Production management system

Abstract

To provide a production management system that detects a start period and an end period of a production process based on a production plan, in a management system for managing the production process.SOLUTION: A production management system includes a worker position information generation unit and a management unit. The worker position information generation unit generates worker position information including information on work locations and positions of workers. The management unit detects a start period and an end period of a production process on the basis of the worker position information in the production process based on production plan information including information on the work location and the worker generated for each production plan.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present disclosure relates to a production management system. [Background technology]

[0002] Systems have been proposed for managing production processes in factories, etc. For example, a system has been proposed that tallys up products flowing on a production line by model, detects the model and number of products produced, and manages production results (see, for example, Patent Document 1). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Publication No. 04-210359 Summary of the Invention [Problem to be solved by the invention]

[0004] The above-mentioned conventional technology has a problem in that when two production processes based on time-series production plans are producing the same model, it is not possible to detect the end of the earlier production process, which makes it difficult to obtain production results.

[0005] The present disclosure provides a production management system that detects the start and end of a production process based on a production plan in a management system that manages a production process. [Means for solving the problem]

[0006] A production management system according to one aspect of the present disclosure includes a worker position information generation unit and a management unit. The worker position information generation unit included in the production management system according to one aspect of the present disclosure generates worker position information including information on workers and their positions. The management unit included in the production management system according to one aspect of the present disclosure detects the start and end of a production process based on the worker position information in a production process based on production plan information including information on work locations and workers generated for each production plan. [Effects of the Invention]

[0007] According to the present disclosure, in a management system that manages a production process, it is possible to detect the start and end of the production process based on a production plan. [Brief explanation of the drawings]

[0008] [Figure 1] FIG. 1 is a diagram illustrating an example of the configuration of a production management system according to an embodiment of the present disclosure. [Figure 2] FIG. 2 is a diagram illustrating an example of a production plan according to an embodiment of the present disclosure. [Figure 3] FIG. 3 is a diagram illustrating an example of a work instruction sheet according to an embodiment of the present disclosure. [Figure 4] FIG. 4 is a diagram illustrating an example of production plan information according to an embodiment of the present disclosure. [Figure 5] FIG. 5 is a diagram illustrating an example of production results according to an embodiment of the present disclosure. [Figure 6A] FIG. 6A is a diagram illustrating an example of a production process according to an embodiment of the present disclosure. [Figure 6B] FIG. 6B is a diagram illustrating an example of a production process according to an embodiment of the present disclosure. [Figure 7] FIG. 7 is a diagram illustrating an example of a factory according to an embodiment of the present disclosure.

[0009] [Production management system] FIG. 1 is a diagram illustrating an example of the configuration of a production management system according to an embodiment of the present disclosure. The figure is a block diagram illustrating an example of the configuration of a production management system 30. The figure also illustrates a core system 10 and a manufacturing execution system (MES) 20. Note that in the figure, the "manufacturing execution system" is abbreviated as "MES."

[0010] The core system 10 is a system that manages core business data such as purchasing management, production management, and inventory management in an integrated manner. This core system 10 generates work instructions (MO: Manufacturing Order) based on the production plan and outputs them to the manufacturing execution system 20. The work instructions are also called manufacturing instructions. Details of the work instructions will be described later.

[0011] The manufacturing execution system 20 is a system that monitors the production process at the manufacturing site. This manufacturing execution system 20 has a worker management function and manages which worker is assigned to which process at which work location. In doing so, the manufacturing execution system 20 assigns workers based on attendance information and qualification information. The manufacturing execution system 20 in FIG. 1 assigns work locations and workers for manufacturing based on work instructions from the core system 10 and generates production plan information. This production plan information includes information on work locations and workers generated for each production plan. Details of the production plan information will be described later. Note that the "production plan information" may also be called by other names, such as "worker assignment information."

[0012] The production management system 30 manages production activities in accordance with a production plan. Specifically, the production management system 30 generates and outputs production results for the production process. Conventionally, workers or the like have generated and recorded production results. In contrast, the production management system 30 in FIG. 1 generates production results on behalf of workers and outputs them to an external device. The production management system 30 in FIG. 1 comprises a management unit 31, a worker position information generation unit 32, a break time management unit 33, and a display unit 34.

[0013] The worker position information generator 32 generates worker position information including information on the worker and the worker's position. This worker position information generator 32 detects the position of each worker and generates the worker position information. The worker's position can be detected, for example, based on a signal from a transmitter installed for each worker.

