Process planning device, process planning system, and process planning method

Abstract

To maintain a conscious state of a worker well to maintain production efficiency.SOLUTION: A process planning device includes: a mind evaluation unit which evaluates mind evaluation values indicative of conscious states of workers during tasks on the basis of indexes showing results of the tasks of the workers; and a planning unit which, if the mind evaluation values do not satisfy a reference, plans a task assignment by which it is estimated that the mind evaluation values satisfy the reference, out of task assignments to the individual workers.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a process planning device, a process planning system, and a process planning method. [Background technology]

[0002] On a production line that produces a product, process plan information is created that assigns multiple workers to multiple tasks based on the work time required for tasks such as assembling and inspecting the multiple parts that make up the product. To maximize throughput and improve production line productivity, it is necessary to accurately predict the work time required for each worker, assign workers so that the difference in total work time between them is small, and eliminate waste on the production line.

[0003] On the other hand, as the workforce becomes more diverse, differences in work ability arise among workers, and the actual work time may differ for each worker even when performing the same work. This reduces the accuracy of work time predictions, and the expected production efficiency may not be achieved. In order to address such differences in work ability among workers, Patent Document 1 discloses a method for predicting the work time of each worker based on production results. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Application Laid-Open No. 2010-79533 Summary of the Invention [Problem to be solved by the invention]

[0005] However, the method of Patent Document 1 does not take into account the aptitude of each worker, such as the tasks that they are good at or bad at. Furthermore, the method of Patent Document 1 does not take into account changes over time, such as fatigue or boredom. As a result, the method of Patent Document 1 does not take into account the worker's state of mind, in which motivation, willingness, satisfaction, etc., decline over time. In such a state of mind, there is a problem that the quality of the product will deteriorate and the stress load on the worker will increase, leading to a long-term decline in labor productivity.

[0006] The present invention has been made in view of the above circumstances, and has as its object to maintain a good state of consciousness of workers and maintain production efficiency. [Means for solving the problem]

[0007] The present application includes a number of means for solving at least part of the above problems, examples of which are as follows.

[0008] In order to solve the above problem, a process planning device according to one embodiment of the present invention has a mind evaluation unit that evaluates a mind evaluation value that indicates the state of consciousness of a worker when performing a task based on an index that indicates the worker's work performance, and a planning unit that, when the mind evaluation value does not satisfy a criterion, plans the allocation of tasks to each worker such that the mind evaluation value is expected to satisfy the criterion. [Effects of the Invention]

[0009] According to the present invention, it is possible to maintain the consciousness of the workers in a good state and maintain production efficiency. [Brief explanation of the drawings]

