Production management assistance system

Abstract

Provided is a production management assistance system that assists in the management of production processes in which processes performed by workers and processes performed by devices that include human-assisted work are mixed, and that does not reduce the work rate of the devices and workers that perform the human-assisted work, thereby improving productivity. The production management assistance system includes a device work information acquisition unit that acquires device work information related to the work state of a device, a worker work information acquisition unit that acquires worker work information related to the work state of a worker, a priority work determination unit that determines which of the work related to a process performed by the worker and the human-assisted work is to be prioritized based on the device work information and the worker work information, and a notification unit that notifies the worker in the case where it is determined that the human-assisted work is to be prioritized.

Description

Technical Field

[0001] This invention relates to a production management support system. Background Technology

[0002] In production lines where semi-automatic machines and operator-driven processes coexist, when a semi-automatic machine finishes its work, the operator needs to perform auxiliary tasks such as retrieving the finished workpiece from the semi-automatic machine and providing workpieces for the next operation. When the semi-automatic machine becomes a bottleneck, the operator performs work without stopping or allowing it to wait. Therefore, other processes the operator is responsible for are interrupted. If a process interruption occurs, work that should have been performed is not carried out, thus posing a risk of producing defective products.

[0003] In response, the following technologies have been proposed: in production processes where operators and automata (robots) coexist, a technology is proposed to calculate the progress of the operation, whether the operation is proceeding according to the production plan, and to reorganize the robot task and human operation instructions based on the operation status and progress (see Patent Document 1); a technology is proposed to determine whether the operation is proceeding according to the production plan and to call the operator if the operation is not proceeding according to the production plan (see Patent Document 2). However, none of these technologies are the following: when a semi-automatic machine becomes a waiting state, a judgment criterion is proposed to prompt the operator to choose whether to interrupt their own operation and switch to the assistance of the semi-automatic machine or continue their own operation.

[0004] Patent Document 1: Japanese Patent Application Publication No. 2021-93957

[0005] Patent Document 2: Japanese Patent Application Publication No. 2015-119646 Summary of the Invention

[0006] The problem that the invention aims to solve

[0007] The present invention was made in view of the aforementioned problems, and its object is to improve productivity by carrying out production without reducing the workload of equipment and operators that require human assistance.

[0008] Methods for solving problems

[0009] The present invention, which addresses the aforementioned problems, is a production management support system that assists in the management of production processes where processes performed by operators and processes performed by equipment including human assistance coexist. The production management support system is characterized by comprising: an equipment operation information acquisition unit that acquires equipment operation information related to the operating status of the equipment; an operator operation information acquisition unit that acquires operator operation information related to the operator's operating status; a priority operation determination unit that, based on the equipment operation information and the operator operation information, determines whether to prioritize the operation related to the process performed by the operator or the auxiliary operation; and a notification unit that, when it is determined that the auxiliary operation should be prioritized, notifies the operator.

[0010] Therefore, in a production process where there is a mixture of processes performed by operators and processes performed by equipment that includes human assistance, the priority operation determination unit determines, based on equipment operation information related to the working status of the equipment and operator operation information related to the working status of the operator, which should take priority: the operation related to the process performed by the operator or the auxiliary operation for the equipment. If it is determined that the auxiliary operation should take priority, the notification unit notifies the operator of this situation. Thus, production can be carried out without reducing the working efficiency of the equipment and the operator, thereby increasing productivity.

[0011] Alternatively, in this invention, it may include: an equipment production plan information acquisition unit that acquires production plan information related to the equipment, i.e., equipment production plan information; an operator production plan information acquisition unit that acquires production plan information related to the operator, i.e., operator production plan information; a first evaluation index calculation unit that calculates an equipment productivity evaluation index to evaluate the productivity of the equipment based on the equipment work information and the equipment production plan information; and a second evaluation index calculation unit that calculates an operator productivity evaluation index to evaluate the productivity of the operator based on the operator work information and the operator production plan information, wherein the priority operation determination unit determines, based on the equipment productivity evaluation index and the operator productivity evaluation index, which of the operations related to the process performed by the operator and the auxiliary operations should be prioritized.

[0012] Therefore, the priority judgment department can more accurately determine which of the operations and auxiliary operations related to the process performed by the operator should be prioritized based on the equipment productivity evaluation index and the operator productivity evaluation index, taking into account the production plan. The equipment productivity evaluation index evaluates the equipment productivity based on equipment working information and production plan information related to the equipment, while the operator productivity evaluation index evaluates the operator productivity based on operator working information and production plan information related to the operator. Thus, production can be carried out without reducing the working efficiency of the equipment and the operator, thereby improving productivity.

[0013] Alternatively, in this invention, the priority operation determination unit may determine which of the operations related to the process performed by the operator and the auxiliary operations should be prioritized based on the equipment productivity evaluation index and the operator productivity evaluation index within a specified time period close to the determination time.

[0014] In this way, based on the equipment productivity evaluation index and the operator productivity evaluation index within a specified time period close to the judgment time, it is determined whether to prioritize the operation or auxiliary operation related to the process performed by the operator. Thus, even if the working rate does not differ much if the judgment is made over a longer period, but the working rate decreases in the immediate preceding period, the judgment can be made more accurately. Therefore, production can be carried out without reducing the working rate of equipment and operators, thereby improving productivity.