[0014] The break time management unit 33 manages break times. Specifically, the break time management unit 33 records the break times of workers.

[0015] The management unit 31 generates production results for a production process based on production plan information. The management unit 31 detects the start and end of the production process and generates production results. In this case, the management unit 31 detects the start and end of the production process based on worker position information. Details of how the management unit 31 detects the start and end of the production process will be described later. The management unit 31 outputs the generated production results to the outside. The management unit 31 also displays the generated production results on the display unit 34.

[0016] The display unit 34 displays the production results. The display unit 34 displays the production results output from the management unit 31.

[0017] [Production Planning] FIG. 2 is a diagram showing an example of a production plan according to an embodiment of the present disclosure. The horizontal axis of the figure represents time. The vertical axis of the figure represents work locations. As these work locations, production lines ("Line A," "Line B," "Line C," and "Line D") where production is carried out using assembly line production are shown. The rectangles marked with "MO" in the figure represent production plans based on manufacturing instructions. Note that production plans are identified by the sub-numbers following "_."

[0018] Production plan "MO_A01" is assigned to Line A from 8:00 on 10 / 17 to 20:00 on 10 / 17. Next, production plan "MO_A02" is assigned to Line A from 20:00 on 10 / 17 to 8:00 on 10 / 18. Production plans are assigned to other lines in the same way.

[0019] [Work Instruction] 3 is a diagram showing an example of a work instruction sheet according to an embodiment of the present disclosure. The work instruction sheet includes an order number, a production start date and time, a production end date and time, a product model, a production quantity, a plant number, and a line number. The work instruction sheet is configured as an electronic file.

[0020] [Production plan information] 4 is a diagram illustrating an example of production plan information according to an embodiment of the present disclosure. The production plan information includes information on a work instruction number, a line number, a process, and a worker. For example, a work item with work instruction number 1 is assigned to line A. Workers A to E corresponding to processes 1 to 5 are assigned to line A.

[0021] [actual production] FIG. 5 is a diagram illustrating an example of actual production results according to an embodiment of the present disclosure. This figure is the graph of FIG. 2 to which actual production results have been added. The rectangles labeled "AP" in this figure represent actual production results based on a production plan. The actual production results are identified by the sub-numbers following the "_" character. For example, on line A, "AP_A01" corresponding to production plan "MO_A01" represents an example in which the work time allocated to the production plan is exceeded. In this way, the end times of actual production results vary due to factors such as process delays. Therefore, a method for detecting the end times of production processes becomes an issue when generating actual production results.

[0022] [Production process] 6A and 6B are diagrams illustrating an example of a production process according to an embodiment of the present disclosure. FIGS. 6A and 6B illustrate how products manufactured in a production process based on a production plan are inspected and the inspection results are registered in the production system 40 along with model information. The rectangles marked "MO" and "AP" in the figures are the same as those in FIG. 5. FIG. 6A illustrates an example in which a product 101 is generated in "AP_A01" corresponding to "MO_A01," and a product 102 is generated in "AP_A02" corresponding to "MO_A02." The solid arrow in FIG. 6A represents the registration of the inspection results for the product 101. The dashed arrow in FIG. 6A represents the registration of the inspection results for the product 102. In this case, since the products are different in the consecutive "AP_A01" and "AP_A02," it is easy to detect the end of the production process.

[0023] On the other hand, Figure 6B shows an example of a case where product 101 is produced in "AP_A01" corresponding to "MO_A01" and "AP_A02" corresponding to "MO_A02." In this case, since the product is the same in the consecutive "AP_A01" and "AP_A02," it becomes difficult to detect the end of the production process. The management unit 31 in Figure 1 can detect the end of the production process even in such a case.

[0024] [Factory layout] FIG. 7 is a diagram illustrating an example of a factory according to an embodiment of the present disclosure. The diagram illustrates an example layout of a factory 200. A production line 201 is arranged in the factory 200. In the diagram, "Line A," "Line B," and "Line C" are shown as the production lines 201. A worker 202 is further arranged on each production line 201. The diagram illustrates an example in which lines and workers are arranged in accordance with the production plan information of FIG. 4. "Worker A" to "Worker E" are arranged on "Line A." "Worker F" to "Worker K" are arranged on "Line B." "Worker L" to "Worker O" are arranged on "Line C." In this way, work locations can be generated based on the production lines and the factory layout.

