Sewing assembly line mixed style intelligent ranking method and system

Abstract

The invention belongs to the field of production management, and discloses a method and a system for intelligently arranging mixed styles on a sewing assembly line, and the method comprises the steps: combining the working procedures of various styles into operation elements according to the similarity detection and mixed style process analysis of single style process analysis data before the mixed arrangement production of various styles; generating a mixed intelligent process flow diagram containing an operation element table based on the operation elements; calculating order values of the operation elements according to the wiring setting parameters in combination with the mixed intelligent process flow diagram, generating an operation element sequence table, and combining the operation elements according to a preset rule to obtain an optimal arrangement scheme of the operation elements; and calculating the commissioning sequence of the mixed arrangement of the styles, and cyclically commissioning in the mixed assembly line according to the commissioning sequence. According to the method, small and medium-sized clothing factories are not subjected to high equipment investment, and for quick-return small bills with multiple styles, small quantity and tight delivery time, the small bills are changed into large bills, so that continuous and efficient output is realized.

Description

Technical Field

[0001] The present invention relates to the field of production management, and in particular to a method and system for intelligently ranking mixed styles of sewing lines. Background Art

[0002] As consumer demand becomes more personalized and diversified, clothing orders become more fragmented. Customers demand the simultaneous production of multiple styles on one assembly line and hope to gradually deliver them in multiple batches, rather than using the traditional single-style batch delivery. Therefore, in order to cope with this change, many clothing manufacturers are in urgent need of the ability to continuously and efficiently mix and produce multiple styles on a single assembly line.

[0003] The existing intelligent balancing technology of sewing lines mainly balances the production line for a single style. It relies on the standard working hours of each single garment process to calculate and configure the production line. It cannot achieve the balance of multiple styles at the same time, which limits the flexibility of the production line and the ability to respond to changing market demands. In addition, the single-style production method may cause the production line to stagnate when processing multiple orders, increase the production cycle, and affect the delivery speed.

[0004] Therefore, how to achieve intelligent ranking of mixed styles on an assembly line and produce multiple styles simultaneously quickly and efficiently is a problem that needs to be solved urgently. Summary of the invention

[0005] The embodiments of the present invention provide a method and system for intelligent ranking of mixed styles of sewing lines, so as to solve the problem that the existing intelligent balancing technology of sewing lines mainly performs balanced arrangement of the line for a single style, and relies on the standard working hours of the process of each single garment to perform calculations and line configuration, and cannot achieve the arrangement balance of multiple styles at the same time, thus limiting the flexibility of the production line and the ability to respond to changing market demands.

[0006] In order to have a basic understanding of some aspects of the disclosed embodiments, a brief summary is given below. This summary is not intended to be a general review, nor is it intended to identify key / important components or to delineate the scope of protection of these embodiments. Its only purpose is to present some concepts in a simple form as a preface to the detailed description that follows.

[0007] According to a first aspect of an embodiment of the present invention, a method for intelligently ranking mixed styles of sewing lines is provided.

[0008] In one embodiment, the method for intelligent ranking of mixed styles on a sewing line includes:

[0009] Before mixed production of various styles, the processes of various styles are merged into operation elements based on the similarity detection of single-style process analysis data and mixed-style process analysis, and a mixed-style intelligent process flow chart containing an operation element table is generated based on the operation elements;

[0010] According to the line setting parameters and combined with the mixed style intelligent process flow chart, the rank value of the operation element is calculated, and the operation element sequence table is generated based on the price value. The operation elements are combined according to the preset rules to obtain the optimal ranking plan for the operation elements; the production order of each style of mixed arrangement is calculated, and the production is cyclically carried out in the mixed assembly line according to the production order.

[0011] In one embodiment, before the mixed production of various styles, the processes of various styles are merged into operation elements according to the similarity detection of single-style process analysis data and mixed-style process analysis, and a mixed-style intelligent process flow chart including an operation element table is generated based on the operation elements, including:

[0012] Select a specified single process data as the reference standard to perform similarity comparison one by one, and match the components and processes in each style to generate a style and process comparison list;

[0013] Based on the style and process comparison list, merge the process data of each single style into comprehensive process data and generate an operation element table;

[0014] Based on the operation element table, a comprehensive process flow chart is automatically generated, and the mixed-mode assembly line problem is converted into a single-mode assembly line problem.

[0015] In one embodiment, the expression for selecting a specified single process data as a reference standard for similarity comparison is:

[0016]

[0017] In the formula, E 相 Indicates the similarity of styles; i represents the style involved in the similarity comparison, and the value ranges from 1 to n. i Indicates the number of basically the same processes for style i; ST i Indicates the total number of processes for style i; D i S represents the number of processes that are more similar to style i; i represents the number of processes with fewer similarities to style i; X D Indicates a similar coefficient (e.g. 0.8); X S Indicates a smaller similarity coefficient (e.g. 0.6).

[0018] In one embodiment, the process of calculating the rank values ​​of the operation elements according to the line setting parameters and combining the mixed-style intelligent process flow chart, generating the operation element sequence table based on the price value, combining the operation elements according to the preset rules, and obtaining the optimal ranking scheme of the operation elements; calculating the production sequence of the mixed-style production, and cyclically producing in the mixed production line according to the production sequence includes:

[0019] Filter comprehensive process analysis data and set wiring parameters;

[0020] Calculate production parameters based on wiring parameters and comprehensive process flow chart, determine the order value of operation elements, and generate the operation element sequence table;

[0021] In the operation element sequence table, the operation elements are combined into operation units according to the wiring parameters, and the operation time is calculated to obtain the optimal operation unit combination plan;

[0022] Sort each work unit according to the average total workstation time, number of work elements, and process difficulty;

[0023] Select the employees to be matched, configure sufficient teams, and establish a data interface with the MES system or hanging system;

[0024] Automatically match employees, generate production line ranking balance table and bar chart balance chart, and allow employee replacement;

[0025] Select the assembly line layout style according to the wiring plan, determine the number of on-site workstations, and generate a production line layout diagram to complete the intelligent mixing of various styles.

[0026] In one embodiment, the production parameters include average production distance, number of workstations, operation element time, total time per person, and upper and lower limits.

[0027] In one embodiment, the calculation of production parameters based on the wiring parameters and the comprehensive process flow chart, determining the order values ​​of the operation elements, and generating the operation element sequence table includes:

[0028] According to the time of each process contained in the operation element, the daily planned quantity of each process, and the comprehensive process flow chart, the operation time of the operation element, the total time per person, the number of operation elements, the upper and lower limits, and the number of required people are automatically calculated in the background;

[0029] According to the comprehensive process flow chart and the operation time of the operation elements, all subsequent operation elements of each operation element are found, and the sum of their operation times is calculated to obtain the order value of the operation element;

[0030] Sort the assembled components and compare the rank value of the first operation element of each component; sort the components from large to small according to the rank value, select all the operation elements of each component from high to low according to the price value, and finally generate the operation element sequence table;

[0031] According to the total time per person and upper and lower limits on the toolbar, pre-process the job elements and combine the job elements into job units.

[0032] In one embodiment, in the operation element sequence table, the operation elements are combined into operation units according to the wiring parameters, and the operation time is calculated to obtain the optimal operation unit combination scheme, which includes:

[0033] Select the operation elements in turn, and calculate the operation time and required number of people for each new operation unit;

[0034] Check whether the current operation unit meets one of the following conditions;

[0035] If the current operation unit does not trigger the end condition, continue to add operation elements to the operation unit, update the operation time and number of people, and return to the step of checking whether the current operation unit meets one of the following conditions to continue the judgment;

[0036] If the end condition is met, the construction of the current work unit is ended. If there are still unassigned work elements, a new work unit construction is restarted, and the process returns to the step of selecting work elements in sequence.

[0037] For each balance rate, evaluate all combinations of work units; select the combination with the highest balance rate of work units and the smallest variance of workstation operation time; if the two conditions are the same, select the combination with the largest number of work units;

[0038] If the balance rate interval is set, the optimal operation unit combination scheme of multiple balance rates is provided.

[0039] In one embodiment, the checking whether the current operation unit meets one of the following conditions includes: the number of workstations exceeds the maximum number of parallel workstations, the number of machines exceeds the maximum number of equipment, and the number of operation elements exceeds the maximum number of operation elements.

