive system claimed in clause 1, characterized in that the configuration of the system parameters (1) is carried out according to the production plan (le), to the available workforce
(Ib) y a la capacidad del equipo y de la logística de suministro de insumos, transporte de partes en proceso y horarios laborales. (Ib) and the capacity of the equipment and the logistics of supply of inputs, transport of parts in process and working hours.
6. El sistema interactivo reivindicado en la cláusula 1, caracterizado porque la computadora de administración de la producción (4c) se enlaza a la consola central (4b) para enviar los resultados de productividad de cada trabajador activo en cada plan de producción monitoreado a través del sistema.  6. The interactive system claimed in clause 1, characterized in that the production management computer (4c) is linked to the central console (4b) to send the productivity results of each active worker in each production plan monitored through of the system.
7. El sistema interactivo reivindicado en la cláusula 1, caracterizado porque ia consola central (4b) es un servidor remoto donde se encuentra instalada la plataforma informática que permite a cada computadora de administración de la producción (4c), con permisos para enlazarse al sistema, acceder a las funcionalidades requeridas para la configuración de parámetros de producción (la), activar y desactivar el acceso a las tabletas electrónicas (4a) en las estaciones de trabajo (2b), dar de alta y de baja a usuarios individuales de las tabletas electrónicas (4a), así como acceso a resultados y estadísticas procesadas con los datos recolectados por cada tableta electrónica (4a), relativos a la actividad de cada trabajador activo en el sistema. 7. The interactive system claimed in clause 1, characterized in that the central console (4b) is a remote server where the computer platform that allows each production management computer (4c) is installed, with permissions to link to the system , access the functionalities required for the configuration of production parameters (la), activate and deactivate access to electronic tablets (4a) at workstations (2b), register and cancel individual users of tablets electronic (4a), as well as access to results and statistics processed with the data collected by each electronic tablet (4a), related to the activity of each active worker in the system.
8. El sistema interactivo reivindicado en ia dáusula 1, caracterizado porque la configuración de ios parámetros del sistema (1) se clasifica en parámetros de producción (la); parámetros de mantenimiento de equipos (Id), y parámetros de competencias de ia mano de obra (Ib). 8. The interactive system claimed in clause 1, characterized in that the configuration of the system parameters (1) is classified into production parameters (la); equipment maintenance parameters (Id), and labor skills parameters (Ib).
9. El sistema interactivo reivindicado en la cláusula 1, caracterizado porque cada orden de trabajo (2) se divide en sub órdenes o vagones de producción (2a) que desagregan la orden total y la distribuyen conforme a tos recursos de mano de obra disponibles y a la capacidad de producción de tos equipos involucrados en el plan de producción (le).  9. The interactive system claimed in clause 1, characterized in that each work order (2) is divided into sub orders or production wagons (2a) that disaggregate the total order and distribute it according to the available labor resources already available. the production capacity of the equipment involved in the production plan (le).
10. El sistema interactivo reivindicado en la cláusula 1, caracterizado porque ei plan de producción (le) toma como base las variables "ciclo estándar y "tiempo de recuperaaón", generándose múltiplos de dichos cálculos conforme al número de vagones (2a) o subórdenes en que se dividió la orden de orden completa. Enseguida se asigna la secuencia de producción de cada vagón (2a), generando una cola de espera de vagones (2a) que de acuerdo a tos parámetros pre-establecidos, permitirán proyectar y comparar, dentro de periodos más cortos, el avance real contra el avance programado en el sistema para cumplir el plan de producción (le) determinado para cada orden de trabajo (2).  10. The interactive system claimed in clause 1, characterized in that the production plan (le) is based on the variables "standard cycle and" recovery time ", generating multiples of said calculations according to the number of wagons (2a) or suborders in which the complete order of order was divided, the production sequence of each car (2a) is then assigned, generating a waiting queue of wagons (2a) that according to the pre-established parameters, will allow to project and compare, within of shorter periods, the real advance against the programmed advance in the system to fulfill the production plan (le) determined for each work order (2).
