JPH09138820A - Process designing system - Google Patents

Abstract

PROBLEM TO BE SOLVED: To speedily design a process with the distribution of operators corresponding to an actual producing process and with optimum equipment constitution. SOLUTION: An operation distribution part 10 distributes each operation process at each equipment and each operator based on the total number of production obtained by a production planning part 8, the arranging constitution of the equipments and the operators set by an arrangement designing part 9 and each operator's grade of operation skill which is set in advance. A process evaluation part 11 executes the simulation of the process set by the operation distribution part 10 and estimates the operating state of the process to process- evaluate the process.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a process design system for designing equipment in a manufacturing process in which a worker handles production equipment and a work process of the worker.

[0002]

2. Description of the Related Art In recent years, it has become important in the manufacturing process of products to create a simulation model such as a manufacturing process design evaluation apparatus and perform design evaluation of the manufacturing process.

Generally, in this type of process design evaluation apparatus, as disclosed in, for example, Japanese Patent Application Laid-Open No. 4-19056, a process design evaluation apparatus having a configuration as shown in FIG. 7 is used.

In order to calculate the production capacity with high accuracy and quantitatively, this process design evaluation device manages the quantity and delivery date of each product type corresponding to the demand fluctuation, and at the same time, manages all the product types corresponding to the demand fluctuation. A production planning unit 38 for estimating the total production quantity, and the number of equipments and the number of workers for obtaining the total production quantity obtained by the production planning unit 8 and setting the arrangement configuration of these equipments and workers. Based on the layout designing unit 39, the total number of productions obtained by the production planning unit 38, and the arrangement configuration of the equipment and the worker obtained by the arrangement designing unit 39 A process knitting unit 40 for knitting a process in accordance with a procedure, and a simulation of the process knitting of each process A to C shown in FIGS. And so on It is usually be composed of process evaluation unit 41 for process evaluation Te.

The process design evaluation apparatus shown in FIG. 7 includes, in addition to the above-mentioned elements, a main control unit 51 including a CPU (central processing unit) and a memory for controlling the whole, and this main control unit. A keyboard 53 is connected to 51 via an input unit 52, and a CRT display 55 and a printer 56 are connected via an output unit 54.

According to the process design evaluation apparatus having the above-described structure, the process evaluation can be performed by obtaining the mobility of the manufacturing process.

[0007]

However, in the conventional process design evaluation apparatus, the total production quantity obtained by the production planning section 38 and the arrangement configuration of the equipment and the workers obtained by the arrangement design section 39 are set. When designing each work procedure for these equipments and workers based on the above, there is no means to efficiently set the worker's work category, and it is necessary to simulate the process unnecessarily and it takes a long time. There is a problem that the process must be designed by using

That is, for example, as shown in FIG.
The equipments 61 to 63 are set in step B, the equipments 64 and 65 are set in step B, the equipments 66 to 68 are set in step C, the work results of the equipments 61 to 63 are processed in parallel by the equipments 64 and 65,
The work results of the equipments 64 and 65 are processed in parallel by the equipments 66 to 68, and as shown in FIG.
The work result of 62 is processed by the equipment 64, the work result of the equipment 62 of the process A is processed in parallel by the equipment 65, and
The work result of the equipment 64 of the process B is processed by the equipments 66 and 67, and the work result of the equipment 65 of the process B is processed by the equipment 68. Further, as shown in FIG. In addition, a complicated process design is performed in which each facility of the processes A to C is brought into a one-to-one correspondence state.
In FIG. 8, 29 and 30 are workers.

Further, each worker has a work field such as his or her weakness, and in some cases, there is also a problem that a work with a low proficiency level is distributed to a certain worker.

Therefore, the present invention has been made in order to solve the above-mentioned problems, and its purpose is to allocate workers according to an actual manufacturing process and to obtain an optimum equipment configuration. An object of the present invention is to provide a process design system capable of quickly performing such process design.

[0011]

A process design system according to claim 1 manages the quantity, delivery date, etc. of each product type corresponding to demand fluctuations, and also the total production of all the product types corresponding to demand fluctuations. A production planning means for estimating the number of products, and a layout design means for obtaining the number of facilities and the number of workers for obtaining the total production number obtained by the production planning means and setting the layout configuration of these facilities and workers, Based on the total production number obtained by the production planning means, the arrangement configuration of the equipment and the workers obtained by the arrangement designing means, and a preset work proficiency value for each worker, A work distribution means for setting each work process in the equipment and each worker, and a process evaluation tool for performing a simulation of the process set by the work distribution means to estimate the operation state of the process to evaluate the process of the process. When, it is characterized in that it comprises a.

