Management device and management method

Abstract

To provide a management method that assists even a person devoid of a preliminary knowledge in discovering a waste of work on a production line.SOLUTION: A management method includes a step of acquiring event information representing occurrence of an event on a production line, a step of acquiring time information, which represents a processing initiation time and processing termination time of each of plural processes, for each product, a step of discriminating a static bottleneck process from the plural processes on the basis of the time information, and a step of calculating a completion forecast time of processing on the production line for each product on the basis of the termination time of the static bottleneck process for each product during a period preceding occurrence of the event.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present disclosure relates to a management device and a management method. [Background technology]

[0002] In order to improve the efficiency of a production line that includes multiple processes, it is desirable to discover various wastes occurring in the multiple processes. In order to discover such wastes, Japanese Patent Application Laid-Open No. 2010-40007 (Patent Document 1) discloses a work management system that manages the time related to each task in multiple processes and displays on a display unit a diagram on a coordinate plane with one axis representing time and the other axis representing the multiple processes. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2010-40007 A Summary of the Invention [Problem to be solved by the invention]

[0004] In the technology disclosed in Patent Document 1, in order to discover waste from a diagram, the manager must have prior knowledge of the state of the diagram when there is no waste, and compare that state with the current diagram. Therefore, there is a problem that those without prior knowledge cannot easily discover waste.

[0005] The present disclosure has been made in consideration of the above problems, and has as its objective to provide a management device and a management method that assist even those without prior knowledge in discovering wasteful work on a production line. [Means for solving the problem]

[0006] According to an example of the present disclosure, a management device manages the operating status of a production line including a plurality of processes. The management device includes a first acquisition unit, a collection unit, an identification unit, and a calculation unit. The first acquisition unit acquires event information indicating the occurrence of an event in the production line. The collection unit collects time information indicating the processing start time and processing end time of each of the plurality of processes for each individual product that is a processing target of the plurality of processes. The identification unit identifies a static bottleneck process among the plurality of processes based on the time information. The calculation unit calculates an expected completion time of processing by the production line for each individual product based on the end time of the static bottleneck process for each individual product during a period before the occurrence of the event.

[0007] According to this disclosure, a manager can find wasteful work in a production line by comparing the estimated completion time for each product with the actual time when the process on the production line was completed. In other words, the manager can find wasteful work in a production line even without prior knowledge.

[0008] In the above disclosure, the management device includes a providing unit that provides a graph in which a first axis represents time and a second axis represents the order of input of individual products. The graph shows the processing time periods of each of a plurality of processes for each individual product.

[0009] According to this disclosure, by checking the graph, the manager can easily grasp the processing time period for each of a plurality of processes for each individual product.

[0010] In the above disclosure, the graph further includes a line indicating the expected completion time for each individual product.

[0011] According to this disclosure, the line showing the expected completion time for each individual product is approximately linear, so that the manager can easily grasp the expected completion time for each individual product.

[0012] In the above disclosure, the graph includes a mark corresponding to the process in which the event occurred and corresponding to the event in the processing time period including the time at which the event occurred.

[0013] According to this disclosure, by checking the graph, a manager can easily identify the cause of a large time difference between the predicted completion time and the actual processing end time of the production line.

[0014] In the above disclosure, the calculation unit calculates a delay time that is the difference between the predicted completion time and the processing end time of the final process among the multiple processes.

[0015] According to this disclosure, a manager can recognize that wasteful work is occurring when there is a long delay time.

[0016] In the above disclosure, the identifying unit calculates the production time per product for each of the multiple processes based on the time information, and identifies a static bottleneck process based on the production time per product.

[0017] According to this disclosure, it is possible to identify static bottleneck processes by taking into account the production time per product.

[0018] In the above disclosure, the management device includes a second acquisition unit that acquires a first video from an imaging device that includes the movement range of workers on the production line in its field of view, and a generation unit that generates a second video that shows a change in the position of each individual product over time based on time information. The provision unit provides a screen on which the first video and the second video are displayed in synchronization with each other.

[0019] According to this disclosure, a manager can easily grasp the relationship between the position of the worker and the position of the individual product by checking the first video and the second video.

[0020] According to an example of the present disclosure, a management method for managing an operating status of a production line including a plurality of processes includes first to fourth steps. The first step is a step of acquiring event information indicating the occurrence of an event in the production line. The second step is a step of collecting time information indicating the process start time and process end time of each of the plurality of processes for each individual product that is the subject of the process. The third step is a step of identifying a static bottleneck process among the plurality of processes based on the time information. The fourth step is a step of calculating an expected time of completion of the process by the production line for each individual product based on the end time of the static bottleneck process for each individual product during a period before the occurrence of the event.

[0021] This disclosure can also help those with no prior knowledge to discover wasteful operations on a production line. Effect of the Invention

[0022] According to the present disclosure, even those without prior knowledge can be assisted in discovering wasteful work on a production line. [Brief description of the drawings]

[0023] [Figure 1] 1 is a diagram illustrating an example of a system to which a management device according to an embodiment is applied; [Diagram 2] FIG. 1 is a diagram showing an example of a production line to which the system of the present embodiment is applied. [Diagram 3] 3 is a diagram showing an example of a single product to be processed by the production line shown in FIG. 2. [Figure 4] FIG. 2 is a schematic diagram illustrating a hardware configuration of a management device. [Diagram 5] FIG. 2 is a schematic diagram showing a functional configuration of a management device. [Figure 6] FIG. 10 is a diagram illustrating an example of a calculation performed to identify a static bottleneck process. [Figure 7] FIG. 11 is a diagram illustrating a method for calculating an estimated completion time. [Figure 8]FIG. 13 is a diagram showing an example of an information providing screen provided by a conventional management system. [Figure 9] FIG. 11 is a diagram showing an example of an information providing screen provided in the present embodiment. [Figure 10] FIG. 13 is a diagram showing an example of a selection screen for a playback time period. [Figure 11] FIG. 11 is a diagram showing another example of an information providing screen provided in the present embodiment. [Figure 12] FIG. 11 is a diagram showing yet another example of an information provision screen provided in the present embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0024] The embodiments of the present invention will be described in detail with reference to the drawings. In the drawings, the same or corresponding parts are denoted by the same reference characters and the description thereof will not be repeated. The modifications described below may be combined as appropriate.