11. El sistema interactivo reivindicado en la cláusula 1, caracterizado porque las desviaciones de productividad (2d) se identifican por las desviaciones de las estaciones de trabajo y las desviaciones de las partes fabricadas que ocurren en cada vagón (2a) en proceso, asignado a una estación de trabajo (2b).  11. The interactive system claimed in clause 1, characterized in that the productivity deviations (2d) are identified by the deviations of the work stations and the deviations of the manufactured parts that occur in each wagon (2a) in process, assigned to a workstation (2b).
12. El sistema interactivo reivindicado en la cláusula 1, caracterizado porque La detección de los tiempos de recuperación (2c) se identifican por los tiempos de recuperación de las estaciones de trabajo y los tiempos de recuperación de las partes fabricadas que ocurren en cada vagón (2a) en proceso, asignado a una estación de trabajo (2b). 12. The interactive system claimed in clause 1, characterized in that the detection of recovery times (2c) is identified by the recovery times of the stations of work and recovery times of the manufactured parts that occur in each wagon (2a) in process, assigned to a workstation (2b).
13. El sistema interactivo reivindicado en la cláusula 1, caracterizado porque las asignaciones y/o reasignaciones de vagones (2a), actualizan en el sistema los balances de producción y la proyección de horas en base a la producción acontecida desde la última actualización del sistema o que se hayan realizado modificaciones a los parámetros iniciales (1).  13. The interactive system claimed in clause 1, characterized in that the assignments and / or reallocations of wagons (2a), update in the system the production balances and the projection of hours based on the production since the last update of the system or that modifications have been made to the initial parameters (1).
14. El sistema interactivo reivindicado en la cláusula 1, caracterizado porque el monitoreo en tiempo real de la producción permite programar a través del sistema paros para todo el proceso de producción o para una estación de trabajo específica (2b). 14. The interactive system claimed in clause 1, characterized in that the real-time monitoring of the production allows to stop through the system stoppages for the entire production process or for a specific work station (2b).
15. El sistema interactivo reivindicado en la cláusula 1, caracterizado porque la Información de mano de obra disponible se alimenta en el sistema bajo los parámetros de competencias y productividad individual (Ib) al registrar las certificaciones de cada trabajador así como su productividad y eficiencia, medióle por los resultados estadísticos del rendimiento individual que el sistema registra y acumula de cada trabajador.  15. The interactive system claimed in clause 1, characterized in that the information on available labor is fed into the system under the parameters of competencies and individual productivity (Ib) when registering the certifications of each worker as well as their productivity and efficiency, measured by the statistical results of the individual performance that the system records and accumulates of each worker.
16. El sistema interactivo reivindicado en la cláusula 1, caracterizado porque al iniciar con la producción de una orden de trabajo (2), se sincroniza la hora de inicio y conclusión de cada turno y por cada trabajador para que el sistema automáticamente establezca la proyección de la producción por estación de trabajo (2b) y el estándar de los ciclos de producción.  16. The interactive system claimed in clause 1, characterized in that when starting with the production of a work order (2), the start and end time of each shift is synchronized and for each worker so that the system automatically establishes the projection of production per work station (2b) and the standard of production cycles.
17. El sistema interactivo reivindicado en la cláusula 1, caracterizado porque cada trabajador interactúa con la tableta (4a) de su estación de trabajo (2b) consultando la producción proyectada para su turno, el estándar de productividad requerido para cumplir con el número de partes proyectadas en ei plan (le), para medir durante todo el tumo su nivel de productividad contra la productividad proyectada y capturando en tiempo real sus avances de producción. 17. The interactive system claimed in clause 1, characterized in that each worker interacts with the tablet (4a) of his workstation (2b) consulting the projected production for his shift, the productivity standard required to comply with the number of parts projected in the plan (le), to measure throughout the whole its level of productivity against the projected productivity and capturing in real time its production advances.
PCT/MX2017/000050 2017-04-25 2017-04-25 Interactive system for improving work productivity in manufacturing processes WO2018199731A1 (en)

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