[0025] Each worker 202 is equipped with a transmitter 203. For example, a Bluetooth (registered trademark) compatible transmitter can be used for this transmitter 203. A receiver 204 that receives signals from the transmitter 203 is also disposed in the factory 200. The worker position information generation unit 32 in FIG. 1 generates position information for the worker 202 based on the reception result of the receiver 204. Note that other methods can also be used to detect the worker's position. For example, the worker's position may be detected using a WiFi compatible transmitter and receiver or by taking a picture with a camera.

[0026] The management unit 31 in Figure 1 can detect the start of a production process based on the production plan information when the presence of a worker corresponding to the information about the worker in the production plan information is detected at the work location in the production plan information. Taking work instruction number 1 in the production plan information in Figure 4 as an example, when the presence of "worker A" to "worker E" is detected at the work location "line A," the management unit 31 can determine that the production process corresponding to work instruction number 1 has started.

[0027] In addition, the management unit 31 can also detect the start of a production process, for example, when the locations of more than a predetermined percentage of workers corresponding to the worker information in the production plan information match the work locations in the production plan information.

[0028] Furthermore, the management unit 31 in Fig. 1 can determine that the production process based on the production plan information is ongoing if a worker corresponding to the worker information in the production plan information is present at the work location in the production plan information. Taking work instruction number 1 in the production plan information in Fig. 4 as an example, if "worker A" to "worker E" are present at the work location "line A," the management unit 31 can determine that the production process corresponding to work instruction number 1 is ongoing.

[0029] In addition, the management unit 31 can also determine that the production process based on the production plan information is ongoing if a worker corresponding to the information about the worker in the production plan information is present at the work location in the production plan information for a predetermined period of time.

[0030] On the other hand, the management unit 31 can detect the end of the production process when the location of the worker corresponding to the information on the worker in the production plan information differs from the work location in the production plan information. In other words, when "Worker A" to "Worker E" are not present in the work location "Line A," the management unit 31 can detect the end of the production process corresponding to work instruction number 1.

[0031] For example, the management unit 31 can detect the end of a production process when the positions of a predetermined percentage or more of the workers corresponding to the information of the workers in the production plan information differ from the work locations in the production plan information. This predetermined percentage can be, for example, 50%. In the previous example, the management unit 31 can detect the end of a production process when the positions of 50% or more of the workers "Worker A" through "Worker E" differ from "Line A." The above-mentioned predetermined percentage can be changed as desired by the user.

[0032] Furthermore, the management unit 31 can detect the end of a production process when, for example, a predetermined percentage or more of the workers in the worker location information generated by the worker location information generation unit 32 become workers corresponding to the worker information in the production plan information for the next production plan. This predetermined percentage can be, for example, 80%. Taking "Line A" in FIG. 5 as an example, the end of a production process can be detected when 80% or more of the workers in "MO_A01" become workers corresponding to the worker information in "MO_A02," the next production plan. The above-mentioned predetermined percentage can be changed as desired by the user.

[0033] Furthermore, the management unit 31 can detect the end of a production process when, for example, the location of a worker corresponding to the information about the worker in the production plan information is different from the work location in the production plan information during a time period different from the break time. In this case, the management unit 31 can obtain the break time from the break time management unit 33.

[0034] The management unit 31 can detect the start and end of the production process even if the order of the workers corresponding to the information of the workers at the work location in the production plan information is different. Specifically, even if the order of "Worker A" to "Worker E" on "Line A" in FIG. 7 is different, the start of the production process can be detected if the combination of workers matches the information of the workers in the production plan information. Furthermore, even if the order of "Worker A" to "Worker E" on "Line A" is different, the management unit 31 can determine that the production process is ongoing if the combination of workers matches the information of the workers in the production plan information. In other words, if only the order of "Worker A" to "Worker E" on "Line A" changes, the management unit 31 will not detect the end of the production process.

[0035] In this way, the production management system 30 of the present disclosure can detect the start and end dates of the production process based on the production plan, thereby generating production results.

[0036] (effect) The production management system 30 is a production management system that includes a worker position information generation unit 32 that generates worker position information including information on workers and their positions, and a management unit 31 that detects the start and end of a production process based on the worker position information in a production process based on production plan information that includes information on work locations and workers generated for each production plan. This brings about the effect of detecting the start and end of a production process for each production plan.