[0040] In one embodiment, the automatic matching of employees, generating a production line ranking balance table and a bar chart balance chart, and allowing employee replacement includes:

[0041] Calculate and display the ranking balance rate of the operation unit in the production line ranking balance table;

[0042] Automatically generate a production line ranking balance table and a corresponding bar chart, which displays the operation time of each operation unit;

[0043] In the production line ranking balance bar chart interface, the operation unit number is displayed at the bottom and the number of people is displayed at the top; the bar chart includes three horizontal lines indicating the upper limit, the total time per person and the lower limit, and also displays the production line ranking balance rate of each operation unit.

[0044] According to a second aspect of an embodiment of the present invention, a system for intelligent ranking of mixed styles on a sewing line is provided.

[0045] In one embodiment, the system for intelligent ranking of mixed styles of sewing lines comprises:

[0046] The process analysis and operation element generation module for mixed styles is used to merge the processes of each style into operation elements based on the similarity detection of single-style process analysis data and mixed-style process analysis before mixed-style production, and generate a mixed-style intelligent process flow chart containing an operation element table based on the operation elements;

[0047] The module for calculating the arrangement and production sequence of operating elements is used to calculate the rank value of operating elements according to the arrangement setting parameters and the mixed-style intelligent process flow chart, and to generate an operating element sequence table based on the price value, and to combine the operating elements according to preset rules to obtain the optimal ranking plan for the operating elements; calculate the production sequence of mixed arrangements of various styles, and cyclically put them into production in the mixed assembly line according to the production sequence.

[0048] According to a third aspect of an embodiment of the present invention, a computer device is provided.

[0049] In one embodiment, the computer device includes a memory and a processor, the memory stores a computer program, and the processor implements the steps of the above method when executing the computer program.

[0050] According to a fourth aspect of embodiments of the present invention, a computer-readable storage medium is provided.

[0051] In one embodiment, the computer-readable storage medium stores a computer program, and the computer program implements the steps of the above method when executed by a processor.

[0052] The technical solution provided by the embodiment of the present invention may have the following beneficial effects:

[0053] 1. The present invention can quickly arrange a high-efficiency mixed-style assembly line, greatly improving the production efficiency of mixed styles. With the improvement of the production efficiency of mixed styles, the factory will have a competitive advantage in accepting small orders with quick returns, and will no longer be limited by professional IE personnel (people engaged in industrial engineering). An ordinary employee can also easily cope with the mixed-style arrangement. The results of the intelligent ranking of mixed styles can be pushed to the intelligent flow trough and hanging, so that the assembly line can be arranged faster and the balance rate is higher, further improving its production efficiency, and giving it an industrial brain; the software has embedded IE professional knowledge, and ordinary small factories can also achieve lean production and intelligent manufacturing, freeing IE from ranking, allowing it to make more valuable process improvements and reduce bottlenecks. With the support of software, the factory can continuously pass on the results of IE engineering and lean production, and will not be terminated due to staff loss.

[0054] 2. The present invention allows small and medium-sized garment factories to quickly arrange multiple small orders with many styles, small quantities and tight delivery dates on one assembly line, just like Toyota's assembly line, without making high equipment investments or hiring professional IE personnel, so that small orders can be turned into large orders, with continuous and efficient output, reducing production efficiency losses caused by frequent changes of machines, frequent allocation of employees, and frequent balancing of production lines. BRIEF DESCRIPTION OF THE DRAWINGS

[0055] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments consistent with the invention and, together with the description, serve to explain the principles of the invention.

[0056] Figure 1 is a flow chart showing a method for intelligent ranking of mixed styles on a sewing line according to an exemplary embodiment;

[0057] Figure 2 It is a principle block diagram of a system for mixed-style intelligent ranking of sewing lines according to an exemplary embodiment;

[0058] Figure 3 The figure is a schematic diagram showing the structure of a computer device according to an exemplary embodiment. DETAILED DESCRIPTION

[0059] The following description and accompanying drawings fully illustrate the specific embodiments of this article so that those skilled in the art can practice them. Parts and features of some embodiments may be included in or replace parts and features of other embodiments. The scope of the embodiments of this article includes the entire scope of the claims, as well as all available equivalents of the claims. Herein, the terms "first", "second", etc. are only used to distinguish one element from another, without requiring or implying any actual relationship or order between these elements. In fact, the first element can also be called the second element, and vice versa. Moreover, the terms "include", "comprise" or any other variant thereof are intended to cover non-exclusive inclusion, so that the structure, device or equipment including a series of elements includes not only those elements, but also other elements that are not explicitly listed, or also include elements inherent to such structure, device or equipment. In the absence of more restrictions, the elements defined by the sentence "including one..." do not exclude the existence of other identical elements in the structure, device or equipment including the elements. Each embodiment is described in a progressive manner herein, and each embodiment focuses on the differences from other embodiments, and the same and similar parts between the embodiments can be referred to each other.

[0060] The terms "longitudinal", "lateral", "upper", "lower", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", etc. in this document indicate the orientation or position relationship based on the orientation or position relationship shown in the drawings, and are only for the convenience of describing this document and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operate in a specific orientation, and therefore cannot be understood as a limitation on the present invention. In the description of this document, unless otherwise specified and limited, the terms "installed", "connected", and "connected" should be understood in a broad sense, for example, it can be a mechanical connection or an electrical connection, it can also be the internal communication of two elements, it can be a direct connection, or it can be an indirect connection through an intermediate medium. For ordinary technicians in this field, the specific meanings of the above terms can be understood according to specific circumstances.

[0061] As used herein, the term "plurality" means two or more than two, unless otherwise specified.

[0062] In this document, the character " / " indicates that the preceding and following objects are in an "or" relationship. For example, A / B means: A or B.

[0063] In this article, the term "and / or" is a description of the association relationship between objects, indicating that three relationships may exist. For example, A and / or B means: A or B, or, A and B.

[0064] It should be understood that, although the various steps in the flow chart are displayed in sequence according to the indication of the arrows, these steps are not necessarily executed in sequence according to the order indicated by the arrows. Unless there is a clear description in this article, the execution of these steps is not strictly limited in order, and these steps can be executed in other orders. Moreover, at least a portion of the steps in the figure may include multiple sub-steps or multiple stages, and these sub-steps or stages are not necessarily executed at the same time, but can be executed at different times, and the execution order of these sub-steps or stages is not necessarily to be carried out in sequence, but can be executed in turn or alternately with other steps or at least a portion of the sub-steps or stages of other steps.

[0065] Each module in the device or system of the present application can be implemented in whole or in part by software, hardware, or a combination thereof. The above modules can be embedded in or independent of a processor in a computer device in the form of hardware, or can be stored in a memory in a computer device in the form of software, so that the processor can call and execute operations corresponding to the above modules.

[0066] In the absence of conflict, the embodiments of the present invention and the features of the embodiments may be combined with each other.

[0067] Figure 1 An embodiment of the method for intelligently ranking mixed styles of sewing lines of the present invention is shown.

[0068] In one embodiment, the method for intelligent ranking of mixed styles on a sewing line includes:

[0069] Step S101, before mixed production of various styles, based on the similarity detection of single-style process analysis data and mixed-style process analysis, the processes of various styles are merged into operation elements, and a mixed-style intelligent process flow chart including an operation element table is generated based on the operation elements.

[0070] In this optional embodiment, before the mixed production of various styles, the processes of various styles are merged into operation elements according to the similarity detection of the single-style process analysis data and the mixed-style process analysis, and a mixed-style intelligent process flow chart including an operation element table is generated based on the operation elements, including:

[0071] Select the designated single-style process data as the reference standard to perform similarity comparison one by one, and match the components and processes in each style to generate a style and process comparison list; based on the style and process comparison list, merge the single-style process data into comprehensive process data, and generate an operation element table; based on the operation element table, automatically generate a comprehensive process flow chart, and convert the mixed-style mode assembly line problem into a single-mode assembly line problem.

[0072] In this optional embodiment, the expression for selecting a specified single process data as a reference standard for similarity comparison one by one is:

[0073]

[0074] In the formula, E 相 Indicates the similarity of styles; i represents the style involved in the similarity comparison, and the value ranges from 1 to n. i Indicates the number of basically the same processes for style i; ST i Indicates the total number of processes for style i; D i S represents the number of processes that are more similar to style i; i represents the number of processes with fewer similarities to style i; X D Indicates a high similarity coefficient (e.g. 0.8); X S Indicates a smaller similarity coefficient (e.g. 0.6).