[0025] §1 Examples of application An overview of a system to which a management device according to the present embodiment is applied will be described. Fig. 1 is a diagram showing an example of a system to which a management device according to the present embodiment is applied. As shown in Fig. 1, system 1 includes a management device 100, a production line 200, a host system 300, a camera 400 which is an imaging device, a terminal 500, and a time synchronization server 600. System 1 is installed at a production site such as a factory.

[0026] The production line 200 includes a plurality of processes 210 that sequentially process the individual products 2, and one or more transport devices 230 that transport the individual products 2 between adjacent processes 210. The individual products 2 are individual products and include intermediate products.

[0027] The upper system 300 has a database 310 that stores information related to the production line 200. The information stored in the database 310 is acquired from an input device, equipment for a plurality of processes 210 included in the production line 200, and a control device (e.g., a programmable logic controller (PLC)) (not shown) that controls the equipment.

[0028] The information stored in the database 310 includes event information indicating the occurrence of an event in the production line 200. An event is an element in which the four elements (4M) of man, machine, material, and method change, and includes, for example, worker reassignment, equipment inspection, equipment repair, equipment troubleshooting, change of material or material manufacturer, change of manufacturing method, change of inspection method, etc. The event information indicates the type of event, the process in which the event occurred, the time when the event occurred, the start time and end time of the event, etc. For example, the event information indicates the time when the event occurred for an event that ends in a short time, such as a change of material, and indicates the start time and end time of the event for an event that takes time, such as equipment repair.

[0029] Furthermore, the information stored in the database 310 may include production record information. The production record information indicates the type of input product, lot number, input start time and input completion time of each lot, production quantity, input man-hours, throughput, etc.

[0030] The camera 400 is installed so that its field of view includes the range of movement of the workers in the production line 200, and captures the field of view. The captured video is used to confirm the movement line of the workers. Note that the system 1 may include multiple cameras 400.

[0031] The management device 100 manages the operation status of the production line 200. The terminal 500 is, for example, a general-purpose computer device (such as a notebook PC, a tablet, or a smartphone) and is communicatively connected to the management device 100. In response to a request from the terminal 500, the management device 100 provides the terminal 500 with information indicating the operation status of the production line 200. The time synchronization server 600 is located on the Internet and manages absolute time.

[0032] The management device 100 executes a management method including steps S1 to S4. In step S1, the management device 100 acquires (reads out) event information indicating the occurrence of an event in the production line 200 from the database 310 of the host system 300.

[0033] In step S2, the management device 100 collects time information indicating the processing start time and processing end time of each of the multiple processes 210 for each single product 2 that is to be processed in the multiple processes 210. The management device 100 receives, from each process 210, a signal indicating that the single product 2 has been carried in (hereinafter referred to as a "carry-in signal") and a signal indicating that the single product 2 has been removed (hereinafter referred to as a "remove-out signal"). The management device 100 acquires the time at which the carry-in signal is received from the time synchronization server 600 as the processing start time. The management device 100 acquires the time at which the carry-out signal is received from the time synchronization server 600 as the processing end time. The management device 100 manages the time information indicating the processing start time and processing end time acquired in this manner.

[0034] The order of execution of steps S1 and S2 is not particularly limited. For example, the management device 100 may execute step S1 every time an event occurs, or may execute step S1 at regular intervals (e.g., one day). In this case, step S1 is executed after step S2. In step S1, the management device 100 acquires event information related to events that have occurred within the regular interval.

[0035] In step S3, the management device 100, based on the time information, identifies a static bottleneck process among the plurality of processes 210. The static bottleneck process is a process that governs the production efficiency of the production line 200.

[0036] The static bottleneck process is a process that constantly has the greatest effect on the pitch time of the entire production line 200 during steady-state process progress. The pitch time is also called takt time, and is the maximum cycle time of each process. The cycle time is the time of a work cycle from the completion of work on a single product 2 to the completion of work on the next single product 2. A process with the maximum cycle time is identified as the static bottleneck process. In other words, a process with the minimum number of single products 2 output per unit time is identified as the static bottleneck process. Note that the bottleneck process also includes a dynamic bottleneck process. A dynamic bottleneck process is a process in which the processing capacity is attenuated due to the occurrence of a sudden event, temporarily affecting the pitch time of the entire production line 200. In this embodiment, a static bottleneck process is identified instead of a dynamic bottleneck process.

[0037] In step S4, the management device 100 calculates an expected completion time of the process by the production line 200 for each individual product 2 based on the end time of the static bottleneck process for each individual product 2 during the period before the occurrence of the event.

[0038] The predicted completion time is the time at which the processing by the production line 200 will be completed, assuming that no event occurs. Therefore, the manager can find wasteful work in the production line 200 by comparing the predicted completion time with the time at which the processing by the production line 200 is actually completed for each single product 2. In other words, the manager can find wasteful work in the production line 200 without having prior knowledge of the state of the diagram when there is no waste.