[0015] Alternatively, in this invention, the priority task determination unit may determine which of the tasks related to the process performed by the operator and the auxiliary tasks should be prioritized based on the equipment productivity evaluation index and the operator productivity evaluation index, which are weighted according to the time up to the determination time.

[0016] In this way, based on the equipment productivity evaluation index and the operator productivity evaluation index, whichever is prioritized between the operation and auxiliary operation related to the process performed by the operator, the judgment can be made more accurately even if the working rate does not differ significantly if the judgment is made based on a longer time period, but the working rate decreases in the immediate period. Therefore, production can be carried out without reducing the working rate of the equipment and the operator, thereby improving productivity.

[0017] Alternatively, in this invention, the priority operation determination unit may exclude the equipment stop time from the equipment operation information and then determine which of the operations related to the process performed by the operator and the auxiliary operations should be prioritized.

[0018] Therefore, even when the working rate is estimated to be low in the event of a sudden equipment stoppage, by excluding the equipment's downtime when evaluating the equipment's working status, it is possible to accurately determine which of the operations and auxiliary operations related to the process performed by the operator takes priority. Thus, production can be carried out without reducing the working rate of the equipment and the operator, thereby increasing productivity.

[0019] Alternatively, in this invention, there may be a first evaluation index calculation unit that calculates an equipment productivity evaluation index to evaluate the productivity of the equipment based on the equipment working information and production plan information related to the equipment; a second evaluation index calculation unit that calculates an operator productivity evaluation index to evaluate the productivity of the operator based on the operator working information and production plan information related to the operator; a productivity reduction judgment unit that determines whether the equipment productivity evaluation index and the operator productivity evaluation index meet the prescribed conditions indicating a reduction in productivity; and a manager notification unit that, if the prescribed conditions are met, notifies the manager.

[0020] Therefore, when the productivity of both equipment and operators decreases, creating the possibility that the predetermined number of products cannot be produced, notification can be sent to management through the management notification department, thereby prompting appropriate countermeasures to be taken to prevent the situation from failing to produce the predetermined number of products.

[0021] Invention Effects

[0022] According to the present invention, production can be carried out without reducing the workload of equipment and operators that require human assistance, thereby increasing productivity. Attached Figure Description

[0023] Figure 1 This is a schematic structural diagram of a production management auxiliary system according to an embodiment of the present invention.

[0024] Figure 2 This is a functional block diagram of the processing unit of the production management auxiliary system according to an embodiment of the present invention.

[0025] Figure 3 This is a diagram illustrating the measurement of operator work time in a production management auxiliary system according to an embodiment of the present invention.

[0026] Figure 4 This is a graph illustrating the relationship between the target achievement rate of the semi-automatic machine and the operator and the threshold in an embodiment of the present invention.

[0027] Label Explanation

[0028] 1: Production Management Auxiliary System; 12: Semi-automatic Machine Data Provision Department; 13: Semi-automatic Machine Data Collection Department; 14: Photography Department; 15: Image Analysis Department; 111: Semi-automatic Machine Work Rate Calculation Department; 114: Operator Work Rate Calculation Department; Eq: Semi-automatic Machine; W1: Operator. Detailed Implementation

[0029] [Application Example]

[0030] Hereinafter, the production management auxiliary system 1 of the present invention will be described with reference to the accompanying drawings.

[0031] like Figure 1 As shown, the production management auxiliary system 1 is a system that assists in the management of the production process of the unit line CL. In the production process of the unit line CL, the processes performed by operators W1 and W2 and the processes performed by the semi-automatic machine Eq, which requires operators W1 to perform auxiliary operations such as workpiece preparation and recycling, coexist.

[0032] The production management support system 1 is roughly composed of a structure on the production line 10 side and a structure on the office 20 side. The production line 10 includes a unit line CL, a semi-automatic machine data collection unit 13 that collects data from the semi-automatic machine Eq, a semi-automatic machine data providing unit 12 that provides data from the semi-automatic machine Eq to the semi-automatic machine data collection unit 13, an imaging unit 14, an image analysis unit 15, a processing unit 11, and a notification unit 16.

[0033] Office 20 is the office space for production line managers, production technology managers, and other managers LL who manage the production line 10, which includes unit lines CL. Office 20 includes a processing unit 21 and a notification unit 22 connected to the processing unit 11 of the production line 10 via a network.

[0034] The processing unit 11 is composed of a general computer device and has... Figure 2 The functional units are as shown.

[0035] The processing unit 11 includes a semi-automatic machine working rate calculation unit 111, a semi-automatic machine production plan information acquisition unit 112, a semi-automatic machine target achievement rate calculation unit 113, an operator working rate calculation unit 114, an operator production plan information acquisition unit 115, an operator target achievement rate calculation unit 116, and a judgment unit 117.

[0036] The semi-automatic machine work rate calculation unit 111 calculates the actual work rate of the semi-automatic machine Eq based on the work-related information collected by the semi-automatic machine data collection unit 13. In the semi-automatic machine target achievement rate calculation unit 113, the target achievement rate of the semi-automatic machine Eq is calculated based on the actual work rate of the semi-automatic machine Eq calculated by the semi-automatic machine work rate calculation unit 111 and the target work rate of the semi-automatic machine Eq obtained from the semi-automatic machine production planning information acquisition unit 112.