According to a second aspect of the present invention, the process design system manages the quantity and delivery date of each product type corresponding to the demand fluctuation, and estimates the total production number of all the product types corresponding to the demand fluctuation. The planning means, the layout designing means for obtaining the number of equipments and the number of workers for obtaining the total production number obtained by the production planning means, and setting the layout configuration of these equipments and workers, and the production drawing means. Based on the obtained total production number, the arrangement configuration of the equipment and the operator obtained by the arrangement designing means, and the preset work proficiency value of each operator, each equipment and each worker In the work distribution means for setting each work process in step 1, and a simulation of the process set by the work distribution means is executed, and the process is performed from the information such as the operation rate of the process, lead time, work in progress, the number of production, waiting time It is characterized in that a step evaluation means for performing a process evaluation of the process to estimate the health.

A process design system according to a third aspect is the process design system according to the first or second aspect, in which each work process for each worker uses the work proficiency value for each worker by the work distribution means. The process design system according to claim 1 or 2, wherein the setting is performed by giving priority to a work having a low work proficiency value for each facility work.

In the process design system according to claim 1, the work distribution means includes the total number of productions obtained by the production planning means, the equipment and worker layout configuration set by the layout design means, and each preset work. Based on the work proficiency value for each person, each work process in each of the equipment and each worker is distributed.

The process evaluation means executes a simulation of the organization of each work process set by the work distribution means, estimates their operating states, and evaluates the process based on this operating state. As a result, it is possible to quickly perform a process design that provides an optimal equipment configuration with worker distribution corresponding to the actual manufacturing process.

In the process design system according to the second aspect, the operating state of the process is estimated from information such as the operating rate, the lead time, the work in progress, the number of products produced, and the waiting time by simulation of the organized work process, Process evaluation is performed based on this operating state. As a result, as in the case of the first aspect of the invention, it is possible to quickly perform a process design that allocates workers corresponding to an actual manufacturing process and has an optimum equipment configuration.

In the process design system according to claim 3, in the process design system according to claim 1 or 2,
The setting of each work process for each worker that uses the work proficiency value for each worker by the work distribution means is to prioritize the work with a low work proficiency value for each facility work. , Appropriate work distribution can be performed according to the degree of work proficiency of each worker.

[0018]

BEST MODE FOR CARRYING OUT THE INVENTION Embodiments of the present invention will be described in detail below with reference to FIGS.

FIG. 1 shows the configuration of a process design system according to an embodiment of the present invention. This process design system has a main control section 1 for controlling the overall operation.

The main control unit 1 comprises a CPU (central processing unit) and a memory. The main control unit 1 is connected to a keyboard 3 via an input unit 2 and an output unit 4. The CRT display 5 and the printer 6 are connected via the. A memory 7 that stores various kinds of information is connected to the main controller 1.

Further, the main control unit 1 includes a production planning unit 8 as a production planning unit, a layout designing unit 9 as a layout designing unit, a work distributing unit 10 as a work distributing unit, and a process evaluating unit as a process evaluating unit. 11 is connected. Incidentally, these respective elements are shown separately from the main control section 1 for the sake of illustration.

The main control unit 1 has a built-in control program that causes each function of the production planning unit 8, the layout designing unit 9, the work distributing unit 10, and the process evaluating unit 11.

The production planning unit 8 has a function of managing the quantity and delivery date of each product type corresponding to the demand fluctuation, and estimating the total production number of all the product types corresponding to the demand fluctuation. .

The layout designing unit 9 has a function of finding the number of facilities and the number of workers for achieving the total number of productions obtained by the production planning unit 8 and the layout configuration of these facilities and workers.

The work distribution unit 10 includes the total number of products obtained by the production planning unit 8 and the arrangement configuration of equipment and workers obtained by the arrangement designing unit 9 and each worker stored in the memory 7 in advance. It has a function of organizing a manufacturing process of a product to be manufactured by obtaining each work procedure (work process) of these facilities and workers based on another work proficiency value.

The process evaluation unit 11 has a function of performing the simulation of the manufacturing process obtained by the work distribution unit 10 as shown in FIG. doing.

Next, the operation of the above process design system will be described. First, design information such as each product type, quantity according to the demand of the product type, delivery date for each product type, material arrangement deadline, etc., and information on the work proficiency value are input by the key operation of the keyboard 3, and these are input. It is stored in the memory 7 according to a command from the main control unit 1.

As shown in FIG. 2, the information of the work proficiency value is work proficiency rank information (O is a proficiency level) in the work for handling all the respective facilities for each worker such as worker a, mouth and ha. Higher grades, x marks are unfamiliar ones).