[0010] [Figure 1] FIG. 1 is a schematic diagram showing an example of the schematic configuration of a process planning system according to this embodiment. [Figure 2] FIG. 2 is a schematic diagram showing an example of product information. [Figure 3] FIG. 3 is a schematic diagram showing an example of process plan information. [Figure 4] FIG. 4 is a schematic diagram illustrating an example of production plan information. [Figure 5] FIG. 5 is a diagram illustrating an example of the process plan information. [Figure 6] FIG. 6 is a schematic diagram illustrating an example of production performance information. [Figure 7] FIG. 7 is a schematic diagram showing an example of worker-specific work performance evaluation information. [Figure 8] FIG. 8 is a diagram showing an example of worker-specific mindset evaluation information. [Figure 9] FIG. 9 is a schematic diagram showing an example of workability evaluation value information. [Figure 10] FIG. 10 is a diagram showing an example of a flowchart of the process planning method according to this embodiment. [Figure 11] FIG. 11 is a diagram illustrating an example of a flowchart of a process for generating worker-specific work performance evaluation information. [Figure 12] FIG. 12 is a diagram illustrating an example of a flowchart of the process for generating worker-specific mind evaluation information. [Figure 13] FIG. 13(a) is a schematic diagram showing an example of the working state of a worker identified by the mind evaluation unit based on production performance information, FIG. 13(b) is a schematic diagram showing an example of a graph showing the distribution of calculated actual working times for each part, FIG. 13(c) is a schematic diagram showing an example of the time progression of calculated actual working times, and FIG. 13(d) is a schematic diagram showing an example of a graph showing the distribution of calculated actual working interval times 1301e for each part. [Figure 14] FIG. 14 is a schematic diagram showing an example of a method for calculating the variation in work time for a part that a worker has never handled before. [Figure 15] FIG. 15 is a schematic diagram showing an example of a screen displayed on the display unit by the planning unit. [Figure 16] FIG. 16 is a diagram illustrating an example of a hardware configuration of a process planning apparatus according to this embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0011] An embodiment of the present invention will be described below with reference to the drawings. In all drawings used to describe the embodiment, the same components are generally designated by the same reference numerals, and repeated description thereof will be omitted where appropriate. It goes without saying that, in the following embodiments, the components (including element steps, etc.) are not necessarily essential unless otherwise specified or considered to be clearly essential in principle. It goes without saying that the terms "consisting of A," "made of A," "having A," and "including A" do not exclude other elements, unless otherwise specified to include only the relevant element. Similarly, in the following embodiments, when referring to the shape, positional relationship, etc. of components, etc., this includes those that are substantially similar or similar to the shape, etc., unless otherwise specified or considered to be clearly essential in principle.

[0012] <Present Embodiment> 1 is a schematic diagram showing an example of the overall configuration of a process planning system according to this embodiment. The process planning system is a system that plans the allocation of tasks to each of a plurality of workers. As an example, the process planning system includes a process planning device 1000 and an external device 2000 that are connected to each other via a network N.

[0013] The network N is, for example, a public network such as the Internet, a local area network (LAN), a wide area network (WAN), etc. The external device 2000 is a control device that instructs the production line to execute production.

[0014] The process planning apparatus 1000 is a server that plans task allocation or a computer such as a PC (Personal Computer). As an example, the process planning apparatus 1000 includes a processing unit 1100, a storage unit 1200, an input unit 1300, a display unit 1400, and a communication unit 1500.

[0015] The input unit 1300 is an input device such as a keyboard or a mouse that allows a user to input various data to the process planning apparatus 1000. The display unit 1400 is a display device such as a liquid crystal display or an organic EL (Electro Luminescence) display that displays a process plan or the like created by the process planning apparatus 1000. The communication unit 1500 is a communication interface that connects the process planning apparatus 1000 to the network N.

[0016] The processing unit 1100 is a functional unit that executes various processes of the process planning apparatus 1000. In this example, the processing unit 1100 includes a process plan calculation unit 1101, a workability evaluation value calculation unit 1102, a planning unit 1103, a workability evaluation unit 1104, and a mind evaluation unit 1105.

[0017] The process plan calculation unit 1101 calculates a plurality of process plans including work sequences and work contents for a plurality of parts that constitute a product.

[0018] The workability evaluation value calculation unit 1102 calculates a workability evaluation value that indicates the work efficiency of each task included in the process plan calculated by the process plan calculation unit 1101.

[0019] The planning unit 1103 creates a process plan for allocating workers to tasks so that the number of products to be produced is equal to or greater than the planned production volume, based on the multiple process plans calculated by the process plan calculation unit 1101 and the production plan information 1203 described below. When planning, the planning unit 1103 allocates workers to tasks so that each worker's state of mind is good, based on a mind evaluation value (described below) that indicates the worker's state of mind.

[0020] The workability evaluation unit 1104 calculates a workability evaluation value for each worker and each part based on the workability evaluation value calculated by the workability evaluation value calculation unit 1102 and production performance information 1205 for each worker, which will be described later.

[0021] The mind evaluation unit 1105 evaluates the mind evaluation value indicating the state of consciousness of each worker based on the workability evaluation value of each worker and the production performance information 1205 .