[0037] The worker productivity calculation unit 114 calculates the actual productivity of worker W1 based on the working time (actual time) and actual production output of worker W1 (and W2) detected by the image analysis unit 15 analyzing the shooting data of the shooting unit 14. In the worker target achievement rate calculation unit 116, the target achievement rate of worker W1 is calculated based on the actual productivity of worker W1 calculated by the worker productivity calculation unit 114 and the target productivity of worker W1 obtained from the worker production plan information acquisition unit 115.

[0038] The judgment unit 117 compares the target achievement rate of the semi-automatic machine Eq with the target achievement rate of the operator W1. If the target achievement rate of the semi-automatic machine Eq is greater than that of the operator W1, it determines that the operator W1 should prioritize increasing the operator W1's work rate. The operator W1 does not return to the semi-automatic machine Eq but proceeds to the next step of their work process. Conversely, if the target achievement rate of the semi-automatic machine Eq is less than that of the operator W1, the judgment unit 117 determines that the operator W1 should prioritize increasing the work rate of the semi-automatic machine Eq, and performs auxiliary work on the semi-automatic machine Eq to avoid it waiting. The notification unit 16 then notifies the operator W1 to switch to the auxiliary work on the semi-automatic machine Eq.

[0039] In addition, if the target achievement rate of the semi-automatic machine Eq is lower than the specified threshold Th1, and the target achievement rate of the operator W1 is also lower than the specified threshold Th2, the judgment unit 117 judges it as an anomaly and notifies the production line manager and others working in the office 20 of the situation through the notification unit 22.

[0040] Thus, according to the production management auxiliary system 1, in order to prevent the working efficiency of the semi-automatic machine Eq and operator W1 from decreasing, it is determined whether operator W1 should continue his own work or switch to the auxiliary work of the semi-automatic machine Eq. If it is necessary to switch to the auxiliary work of the semi-automatic machine Eq, the situation is notified to operator W1. Therefore, production can be carried out without reducing the working efficiency of the semi-automatic machine Eq and operator W1, thereby improving productivity.

[0041] [Example 1]

[0042] Hereinafter, the structure of the production management auxiliary system 1 according to Embodiment 1 of the present invention will be described with reference to the accompanying drawings. The structure of the apparatus described in this embodiment should be appropriately modified according to various conditions. That is, the scope of the present invention is not limited to the following embodiments.

[0043] Figure 1 This indicates the overall structure of Production Management Auxiliary System 1.

[0044] The production management support system 1 includes a structure on the production line 10 side and a structure on the office 20 side. Production is carried out on the production line 10 via a unit line CL consisting of workstations operated by workers W1 and W2 and a semi-automatic machine Eq. The production line 10 includes: a semi-automatic machine data supply unit 12, which includes sensors installed on the semi-automatic machine Eq; a semi-automatic machine data collection unit 13, which collects data from the semi-automatic machine data supply unit 12; an image analysis unit 15, which performs image analysis such as motion detection of workers W1 and W2 operating on the unit line CL based on image information captured by the image capture unit 14; a processing unit 11, which performs the processing described later based on the data collected by the semi-automatic machine data collection unit 13 and information related to the working status of worker W1 of workers W1 and W2 detected by the image analysis unit 15; and a notification unit 16, which notifies workers W1 and W2 operating on the unit line CL of the information output based on the processing in the processing unit 11. Furthermore, the semi-automatic machine data collection unit 13, image analysis unit 15, and processing unit 11 are connected to the processing unit 21 located in the office 20 via a network. The office 20 includes the processing unit 21 and a notification unit 22 for providing information to managers such as production line managers (production technology managers) working in the office 20. Here, the semi-automatic machine Eq corresponds to the device of the present invention. Additionally, the semi-automatic machine data providing unit 12, the semi-automatic machine data collection unit 13, and the semi-automatic machine work rate calculation unit 111 (described later) correspond to the device work information acquisition unit of the present invention. The imaging unit 14, the image analysis unit 15, and the operator work rate calculation unit 114 (described later) correspond to the operator work information acquisition unit of the present invention.

[0045] The semi-automatic machine data supply unit 12 may be configured to include, for example, an OCR (Optical Character Reader), a BCR (Barcode Reader), a switch, a photoelectric sensor, an image sensor, etc. Alternatively, the semi-automatic machine data supply unit 12 may also include a PLC (Programmable Logic Controller) that controls the semi-automatic machine Eq. Depending on the configuration, the BCR, switch, photoelectric sensor, etc., may be connected via a slave terminal.

[0046] The image analysis unit 15 analyzes, for example, the shooting information captured by the shooting unit 14 such as a camera to detect the movement routes of operators W1 and W2, or to detect the production quantity of operators W1 and W2, thereby generating information related to the working status of operator W1. Alternatively, the movement lines of operators W1 and W2 can be detected using RFID tags carried by operators W1 and W2, and appropriate detection units can be used.