[0039] §2 Specific examples <Example of a production line> The production line 200 included in the system 1 is not limited to the line including the three processes 210 shown in FIG. 1, but may take various forms.

[0040] Fig. 2 is a diagram showing an example of a production line applied to the system of the present embodiment, showing a production line 200A that performs surface mounting (SMT: Surface Mount Technology).

[0041] Fig. 3 is a diagram showing an example of a single product to be processed by the production line shown in Fig. 2. As shown in Fig. 3, the single product 2 has a PCB board 5 and is also called an "individual piece." An electronic circuit 6 is mounted on the PCB board 5 by processing the single product 2 by the production line 200A.

[0042] A two-dimensional code 3 indicating an individual ID for identifying the single product 2 is printed in advance on the PCB board 5. In the example shown in Fig. 3, the two-dimensional code 3 is printed in multiple locations, but the two-dimensional code 3 may be printed in only one location. By printing the two-dimensional code 3 in multiple locations, a code reader (described later) can be installed in a position where it can read one of the two two-dimensional codes 3. This increases the degree of freedom in the installation location of the code reader.

[0043] As shown in FIG. 2, the production line 200A includes six processes 210a to 210f. The unit products 2 are transported in the order of the processes 210a to 210f. Hereinafter, when there is no particular distinction between the processes 210a to 210f, each of the processes 210a to 210f will be referred to as "process 210." Each process 210 processes the unit products 2 transported from the upstream side, and outputs the processed unit products 2 downstream. Equipment 220 is installed in each process 210.

[0044] The first process 210a is a printing process. In the process 210a, a printer 220a is installed as the equipment 220. The printer 220a receives the single product 2 from the loader 220g and applies cream solder to the PCB board 5. After the processing of the single product 2 in the process 210a is completed, the single product 2 is transported to the process 210b by the transport device 230a.

[0045] The second step 210b is a print inspection step. In step 210b, a print inspection machine 220b is installed as equipment 220. For example, the print inspection machine 220b inspects whether the shape of the cream solder is within a standard range based on an image obtained by imaging the PCB board 5 on which the cream solder is applied. The single product 2 that has completed the processing of step 210b is transported to step 210c by a transport device 230b.

[0046] The third process 210c is a mounting process. In the process 210c, a mounter 220c is installed as the equipment 220. The mounter 220c mounts electronic components at predetermined positions on the PCB board 5. The single product 2 that has completed the process 210c is transported to the process 210d by the transport device 230c.

[0047] The fourth step 210d is a mounting inspection step. In step 210d, a mounting inspection machine 220d is installed as equipment 220. For example, the mounting inspection machine 220d inspects whether the position of the electronic component is within a reference range based on an image obtained by imaging the PCB board 5 on which the electronic component is mounted. The single product 2 that has completed the processing of step 210d is transported to step 210e by a transport device 230d.

[0048] The fifth process 210e is a reflow process. In the process 210e, a reflow furnace 220e is installed as the equipment 220. The reflow furnace 220e melts the cream solder by heating the PCB board 5, and solders the electronic components. The single product 2 that has completed the process 210e is transported to the process 210f by the transport device 230e.

[0049] The sixth process 210f is a reflow inspection process. In the process 210f, a reflow inspection machine 220f is installed as the equipment 220. The reflow inspection machine 220f inspects for the presence or absence of soldering defects, for example, based on an image obtained by imaging the PCB board 5 to which electronic components are soldered. The single product 2 that has completed the processing in the process 210f is transported to the unloader 220h by the transport device 230f. The unloader 220h carries out the single product 2 produced by the production line 200A to the outside.

[0050] Each of the pieces of equipment 220 (printer 220a, print inspection machine 220b, mounter 220c, mount inspection machine 220d, reflow furnace 220e, and reflow inspection machine 220f) installed in steps 210a to 210f has code readers 240, 242. Note that in Fig. 2, only the code readers of the printer 220a installed in step 210a are indicated with the symbols "240" and "242."

[0051] The code reader 240 is disposed near the entrance of the equipment 220, reads the two-dimensional code 3 of the single product 2 put into the equipment 220, and outputs a carry-in signal including the read individual ID. The carry-in signal is output to the management device 100.

[0052] The code reader 242 is disposed near the exit of the equipment 220, reads the two-dimensional code 3 of the single product 2 discharged from the equipment 220, and outputs an unloading signal including the read individual ID. The unloading signal is output to the management device 100.

[0053] <Hardware configuration of management device> 4 is a schematic diagram showing the hardware configuration of the management device 100. The management device 100 typically has a structure conforming to a general-purpose computer architecture.

[0054] As shown in FIG. 4, the management device 100 includes a processor 101, a memory 102, a storage 103, and a communication interface 104.

[0055] The processor 101 is composed of a central processing unit (CPU), a micro processing unit (MPU), etc. The memory 102 is composed of a volatile storage device such as a dynamic random access memory (DRAM) or a static random access memory (SRAM). The storage 103 is composed of a non-volatile storage device such as a solid state drive (SSD) or a hard disk drive (HDD). The storage 103 stores a management program 110 for managing the operation status of the production line 200. The communication interface 104 exchanges data with external devices (for example, the equipment 220 of each process 210, the upper system 300, and the camera 400).