[0022] The storage unit 1200 is a functional unit that stores various information. As an example, the storage unit 1200 stores product information 1201, process plan information 1202, production plan information 1203, process plan information 1204, production performance information 1205, worker-specific workability evaluation information 1206, worker-specific mindset evaluation information 1207, and workability evaluation value information 1208.

[0023] 2 is a schematic diagram showing an example of product information 1201. The product information 1201 is information relating to parts that make up a product, and is information that associates a product number 1201a, a part ID 1201b, a part number 1201c, and a part name 1201d with each other.

[0024] The product number 1201a is a character string that uniquely identifies a product. The part ID 1201b is a character string that is assigned to each of multiple parts included in a product, with no duplication allowed. The part number 1201c is a character string that uniquely identifies multiple parts. The part name 1201d is the name of each part.

[0025] 3 is a schematic diagram showing an example of the process plan information 1202. The process plan information 1202 is information indicating a plurality of process plans.

[0026] As an example, the process plan information 1202 is information that associates a product number 1202a, a candidate ID 1202b, a process ID 1202c, a work content 1202d, a part ID 1202e, a workability evaluation element 1202f, and a workability evaluation value 1202g.

[0027] The product number 1202a is information corresponding to the product number 1201a in the product information 1201. The candidate ID 1202b is information that uniquely identifies multiple process plan candidates. For example, a row in which the candidate ID 1202b is "1" is a candidate for one process plan.

[0028] The process ID 1202c is an integer value that uniquely identifies multiple processes in a candidate. For example, a candidate with a candidate ID 1202b of "1" includes process IDs 1202c of "1," "2," and "3." Therefore, a candidate with a candidate ID 1202b of "1" consists of three processes identified by the process IDs 1202c of "1," "2," and "3." In this example, the integer values ​​of the process IDs indicate the order of the processes. For example, the smaller the process ID value, the earlier the process is performed. Furthermore, if the process plan information 1202 contains multiple rows with the same process ID 1202c, the order of the work in those processes is indicated by the order of the rows. For example, a candidate with a candidate ID 1202b of "1" includes four rows with a process ID 1202c of "1." In this case, the work in the top row with the part ID 1202e of "1" is performed first, followed by the work in the second row.

[0029] The work content 1202d is information indicating the work content of each process. For example, the work content of the process identified by the process ID 1202c of "1" is "case assembly."

[0030] The part ID 1202e is information corresponding to the part ID 1201b in the product information 1201. The workability evaluation element 1202f is the work content for each part. For example, if the process ID 1202c is "1" and the part ID 1202e corresponds to "1", the workability evaluation element 1202f is "installation". According to FIG. 2, the part corresponding to the part ID 1202e "1" is a "plate", so this indicates the work content of "installing a plate."

[0031] In the following, when simply referring to a task, it refers to the task indicated by the workability assessment element 1202f. The workability assessment element 1202f is uniquely determined by the process ID 1202c and the part ID 1202e. Therefore, a task can be specified by a combination of a process and a part.

[0032] The workability evaluation value 1202g indicates the work efficiency of the work indicated by the workability evaluation element. In this example, work efficiency is evaluated based on the work time required for the work, with shorter work times indicating better work efficiency. The workability evaluation value 1202g is a value proportional to the past performance of the work time. For example, if the workability evaluation element 1202f is "installation" and the average work time when multiple workers have previously performed the "installation" work is 10 seconds, the workability evaluation value is calculated by multiplying this average by a proportionality constant of 0.1 (1.0). This proportionality constant is the same for all workability evaluation elements 1202f. For example, if the workability evaluation element 1202f is "positioning" and the average work time when multiple workers have previously performed the "positioning" work is 11 seconds, the workability evaluation value for "positioning" is calculated by multiplying this average by 0.1 (1.1).

[0033] 4 is a schematic diagram showing an example of production plan information 1203. The production plan information 1203 is information indicating the planned production volume of each product to be produced in the factory in the future. As an example, the production plan information 1203 is information that associates a product number 1203a, a production month 1203b, and a quantity 1203c.