[0047] For example, unit line CL Figure 3 That's how it's structured. Here, the unit line CL consists of 5 workstations WB1-WB5. Operator W1 performs work on workstations WB1 and WB2. A semi-automatic machine Eq is installed on workstation WB3. Then, operator W2 performs work on workstations WB4 and WB5. Work areas WA1, WA2, WA3, WA4, and WA5 are respectively set in front of workstations WB1, WB2, WB3, WB4, and WB5. The product (also called the workpiece) PD moves from workstation WB1 to workstation WB5 in the order of arrow FL, advancing the production process. Operator W1 moves from workstation WB1 to workstation WB2 according to the work process, and then moves to workstation WB3 to perform auxiliary work for the semi-automatic machine Eq. At this time, as shown by arrow R1, operator W1 moves between work areas WA1, WA2, and WA3 according to the work. Similarly, operator W2 moves from workbench WB4 to workbench WB5 according to the work procedure. At this time, as shown by arrow R2, operator W2 moves between work area WA4 and work area WA5 according to the work.

[0048] The image analysis unit 15 analyzes the captured data from the imaging unit 14 to detect the entry and exit of operators W1 and W2 into various work areas such as WA1, calculates the working time of each work process, and generates information related to the working status, such as the production numbers of operators W1 and W2.

[0049] The processing unit 11 can be composed of a general computer device including a CPU, memory, input device, output device and communication interface.

[0050] Figure 2 This is a functional block diagram of the processing unit 11. The processing unit 11 includes a semi-automatic machine work rate calculation unit 111, a semi-automatic machine production plan information acquisition unit 112, a semi-automatic machine target achievement rate calculation unit 113, an operator work rate calculation unit 114, an operator production plan information acquisition unit 115, an operator target achievement rate calculation unit 116, and a judgment unit 117. Each of these functions is implemented by executing programs stored in memory within the CPU. The functions of each unit will be described later.

[0051] The notification unit 16 can be composed of suitable units such as a touch panel (HMI), a tablet terminal, an indicator light, and a buzzer, capable of notifying the operator W1 who is working on the unit line CL. Here, the notification unit 16 corresponds to the notification unit of the present invention.

[0052] The processing unit 21 can be composed of a general computer device including a CPU, memory, input device, output device and communication interface.

[0053] The notification unit 22 can be composed of suitable units such as PCs or tablet terminals capable of notifying managers LL, such as production line managers or production technology managers, who are working in the office 20. The notification unit 22 is connected to the processing unit 21 via a suitable communication means such as Ethernet (registered trademark) or Wi-Fi (registered trademark). Here, the notification unit 22 is equivalent to the manager notification unit of the present invention.

[0054] (Priority task determination and processing for operator W1 in processing unit 11)

[0055] The following explains the process of determining how operator W1 should respond in the processing unit 11.

[0056] The target achievement rate of the semi-automatic machine Eq is calculated in the semi-automatic machine target achievement rate calculation unit 113 of the processing unit 11. Here, the semi-automatic machine target achievement rate calculation unit 113 is equivalent to the first evaluation index calculation unit of the present invention, and the target achievement rate of the semi-automatic machine Eq is equivalent to the equipment productivity evaluation index of the present invention.

[0057] The target achievement rate of the semi-automatic machine Eq is calculated by the following formula (1).

[0058] Target achievement rate = (actual work rate of semi-automatic machine Eq) / (target work rate of semi-automatic machine Eq) ... (1)

[0059] Here, the target working rate of the semi-automatic machine is calculated in the semi-automatic machine production planning information acquisition unit 112 by the following formula (2), and the actual working rate of the semi-automatic machine Eq is calculated in the semi-automatic machine working rate calculation unit 111 by formula (3).

[0060] The target working rate of the semi-automatic machine Eq = target production time / planned working time...(2)

[0061] The actual working rate of the semi-automatic machine Eq = actual production time / actual working time...(3)

[0062] In addition, the target production time is calculated in the semi-automatic machine production planning information acquisition unit 112 using the following formula (4), and the actual production time is calculated in the semi-automatic machine working rate calculation unit 111 using the following formula (5).

[0063] Target production time = target production quantity × processing time of semi-automatic machine Eq…(4)

[0064] Actual production time = Actual production quantity × Processing time of semi-automatic machine Eq…(5)

[0065] Here, the target working rate, target production time, planned working time, target production quantity, and processing time of the semi-automatic machine Eq correspond to the equipment production planning information of the present invention, and the semi-automatic machine production planning information acquisition unit 112 corresponds to the equipment production planning information acquisition unit of the present invention. Furthermore, the actual working rate, actual production time, actual working time, and actual production quantity of the semi-automatic machine Eq correspond to the equipment working information of the present invention.

[0066] In the worker target achievement rate calculation unit 116 of the processing unit 11, the target achievement rate of worker W1 is similarly calculated using the following formula (6). Here, the worker target achievement rate calculation unit 116 is equivalent to the second evaluation index calculation unit of the present invention, and the target achievement rate of worker W1 is equivalent to the worker productivity evaluation index of the present invention.

[0067] Target achievement rate = (actual work rate of worker W1) / (target work rate of worker W1) ... (6)

[0068] Here, the target work rate of worker W1 is calculated in the worker production plan information acquisition unit 115 by the following formula (7), and the actual work rate of worker W1 is calculated in the worker work rate calculation unit 114 by the following formula (8).

[0069] The target working rate of operator W1 = (standard time × target production) / planned working time…(7)

[0070] Worker W1's actual work rate = Actual production time / Actual working time...(8)

[0071] Here, the target work rate, standard time, planned work time, and target production quantity of operator W1 correspond to the operator production plan information of the present invention, and the operator production plan information acquisition unit 115 corresponds to the operator production plan information acquisition unit of the present invention. Furthermore, the actual work rate, actual production time, and actual work time of operator W1 correspond to the operator work information of the present invention.