[0075] It needs to be explained that before the various styles are mixed, the process data of a single style must be available first. In the standard working time module of the system, single process analysis, employee files, and employee skill matrix must be carried out first to issue a single process table and a single process flow chart; single process list information (including: components, process code, process name, process standard time, process level, process category, machine type (whether it is "off-line"), auxiliary tools (whether it is "need to be installed"), etc.); in the process flow chart, based on the component assembly relationship defined in the process flow chart, the system automatically calculates and generates a process sequence table for the entire style; this information can be implemented in the standard working time software module, or in manually entered or imported working time data.

[0076] Among them, single process analysis includes: establishing a process vocabulary, component vocabulary, and style analysis in the standard working time software to issue a single process list and process flow chart.

[0077] The process word library includes: establishing a process database by style category and component, defining process code, name, standard time, process level, standard labor price, machine type, auxiliary tools (whether "need to be installed"), process category and other parameters. When adding, you can choose to create a new one, copy a process from the word library, or copy a process from a previous style analysis.

[0078] Among them, the parts vocabulary includes: establishing a parts database according to style categories and parts, defining the codes and names of parts, and when adding processes in the parts-process list, you can choose to copy processes from the vocabulary, copy processes from parts, and copy processes from previous style analysis.

[0079] Among them, style analysis includes: establishing style vocabulary according to style category, copying process and component content from process vocabulary, component vocabulary and previous style analysis to form the process data of a style; for processes that do not participate in wiring, select "out-of-line" mark in Style Analysis-Edit Process, and for components that do not participate in wiring, mark "out-of-line" in Style Analysis-Component List. This component is not displayed in the process flow chart. Processes like cutting and packaging usually do not participate in assembly line ranking and are only used for piecework wages; in style analysis, you can use the mouse to drag the up and down order of components. The component order here is the left and right order of components in the process flow chart.

[0080] Among them, the process list includes: based on the style analysis, the system will automatically generate a process list for the entire style. You can use the mouse to drag the up and down order of the processes. The order of the processes in the components is the order of the processes in the components in the process flow chart.

[0081] Among them, the single process flow chart includes: according to the style analysis, the system will automatically generate a process flow chart. You only need to connect the parts with arrows to mark the assembly relationship between the parts. The system will automatically calculate and generate a process sequence table according to the algorithm. The algorithm is as follows: According to the process flow chart, find all subsequent processes of each process and calculate their total working hours, that is, the rank value of each process (rank value = the sum of the process time and the time of all subsequent processes). For the component assembly process, judge in order from large to small according to the price value, and sort the processes of the components one by one according to the total accumulated time of the immediately preceding component processes from large to small (if there is no process in the component, sort them according to the rank value from large to small) until all the immediately preceding component processes are arranged. Then, judge the next component assembly process until all processes are sorted, and finally generate the process sequence table of the entire style; if you want to adjust the position of the component in the process flow chart, drag and adjust the order of the components in the style analysis; if you want to adjust the order of the components in the process flow chart, drag and adjust the order of the components in the process list. If the original process flow chart is deleted, the system will regenerate the process flow chart, and then manually connect the components with arrows to mark the assembly relationship between the components.

[0082] Among them, employee files include: maintaining employee files by production line, selecting multiple employees, setting interpersonal relationships, and employees with "tense" interpersonal relationships cannot be arranged in the same work unit when matching employees, and cannot be adjacent to workstations in front, behind, left, or right when arranging vehicles.

[0083] Among them, employee skills include: maintaining employee skill categories and skill matrices by style category. When ranking and matching employees, the system automatically selects employees with the least skill hours from unassigned employees in order of work units, from high to low (skill hours = standard hours / skill degree), and matches employees one workstation at a time.

[0084] Among them, the process category settings include: divided into three levels (public process category, major process category, and minor process category). The subclass inherits the process category of the parent class and is updated synchronously. The process categories of different levels can be marked with colors. The first level is: public process category, whose content can be inherited by style category-major category. The second level is: style category-major process category, which inherits the public process category and defines the private process category of each major category. The third level is: style category-major category-minor category process category, which inherits the process category of the major category to which it belongs and defines the private process category of each minor category. When the private process category of the subclass changes, it only affects itself and is not updated synchronously. When creating a new process word library, the process categories corresponding to the minor category (including: the private process categories of the parent category and the minor category) are listed for selection. When the process word library is copied across major categories (parent categories), except for the public process categories, all others must be re-selected in the process category of the target category (major category + minor category private). When the process word library is copied across subcategories (subcategories), except for the process categories of the main category (parent category), all others must be reselected from the process categories of the target category (private to the subcategory). The process categories of the next level can be migrated to the process categories of the upper level, and the corresponding process word library-process category corresponding level will automatically change.

[0085] Among them, skill level settings include: defining employee skill levels and using them in the skill matrix.

[0086] Among them, the employee skill matrix includes: selecting the style category-subcategory, bringing out its process category, and setting the skill matrix of the production line employees. Or after completing the style analysis, extract all the process categories of the style process, filter, and set the employee skill matrix, because the style analysis may select components and processes across categories for combination, and its process category may belong to different style categories. Define the proficiency of each process category mastered by the employee. When arranging the production line, the system automatically selects the employee with the least skill hours (skill hours = standard hours / skill degree) from the unassigned employees in the order of the work units, from high to low, and matches the employees one by one at each workstation.

[0087] Among them, employee skill updates include: the detailed data of employee workmanship that can be imported into MES (manufacturing execution system) and hung, and the system calculates the employee's latest process workmanship skills (skill rate = output * standard working hours / working time), and after comparing with historical skills, batch updates are performed (reducing the workload of manual maintenance) to participate in the next intelligent ranking. For example, multiple models are as follows: On the mixed-model assembly line, there are currently model A: 321FB (style), model B: 321DB (style), with an average daily output of 350 and 400 pieces respectively, and an effective working time of 9 hours in a working day. For example, a single model is as follows: On a single-model assembly line, there are currently model A: 321FB, with an average daily output of 750 pieces respectively, and an effective working time of 9 hours in a working day. 321FB, standard working hours A = 513.2 (seconds). 321DB, standard working hours B = 502.5 (seconds).

[0088] Among them, similarity detection-comprehensive process analysis includes: once the process data of a single model is available, before the models are mixed, a single process analysis data (multiple or 1) must be selected to perform similarity detection and comprehensive process analysis on each model, and each process step is merged into an elemental task, a task element table is generated, and a comprehensive process flow chart is automatically generated, thereby converting the mixed mode assembly line problem into a single mode assembly line problem for solution.

[0089] Among them, style similarity detection includes: not all styles are suitable for mixed production on a single assembly line. Only when the structure, process and equipment are similar, can mixed production make sense. Otherwise, the efficiency of mixed production is too low. Therefore, before issuing a mixed production plan to the production line, it is necessary to first perform style similarity detection on multiple mixed styles. Select single process analysis data (multiple or 1), the system uses the first style as the benchmark, compares and matches each component and each process, merges each style in turn (off-line processes do not participate in the comparison), and generates a style process comparison list (each style is displayed in a vertical column). Different similarities can be distinguished by color. Basically the same process (same parts, same process abbreviation, same machine, auxiliary tools (considered the same without installation), same skill process type, i represents the style participating in the similarity comparison, the value ranges from 1-n, and the number of basically the same processes for each style is expressed by T. i The processes with more similarities (same parts, same machines, same skill process types) are calculated based on 80% similarity (the coefficient is expressed as X D Indicated by %, % custom), the quantity is expressed by D i For processes with less similarity (same parts, same machines), the similarity is calculated as 60% (the coefficient is expressed as X S Indicated by %, % custom), the quantity is expressed by S i Indicates; ST iIndicates the total number of processes for style i; the system calculates the similarity %, and manually determines whether it can be mixed. The calculation formula is as follows:

[0090]

[0091] An example is as follows: The number of process steps for model 321FB is 13, the number of process steps for model 321DB is 13, there are 12 basically identical process steps, 0 more similar process steps, and 0 less similar process steps. The calculation formula is: [(12+12)+0.8*0+0.6*0]*100% / (13+13)=[24 / 26]*100%≈92%.