[0034] The product number 1203a is information corresponding to the product number 1201a in the product information 1201. The production month is the month in which the product is produced. The quantity 1203c is the planned production amount of the product to be produced in the production month. For example, 200 units of a product with the product number "PR001" are scheduled to be produced in February 2022.

[0035] 5 is a diagram showing an example of the process plan information 1204. The process plan information 1204 is information in which a worker is assigned to one of a plurality of process plans identified by a process ID 1202b in the process plan information 1202. Here, among the plurality of process plans, when the production volume per product production month 1203b is calculated based on the workability evaluation value 1202g in the process plan information 1202, the worker is assigned to the process plan in which the production volume is equal to or greater than the quantity 1203c in the production plan information 1203.

[0036] As mentioned above, the workability evaluation value 1202g is proportional to the time required to handle a certain part in a certain process, and therefore the total workability evaluation value 1202g of all parts handled in that process is proportional to the time required for that process. In production by multiple workers, when the worker in the first process finishes work on a certain product, he or she hands that product over to the next process. At the same time that the worker in the next process starts work on that product, the worker in the first process starts work on the next product. In this way, since multiple workers work in parallel, the longest time among the work times of each process is the time required to manufacture one product. This determines the production volume per unit time, and also the production volume per production month 1203b.

[0037] As an example, the process plan information 1204 is information in which a product number 1204a, a process ID 1204b, a part ID 1204c, and a worker ID 1204d are associated with each other.

[0038] Product 1204a is information corresponding to product number 1201a in product information 1201. Process ID 1204b is information corresponding to process ID 1202c in process plan information 1202. Part ID 1204c is information corresponding to part ID 1201b in product information 1201. Worker ID 1204d is an identifier that uniquely identifies each of multiple workers in the factory.

[0039] The example in Figure 5 shows a process plan for manufacturing a product with product number 1204a "PR001" using three processes with process IDs 1204b "1," "2," and "3." In the following, it is assumed that the same worker is assigned to the same process. For example, a worker with worker ID 1204d "1" is assigned to the process with process ID 1204b "1."

[0040] 6 is a schematic diagram showing an example of the production performance information 1205. The production performance information 1205 is information showing past production performance.

[0041] As an example, the production performance information 1205 is information associating a product number 1205a, a process ID 1205b, a part ID 1205c, a worker ID 1205d, a work start date and time 1205e, a work end date and time 1205f, and a work result 1205g.

[0042] Of these, the product number 1205a and the part ID 1205c are information corresponding to the product number 1201a and the part ID 1201b, respectively, of the product information 1201. The process ID 1205b is information corresponding to the process ID 1202c in the process plan information 1202. The worker ID 1205d is information corresponding to the worker ID 1204d in the process plan information 1204.

[0043] Furthermore, the work start date and time 1205e and the work end date and time 1205f are the dates and times when the work on the component indicated by the component ID 1204 started and ended, respectively. The work result 1205g is information indicating whether the work was successful or unsuccessful. In this example, success is represented by "1" and failure is represented by "0".

[0044] 7 is a schematic diagram showing an example of the worker-specific work performance evaluation information 1206. The worker-specific work performance evaluation information 1206 is information indicating the work performance evaluation value for each worker.

[0045] For example, the worker-specific workability evaluation information 1206 is information associating a worker ID 1206a, a target period 1206b, a product number 1206c, a candidate ID 1206d, a process ID 1206e, a part ID 1206f, and a worker-specific workability evaluation value 1206g.

[0046] The worker ID 1206a is information corresponding to the worker ID 1204d in the process plan information 1204. The target period 1206b is the period during which the worker-specific workability evaluation value 1206g was evaluated. The product number 1206c and the part ID 1206f are information corresponding to the product number 1201a and the part ID 1201b in the product information 1201, respectively. The process ID 1206e is information corresponding to the process ID 1202c in the process plan information 1202. The candidate ID 1206d is information corresponding to the candidate ID 1202b in the process plan information 1202. The worker-specific workability evaluation value is a value defined in the same way as the workability evaluation value 1202g in the process plan information 1202, and is a value indicating the work efficiency of the work of each worker.