[0056] <Functional configuration of management device> FIG. 5 is a schematic diagram showing the functional configuration of the management device. As shown in FIG. 5, the management device 100 includes a first acquisition unit 11, a collection unit 12, a second acquisition unit 13, a storage unit 14, an identification unit 15, a calculation unit 16, a work position detection unit 17, a second video generation unit 18, and an information provision unit 19. The storage unit 14 is realized by the memory 102 and the storage 103 shown in FIG. 4. The first acquisition unit 11, the collection unit 12, and the second acquisition unit 13 are realized by the communication interface 104 and the processor 101 that executes the management program 110. The identification unit 15, the calculation unit 16, the work position detection unit 17, the second video generation unit 18, and the information provision unit 19 are realized by the processor 101 that executes the management program 110.

[0057] The first acquisition unit 11 acquires event information 21 indicating the occurrence of an event in the production line 200 from the host system 300. Furthermore, the first acquisition unit 11 also acquires production record information 20 from the host system 300. The first acquisition unit 11 stores the acquired production record information 20 and event information 21 in the storage unit 14. The first acquisition unit 11 may acquire new production record information 20 and event information 21 from the host system 300 every time new production record information 20 and event information 21 are accumulated in the host system 300. Alternatively, the first acquisition unit 11 may acquire production record information 20 and event information 21 accumulated within a certain period (for example, every day) from the host system 300.

[0058] The collection unit 12 collects time information 22 indicating the processing start time and processing end time of each of the multiple processes 210 for each individual product 2 that is the processing target of the multiple processes 210. The collection unit 12 receives a carry-in signal and an unloading signal from equipment 220 installed in each process 210. The collection unit 12 acquires the time at which the carry-in signal is received from the time synchronization server 600 as the processing start time. The collection unit 12 acquires the time at which the unloading signal is received from the time synchronization server 600 as the processing end time. The collection unit 12 generates time information 22 indicating the processing start time and processing end time for each individual product 2 for each process 210, and stores the generated time information 22 in the storage unit 14. In this manner, the collection unit 12 collects time information 22 for each individual product 2 for each process 210.

[0059] The time information 22 is information that associates a process ID that identifies the process 210 in which the equipment 220 is installed, an individual ID that identifies the single product 2, a processing start time, and a processing end time. The collection unit 12 causes the time information 22 to include a process ID that identifies the process 210 that includes the equipment 220 that is the transmission source of the carry-in signal and the carry-out signal. Furthermore, the collection unit 12 causes the time information 22 to include an individual ID (an individual ID corresponding to the two-dimensional code 3 of the single product 2) read from the carry-in signal and the carry-out signal.

[0060] The second acquisition unit 13 acquires first video data (hereinafter simply referred to as "first video") 24 from the camera 400. The first video 24 is acquired by capturing an image of the camera 400. As described above, the field of view of the camera 400 includes the range of movement of the workers on the production line 200. Therefore, the first video 24 captures the workers working on the production line 200. The second acquisition unit 13 acquires the first video 24 for each predetermined time period (for example, one minute). The second acquisition unit 13 stores the acquired first video 24 in the storage unit 14. When the system 1 includes multiple cameras 400, the first video 24 is stored in the storage unit 14 in association with a camera ID that identifies the camera 400 that captured the image.

[0061] The identifying unit 15 identifies a static bottleneck process among the plurality of processes 210 based on the time information 22 stored in the storage unit 14. The identifying unit 15 performs a calculation to identify a static bottleneck process.

[0062] 6 is a diagram illustrating an example of a calculation performed to identify a static bottleneck process. The identification unit 15 calculates the standard time of each process 210 based on the time information 22 acquired from the equipment 220 of the process 210.

[0063] Specifically, for each of the multiple processes 210, the identifying unit 15 extracts time information 22 including a process ID corresponding to that process 210 from the time information 22 stored in the memory unit 14. The identifying unit 15 calculates the processing time from the processing start time to the processing end time for each of the extracted time information 22. As shown in Fig. 6, the identifying unit 15 creates a histogram of the calculated processing times and determines the median value as the standard time. The standard time is also called RPT (Raw Process Time) and corresponds to the standard processing time for the process 210.

[0064] Next, the specifying unit 15 calculates the production time per product for each of the multiple processes 210. Specifically, the specifying unit 15 pre-stores the number N of products that can be processed simultaneously for each process 210. The specifying unit 15 calculates the production time per product by dividing the standard time by N.

[0065] For example, for a process 210 in which p pieces of equipment 220 capable of processing only one single product 2 are installed, the specifying unit 15 stores "p" as the number of products that can be processed simultaneously. Also, for a process 210 in which one piece of equipment 220 (e.g., a reflow furnace 220e) capable of simultaneously accommodating q pieces of single product 2 is installed, the specifying unit 15 stores "q" as the number of products that can be processed simultaneously.

[0066] The identifying unit 15 identifies the process that has the longest production time per product as the static bottleneck process.

[0067] The static bottleneck process may vary for each product type or lot. Therefore, the identifying unit 15 may read out the input start time and input completion time for each product type or lot from the production record information 20. The identifying unit 15 may then identify the static bottleneck process for each product type or lot based on the time information 22 including the individual IDs of the single products 2 input from the read input start time to the input completion time.

[0068] The calculation unit 16 calculates the expected completion time of the processing by the production line 200 for each individual product 2 based on the processing end time of the static bottleneck process for each individual product 2 during the period before the occurrence of the event. Processing is performed in lot units in the production line 200. Therefore, the calculation unit 16 calculates the expected completion time for each individual product 2 for each lot.

[0069] Fig. 7 is a diagram for explaining a method for calculating an estimated completion time. Fig. 7 shows an example in which a production line 200 includes three processes 210x, 210y, and 210z, and the process 210y is a static bottleneck process. Fig. 7 shows a graph 30 in which the horizontal axis represents time and the vertical axis represents the input order of the individual products 2. The graph 30 shows processing time periods 31x, 31y, and 31z of the processes 210x, 210y, and 210z for each individual product 2. In the graph 30, the processing time periods 31x, 31y, and 31z are defined by the time information 22.