[0072] Then, if the following formula (9) is true, the judgment unit 117 of the processing unit 11 determines that it is necessary to prioritize improving the work efficiency of operator W1, and operator W1 should not return to the semi-automatic machine Eq to deal with it, but enter its next process.

[0073] The target achievement rate of operator W1 is less than the target achievement rate of semi-automatic machine Eq…(9)

[0074] On the other hand, if the following formula (10) is true, the judgment unit 117 of the processing unit 11 determines that it is necessary to prioritize improving the working efficiency of the semi-automatic machine Eq, and the operator W1 should return to the semi-automatic machine Eq to perform auxiliary operations such as collecting the finished workpieces in the semi-automatic machine Eq and preparing workpieces for the next operation.

[0075] The target achievement rate of operator W1 is greater than the target achievement rate of semi-automatic machine Eq…(10).

[0076] Here, the determination unit 117 corresponds to the priority operation determination unit of the present invention.

[0077] The judgments based on the above formulas will be explained using specific numerical examples.

[0078] Here, as planned values, the planned working time is set to 6 hours = 21600 seconds, the target production quantity is 200 units, the processing time for each unit is 90 seconds, and the standard operator time for each unit is 80 seconds.

[0079] In addition, as a performance value, for half a day (3 hours), the semi-automatic machine's performance production count is 80 units, the operator's performance production count is 90 units, and the operator's performance time (per unit) is 90 seconds.

[0080] Based on the above numerical examples, we obtain:

[0081] The target working rate of the semi-automatic machine Eq = 90 × 200 / 21600 = 83%.

[0082] The target work rate for worker W1 = 80 × 200 / 21600 = 74%.

[0083] The actual work rate of the semi-automatic machine Eq = 90 × 80 / 10800 = 66%.

[0084] The actual work rate of worker W1 = 90 × 90 / 10800 = 75%.

[0085] If we substitute the target work rate and actual work rate mentioned above into equations (1) and (6) respectively, and calculate the target achievement rates of the semi-automatic machine Eq and the operator W1, then:

[0086] The target achievement rate of the semi-automatic machine Eq is 0.66 / 0.83 = 79%.

[0087] The target achievement rate of worker W1 is 0.75 / 0.74 = 101%.

[0088] Here, the target achievement rate of operator W1 is greater than the target achievement rate of semi-automatic machine Eq, and the inequality in equation (10) holds. Therefore, prioritizing the improvement of the working rate of semi-automatic machine Eq, the judgment unit 117 of the processing unit 11 notifies operator W1 to return to semi-automatic machine Eq through the notification unit 16, preventing semi-automatic machine Eq from waiting. According to this notification, operator W1 does not enter the next process, but returns to semi-automatic machine Eq to perform auxiliary work, thereby improving the working rate of semi-automatic machine Eq. Therefore, production can be carried out without reducing the working rates of semi-automatic machine Eq and operator W1, thus improving productivity.

[0089] [Example 2]

[0090] Hereinafter, the production management auxiliary system 1 of Embodiment 2 of the present invention will be described. For structures identical to those in Embodiment 1, the same reference numerals will be used and detailed descriptions will be omitted. The device structure of the production management auxiliary system 1 of Embodiment 2 is the same as that of the production management auxiliary system 1 of Embodiment 1. However, in the production management auxiliary system 1 of Embodiment 2, the method for determining the priority of work for the operator W1 in the processing unit 11 differs from that in the production management auxiliary system 1 of Embodiment 1.

[0091] In Example 1, the target achievement rates of the semi-automatic machine Eq and the operator W1 are used to determine which of the two should have its work rate increased. Specifically, it is determined whether the operator W1 should proceed to the next process or return to the semi-automatic machine Eq. Even if the work rates are the same, if the work rate decreases in the preceding time step, then the work rate needs to be increased. Therefore, in Example 2, the target achievement rate at the time of determination is used to determine which of the two should be prioritized.

[0092] That is, the target achievement rate of operator W1 in the immediate preceding time of judgment is less than the target achievement rate of semi-automatic machine Eq...(11)

[0093] If the condition is met, the judgment unit 117 of the processing unit 11 determines that in order to prioritize improving the work efficiency of operator W1, operator W1 should not return to the semi-automatic machine Eq to deal with the situation, but instead proceed to its next process.

[0094] On the other hand, the target achievement rate of operator W1 in the immediate lead time is greater than the target achievement rate of semi-automatic machine Eq…(12)

[0095] If this is established, the judgment unit 117 of the processing unit 11 determines that it is necessary to prioritize increasing the working efficiency of the semi-automatic machine Eq, and the operator W1 should return to the semi-automatic machine Eq.

[0096] The judgment based on the above formula will be explained using specific numerical examples.

[0097] Here, similar to Example 1, the planned working time is set to 6 hours = 21600 seconds, the target production quantity is 200 units, the processing time for each unit is 90 seconds, and the standard operator time for each unit is 80 seconds.

[0098] In addition, as a performance value, for half a day (3 hours), the semi-automatic machine's performance production count is 40 in the first hour and 60 in the remaining 2 hours, the operator's performance production count is 40 in the first hour and 65 in the remaining 2 hours, and the operator's performance time (per unit) is 90 seconds.