[0092] Among them, the comprehensive process analysis includes: after the style similarity test is passed, the processes of each style are merged into "operation elements", that is, the process data of each single style are merged into a comprehensive process data (if only one style is selected, the name of the operation element is automatically taken from the process abbreviation), and its smallest operation unit is the "operation element"

[0093] (Elemental Task), generate the job element table, the system will automatically generate a comprehensive process flow chart, so as to convert the mixed mode assembly line problem into a single mode assembly line problem (only the in-line process generates job elements).

[0094] Among them, the synthesis of operation elements includes: based on the style and process comparison list, the system uses the first style as the benchmark to merge and generate the operation element table, merge styles one by one, parts one by one, and processes one by one. If there is only one style, the system automatically takes the process abbreviation as the name of the operation unit. The merging principle is: the same process abbreviations are merged, and different processes are retained. Basically the same processes (same parts, same process abbreviations, same machines, same auxiliary tools (considered the same without installation), and the same skill process type are automatically merged, and the operation element name defaults to the process abbreviation. When similar processes (same parts, same machines, same skill process types) are manually dragged to a certain operation element, the system prompts "Change the name of the operation element", or manually drag and insert them into the operation element table, and the operation element name defaults to the process abbreviation. Processes with different parts and machines cannot be merged, and can only be manually dragged and inserted into the operation element table. The operation element name defaults to the process abbreviation. For parts that are not in the first base style, the entire part can be directly dragged from other styles to merge. Note: The order of manually dragging the entire part is allowed, which determines the left and right positions of the parts in the comprehensive operation flow chart for easy connection.

[0095] Among them, the assembly relationship line between components: allows manual dragging of the order of the operation elements in the components, which determines the front and back positions of the operation elements in the comprehensive operation flow chart. It allows the processes contained in the operation elements to be released and manually re-merged. An "operation element" may correspond to one process, or it may correspond to multiple processes (which can be exactly the same or partially the same). The combined processes are marked with colors for easy search.

[0096] Among them, the comprehensive process flow chart includes: after confirming the synthetic operation elements, the system will automatically generate a comprehensive process flow chart. You only need to connect the components with arrows to mark the assembly relationship between the components, so as to convert the mixed-mode assembly line problem into a single-mode assembly line problem to solve; in the comprehensive process flow chart interface, its smallest operation unit is the "operation element" (Elemental Task). Select a certain operation element to view the processes it contains. One operation element may correspond to one or more processes for multiple styles; it will take effect after confirmation, and you can see the comprehensive process data source in the mixed-mode ranking navigation.

[0097] Step S103, according to the line setting parameters, combined with the mixed style intelligent process flow chart, calculate the rank value of the operation element, and generate the operation element sequence table based on the price value, combine the operation elements according to the preset rules, and obtain the optimal ranking plan for the operation elements; calculate the production order of each style of mixed arrangement, and cyclically put them into production in the mixed assembly line according to the production order.

[0098] In this optional embodiment, the order values ​​of the operation elements are calculated according to the line setting parameters in combination with the mixed-style intelligent process flow chart, and the operation element sequence table is generated based on the price value, and the operation elements are combined according to the preset rules to obtain the optimal ranking scheme of the operation elements; the production order of each style of mixed arrangement is calculated, and the production is cyclically started in the mixed assembly line according to the production order, including:

[0099] It should be explained that after selecting the effective comprehensive process analysis data and setting the line arrangement parameters (the planned quantity of each item, the effective working time or the start and end time period, the balance rate or the upper and lower limits), the system will automatically calculate the average production distance, the number of workstations, the operation element time, the total time per person, and the upper and lower limits, and then combine it with the mixed intelligent process flow chart to calculate the operation element rank value and generate the operation element sequence table.

[0100] In specific applications, the work elements are automatically (or manually) combined into "work cells" (1 work cell corresponds to 1 or more workstations or workers) according to preset rules. The average total time of the workstation cannot exceed the upper and lower limits. The group with the highest work unit balance rate and the smallest variance of the average total time of the workstation is taken as the optimal ranking scheme for the work elements. The cycle and production order of mixed styles are also calculated. Each style is put into production in a cycle in the mixed assembly line according to the production order, which effectively reduces the uneven load of the work unit and realizes leveled production. Then sort the work units (can be adjusted manually by dragging and dropping), match the best employees to the work units (intelligent or manual) according to the style classification-skill category, quickly realize the balance of production line ranking, and automatically (or manually) generate the production line arrangement according to the production line layout style. Filter the comprehensive process analysis data and set the line arrangement parameters. Then enter the restriction parameters used to set the combination of work elements, including: maximum number of equipment, maximum parallel workstations, and maximum number of work elements. You also need to set the assembly line parameters, including: the number of combined lines (for simple styles, several identical sections are arranged on one assembly line), unit group (for complex styles, they are split into multiple component production lines), and transfer batch (for a single style, the minimum number of pieces in the transfer batch).

[0101] Among them, the wiring parameter settings include: selecting the effective comprehensive process analysis data (which styles the system detects), entering the planned quantity of each style, effective working time (or start and end time period), balance rate or upper and lower limits, and the system background automatically calculates the average production distance, number of workstations, operation element time, total time per person and upper and lower limits, and then combines the mixed style intelligent process flow chart to calculate the operation element rank value, generate the operation element sequence table, and also calculate the mixed style cycle, production ratio, inverse of production ratio, and mixed style production order.

[0102] The following are the descriptions of the line arrangement parameters: Production mode: arrange workers by work - automatic (the system calculates the total time per person, upper and lower limits, and automatically or manually combines the work elements into work units); Working time: enter the effective working time of the production line, or enter the start time and end time of production; Planned quantity: enter the daily planned quantity of each item, and each item is displayed separately; Balance rate: enter the target efficiency of the production line ranking, or, Upper and lower limits %: fill in the upper and lower limits % [Upper and lower limits = total time per person * (1 ± upper and lower limits %)]; Balance rate interval: fill in a balance rate interval value (if the balance rate interval is selected =Time, the balance rate, upper and lower limits (%) will no longer be displayed. In manual mode, the balance rate interval will not be displayed); Maximum number of equipment: the maximum number of equipment allowed to be placed at a workstation; Maximum parallel workstation: the maximum number of workstations (number of people) allowed in a work unit; Number of work elements: the maximum number of work elements that can be assigned to a work unit. If no limit is set, fill in 0; Number of combined lines: the default is 1, and manual modification is allowed (the content of the balance sheet of N segments of the same work unit is combined on one physical line. There are several online and offline ports, the number of people at the workstation doubles, and the working time doubles). Split group: the default is 1 group, which can be split into multiple groups for parallel production (each group has 1 or more parts). The grouping and combining work elements are one work unit each, and the work unit balance is achieved separately. Transfer batch: the minimum number of pieces in the transfer batch, the default is 1, and manual modification is allowed. The comprehensive process analysis data is only displayed when there is only one model. The assembly line rhythm = bottleneck time * transfer batch will be displayed in the work unit balance sheet.

[0103] Among them: balance rate, upper and lower limits, can only choose 1 out of 2, and they are mutually exclusive with the balance rate range, so choose 1 out of 2. The number of combined lines and unit group are mutually exclusive, so choose 1 out of 2. The daily planned quantity of each item can be manually calculated and input or from APS advanced planning and scheduling.

[0104] As for calculating the number of workstations, in the line arrangement parameter settings, fill in the daily planned output and effective working time (or enter the start time and end time of production). The system automatically calculates the average production distance in the background, then calculates the minimum number of workstations, and finally calculates the target number of workstations.

[0105] For the average production distance, since multiple styles are produced at the same time, it is impossible to determine the specific production distance time of a certain style. We can only calculate the average production distance time of all styles in the planning period (also applicable to a single style). The formula is as follows:

[0106]

[0107] In the formula, C 混 Indicates the average production time of each model on the mixed model production line; F e Indicates the planned effective working time; N 混Indicates the planned quantity of each style during the planning period; N i It represents the planned quantity of style i during the planning period; n represents the number of mixed styles.

[0108] For example, there are many options as follows:

[0109] For example, the following is a single item:

[0110] For the minimum number of workstations, the total cycle time is divided by the total workload time to obtain the theoretical minimum number of workstations (number of people). The formula is as follows:

[0111]

[0112] In the formula, S min Indicates the minimum number of workstations (number of people); N i represents the planned quantity of style i during the planning period; T i Indicates the standard time for the entire model (on-line process) of style i; C 混 It represents the average production time of the mixed-style production line; n represents the number of mixed styles.