[0070] When no event occurs, the production speed depends on the processing speed of the process 210y, which is a static bottleneck process. Therefore, the calculation unit 16 identifies a period T before the occurrence time (or start time) of the first event indicated by the event information 21. The calculation unit 16 calculates the number of individual products 2 that have completed the process 210y per unit time in the period T (hereinafter referred to as the "ideal processing speed"). Specifically, the calculation unit 16 finds an approximation line 32 for a point 33 that corresponds to the end time of the processing of the process 210y for each individual product 2 in the period T. The ideal processing speed corresponds to the slope of the approximation line 32.

[0071] Furthermore, the calculation unit 16 finds a line 35 that passes through a point 34 corresponding to the end time of the processing of the final process 210 for the first individual product 2 and is parallel to the approximation line 32. The calculation unit 16 calculates the time of intersection 37 between the line 35 and a line 36 whose vertical axis value is k (k=6 in the figure) as the expected completion time of the kth individual product 2.

[0072] The calculation unit 16 calculates a delay time, which is the difference between the predicted completion time and the processing end time of the final process 210 among the multiple processes.

[0073] Information indicating the standard time of each process 210 calculated by the specifying unit 15 and information indicating the expected completion time and delay time calculated by the calculating unit 16 are stored in the storage unit 14 as calculation result information 23.

[0074] The work position detection unit 17 detects the position of the worker at each time (hereinafter referred to as the "work position") based on the first video 24. For example, the work position detection unit 17 detects the area in which the worker appears in each frame of the first video 24 using a known object recognition technique. The work position detection unit 17 determines, for example, the center of a circumscribing rectangle of the detected area as the work position. The work position detection unit 17 generates work position information 25 that associates the time of each frame with the work position detected from that frame, and stores the generated work position information 25 in the storage unit 14.

[0075] The second video generator 18 generates a second video showing the change over time in the position of each individual product 2 (hereinafter referred to as "product position") based on the time information 22. The second video is, for example, an animation in which a mark (hereinafter referred to as "product mark") corresponding to each individual product 2 is superimposed on a model image of the production line 200.

[0076] Specifically, the second video generation unit 18 extracts time information 22 for each process 210 for each single product 2. For each process 210, the second video generation unit 18 determines the product position at the processing start time as the entrance position of the process 210, and the product position at the processing end time as the exit position of the process 210. The second video generation unit 18 assumes that the product moves at a constant speed from the entrance to the exit of the process 210, and determines the product position at each time from the processing start time to the processing end time.

[0077] Furthermore, the second video generation unit 18 assumes that each individual product 2 moves at a constant speed from the exit of the upstream process 210 of two adjacent processes 210 to the entrance of the downstream process 210, and determines the product position at each time from the end time of processing at the upstream process 210 to the start time of processing at the downstream process 210.

[0078] The second video generator 18 generates the second video by superimposing a product mark on a location on the model image of the production line 200 that corresponds to the product position at each time frame of the second video. The second video generator 18 generates the second video 26 for each predetermined time (for example, in units of one minute).

[0079] The information providing unit 19 provides various information. Specifically, the information providing unit 19 provides the terminal 500 with an information providing screen generated from the information stored in the storage unit 14 in response to a request from the terminal 500. The information providing screen includes, for example, the standard time and the estimated completion time indicated by the calculation result information 23, the delay time which is the difference between the estimated completion time and the actual processing end time of the final process 210, the first video 24, the second video 26, the movement line of the worker generated from the work position information 25, and the like.

[0080] <Example of information provision screen> FIG. 8 is a diagram showing an example of an information providing screen provided by a conventional management system. FIG. 8 shows an information providing screen 940 including a diagram with time on the horizontal axis and multiple processes on the vertical axis. The information providing screen 940 shows a diagram corresponding to a production line 200 including three processes. That is, the diagram shows a processing time 941 of the first process, a processing time 942 of the second process, and a processing time 943 of the third process. In such a diagram, it is difficult to show the expected completion time of the production line 200 of each individual product 2 when no event occurs. If the expected completion time is to be shown in the diagram, it is conceivable to add multiple points corresponding to the expected completion times of multiple individual products 2 to the line corresponding to the final process. In this case, it is difficult for the manager to grasp the correspondence between each of the multiple points and the multiple individual products 2 that have been input. As a result, it is difficult for the manager to find waste.

[0081] Even if waste is discovered, the manager cannot easily identify the cause of the waste. The processing end time for each process of each individual product 2 is indicated by line 945. Waste on the production line is caused by events that occurred in the past. Therefore, the manager must identify the cause of the waste by tracing the lines 945. However, the number of lines 945 is equal to the number of individual products 2. Therefore, it is difficult to identify the target line 945 from among the many lines 945 and trace the identified line 945. As a result, it is difficult to identify the cause of the waste. In particular, when multiple events occur, it is even more difficult to identify the cause of the waste.

[0082] In response to this, the administrator can easily identify the cause of the waste by using the management device 100 according to this embodiment.

[0083] Fig. 9 is a diagram showing an example of an information provision screen provided in the present embodiment. Fig. 9 shows an information provision screen 40 including a graph 30 in which the first axis (horizontal axis) represents time and the second axis (vertical axis) represents the input order of the single product 2. The graph 30 shows, for each single product 2, processing time periods 41h to 41k from the processing start time to the processing end time of each of the four processes. The information provision screen 40 shown in Fig. 9 is displayed for a target lot.