[0099] Based on the above numerical examples, we obtain:

[0100] The target working rate of the semi-automatic machine Eq = 90 × 200 / 21600 = 83%.

[0101] The target work rate for worker W1 is 80 × 200 / 21600 = 74%.

[0102] At this point, for half a day (3 hours), it is

[0103] The actual work rate of the semi-automatic machine Eq = 90 × 100 / 10800 = 83%.

[0104] The actual work performance rate of worker W1 = 90 × 10⁵ / 10⁸00 = 87%.

[0105] Therefore, from the perspective of the entire 3-hour period, both the semi-automatic machine Eq and the operator W1 ensured the target work rate.

[0106] However, if we look at the latter two hours, then it is...

[0107] The actual work efficiency of the semi-automatic machine Eq = 90 × 60 / 7200 = 75%.

[0108] The actual work performance rate of worker W1 = 90 × 65 / 7200 = 81%.

[0109] Therefore, the efficiency of the semi-automatic machine Eq decreases in the latter half of the 2-hour period.

[0110] Therefore, if we calculate the target achievement rates of the semi-automatic machine Eq and the operator W1 in the immediate preceding time, i.e., the latter half of the 2 hours, using equations (1) and (6), then in the latter half of the 2 hours, the target achievement rate is...

[0111] The target achievement rate of the semi-automatic machine Eq is 0.75 / 0.83 = 90%.

[0112] The target achievement rate of worker W1 is 0.81 / 0.74 = 109%.

[0113] Here, the latter two hours correspond to a predetermined time period close to the judgment time of this invention. The length of the predetermined time period can be appropriately set.

[0114] At this point, since the inequality in equation (12) holds, the judgment unit 117 of the processing unit 11 prioritizes increasing the working efficiency of the semi-automatic machine Eq and notifies the operator W1 to return to the semi-automatic machine Eq via the notification unit 16, preventing the semi-automatic machine Eq from waiting. According to this notification, the operator W1 does not proceed to the next process but returns to the semi-automatic machine Eq, thereby increasing the working efficiency of the semi-automatic machine Eq. Therefore, production can be carried out without reducing the working efficiency of the semi-automatic machine Eq and the operator W1, thus improving productivity.

[0115] [Example 3]

[0116] Hereinafter, the production management auxiliary system 1 of Embodiment 3 of the present invention will be described. For structures identical to those in Embodiments 1 and 2, the same reference numerals will be used and detailed descriptions will be omitted. The device structure of the production management auxiliary system 1 of Embodiment 3 is the same as that of the production management auxiliary systems 1 of Embodiments 1 and 2. In the production management auxiliary system 1 of Embodiment 3, the method for determining the priority of work for the operator W1 in the processing unit 11 differs from that in the production management auxiliary systems 1 of Embodiments 1 and 2.

[0117] In Example 2, even if the work rates are the same, if the work rate decreases in the time immediately preceding the judgment, the work rate needs to be increased. Therefore, the target achievement rate in the preceding period is used to determine which of the priority semi-automatic machine Eq and the operator W1 is working. Similarly, in Example 3, even if the work rates are the same, if the work rate decreases in the time immediately preceding the judgment, the work rate also needs to be increased. Therefore, the target achievement rates are weighted and averaged to determine which of the priority semi-automatic machine Eq and the operator W1 is working.

[0118] In embodiment 3, the judgment unit 117 of the processing unit 11 determines which of the semi-automatic machine Eq and the operator W1 should prioritize work based on which inequality in equation (9) or equation (10) is true, according to the target achievement rate of each of the semi-automatic machine Eq and the operator W1.

[0119] Here, at 11:30, the judgment unit 117 of the processing unit 11 determines which of the two tasks, the semi-automatic machine Eq and the operator W1, should be prioritized. The target achievement rates of the operator W1 and the semi-automatic machine Eq for each 30-minute period from 9:00 to 11:30 are as shown in Table 1 below.

[0120] [Table 1]

[0121] 09:00～09:30 90 90 09:30～10:00 90 90 10:00～10:30 70 80 10:30～11：00 60 80 11:00～11:30 60 75

[0122] At this point, the target achievement rates of worker W1 and semi-automatic machine Eq are calculated using weighted moving averages, with the weights of the values ​​for the most recent time periods increasing. Specifically, the weights of the target achievement rates for the time periods 09:00-09:30, 09:30-10:00, 10:00-10:30, 10:30-11:00, and 11:00-11:30 are set to 1, 2, 3, 4, and 5 respectively, with the weights increasing for the most recent time periods.

[0123] The target achievement rates of operator W1 and semi-automatic machine Eq, calculated using a weighted moving average with these weights, are expressed by the following formulas. Here, the weighted moving average with these weights corresponds to the weighting of the time up to the judgment point according to the present invention.