[0113] For example, there are many options as follows:

[0114]

[0115] For example, the following is a single item:

[0116]

[0117] For the target number of workstations, the target number of workstations is calculated based on the minimum number of workstations and the balance rate (or upper and lower limits). The target number of workstations (number of production personnel) is as follows:

[0118] S=[S min / E];

[0119] In the formula, S represents the target number of workstations (number of people); S min Indicates the minimum number of workstations (people); E indicates the balance rate; [] symbol indicates greater than or equal to [S min / E]; E = 1 / (1+upper and lower limits%). When the upper and lower limits are entered, the system automatically converts them into a balance rate (e.g., if the upper and lower limits are 8%, the corresponding balance rate = 1 / (1+8%) = 92.6%)).

[0120] For example, the following are some examples: If the balance rate E = 85%, the target number of workstations is as follows:

[0121] S=[S min / E] = [11.88 / 0.85] = 14;

[0122] For example, a single item is as follows: If the balance rate E = 85%, the target number of workstations is as follows:

[0123] S=[S min / E]=[11.75 / 0.85]=14.

[0124] For the calculation of production sequence, the mixed style assembly line must achieve balanced production. In addition to achieving production line balance, the production sequence of each style must be reasonably matched (single style is not necessary), otherwise it will cause uneven busyness of production line stations. Different styles are combined into a group according to the production sequence, and groups are put into production on the assembly line in a cycle. According to the planned quantity of each style of the mixed style, the system automatically calculates the number of cycle pieces, cycle period, production ratio, production ratio countdown and production sequence in the background, and puts them into production in sequence.

[0125] Note: Different styles have different load differences in each operation unit. Only by reasonably configuring the production sequence and using the time saved by the products with short working hours in the operation unit to make up for the products with long working hours in the operation unit, can the uneven load of the operation unit be effectively reduced, and the idle time of each operation unit can be kept balanced and minimized as much as possible to achieve production leveling. The production sequence of each style on the mixed style assembly line is called a "cycle", that is, the production sequence of each style in a cycle. The system generates the production sequence through the following calculations.

[0126] Among them, mixed styles are put into production in groups according to cycles. The production cycle time required for one cycle is calculated as follows:

[0127]

[0128] Where, t 周 Indicates the time required for a cycle; N 循 Indicates the number of pieces in a cycle; C 混 represents the average production time of the mixed-style production line; i represents the style; N i represents the planned quantity of style i; m represents the greatest common divisor of the planned quantities of all styles, i.e. the number of cycles;

[0129] For example:

[0130]

[0131] Note: 2 styles, 750 pieces, 50 cycles in total, 15 pieces per cycle, 648 seconds.

[0132] From the planned quantity of each style of the mixed style, find the greatest common divisor and calculate the production ratio. The formula is:

[0133]

[0134] In the formula, x irepresents the production ratio of style i; N i Indicates the style i The planned output of each model; m represents the greatest common divisor of the planned output of each model. For example: x 1 =350 / 50=7;x 2 =400 / 50=8;

[0135] The formula for calculating the inverse of the production ratio is:

[0136]

[0137] In the formula, x i represents the production ratio of style i; m i Indicates the inverse of the production ratio of style i. For example: m 1 =1 / 7; m 2 =1 / 8.

[0138] In addition, the calculation of the production order includes: in a cycle of the mixed style assembly line, the production order of each style is generated according to the following rules: the style with the smallest production ratio inverse value among all styles is put into production first. In the case of multiple minimum production ratio inverse values, the style with the smallest production ratio inverse value appearing later is put into production first. If the same style is put into production continuously, this style should be excluded, and the style with the smallest production ratio inverse value appearing later should be selected from the remaining styles to be put into production first. The production ratio inverse of the selected style is added to the production ratio inverse of the style to form a new m for the style. j value; the new m j Value and other styles of m j The values ​​are compared and the styles to be put into production in this round are determined according to the above rules. This process is repeated until all pieces in one cycle are arranged and the production order of mixed styles in one cycle is generated.

[0139] In this optional embodiment, the production parameters are calculated based on the wiring parameters and the comprehensive process flow chart, the rank values ​​of the job elements are determined, and a sequence table of the job elements is generated, including: according to the time of each process included in the job element, the daily planned quantity of each item, and the comprehensive process flow chart, the job element operation time, the total time per person, the number of job elements, the upper and lower limits, and the required number of people are automatically calculated in the background; according to the comprehensive process flow chart and the job element operation time, all subsequent job elements of each job element are searched, and their total operation time is calculated to obtain the rank value of the job element; the assembled components are sorted, and the rank value of the first job element of each component is compared; the components are sorted from large to small according to the rank value, and all the job elements of each component are selected in turn according to the price value from high to low, and finally a sequence table of the job elements is generated; according to the total time per person and the upper and lower limit prompts on the toolbar, the job elements are pre-processed, and the job elements are combined into job units.

[0140] In this optional embodiment, the production parameters include average production distance, number of workstations, operation element time, total time per person, and upper and lower limits.

[0141] What needs to be explained is the sorting of job elements: based on the time of each process contained in the job element, the daily planned quantity of each item, and the comprehensive process flow chart, the system automatically calculates the job element time, the total time per person, the number of job elements, the upper and lower limits, and the required number of people in the background, and then automatically calculates the job element rank value and the job element sequence table, and prompts the total time per person and the upper and lower limits of the number of people in the toolbar. Here, it is allowed to pre-process the job elements and manually combine the job elements into "job units" (which can be manually dragged, combined, and split).

[0142] The specific steps are as follows: The operation element time includes: according to the time of each process contained in the operation element and the daily planned quantity of each style, the system automatically calculates the operation element operation time in the background, and uses the total operation time of each mixed style planned quantity of the operation element to balance the mixed style assembly line. The operation element time formula is as follows:

[0143]

[0144] Where, d i Indicates the operation time of the i-th operation element; N j represents the planned quantity of style j; n represents the number of styles, represented by j, with a value ranging from 1 to n; m represents the number of processes in the operation element, represented by k, with a value ranging from 1 to m; t ijk Indicates the operation time of the kth process of the jth style of the ith operation element.

[0145] The average total time per person Smt (Standard Mean Time) is the sum of the time of each operation element during the planning period divided by the number of people (workstations), the formula is as follows:

[0146] Average total time per person

[0147] Where, d i represents the operation time of the operation element; S represents the number of production personnel; n represents the number of operation elements; C 混 Indicates the average production time of the mixed production line; N 混 Indicates the planned quantity of the product group during the planning period.

[0148] For example, the following are some examples: Total time per person Note: The sum of each person's working time for each work element during the planning period is less than or equal to, but close to the effective working time during the planning period.

[0149] For example, the following is a single item:

[0150] Average total time per person

[0151] When calculating the number of people (workstations) required for each work element, the calculation formula is as follows: N i =d i / Smt; where N i Indicates the number of operating elements (number of workstations); d i Indicates the working time of the work element; Smt indicates the average working time (Standard Mean Time); for example: Work element 14: Tie the foot and mouth 4, work element working time: 28500, average working time Smt: 27187 Substitute into the formula: N 14 =28500 / 27187≈1.05(people);

[0152] When setting the upper and lower limits, the system calculates the corresponding upper and lower limit time, theoretical workstations (number of people) according to the total time per person and the upper and lower limit% (or balance rate) set in the parameters, and determines the N-fold rate boundary of the combined operation elements of the operation unit (in the parameter setting, the upper and lower limit%, and the balance rate are 2 to choose 1). Among them, the upper limit = total time per person / balance rate, or, the upper limit = total time per person*(1+upper and lower limit%); the lower limit = 2*total time per person-upper limit of total time per person, or, the lower limit = total time per person*(1-upper and lower limit%); the upper limit number of people = upper limit / total time per person; the lower limit number of people = lower limit / total time per person.

[0153] For example, a single item is as follows: calculated based on a balance rate of 85%: upper limit = 27493 / 0.85 = 32345, 32345 / 27493≈1.18 (persons); lower limit = 2*27493-32345 = 22641, 22641 / 27493≈0.82 (persons).