[0047] For example, consider the first row of the worker-specific workability evaluation information 1206. The first row is information about work performed by a worker whose worker ID 1206a is "1" between 8:00 and 10:00 on 2022 / 02 / 01. This work involves handling a product whose product number 1206c is "PR001" in a process whose process ID 1206e is "1" and a part whose part ID 1206f is "1". In this example, the worker-specific workability evaluation value 1206g for this work is "1.0".

[0048] 8 is a diagram showing an example of the worker-specific mind evaluation information 1207. The worker-specific mind evaluation information 1207 is information showing, for each worker, a mind evaluation value that indicates the state of consciousness during work.

[0049] As an example, the worker-specific mind evaluation information 1207 is information that associates each of the worker ID 1207a, target period 1207b, product number 1207c, candidate ID 1207d, process ID 1207e, part ID 1207f, mind evaluation value 1207g, failure rate 1207h, work time variation 1207i, familiarization time 1207j, and work interval time 1207k.

[0050] The worker ID 1207a, target period 1207b, product number 1207c, candidate ID 1207d, process ID 1206e, and part ID 1207f correspond to the worker ID 1206a, target period 1206b, product number 1206c, candidate ID 1206d, process ID 1206e, and part ID 1206f in the worker-specific workability evaluation information 1206, respectively.

[0051] The failure rate 1207h is the failure rate of work performed by a certain worker during the target period 1207b. As an example, the failure rate 1207h is defined as the ratio of work whose work result 1205g is "0" to work whose work result 1205g is "1" and "0" during the target period 1207b.

[0052] The task time variation 1207i is the standard deviation of the task time for each task performed during the target period 1207b. The mastery time 1207j is the time required to master the task performed during the target period 1207b. The task interval time 1207k is the average value of the interval time for each task during the target period 1207b.

[0053] The mind evaluation value 1207g indicates the state of consciousness of the worker when handling the part with part ID 1207f during the target period 1207b, and the higher the value, the better the worker's state of consciousness. A good state of consciousness is, for example, a state of consciousness that is effective in improving product productivity, such as not feeling stressed and concentrating on the work.

[0054] When the worker's state of consciousness is not good, any of the failure rate 1207h, work time variation 1207i, familiarization time 1207j, and work interval time 1207k is expected to be larger than when the worker's state of consciousness is good. Therefore, in this embodiment, the reciprocal of the square root of the sum of the squares of the failure rate 1207h, work time variation 1207i, familiarization time 1207j, and work interval time 1207k is set as the mind evaluation value 1207f. Note that the failure rate 1207h, work time variation 1207i, familiarization time 1207j, and work interval time 1207k are each an example of an index indicating the worker's work performance.

[0055] 9 is a schematic diagram showing an example of workability evaluation value information 1208. The workability evaluation value information 1208 is information used when creating the process plan information 1202 (see FIG. 3), and is information that associates workability evaluation elements 1208a with workability evaluation values ​​1208b. The workability evaluation elements 1208a and the workability evaluation values ​​1208b are information that correspond to the workability evaluation elements 1202f and the workability evaluation values ​​1202g, respectively, of the process plan information 1202 (see FIG. 3).

[0056] Next, a process planning method according to this embodiment will be described.

[0057] 10 is a diagram showing an example of a flowchart of the process planning method according to this embodiment. Each of the following processes is started, for example, when the process planning apparatus 1000 receives a process start instruction from an operator via the input unit 1300.

[0058] When the process starts, the process plan calculation unit 1101 acquires the product information 1201 and the workability evaluation value information 1208 from the storage unit 1200 (S010).