[0124] Worker W1 target achievement rate

[0125] = (90 + 90 × 2 + 70 × 3 + 60 × 4 + 60 × 5) / (1 + 2 + 3 + 4 + 5)

[0126] =68 (%)

[0127] Target achievement rate of semi-automatic machine Eq

[0128] = (90 + 90 × 2 + 80 × 3 + 80 × 4 + 75 × 5) / (1 + 2 + 3 + 4 + 5)

[0129] =80%

[0130] At this point, the target achievement rate of operator W1 is less than the target achievement rate of semi-automatic machine Eq, and the inequality in equation (9) holds. Therefore, prioritizing the improvement of operator W1's work rate, the judgment unit 117 of the processing unit 11 determines that operator W1 should not return to semi-automatic machine Eq but should proceed to the next process. The judgment unit 117 of the processing unit 11 can notify operator W1 not to return to semi-automatic machine Eq and proceed to the next process through the notification unit 16, but if operator W1 will proceed to the next process in the first place, no special notification is necessary. In this way, operator W1 proceeds to the next process, thereby improving operator W1's work rate, thus enabling production without reducing the work rate of semi-automatic machine Eq and operator W1, thereby increasing productivity.

[0131] [Example 4]

[0132] Hereinafter, the production management auxiliary system 1 of Embodiment 4 of the present invention will be described. For structures identical to those in Embodiments 1-3, the same reference numerals will be used and detailed descriptions will be omitted. The device structure of the production management auxiliary system 1 of Embodiment 4 is the same as that of the production management auxiliary system 1 of Embodiment 1. However, in the production management auxiliary system 1 of Embodiment 4, the method for determining the priority of operator W1 in the determination unit 117 of the processing unit 11 differs from that in the production management auxiliary system 1 of Embodiment 1.

[0133] In Example 4, if the target achievement rate of the semi-automatic machine Eq and the operator W1 decreases, the predetermined number may not be produced. Therefore, when the target achievement rate of the semi-automatic machine Eq and the operator W1 is lower than their respective thresholds, the processing unit 11 reports the error to the notification unit 22 via the processing unit 21 and notifies the production line manager and other managers LL.

[0134] That is, a threshold Th1 is set for the target achievement rate of the semi-automatic machine Eq, and a threshold Th2 is set for the target achievement rate of the operator W1. Figure 4 (A) is a graph showing the change in the target achievement rate of the semi-automatic machine Eq, with the horizontal axis representing time and the vertical axis representing the target achievement rate. Figure 4 (B) also uses time on the horizontal axis and target achievement rate on the vertical axis, showing the change in the target achievement rate of worker W1. Figure 4 As shown in (A), at times T3 and T4, the objective achievement rate of the semi-automatic machine Eq is lower than the threshold Th1. Figure 4 As shown in (B), at times T3 and T4, similarly, the target achievement rate of operator W1 is also lower than the threshold Th2. For example, as Figure 4 (A) and Figure 4 As shown in (B), when the target achievement rates of both the timed semi-automatic machine Eq and the operator W1 fall below their respective thresholds Th1 and Th2 for two consecutive times, the judgment unit 117 of the processing unit 11 notifies the production line manager or other manager LL working in the office 20 of an error by displaying the situation on the display of the PC constituting the notification unit 22, or by illuminating or flashing the overlay indicator lights constituting the notification unit 22. Thus, the production line manager or other manager LL can identify the abnormality of the unit line CL and implement countermeasures required for a predetermined number of production runs. The judgment unit 117 corresponds to the productivity reduction judgment unit of the present invention.

[0135] Here, whether the target achievement rates of the semi-automatic machine Eq and the operator W1 in two consecutive timed semi-automatic tests are lower than their respective thresholds Th1 and Th2 is equivalent to whether the prescribed conditions representing a decrease in productivity of the present invention are met.

[0136] [Example 5]

[0137] Hereinafter, the production management auxiliary system 1 of Embodiment 5 of the present invention will be described. For structures identical to those in Embodiments 1-4, the same reference numerals will be used and detailed descriptions will be omitted. The device structure of the production management auxiliary system 1 of Embodiment 5 is the same as that of the production management auxiliary system 1 of Embodiment 1. However, in the production management auxiliary system 1 of Embodiment 5, the method for determining the priority of operator W1 in the determination unit 117 of the processing unit 11 differs from that in the production management auxiliary system 1 of Embodiment 1.

[0138] If there is a sudden stop such as the semi-automatic machine Eq stopping (sudden stop), the time of the sudden stop is removed from the target achievement rate calculation because the work rate is estimated to be low. Based on the target achievement rate calculated in this way, the judgment unit 117 of the processing unit 11 determines which of the semi-automatic machine Eq and the operator W1 should have its work rate increased. In the event of a sudden stop of the semi-automatic machine Eq, an abnormal signal is emitted from the semi-automatic machine Eq. Therefore, the abnormal signal is received by the semi-automatic machine data providing unit 12 and the semi-automatic machine data collecting unit 13, thereby enabling the processing unit 11 to identify the sudden stop of the semi-automatic machine Eq.

[0139] The following explanation is based on specific numerical examples.

[0140] Here, similar to Example 1, the planned working time is set to 6 hours = 21600 seconds, the target production quantity is 200 units, the processing time for each unit is 90 seconds, and the standard operator time for each unit is 80 seconds.

[0141] In addition, as a performance value, for half a day (3 hours), assume that the semi-automatic machine Eq stops in the first 30 minutes and produces 90 units in the following 2.5 hours, the operator's performance production count is 80 units, and the operator's performance time (per unit) is 90 seconds.

[0142] Here, the initial 30 minutes correspond to the stop time of the device of the present invention.

[0143] Based on the above values, we can conclude that

[0144] The target work rate of the semi-automatic machine Eq is 83%.