[0037] Furthermore, the management unit 31 may detect the start of the production process based on the production plan information when a worker corresponding to the information about the worker in the production plan information is present at the work location in the production plan information, and may detect the end of the production process when the location of the worker corresponding to the information about the worker in the production plan information is different from the work location in the production plan information. This makes it possible to determine the start and end of the production process.

[0038] Furthermore, the management unit 31 may detect the end of the production process when the positions of a predetermined percentage or more of the workers corresponding to the information on the workers in the production plan information differ from the work locations in the production plan information, thereby making it possible to detect the end of the production process based on a change in workers.

[0039] In addition, the management unit 31 may detect the end of the production process when the locations of 50% or more of the workers corresponding to the information of the workers in the production plan information are different from the work locations in the production plan information.

[0040] Furthermore, the management unit 31 may detect the end of the production process when a predetermined percentage or more of the workers in the generated worker position information become workers corresponding to the worker information in the production plan information for the next production plan. This makes it possible to detect the end of the production process based on a change in workers.

[0041] In addition, the management unit 31 may detect the end of the production process when 80% or more of the workers in the generated worker position information become workers corresponding to the worker information in the production plan information for the next production plan.

[0042] In addition, the management unit 31 may determine that the production process based on the production plan information is ongoing if a worker corresponding to the information about the worker in the production plan information is present at the work location in the production plan information for a predetermined period of time.

[0043] The system may further include a break time management unit 33 that records break times, and the management unit 31 may detect the end of the production process when the location of the worker corresponding to the information about the worker in the production plan information is different from the work location in the production plan information during a time period different from the recorded break time. This makes it possible to eliminate the influence of break times.

[0044] The management unit 31 may further generate a production record for the production process for which the end of the production process has been detected, thereby improving convenience.

[0045] The system may further include a display unit 34 for displaying the generated production results, thereby improving convenience.

[0046] The work locations may also be generated based on production lines and factory layouts.

[0047] The worker position information generating unit 32 may generate the worker position information based on a signal from a transmitter provided for each worker, thereby improving the accuracy of detecting the worker's position.

[0048] The effects described in this specification are merely examples and are not limiting, and other effects may also be present. [Explanation of symbols]

[0049] 30 Production Management System 31 Management Department 32 Worker position information generation section 33 Break time management department 34 Display section

Claims

1. a worker position information generating unit that generates worker position information including information about a worker and the worker's position; a management unit that detects the start and end of a production process based on production plan information including information on work locations and workers generated for each production plan, based on the worker position information; A production management system equipped with:

2. 2. The production management system according to claim 1, wherein the management unit detects the start of a production process based on the production plan information when a worker corresponding to the information about the worker in the production plan information is present at the work location in the production plan information, and detects the end of the production process when the location of the worker corresponding to the information about the worker in the production plan information is different from the work location in the production plan information.

3. 3. The production management system according to claim 2, wherein the management unit detects the end of the production process when the positions of a predetermined percentage or more of the workers corresponding to the information of the workers in the production plan information differ from the work locations in the production plan information.

4. 4. The production management system according to claim 3, wherein the management unit detects the end of the production process when the positions of 50% or more of the workers corresponding to the information of the workers in the production plan information are different from the work locations in the production plan information.

5. 3. The production management system according to claim 2, wherein the management unit detects the end of the production process when a predetermined percentage or more of the workers in the generated worker position information become workers corresponding to the worker information in the production plan information for the next production plan.

6. 6. The production management system according to claim 5, wherein the management unit detects the end of the production process when 80% or more of the workers in the generated worker position information become workers corresponding to the worker information in the production plan information for the next production plan.

7. 3. The production management system according to claim 2, wherein the management unit determines that a production process based on the production plan information is ongoing if a worker corresponding to the worker information in the production plan information is present at the work location in the production plan information for a predetermined period of time.

8. Further provided is a break time management unit that records break times, 3. The production management system according to claim 2, wherein the management unit detects the end of the production process when the location of the worker corresponding to the information about the worker in the production plan information is different from the work location in the production plan information during a time period different from the recorded break time.

9. The production management system according to claim 1 , wherein the management unit further generates a production record for the production process for which the end of the production process has been detected.

10. The production management system according to claim 9, further comprising a display unit that displays the generated production results.

11. The production management system according to claim 1 , wherein the work locations are generated based on a production line and a factory layout.

12. 2. The production management system according to claim 1, wherein the worker position information generating unit generates the worker position information based on a signal from a transmitter disposed for each worker.

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