[0059] Next, the process plan calculation unit 1101 generates process plan information 1202 based on the product information 1201 and the workability evaluation value information 1208 (S020).

[0060] When producing a product made up of multiple parts, multiple process plans with different work orders may exist. Such process plans can be derived using publicly known techniques. A representative technique for calculating the work order is described in Japanese Patent No. 4859590, which uses adjacency relationships and other information that can be acquired from the three-dimensional shapes of the parts. Furthermore, the work content 1202d and workability evaluation element 1202f in the process plan information 1202 can be calculated using a method described in Japanese Patent Application Laid-Open No. 2011-248622. This method uses the actual process information and product information of past products to reuse the actual process information based on the similarity between the parts of the past product and the new product.

[0061] The process plan information 1202 generated in this manner includes a plurality of process plans identified by candidate IDs 1202b.

[0062] At this stage, the process plan calculation unit 1101 leaves the workability evaluation value 1202g of the process plan information 1202 blank.

[0063] Next, the workability evaluation value calculation unit 1102 calculates a workability evaluation value 1202g of the process plan information 1202 based on the workability evaluation value information 1208 (S030). As an example, the workability evaluation value calculation unit 1102 identifies a workability evaluation value 1202g corresponding to a workability evaluation element 1202f of the process plan information 1202 from the workability evaluation value information 1208. Then, the workability evaluation value calculation unit 1102 stores the identified workability evaluation value 1202g in the process plan information 1202.

[0064] Next, the planning unit 1103 acquires the production plan information 1203 from the storage unit 1200, and generates the process plan information 1204 based on the production plan information 1203 and the process plan information 1202 (S040).

[0065] As an example, the planning unit 1103 identifies, for each product, a process plan among the multiple process plans indicated by the process plan information 1202, which will result in a production volume of the product per production month 1203b in the production plan information 1203 equal to or greater than the quantity 1203c, and generates process plan information 1204 related to that process plan. If multiple such process plans exist, the planning unit 1103 may identify a process plan that maximizes the manufacturing throughput or minimizes the manufacturing lead time when manufacturing the product by solving an integer programming problem. The production volume for each process plan can be calculated based on the process plan information 1202. For example, in each process plan, the sum of the workability evaluation values ​​1202g for a certain process for all part IDs 1202e used in that process is proportional to the time required for that process. Therefore, the maximum value of the sum for each process is proportional to the time required to manufacture the product. Since the number of products manufactured per unit time can be determined from that time, the production volume per production month 1203b can also be calculated.

[0066] If the workability evaluation value of each worker is known in advance, the work time for each task can be determined based on the workability evaluation value, and the manufacturing throughput and manufacturing lead time can be calculated based on the work time. The worker ID 1204d in the process plan information 1204 is the worker ID corresponding to the workability evaluation value used to calculate the manufacturing throughput or manufacturing lead time. Even if the workability evaluation value of each worker is not known in advance, the manufacturing throughput and manufacturing lead time can be calculated using the workability evaluation value 1202g in the process plan information 1202. In this case, the planning unit 1103 simply assigns the worker ID in the process plan information 1204 as appropriate.

[0067] Here, the constraint that the production volume must be equal to or greater than the planned production volume is imposed. However, in addition to this, a constraint that the working hours per day of each worker must not exceed the working hours per day set for each worker may also be imposed.

[0068] As described above, it is assumed here that one process is handled by one worker. In this case, in the process plan information 1204, the same process ID 1204b corresponds to the same worker ID 1204d.

[0069] Next, the process planning device 1000 instructs the production line to carry out production based on the process planning information 1204 generated in step S040 through the communication unit 1500, the network N, and the external device 2000, and acquires from the memory unit 1200 the production performance information 1205 accumulated as each worker on the production line carries out production (S050).

[0070] Next, the workability evaluation unit 1104 performs processing to generate workability evaluation information for each worker 1206 based on the workability evaluation value of the process plan that is the basis of the process plan information 1204 and the production performance information 1205 (S060). Details of this processing will be described later.