[0154] For the N-ratio limit, when combining work elements into work units, the work element work time and number of people are accumulated to determine whether it is within the upper and lower limits of the N-ratio, where N = the maximum number of parallel workstations. N-ratio upper limit = N*upper limit; N-ratio lower limit = N*lower limit; N-ratio upper limit number of people = N*upper limit number of people; N-ratio lower limit number of people = N*lower limit number of people.

[0155] For the operation element sequence table, the system finds all subsequent operation elements of each operation element according to the comprehensive process flow chart and the operation time of the operation element, and calculates the sum of their operation time, which is the rank value of each operation element. For each component to be assembled, compare the price value of its first operation element, sort the components from large to small according to the rank value, and take all its operation elements one by one until all components and all operation elements are sorted, and finally generate the operation element sequence table. When the wiring parameter-split group is not 1, the operation element sequence table is split into multiple groups according to the component group set by the parameter (the average total time of each group is the same), and each group (manually or automatically) combines the operation elements into operation units, and the balance rate of the operation units of each group may be different. In the operation element sequence table, the operation elements are combined into operation units according to the wiring parameters, and the operation time is calculated to obtain the optimal operation unit combination plan.

[0156] In this optional embodiment, in the operation element sequence table, the operation elements are combined into operation units according to the wiring parameters, and the operation time is calculated to obtain the optimal operation unit combination plan, including: selecting operation elements in turn, calculating the operation time and required number of people of the operation elements for each new operation unit; checking whether the current operation unit meets one of the following conditions; if the current operation unit has not triggered the end condition, continue to add operation elements to the unit, update the operation time and number of people, and return to the step of checking whether the current operation unit meets one of the following conditions to continue judging; if the end condition is met, end the construction of the current operation unit, if there are still unassigned operation elements, restart the construction of a new operation unit, and return to the step of selecting operation elements in turn; for each balance rate, evaluate all operation unit combination plans; select the combination plan with the highest operation unit balance rate and the smallest variance of workstation operation time; if the two conditions are the same, select the plan with a large number of operation units; if a balance rate interval is set, provide the optimal operation unit combination plan for multiple balance rates.

[0157] In this optional embodiment, the checking whether the current operation unit meets one of the following conditions includes: the number of workstations exceeds the maximum number of parallel workstations, the number of machines exceeds the maximum number of equipment, and the number of operation elements exceeds the maximum number of operation elements. According to the total time per person and the upper and lower limit prompts on the toolbar, the operation elements can be pre-processed and the operation elements can be manually combined into operation units. The operation units are sorted according to the average total time of the workstations, the number of operation elements, and the difficulty of the process.

[0158] For example, in the case of manual-automatic scheduling, the job elements can be pre-processed (manually dragging positions, combining, and splitting), and then the system will calculate in the next step "Job Element Combination" to combine the job elements into job units and generate the optimal combination plan for the job elements. During pre-processing, for special job elements, over-limit can be allowed, or a certain job element can be temporarily set as off-line and not participate in the assembly line scheduling.

[0159] Taking manual work scheduling as an example, you can select multiple work elements and manually (drag, combine, split) combine them into work units. The system automatically calculates the theoretical number of people, fills in the actual number of people (number of workstations), and calculates the average total time at the workstation. The result is the presentation of the work elements combined into work units, which is not restricted by other parameters.

[0160] It needs to be explained that for the balance rate (or upper and lower limits %) and balance rate interval set in the wiring parameters, the work elements are automatically (or manually) combined into "work units" (Work Cell, 1 work unit corresponds to 1 or more workstations or workers) according to preset rules. The work unit operation time is within the N-fold rate limit (N = maximum number of parallel workstations). The group with the highest work unit balance rate and the smallest average total workstation time variance is taken as the optimal ranking plan for the work elements.

[0161] When the cable arrangement parameter - split group is not 1, each group (manually or automatically) combines the operation elements into operation units. The average total time of each group is the same, and the balance rate of the operation units of each group may be different.

[0162] In addition, the operation element combination algorithm includes: according to the order of operation elements, the operation elements are taken in sequence, and they are accumulated and combined into operation units. The operation time of the operation unit is within the N-multiple limit (N = the maximum number of parallel workstations). When the limits of the maximum number of equipment, the maximum number of parallel workstations, and the maximum number of operation elements are triggered, the accumulation and combination of the current operation unit is terminated, and the operation elements of the next operation unit are accumulated and combined until all operation elements are accumulated and combined into the operation unit. One operation unit can correspond to multiple workstations (number of people), because some combinations of operation elements require multiple workstations to share, and their workstation operation time can fall within the upper and lower limits. According to the order of operation elements, the operation elements are taken in sequence, and the algorithm for automatically combining the operation elements into "operation units" is as follows:

[0163] Step 1: Take one work element at a time, and for a new work unit, calculate the work element's work time and number of people. Step 2: Determine the trigger conditions (workstation > maximum parallel workstation, machine > maximum number of equipment, number of work elements > maximum number of work elements). If none of the three conditions are triggered, you can continue to accumulate and go to step 3. If any condition is triggered, you cannot continue to accumulate and go to step 4. Step 3: Take one work element at a time, and continue to accumulate the work element's work time and number of people to this work unit, and go to step 2. Step 4: Continue to accumulate work elements at the end of this work unit. If there are still unassigned work elements, go to step 1.

[0164] There may be multiple combinations of work elements for a balance rate. The one with the highest balance rate and the smallest variance of workstation operation time is selected. If the two are the same, the one with more work units is selected as the optimal combination of work elements for this balance rate. If the balance rate interval is set, the optimal combination of work elements for work units with multiple balance rates will be given. Here, it is allowed to merge and split work units (work units with more than 2 people, and the average number of workstations in the work unit cannot exceed the upper limit when splitting).

[0165] Among them, the calculation formula for the variance of workstation operation time is:

[0166]

[0167] Where N is the number of production line stations, represented by j, from 1 to N; d i It represents the time of the work element of the work unit; m represents the number of work elements of the work unit, represented by i, where i ranges from 1-m; s represents the number of workstations in the work unit; Smt represents the total time per person.

[0168] For the production line unit balance rate, the system calculates it in the background and displays it in the toolbar of the unit balance table. The calculation formula is as follows: Where Smt represents the total time per person; Pt = bottleneck time = total time of bottleneck operation unit / number of workstations in bottleneck operation unit (the operation unit with the longest average total time is the bottleneck operation unit); d i represents the time of the operation element; n represents the number of operation elements; N represents the number of workstations (total number of people) on the production line;

[0169] For example, the mixed money is as follows: Substitute into the formula: work unit balance rate = 380620 / [14*(10745+5100) / 2]*100%≈88%.

[0170] For example, the following is a single item: Substitute into the formula: business unit balance rate = 380620 / [14*(10745+5100) / 2]*100%≈88%.

[0171] For the assembly line rhythm time, for a single arrangement, the system calculates the assembly line rhythm time based on the bottleneck time in the background, and displays this value in the work unit balance sheet. The formula is as follows: assembly line rhythm time = bottleneck time * transfer batch.

[0172] For the production line operation unit balance sheet, the system assigns the operation element combination to the operation unit according to the algorithm to achieve the optimal balance of the operation unit, generate the operation unit balance sheet and operation unit balance bar chart, and display different prompt information according to single item and multiple items.

[0173] The toolbar displays the following information for mixed items: total time per person, upper limit, lower limit, number of workstations, ranking efficiency, production distance, cycle time, and production sequence. The toolbar displays the following information for single items: total time per person, upper limit, lower limit, number of workstations, ranking efficiency, production distance, bottleneck time, and rhythm time.

[0174] Here, you are allowed to manually merge and split the work unit work elements (for work units with more than 2 people, and the average total time of the work unit workstation cannot exceed the upper limit when splitting). You can also view the work unit balance bar chart, which displays the work unit number at the bottom and the number of people in the work unit at the top. The three horizontal lines in the middle are the upper limit, the total time per person, and the lower limit, and also displays the work unit balance rate.

[0175] When the number of wires in the wiring parameter is not 1, the work unit balance table shows several identical arrangement contents. The number of workstations (people) doubles, and the working hours doubles. Select the employees to be matched, configure enough teams, and establish a data interface with the MES system or hanging system.