[0145] The target work rate for worker W1 is 74%.

[0146] At this point, for half a day (3 hours), the conclusion is...

[0147] The actual work efficiency of the semi-automatic machine Eq = 90 × 90 / 10800 = 75%.

[0148] The actual work rate of worker W1 = 90 × 80 / 10800 = 66%.

[0149] Here, the semi-automatic machine Eq stops for the first 30 minutes of the half-day (3 hours). Therefore, if we exclude these 30 minutes and calculate the actual work efficiency for the actual 2.5 hours (9000 seconds) of work, it would be:

[0150] The actual work rate of the semi-automatic machine Eq = 90 × 90 / 9000 = 90%.

[0151] The performance rate of worker W1 remained unchanged at 66%.

[0152] If we calculate the target achievement rate of the semi-automatic machine Eq after it recovers from a stop, then it is:

[0153] The target achievement rate of the semi-automatic machine Eq is 0.90 / 0.83 = 108%.

[0154] The target achievement rate of worker W1 is 0.66 / 0.74 = 89%.

[0155] At this point, since the inequality in equation (9) holds, the judgment unit 117 of the processing unit 11 determines that prioritizing the improvement of operator W1's work rate is crucial. Operator W1 should not return to the semi-automatic machine Eq to respond, but instead proceed to its next process. The judgment unit 117 of the processing unit 11 can also notify operator W1 not to return to the semi-automatic machine Eq and proceed to the next process through the notification unit 16. However, if operator W1 will proceed to the next process regardless of circumstances, no special notification is necessary. In this way, operator W1 proceeds to the next process, thereby increasing operator W1's work rate. Thus, production can be carried out without reducing the work rate of the semi-automatic machine Eq and operator W1, thereby improving productivity.

[0156] [Variation Example]

[0157] In the above embodiment, the target work rate of operator W1 varies according to the proficiency of operator W1. Therefore, the target work rate can also be set for each operator W1. Based on this, the judgment unit 117 of the processing unit 11 calculates the target achievement rate of the semi-automatic machine Eq and operator W1, and determines which side's work should be prioritized.

[0158] In addition, when the product PD type or model changes, the target work rate also changes, so the target achievement rate can also be calculated according to the type or model.

[0159] Alternatively, past target achievement rates, such as those from yesterday and the day before, can be pre-stored and used to predict the target achievement rate for the current day. The predicted target achievement rate can then be used as the threshold for notification in Example 4.

[0160] <Postscript 1>

[0161] A production management auxiliary system (1) assists in the management of production processes in which processes performed by an operator (W1) and processes performed by equipment (Eq) including human assistance exist. The production management auxiliary system (1) is characterized by comprising: an equipment operation information acquisition unit (12, 13, 111) that acquires equipment operation information related to the operation status of the equipment (Eq); an operator operation information acquisition unit (14, 15, 114) that acquires operator operation information related to the operation status of the operator (W1); a priority operation determination unit (117) that determines, based on the equipment operation information and the operator operation information, which operation related to the process performed by the operator and the auxiliary operation should be prioritized; and a notification unit (16) that notifies the operator when it is determined that the auxiliary operation should be prioritized.

Claims

1. A production management support system that assists in the management of production processes where processes performed by operators and processes performed by equipment involving human assistance coexist, the production management support system being characterized by comprising: The Equipment Operation Information Acquisition Department acquires equipment operation information related to the operating status of the equipment. The Worker Work Information Acquisition Department acquires worker work information related to the worker's work status. The equipment production planning information acquisition department acquires production planning information related to the equipment, i.e., equipment production planning information; The operator production plan information acquisition unit acquires production plan information related to the operator, namely, operator production plan information; The first evaluation index calculation unit calculates an equipment productivity evaluation index to evaluate the productivity of the equipment based on the equipment working information and the equipment production plan information. The second evaluation index calculation unit calculates an operator productivity evaluation index to evaluate the operator's productivity based on the operator's work information and the operator's production plan information. The priority task determination unit determines, based on the equipment productivity evaluation index and the operator productivity evaluation index, which of the tasks related to the process performed by the operator and the auxiliary tasks should be prioritized. as well as The notification department, when determining that the auxiliary operation should be given priority, notifies the operator.

2. The production management auxiliary system according to claim 1, characterized in that, The priority task determination unit determines, based on the equipment productivity evaluation index and the operator productivity evaluation index within a specified time period close to the determination time, which of the tasks related to the process performed by the operator and the auxiliary tasks should be prioritized.

3. The production management auxiliary system according to claim 1, characterized in that, The priority task determination unit determines, based on the equipment productivity evaluation index and the operator productivity evaluation index weighted according to the time up to the determination time, which of the tasks related to the process performed by the operator and the auxiliary tasks should be prioritized.

4. The production management auxiliary system according to any one of claims 1 to 3, characterized in that, After excluding the equipment stop time from the equipment work information, the priority operation determination unit determines which of the operations related to the process performed by the operator and the auxiliary operations should be prioritized.

5. The production management auxiliary system according to claim 1, characterized in that, The production management auxiliary system has the following features: The productivity reduction judgment unit determines whether the equipment productivity evaluation index and the operator productivity evaluation index meet the prescribed conditions indicating a reduction in productivity; and The management notification department notifies the manager if it determines that the specified conditions are met.

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