[0084] The information providing unit 19 identifies the process in which each event occurred and the occurrence or end time of each event (hereinafter referred to as "event time") based on the event information 21. The information providing unit 19 determines a processing time period that corresponds to the identified process and includes the identified event time. The information providing unit 19 displays marks 42 (including marks 42a and 42b) indicating the occurrence of an event in the determined processing time period on the graph 30 of the information providing screen 40. That is, the graph 30 includes marks 42 corresponding to the event in a processing time period that corresponds to the process in which the event occurred and includes the time at which the event occurred.

[0085] The information providing unit 19 includes, in the graph 30 on the information providing screen 40, a straight line 44 connecting points 43 corresponding to the predicted completion times of each individual product 2. In other words, the graph 30 includes a straight line 44 indicating the predicted completion time for each individual product 2. Furthermore, the information providing unit 19 includes, in the graph 30, a line 46 connecting points 45 corresponding to the end time of the final process of each individual product 2. The information providing unit 19 includes, in the graph 30, an arrow 47 indicating the delay time, which is the difference between the predicted completion time and the end time of the final process, for the individual product 2 inserted last in the target lot.

[0086] The manager can grasp the delay time in the target lot by checking the length of the arrow 47. Furthermore, the manager can easily grasp, by checking the time difference between the straight line 44 and the line 46, which of the multiple single products 2 included in the target lot caused waste in the processing of which single product 2.

[0087] For example, the manager confirms that the time difference between the line 44 and the line 46 is large for the single product 2 corresponding to the processing time period including the mark 42a, compared to the single product 2 that was inserted immediately before. As a result, the manager can infer that the event corresponding to the mark 42a is the cause of the time difference 48a.

[0088] Furthermore, the administrator can confirm that for the single product 2 that was introduced after the single product 2 corresponding to the mark 42a, the time between the line 44 and the line 46 coincides with the time difference 48a. As a result, the administrator can understand that the effect of the event corresponding to the mark 42a will be maintained for the single product 2 that is processed after the occurrence of the event.

[0089] Furthermore, the manager confirms that for the single product 2 corresponding to the processing time period including mark 42b, the time difference between line 44 and line 46 is large compared to the single product 2 inserted immediately before. As a result, the manager can infer that the event corresponding to mark 42b is the cause of time difference 48b.

[0090] Furthermore, the administrator can confirm that for the single product 2 that was introduced after the single product 2 corresponding to mark 42b, the time between line 44 and line 46 coincides with time difference 48b. As a result, the administrator can understand that the effect of the event corresponding to mark 42b will be maintained for the single product 2 that is processed after the occurrence of the event.

[0091] In this way, the administrator can identify the two events corresponding to the marks 42a and 42b as the cause of the delay time indicated by the arrow 47 by checking the information provision screen 40 shown in FIG.

[0092] 9 accepts an operation for instructing playback of a video. For example, in response to a click on the mark 42, the information providing unit 19 provides a playback time zone selection screen.

[0093] 10 is a diagram showing an example of a selection screen for a playback time period. The selection screen 70 includes an input field 71 for specifying the production line 200, input fields 72 and 73 for selecting a video time period, and an input field 74 for selecting a camera 400. The manager inputs necessary information into the input fields 71 ​​to 74 according to the production line 200, time period, and camera 400 for which the manager wishes to check the video.

[0094] Furthermore, the selection screen 70 includes radio buttons 75a to 75c and a play button 76. The radio button 75a is selected when playing the first video 24 is desired. The radio button 75b is selected when playing the first video 24 and the second video 26 is desired. The radio button 75c is selected when displaying the worker's movement line is desired. In response to clicking the play button 76, the information providing unit 19 provides an information providing screen according to the selection of the radio buttons 75a to 75c.

[0095] The information providing unit 19 creates a video for playback in response to clicking the play button 76. For example, the information providing unit 19 reads out from the storage unit 14 one or more first videos 24 that correspond to the camera ID of the camera 400 input in the input field 74 and are included in the playback time period input in the input fields 72 and 73, and links the one or more first videos 24. Similarly, the information providing unit 19 reads out from the storage unit 14 one or more second videos 26 that are included in the playback time period, and links the one or more second videos 26.

[0096] Fig. 11 is a diagram showing another example of an information provision screen provided in the present embodiment. Fig. 10 shows an information provision screen 50 that is provided when the play button 76 is clicked in a state in which the radio button 75b is selected on the selection screen 70 shown in Fig. 10.

[0097] The information provision screen 50 includes areas 51 and 52 , a play button 53 , a scroll bar 54 , a speed change button 56 , and a download button 57 .

[0098] In response to clicking the play button 53, the information provider 19 synchronizes the first video 24 and the second video 26 and displays them on the information provider screen 50. Specifically, the first video 24 is displayed in an area 51, and the second video 26 is displayed in an area 52.

[0099] The first video 24 shows a worker 58. The second video 26 also includes a product mark 59 at the position of each single product 2. When the single product 2 is housed in the equipment 220 of each process 210, it is not shown in the first video 24. In contrast, in the second video 26, the product mark 59 is displayed at the position of the single product 2 housed in the equipment 220. Therefore, by checking the areas 51 and 52, the manager can easily grasp the relationship between the position of the worker 58 and the position of each single product 2 at each time.

[0100] It is preferable that the display form of the product mark 59 is different for each lot of the single unit product 2. This allows the manager to understand the change in lot. For example, the product mark 59b indicates the product position of the lot that was input next to the lot of the single unit product 2 corresponding to the product mark 59a.