[0071] Next, the mindset evaluation unit 1105 performs processing to generate mindset evaluation information for each worker 1207 based on the worker performance evaluation information for each worker 1206 and the production performance information 1205 (S070). Details of this processing will also be described later.

[0072] Next, the planner 1103 determines whether the mind evaluation value satisfies a standard (S080).

[0073] As an example, the planner 1103 calculates the total of the mind evaluation values ​​1207f for all parts handled by a certain worker in a certain process as the consciousness state evaluation value indicating the consciousness state of the worker in that process. Then, if the total of the consciousness state evaluation values ​​for all workers is equal to or greater than a predetermined threshold, the planner 1103 determines that the mind evaluation value satisfies the criterion.

[0074] Alternatively, the planner 1103 may determine that the mind evaluation value satisfies the criterion when there is no worker whose consciousness state evaluation value is less than a predetermined threshold value.

[0075] Furthermore, if there is no worker whose current consciousness state evaluation value is lower than the consciousness state evaluation value calculated last time (the previous day or the previous shift), the planner 1103 may determine that the mind evaluation value meets the criterion.

[0076] If it is determined that the mind evaluation value satisfies the criteria (YES), the process returns to step S050.

[0077] On the other hand, if it is determined that the mind evaluation value does not satisfy the standard (NO), the process proceeds to step S090. In this case, it is considered that the worker's state of consciousness is deteriorating due to a mismatch between the worker's aptitude and the work, or due to changes over time such as the worker's fatigue or boredom.

[0078] Therefore, in step S090, the planning unit 1103 changes the process plan information 1204 to plan the allocation of workers whose mind evaluation values ​​are expected to satisfy the criteria in step S080.

[0079] As an example, the planning unit 1103 generates multiple change proposals in which the worker ID 1204d to be assigned to the part ID 1204c is variously changed in the current process plan information 1204. In the example of Fig. 5, the worker ID 1204d "1" has already been assigned to the part ID 1204c "1", but the planning unit 1103 also assigns worker IDs 1204d "2", "3", ... to the part ID 1204c "1". The same applies to part IDs 1204c other than "1".

[0080] Furthermore, the planner 1103 calculates an awareness state evaluation value for each worker in each of the multiple change plans. For example, in a certain change plan, a worker whose worker ID 1204d is "1" is assigned to parts whose part IDs 1204c are "5," "6," "7," and "8." In this case, the planner 1103 identifies the mind evaluation values ​​1207g corresponding to the part IDs 1204c of "5," "6," "7," and "8" from the mind evaluation values ​​1207g corresponding to the worker ID 1204d of "1" in the worker-specific mind evaluation information 1207. Then, the planner 1103 calculates the awareness state evaluation value of the worker whose worker ID 1204d is "1" by summing up the identified mind evaluation values ​​1207g.

[0081] If a part that a certain worker has never handled is included in the change plan, the mind evaluation value 1207g corresponding to that worker and that part does not exist in the worker-specific mind evaluation information 1207. In this case, the planning unit 1103 can calculate the mind evaluation value 1207g corresponding to that worker and that part by using an approximation formula 1401 in Fig. 14, which will be described later.

[0082] The planning unit 1103 then generates, as changed process plan information 1204, the process plan information corresponding to the change plan among the multiple change plans that results in the production volume per production month 1203b being equal to or greater than the quantity 1203c in the production plan information 1203 and that results in the largest total sum of the consciousness state evaluation values ​​for all workers. The production volume for each change plan can be calculated based on the worker-specific performance evaluation information 1206. For example, in each change plan, the total sum of the worker-specific performance evaluation values ​​1206g of a certain worker for all part IDs 1204c handled by that worker is proportional to the time required for the process assigned to that worker. Therefore, the maximum value of the total value for each process is proportional to the time required to manufacture the product. Since the number of products manufactured per unit time can be determined from that time, the production volume per production month 1203b can also be calculated.