When the design information is stored in the memory 7, the main controller 1 executes the function of the production planning unit 8. The production planning unit 8 causes the CRT display 5 to display, for example, the quantity, delivery date, material arrangement deadline, etc. for each production type, and obtains an estimate of the total number of productions of all production types from these design information.

Next, the main control section 1 commands the layout design section 9 to execute the function. The layout designing unit 9 uses the production planning unit 8
Calculate the total number of machine tools, etc. and the number of workers from the total production of all product types obtained in. In this case, if the manufacturing process is composed of the processes A, B, and C as shown in FIG. 3, the layout designing unit 9 achieves the total number of products of all products in the processes A, B, and C. The number of equipment (for example, 8 units) and the number of workers (for example, 2 people) are obtained, and then the arrangement of these facilities and workers is set.

The arrangement of these equipments and workers is, for example, as shown in FIG. 3, three equipments 21, 22, 23 in the process A.
In addition to arranging, the two facilities 24 and 25 are arranged in the process B, and the three facilities 26, 27 and 28 are arranged in the process C. Further, regarding the worker, the worker 29 is arranged in the equipment 23 of the process A, and the worker 30 is arranged in the equipment 28 of the process C.

Then, the layout designing unit 9 moves the moving distance of the product to be manufactured between the facilities, for example, the facilities 21 and 24, 2.
5 and the equipment 24, 25 and each equipment 26, 2
The distance between the equipment 7 and the equipment 28 is set, and the conveyance route of the product to be manufactured and the conveyance frequency thereof are set between the facilities.

Next, when the main control unit 1 issues a command to the work distribution unit 10 to execute the function, the information on the work learning value is sent from the memory 7 to the work distribution unit 10, and the work distribution unit 10 learns the work. Based on the value information, work distribution and work procedures for the respective facilities 21 to 28 arranged as shown in FIG. 3 are set. The setting method in this case is as follows.
For each equipment work, the work is distributed to each worker from the one having the smallest O mark (circle mark) shown in FIG.

For example, in the example shown in FIG. 2, of the equipment works A to E, the equipment works A, B and D have an O mark of 1.
There is only one, and the level of proficiency is low when all the workers a, b, and c see it.

Therefore, the work distribution unit 10 gives priority to each of the equipment works A, B, and D having only one O mark and distributes them to each worker, and then the equipment work E having two O marks. Is distributed to the workers a or Roni, and finally, the equipment work C having many O marks is distributed to the remaining workers.

This series of work distribution is performed by the work distribution unit 10 and the work procedure for all workers is set. As a result, the production process including the processes A, B, and C is organized, and the main control unit 1 issues a command to execute the function.

The process evaluation unit 11 executes the simulation of the manufacturing process organized by the work distribution unit 10 based on the command of the main control unit 1, and the operating rate, lead time, rank, and the number of production of this manufacturing process. , Ask for handheld time etc.

Then, the process evaluation unit 11 obtains the evaluation value 1 of the manufacturing process organized from the lead time, the work in progress, the number of productions, the handheld time and the like. Next, the process evaluation unit 11
Compares the obtained evaluation value 1 with a predetermined value obtained in the manufacturing process (steps S1 and S2). If the evaluation value 1 is lower than the predetermined value, the main control unit 1 issues a command again to the production planning unit 8, the layout designing unit 9, and the work distribution unit 10 to notify the number of equipments, the number of workers, and the equipment configuration. Change, each of the facilities 21 to 28, each worker, and the like perform change setting (step S3).

Based on the result of this change setting, as shown in FIG.
By means of 5, the composition change is performed so as to be processed in parallel.
Then, the simulation of the manufacturing process after such knitting is performed by the process evaluation unit 11, and the evaluation value 2 of this manufacturing process is obtained (step S4).

Next, the process evaluation section 11 determines the obtained evaluation value 2
And a predetermined value obtained in the manufacturing process are compared (step S5). If the evaluation value 5 obtained by the simulation of the process evaluation unit 11 is lower than a predetermined value,
The process of step S3 described above is repeated.

Such processing is repeated N times (N is a positive integer) to obtain the evaluation value N of the manufacturing process (step S6). The evaluation value N is compared with a predetermined value (step S7), and if the evaluation value N is higher than the predetermined value, the manufacturing process in this case is determined as the optimum process corresponding to the demand (step S8).

As the process organization in the processes A, B, and C, equipment 29 is added to the process B as shown in FIG. 6 according to the demand fluctuation, and each equipment of the processes A, B, and C is added. 21 to 23, facilities 24, 25, 29, and facilities 26 to 28 may be organized in a one-to-one correspondence.