[0101] For example, when the manager identifies an event that is causing a delay on the information provision screen 40 shown in Fig. 9, the manager checks the first video 24 and the second video 26 for the time period that includes the occurrence time of the event. As a result, the manager can check whether the work situation at the time the event occurred was appropriate.

[0102] Alternatively, when the same event occurs but there is a large difference in delay time between workers, the manager may determine that the video of the worker with the shortest delay time is the ideal work, and use that video to train the worker with the longest delay time. By checking the video of the worker with the shortest delay time, the appropriate relationship between the position of the single product 2 and the worker's position is understood. The worker with the longest delay time can learn the appropriate position for himself / herself according to the position of the single product 2 based on that relationship.

[0103] Furthermore, if the display format of the product mark 59 differs for each lot, the manager can understand the relationship between the worker's work position and the product position when the lot is changed. The manager can use the information provision screen 50 shown in Fig. 10 for training on work when changing lots. That is, a worker who takes a long time to change a lot can understand the appropriate relationship between the product positions of the lot before the change and the product positions of the lot after the change and the worker's position by watching videos of other workers, and can learn the appropriate position for himself according to the product positions of each lot.

[0104] The information providing unit 19 changes the frames displayed in the areas 51 and 52 in response to an operation on the cursor 54a of the scroll bar 54. The information providing unit 19 changes the playback speed in response to an operation on the speed change button 56. This allows the administrator to check the details of the first video 24 and the second video 26 for a desired time period by appropriately operating the scroll bar 54 and the speed change button 56.

[0105] In response to clicking the download button 57, the information provider 19 saves files indicating the first moving images 24 and second moving images 26 to be played in a specified folder in the terminal 500. This allows the administrator to check the first moving images 24 and second moving images 26 using the files saved (downloaded) in the specified folder in the terminal 500 without accessing the management device 100. The files downloaded to the terminal 500 indicate a moving image in which one or more first moving images 24 included in the playback time period are linked, and a moving image in which one or more second moving images 26 included in the playback time period are linked.

[0106] 10, when the play button 76 is clicked with the radio button 75a selected, the information providing unit 19 provides an information providing screen on which the first video 24 is displayed. In addition, when the play button 76 is clicked with the radio button 75c selected on the selection screen 70 shown in FIG. 10, the information providing unit 19 provides the terminal 500 with an information providing screen showing the movement line of the worker based on the work position information 25.

[0107] Fig. 12 is a diagram showing yet another example of an information provision screen provided in this embodiment. The information provision screen 60 shown in Fig. 12 includes a table 61 showing the transition of monthly production volume for each variety. By checking the information provision screen 60, the manager identifies a variety whose monthly production volume is less than the planned volume, and checks the information provision screen 40 shown in Fig. 9 for the identified variety. Alternatively, the manager may check the effect of the education using the information provision screen 50 shown in Fig. 11 on the information provision screen 60 shown in Fig. 12.

[0108] The information providing unit 19 may provide the terminal 500 with an information providing screen showing the standard time for each process 210.

[0109] <Modification> In the above description, the code readers 240, 242 are installed in the equipment installed in the process 210. In addition to this, the code readers 240, 242 may also be installed in the conveying device 230 between adjacent processes 210, and the period during which the single product 2 is conveyed by the conveying device 230 may be managed.

[0110] In the above description, the identifying unit 15 calculates the production time per product by dividing the standard time by the number N of products that can be processed simultaneously. However, the method of calculating the production time per product is not limited to this. A process with a large variation in the histogram shown in FIG. 6 may be a static bottleneck process. Therefore, the production time per product may be calculated by taking the variation in the histogram into consideration. For example, the sum of the standard time and the time multiplied by a predetermined coefficient of the standard deviation of the histogram may be calculated, and the production time per product may be calculated by dividing the sum by the number N of products that can be processed simultaneously.

[0111] §3 Supplementary Note As described above, the present embodiment includes the following disclosure.

[0112] (Configuration 1) A management device (100) for managing an operational status of a production line (200) including a plurality of processes (210), a first acquisition unit (11) that acquires event information (21) indicating an occurrence of an event in the production line (200); a collection unit (12) that collects time information (22) indicating a processing start time and a processing end time of each of the plurality of processes (210) for each single product (2) to be processed in the plurality of processes (210); an identification unit (15) that identifies a static bottleneck process among the plurality of processes (210) based on the time information (22); a calculation unit (16) that calculates an estimated completion time of processing by the production line (200) for each of the individual products (2) based on the end time of the static bottleneck process for each of the individual products (2) during a period prior to the occurrence of the event.

[0113] (Configuration 2) a providing unit (19) for providing a graph (30) in which a first axis represents time and a second axis represents the order of input of the single product (2); 2. The management device (100) according to configuration 1, wherein the graph (30) indicates, for each of the single products (2), a processing time period (41h to 41k) of each of the plurality of steps (210).

[0114] (Configuration 3) 3. The management device (100) according to configuration 2, wherein the graph (30) further includes a line (44) indicating the predicted completion time for each of the single products (2).

[0115] (Configuration 4) The management device (100) according to configuration 2 or 3, wherein the graph (30) corresponds to the process in which the event occurred and includes a mark (42) corresponding to the event in the processing time period (41h to 41k) including the time at which the event occurred.

[0116] (Configuration 5) 5. The management device (100) according to any one of configurations 1 to 4, wherein the calculation unit (16) calculates a delay time that is a difference between the predicted completion time and the processing end time of a final process among the plurality of processes.