[0176] It needs to be explained that the work units are automatically sorted according to the average total time of each work unit, the number of work elements, and the difficulty of the process. They are sorted from high to low by the average total time of the work unit; for the same average total time of the work unit, they are sorted by the number of work elements, with the larger number being ranked first; for the same number of work elements, they are sorted by the difficulty of the process, with the more difficult being ranked first. Here, you can drag and drop the mouse to adjust the order of the work units.

[0177] When matching employees, the system matches the best employees to the operating units in order from the front to the back according to the matching rules. Automatically match employees, generate a production line ranking balance table and a bar chart balance chart, and allow employee replacement.

[0178] In this optional embodiment, the automatic matching of employees, generation of production line ranking balance table and bar chart balance chart, and allowing employee replacement include: calculating and displaying the ranking balance rate of the work unit in the production line ranking balance table; automatically generating a production line ranking balance table and a corresponding bar chart, the bar chart showing the working time of each work unit; in the production line ranking balance bar chart interface, the work unit number is displayed at the bottom and the number of people is displayed at the top; the bar chart includes three horizontal lines to indicate the upper limit, the total time per person and the lower limit, and the production line ranking balance rate of the work unit is displayed at the same time.

[0179] It should be explained that when selecting employees to match, you can select multiple teams, and the number of people selected must be ≥ the number of workstations. At this time, if you want to see the real-time work status of employees, the planned number, the number of completed and the number of unfinished in a certain period of time, you need to establish a data interface with MES or hanging; here, you can match employees automatically or manually to quickly achieve the balance of production line ranking.

[0180] During automatic matching, the system automatically selects the employees with the shortest skill hours (skill hours = standard hours / skill degree) from the assignable employees (only employees who have not been matched in this period are listed) in the order of the work units, from front to back, and automatically matches them to the work units in turn. If there are multiple suitable employees with the same skill hours for a certain work unit, employees with fewer skill categories will be matched first. Employees marked as "leave work early" have the lowest priority and are matched last. The work unit with the largest average total workstation time is the bottleneck work unit, and the adjacent work units will select employees with skill hours closest to the average total time per person, rather than employees with the least skill hours.

[0181] When manually matching, click on the work unit, and the system will give you multiple qualified (or unassigned) employees and their skills and efficiency. You can manually drag and select them. If the skills of a process are not set, assign a skill value here and mark it with a color (to avoid going back to the skill matrix to set employee skills). After matching, double-click an employee, and in the pop-up employee exchange interface, query and filter out other employees and skill hours who can do the work element of this station, and manually select and replace them.

[0182] When the line arrangement parameter - unit group is not 1, employees can be matched completely or separately by component group. According to the line arrangement plan, select the assembly line layout style, determine the number of on-site workstations, and generate the production line arrangement diagram to complete the intelligent mixed arrangement of various styles. It should be explained that the production line ranking: the system automatically generates the production line ranking balance table and the production line ranking bar chart balance chart, and allows manual replacement of employees.

[0183] Among them, the calculation formula of the production line ranking balance rate is:

[0184] Where, d irepresents the time of the operation element; N represents the number of workstations (number of people) in the production line; n represents the number of operation elements; Smt represents the total time per person; Ct represents the takt time, which is the longest skill time per person in the operation unit, and determines the takt time of the production line;

[0185] The calculation formula of the takt time Ct is: In the formula, Ti represents the standard working time of the process; m represents the number of processes in the operation element, represented by i, i ranges from 1 to m; n represents the number of operation elements in the operation unit, represented by j, j ranges from 1 to n; S represents the number of workstations (number of people) in the operation unit, represented by k, k ranges from 1 to s; Y ijk % = Standard working hours of operation element j, process i / employee Y k Skill hours for process i of operation element j * 100%, indicating that employee Y k The skill proficiency of doing task element j and process i.

[0186] For example: If the standard working time of operation element 1 process 1 is 18 seconds, employee Y k It takes 20 seconds to complete process 1. ijk Skill% = 18 / 20*100% = 90%.

[0187] For the production line ranking balance, the system generates a production line ranking balance table and a production line ranking balance bar chart based on the algorithm. The toolbar can display: total time per person, ranking efficiency, skill efficiency, number of workstations, production distance, cycle, production sequence, bottleneck time, and rhythm time. The same work unit number can have multiple workstations (employees) with the same work unit number but different workstation numbers. In the production line ranking balance bar chart interface, the work unit number is displayed at the bottom and the number of work units is displayed at the top. The three horizontal lines in the middle are the upper limit, total time per person, and lower limit, respectively. The production line ranking balance rate is also displayed. Select a work unit and the pop-up interface will display detailed information, which can help the on-site IE quickly find the bottleneck employees of the production line and improve the balance of the production line.

[0188] When arranging the production line, according to the arrangement plan, select the assembly line layout style, the number of on-site workstations, and automatically or manually generate the production line arrangement diagram. Among them, the automatic method is: specify the upper and lower line workstations, specify the front and back, left and right filling rules, the system automatically fills in the data, generates the production line arrangement diagram, and marks the flow direction of the cut pieces on the arrangement diagram. The manual method is: drag the employee workstation matching information in the arrangement balance table to the physical workstation one by one, and multiple workstations (workers) with the same operation unit number must be adjacent.

[0189] The production line layout style can be customized in the system, usually there are the following types: U-shaped, ring-shaped (hanging), straight line, double-row desk style, straight line, and double-row horizontal style.

[0190] Figure 2An embodiment of the present invention is shown in which a system for intelligent ranking of mixed styles on a sewing line is provided.

[0191] In this optional embodiment, the system for intelligent ranking of mixed styles of sewing lines includes:

[0192] The process analysis and operation element generation module 201 for mixed style production is used to combine the processes of each style into operation elements based on the similarity detection of the single-style process analysis data and the mixed style process analysis before the mixed style production, and generate a mixed style intelligent process flow chart containing an operation element table based on the operation elements;

[0193] The module 203 for calculating the order of operation element arrangement and production sequence is used to calculate the rank value of the operation element according to the arrangement setting parameters and the mixed style intelligent process flow chart, and generate the operation element sequence table based on the price value, combine the operation elements according to the preset rules, and obtain the optimal ranking plan for the operation elements; calculate the production sequence of the mixed arrangement of each style, and cyclically put them into production in the mixed assembly line according to the production sequence.

[0194] In one embodiment, a computer device is provided. The computer device may be a server, and its internal structure diagram may be as follows: Figure 3 As shown. The computer device includes a processor, a memory and a network interface connected through a system bus. Among them, the processor of the computer device is used to provide computing and control capabilities. The memory of the computer device includes a non-volatile storage medium and an internal memory. The non-volatile storage medium stores an operating system, a computer program and a database. The internal memory provides an environment for the operation of the operating system and the computer program in the non-volatile storage medium. The database of the computer device is used to store static information and dynamic information data. The network interface of the computer device is used to communicate with an external terminal through a network connection. When the computer program is executed by the processor, the steps in the above method embodiment are implemented.

[0195] Those skilled in the art will understand that Figure 3 The structure shown in the figure is only a block diagram of a part of the structure related to the solution of the present invention, and does not constitute a limitation on the computer device to which the solution of the present invention is applied. The specific computer device may include more or fewer components than those shown in the figure, or combine certain components, or have a different arrangement of components.

[0196] In addition, the present invention also provides a computer device, including a memory and a processor, wherein a computer program is stored in the memory, and the processor implements the steps in the above method embodiment when executing the computer program.

[0197] In addition, the present invention further provides a computer-readable storage medium on which a computer program is stored. When the computer program is executed by a processor, the steps in the above method embodiment are implemented.

[0198] The present invention can quickly arrange a high-efficiency mixed-style production line, greatly improving the production efficiency of mixed styles. With the improvement of mixed-style production efficiency, the factory has a competitive advantage in accepting small orders with quick returns, and is no longer limited by professional IE personnel. An ordinary employee can also easily handle the mixed-style arrangement. The results of the mixed-style intelligent ranking can be pushed to the intelligent flow trough and hanging, so that the assembly line can be arranged faster and the balance rate is higher, further improving its production efficiency and giving it an industrial brain; the software is embedded with IE professional knowledge, and ordinary small factories can also achieve lean production and intelligent manufacturing, freeing IE from ranking and allowing it to do More valuable process improvements and reduction of bottlenecks. With the support of software, factories can continuously pass on the results of IE engineering and lean production without being interrupted by staff loss. The present invention allows small and medium-sized clothing factories to quickly arrange multiple small orders with many styles, small quantities and tight delivery periods on one assembly line, just like Toyota's assembly line, without making high equipment investments or hiring professional IE personnel, so that small orders can be turned into large orders, with a steady stream of efficient output, reducing production efficiency losses caused by frequent machine changes, frequent employee allocations and frequent balancing of production lines.