According to the process design system described above,
In addition to managing the quantity and delivery date of each product type that responds to demand fluctuations, obtain an estimate of the total production number of all product types that respond to demand fluctuations, and determine the number of equipment and the number of workers to obtain this total production number. Set the arrangement of equipment and work manuals
In order to obtain work distribution and each work procedure among these facilities and workers that is close to the actual manufacturing process and with high accuracy, the manufacturing process is organized according to the information of the work familiarity value, and the manufacturing process is organized. The simulation is executed to obtain the evaluation value.

Therefore, it is possible to more clearly and swiftly organize the manufacturing process according to the demand fluctuation than the conventional process knitting apparatus, and at this time, immediately respond to the frequent addition of equipment and the increase or decrease of the number of workers. You can Further, even if the demand fluctuates, it is possible to minimize the change in the number of facilities and the number of workers in each process A, B, and C.

The present invention is not limited to the above-mentioned embodiments, but can be modified as appropriate without departing from the spirit of the invention.

[0046]

According to the first aspect of the present invention, there is provided a process design system capable of swiftly designing a process that allocates workers corresponding to an actual manufacturing process and has an optimum equipment configuration. Can be provided.

According to the second aspect of the present invention, the information such as the operating rate, the lead time, the work in progress, the number of products produced, the waiting time for the work, etc. is utilized in the same manner as the first aspect of the invention. It is possible to provide a process design system capable of swiftly designing a process in which workers are distributed according to the manufacturing process and an optimum equipment configuration is obtained.

According to the third aspect of the present invention, it is possible to provide a process design system capable of performing appropriate work distribution according to the degree of work proficiency of each worker.

[Brief description of the drawings]

FIG. 1 is a block diagram showing a configuration of a process design system according to an embodiment of the present invention.

FIG. 2 is an explanatory diagram showing information on a work proficiency value for each worker according to the embodiment of the present invention.

FIG. 3 is a block diagram showing an example of organization of work processes in the embodiment of the present invention.

FIG. 4 is a flowchart showing an evaluation procedure in the embodiment of the present invention.

FIG. 5 is a block diagram showing another example of organization of work processes in the embodiment of the present invention.

FIG. 6 is a block diagram showing still another example of organization of work processes in the embodiment of the present invention.

FIG. 7 is a block diagram showing a configuration of a conventional process design device.

FIG. 8 is a schematic diagram of a manufacturing process organized by a conventional process design device.

FIG. 9 is a schematic view of a manufacturing process organized by a conventional process design device.

FIG. 10 is a schematic diagram of a manufacturing process organized by a conventional process design device.

[Explanation of symbols]

 1 Main Control Section 2 Input Section 3 Keyboard 4 Output Section 5 CRT Display 7 Memory 8 Production Planning Section 9 Layout Design Section 10 Work Distribution Section 11 Process Evaluation Section 21 to 28 Equipment

─────────────────────────────────────────────────── ─── Continuation of front page (51) Int.Cl. ⁶ Identification code Office reference number FI technical display location // G05B 15/02 G06F 15/60 636A 0360-3H G05B 15/02 Z

Claims (3)

[Claims] 1. A production planning means for managing the quantity, delivery date, etc. of each production type corresponding to demand fluctuations, and estimating the total production quantity of all the production types corresponding to demand fluctuations, and this production planning means. In the layout design means for determining the number of equipment and the number of workers to obtain the total production number obtained in, and setting the layout configuration of these equipment and workers, the total production number obtained in the production planning means, and Work distribution for setting each work process in each equipment and each worker based on the arrangement configuration of the equipment and the worker obtained by the layout designing means and the preset work proficiency value for each worker Means, and process evaluation means for executing the simulation of the process set by the work distributing means, estimating the operating state of the process, and performing the process evaluation of the process, the process design system comprising: 2. A production planning means for managing the quantity, delivery date, etc. of each production type corresponding to demand fluctuations and estimating the total production quantity of all the production types corresponding to demand fluctuations, and this production planning means. In the layout design means for determining the number of equipment and the number of workers to obtain the total production number obtained in, and setting the arrangement configuration of these equipment and workers, and the total production number obtained by the production sketching means, Work for setting each work process in each equipment and each worker based on the layout configuration of the equipment and the worker obtained by the layout designing unit and the preset work proficiency value for each worker A process for simulating the process set by the distribution unit and the work distribution unit is performed, and the operating state of the process is estimated by estimating the operating state of the process from information such as the operating rate of the process, lead time, work in progress, the number of production, waiting time for the process. Work of A process design system comprising: a process evaluation means for performing a process evaluation. 3. The setting of each work process for each worker using the work learning value for each worker by the work distributing means is set by giving priority to a work having a low work learning value for each facility work. The process design system according to claim 1 or 2, wherein