[0117] (Configuration 6) The specific portion (15) is Calculating a production time per product for each of the plurality of processes based on the time information; 6. The management device (100) according to any one of configurations 1 to 5, wherein the static bottleneck process is identified based on the production time per product.

[0118] (Configuration 7) a second acquisition unit (13) that acquires a first video (24) from an imaging device (400) whose field of view includes the movement range of a worker on the production line (200); a generation unit (18) that generates a second video (26) showing a change in the position of each of the individual products (2) over time based on the time information (22), The management device (100) according to configuration 2, wherein the providing unit (19) provides a screen on which the first moving image (24) and the second moving image (26) are displayed in synchronization with each other.

[0119] (Configuration 8) A method for managing an operating status of a production line (200) including a plurality of processes, comprising the steps of: acquiring event information indicative of an occurrence of an event in the production line (200); collecting time information indicating a processing start time and a processing end time of each of the plurality of processes (210) for each single product (2) to be processed in the plurality of processes (210); identifying a static bottleneck process among the plurality of processes (210) based on the time information; and calculating an estimated time of completion of processing by the production line (200) for each of the individual products (2) based on the end time of the static bottleneck process for each of the individual products (2) during a period before the occurrence of the event.

[0120] Although the embodiment of the present invention has been described, the embodiment disclosed herein should be considered as illustrative and not restrictive in all respects. The scope of the present invention is defined by the claims, and it is intended to include all modifications within the scope and meaning equivalent to the claims. [Explanation of symbols]

[0121] 1 System, 2 Single product, 3 Two-dimensional code, 5 Board, 6 Electronic circuit, 11 First acquisition unit, 12 Collection unit, 13 Second acquisition unit, 14 Memory unit, 15 Identification unit, 16 Calculation unit, 17 Work position detection unit, 18 Second video generation unit, 19 Information provision unit, 20 Production record information, 21 Event information, 22 Time information, 23 Calculation result information, 24 First video, 25 Work position information, 26 Second video, 30 Graph, 31x, 31y, 31z, 41h, 41k, 941, 942 Processing time period, 32 Approximation line, 35, 36, 46, 945 Line, 37 Intersection, 40, 50, 60, 940 Information provision screen, 42, 42a, 42b Mark, 44 Straight line, 47 Arrow, 51, 52 Area, 53, 76 Playback button, 54 scroll bar, 54a cursor, 56 speed change button, 57 download button, 58 worker, 59, 59a, 59b product mark, 61 table, 70 selection screen, 71-74 input field, 75a-75c radio button, 100 management device, 101 processor, 102 memory, 103 storage, 104 communication interface, 110 management program, 200, 200A production line, 210, 210a-210f, 210x-210z process, 220 equipment, 220a printing machine, 220b printing inspection machine, 220c mounting machine, 220d mounting inspection machine, 220e reflow oven, 220f reflow inspection machine, 220g loader, 220h unloader, 230, 230a-230f Conveyor device, 240, 242 code readers, 300 upper system, 310 database, 400 camera, 500 terminal, 600 time synchronization server.

Claims

1. A management device for managing an operation status of a production line including a plurality of processes, a first acquisition unit that acquires event information indicating an occurrence of an event in the production line; a collection unit that collects time information indicating a processing start time and a processing end time of each of the plurality of processes for each individual product that is a processing target of the plurality of processes; an identification unit that identifies a static bottleneck process among the plurality of processes based on the time information; a calculation unit that calculates, for each of the individual products, an estimated time of completion of processing by the production line on the assumption that the event does not occur, based on an end time of the static bottleneck process for each of the individual products during a period before the occurrence of the event; a providing unit that provides a graph in which a first axis represents time and a second axis represents an order of input of the individual products, The graph is A processing time period for each of the plurality of steps is indicated for each of the individual products; and A management device including a line indicating the estimated completion time for each of the individual products.

2. The calculation unit, determining an approximation line for a point on the graph that corresponds to an end time of the static bottleneck process for each of the products during a period before the occurrence of the event; 2. The management device according to claim 1, wherein the estimated completion time for each individual product is calculated so that the line passes through a point corresponding to an end time of a final process for a first individual product and is parallel to the approximation line.

3. 3. The management device according to claim 1, wherein the graph includes a mark corresponding to the process in which the event occurred and corresponding to the event in the processing time period including the time at which the event occurred.

4. The management device according to claim 1 , wherein the calculation unit calculates a delay time that is a difference between the predicted completion time and the processing end time of a final process of the plurality of processes.

5. The identification unit is Calculating a production time per product for each of the plurality of processes based on the time information; The management device according to claim 1 , wherein the static bottleneck process is identified based on a production time per product.

6. a second acquisition unit that acquires a first video from an imaging device that has a field of view including a range of movement of a worker on the production line; a generating unit configured to generate a second video showing a change in a position of each of the individual products over time based on the time information, The management device according to claim 1 , wherein the providing unit provides a screen on which the first video and the second video are displayed in synchronization with each other.

7. A management method for managing the operation status of a production line including a plurality of processes, comprising the steps of: acquiring event information indicative of an occurrence of an event on the production line; collecting time information indicating a processing start time and a processing end time of each of the plurality of processes for each product to be processed in the plurality of processes; identifying a static bottleneck process among the plurality of processes based on the time information; calculating an estimated time of completion of processing by the production line for each of the products on the assumption that the event does not occur, based on the end time of the static bottleneck process for each of the products during a period before the event occurs; providing a graph having a first axis representing time and a second axis representing the order of introduction of the individual products; The graph is A processing time period for each of the plurality of steps is indicated for each of the individual products; and including a line indicating the estimated completion time for each of the products.

Images