[0199] Those skilled in the art can understand that all or part of the processes in the above-mentioned embodiment methods can be completed by instructing the relevant hardware through a computer program, and the computer program can be stored in a non-volatile computer-readable storage medium. When the computer program is executed, it can include the processes of the embodiments of the above-mentioned methods. Among them, any reference to memory, storage, database or other media used in the embodiments provided by the present invention can include at least one of non-volatile and volatile memory. Non-volatile memory can include read-only memory (ROM), magnetic tape, floppy disk, flash memory or optical memory, etc. Volatile memory can include random access memory (RAM) or external cache memory. As an illustration and not limitation, RAM can be in various forms, such as static random access memory (SRAM) or dynamic random access memory (DRAM).

[0200] The present invention is not limited to the structures which have been described above and shown in the drawings, and various modifications and changes may be made without departing from the scope thereof. The scope of the present invention is limited only by the appended claims.

Claims

1. A method for intelligent ranking of mixed styles of sewing lines, characterized in that: The mixed-style intelligent ranking method of the sewing line includes: Before mixed production of various styles, the processes of various styles are merged into operation elements based on the similarity detection of single-style process analysis data and mixed-style process analysis, and a mixed-style intelligent process flow chart containing an operation element table is generated based on the operation elements; According to the line setting parameters and combined with the mixed style intelligent process flow chart, the rank value of the operation element is calculated, and the operation element sequence table is generated based on the price value. The operation elements are combined according to the preset rules to obtain the optimal ranking plan for the operation elements; based on the optimal ranking plan for the operation elements, the production order of the mixed styles is calculated, and the mixed production line is put into production cyclically according to the production order.

2. A method for intelligent ranking of mixed styles of sewing lines according to claim 1, characterized in that: Before the mixed production of various styles, the processes of various styles are merged into operation elements according to the similarity detection of single-style process analysis data and mixed-style process analysis, and a mixed-style intelligent process flow chart including an operation element table is generated based on the operation elements, including: Select a specified single process data as the reference standard to perform similarity comparison one by one, and match the components and processes in each style to generate a style and process comparison list; Based on the style and process comparison list, merge the process data of each single style into comprehensive process data and produce the operation element table; Based on the operation element table, a comprehensive process flow chart is automatically generated, and the mixed-mode assembly line problem is converted into a single-mode assembly line problem.

3. A method for intelligent ranking of mixed styles of sewing lines according to claim 2, characterized in that: The expression for selecting a specified single process data as a reference standard and performing similarity comparison one by one is: In the formula, E 相 Indicates the similarity of styles; i represents the style involved in the similarity comparison, and the value ranges from 1 to n. i Indicates the number of basically the same processes for style i; ST i Indicates the total number of processes for style i; D i S represents the number of processes that are more similar to style i; i represents the number of processes with fewer similarities to style i; X D Indicates a similar coefficient; X S Indicates a smaller similarity coefficient.

4. The method for intelligent ranking of mixed styles of sewing lines according to claim 1 is characterized in that: The above method calculates the rank value of the operation element according to the line arrangement setting parameters and combines the mixed intelligent process flow chart, generates the operation element sequence table based on the price value, combines the operation elements according to the preset rules, and obtains the optimal ranking scheme of the operation elements; Calculate the production sequence of mixed styles, and cycle production in the mixed production line according to the production sequence, including: Filter comprehensive process analysis data and set wiring parameters; Calculate production parameters based on wiring parameters and comprehensive process flow chart, determine the order value of operation elements, and generate the operation element sequence table; In the operation element sequence table, the operation elements are combined into operation units according to the wiring parameters, and the operation time is calculated to obtain the optimal operation unit combination plan; Sort each work unit according to the average total workstation time, number of work elements, and process difficulty; Select the employees to be matched, configure sufficient teams, and establish a data interface with the MES system or hanging system; Automatically match employees, generate production line ranking balance table and bar chart balance chart, and allow employee replacement; Select the assembly line layout style according to the wiring plan, determine the number of on-site workstations, and generate a production line layout diagram to complete the intelligent mixing of various styles.

5. The method for intelligent ranking of mixed styles of sewing lines according to claim 4 is characterized in that: The production parameters include average production distance, number of workstations, operation element time, total time per person, and upper and lower limits.

6. A method for intelligent ranking of mixed styles of sewing lines according to claim 5, characterized in that: The method of calculating the production parameters based on the wiring parameters and the comprehensive process flow chart, determining the order values ​​of the operation elements, and generating the operation element sequence table includes: According to the time of each process contained in the operation element, the daily planned quantity of each process, and the comprehensive process flow chart, the operation time of the operation element, the total time per person, the number of operation elements, the upper and lower limits, and the number of required people are automatically calculated in the background; According to the comprehensive process flow chart and the operation time of the operation elements, all subsequent operation elements of each operation element are found, and the sum of the operation time of the operation elements is calculated to obtain the rank value of the operation element; Sort the assembled components and compare the rank value of the first operation element of each component; sort the components from large to small according to the rank value, and select all the operation elements of each component from high to low in order of price value; finally generate the operation element sequence table; According to the total time per person and upper and lower limits on the toolbar, pre-process the job elements and combine the job elements into job units.

7. A method for intelligent ranking of mixed styles of sewing lines according to claim 6, characterized in that: In the operation element sequence table, the operation elements are combined into operation units according to the wiring parameters, and the operation time is calculated to obtain the optimal operation unit combination scheme, which includes: Select the operation elements in turn, and calculate the operation time and required number of people for each new operation unit; Check whether the current operation unit meets one of the following conditions; If the current operation unit does not trigger the end condition, continue to add operation elements to the operation unit, update the operation time and number of people, and return to the step of checking whether the current operation unit meets one of the following conditions to continue the judgment; If the end condition is met, the construction of the current work unit is ended. If there are still unassigned work elements, a new work unit construction is restarted, and the process returns to the step of selecting work elements in sequence. For each balance rate, evaluate all combinations of work units; select the combination with the highest balance rate of work units and the smallest variance of workstation operation time; if the two conditions are the same, select the combination with the largest number of work units; If the balance rate interval is set, the optimal operation unit combination scheme of multiple balance rates is provided.

8. The method for intelligent ranking of mixed styles of sewing lines according to claim 7 is characterized in that: The checking whether the current operation unit meets one of the following conditions includes: the number of workstations exceeds the maximum number of parallel workstations, the number of machines exceeds the maximum number of equipment, and the number of operation elements exceeds the maximum number of operation elements.

9. A method for intelligent ranking of mixed styles of sewing lines according to claim 8, characterized in that: The automatic matching of employees, generation of production line ranking balance table and bar chart balance chart, and the allowance for employee replacement include: Calculate and display the ranking balance rate of the operation unit in the production line ranking balance table; Automatically generate a production line ranking balance table and a corresponding bar chart, which displays the operation time of each operation unit; In the production line ranking balance bar chart interface, the operation unit number is displayed at the bottom and the number of people is displayed at the top; the bar chart includes three horizontal lines indicating the upper limit, the total time per person and the lower limit, and also displays the production line ranking balance rate of each operation unit.

10. A system for intelligent ranking of mixed styles of sewing lines, characterized in that: The mixed-model intelligent ranking system of the sewing line includes: The process analysis and operation element generation module for mixed styles is used to merge the processes of each style into operation elements based on the similarity detection of single-style process analysis data and mixed-style process analysis before mixed-style production, and generate a mixed-style intelligent process flow chart containing an operation element table based on the operation elements; The module for calculating the arrangement and production sequence of operating elements is used to calculate the rank value of operating elements according to the arrangement setting parameters and the mixed-style intelligent process flow chart, and to generate an operating element sequence table based on the price value, and to combine the operating elements according to preset rules to obtain the optimal ranking plan for the operating elements; calculate the production sequence of mixed arrangements of various styles, and cyclically put them into production in the mixed assembly line according to the production sequence.

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