[0083] By changing the process plan information 1204 in this way, the total value described above becomes equal to or greater than the threshold value, and the possibility that the mind evaluation value will be determined to satisfy the criteria in step S080 can be increased.

[0084] Furthermore, even with the changed process plan information 1204, the production volume per production month 1203b is equal to or greater than the quantity 1203c in the production plan information 1203, so that the production plan can be adhered to.

[0085] Although the total of the consciousness state evaluation scores of all workers is used as the objective function here, the total of the differences in the consciousness state evaluation scores from the previous time for all workers may be used as the objective function, and a process plan that maximizes this objective function may be specified. Alternatively, the average of the increments in the consciousness state evaluation scores from the previous time for all workers may be used as the objective function, and a process plan that maximizes this objective function may be specified.

[0086] Next, the planning unit 1103 determines whether or not the production of the product has been completed (S100). If it is determined that the production has not been completed (NO), the process returns to step S050.

[0087] As a result, the planner 1103 repeatedly makes the determination in step S080 while the worker is working based on the process plan information 1204, and each time the determination is negative, changes the process plan information 1204 in step S090 to replan the work allocation. By repeatedly making the determination in step S080 in this way, it is possible to capture changes in the worker's state of mind while a product is being manufactured, and furthermore, by changing the process plan information 1204, it is possible to maintain the worker's state of mind in a good state.

[0088] On the other hand, if it is determined in step S100 that production has ended (YES), the process ends. Note that even if the determination in step S080 is never negative after repeated execution, the process ends when production has ended.

[0089] Next, the process of generating the worker-specific work performance evaluation information 1206 in step S060 will be described.

[0090] FIG. 11 is a diagram showing an example of a flowchart of the process for generating the worker-specific productivity evaluation information 1206.

[0091] First, the workability evaluation unit 1104 acquires the workability evaluation value 1202g from the process plan information 1202 (S061).

[0092] Next, the workability evaluation unit 1104 acquires the work start date and time 1205e and the work end date and time 1205f for each part of each worker from the production performance information 1205 (S062).

[0093] Next, the workability evaluation unit 1104 obtains the difference between the work end date and time 1205f and the work start date and time 1205e for each part and each worker, and calculates it as the actual work time (S063).

[0094] Next, the workability evaluation unit 1104 calculates the workability evaluation value 1206g for each worker and for each part based on the workability evaluation value 1202g and the actual work time (S064).

[0095] As an example, the workability evaluation unit 1104 sums up the workability evaluation values ​​1202g of the process plan that formed the basis of the process plan information 1204 for all parts handled by a certain worker. Furthermore, the workability evaluation unit 1104 sums up the actual work times for all parts handled by a certain worker. The workability evaluation unit 1104 calculates the worker-specific workability evaluation value 1206g for a certain worker for each part based on the ratio between the total of the workability evaluation values ​​1202g thus obtained and the total of the actual work times. For example, the workability evaluation unit 1104 calculates the worker-specific workability evaluation value 1206g for that part by multiplying the ratio between the total of the workability evaluation values ​​1202g and the total of the actual work times by the actual work time for that part.

[0096] The worker-specific workability evaluation value 1206g for a part without actual work time is calculated based on the actual work time of a part similar to that part. Whether parts are similar to each other can be determined arbitrarily from information indicating the characteristics of the parts, such as the work content, part shape, and part mass. Similarly, the worker-specific workability evaluation value 1206g for other process plan candidates in the process plan information 1202 that were not adopted in the process planning information 1204 can also be calculated based on the similarity of the parts. By using the similarity of the parts in this way, the worker-specific workability evaluation value 1206g can be calculated for parts without actual work time or for process plan candidates that were not adopted.

[0097] Next, the workability evaluation unit 1104 determines whether the process of calculating the workability evaluation value 1206g for each worker has been completed for all workers (S065). If it is determined that the process for all workers has not been completed (NO), the process returns to step S064. On the other hand, if it is determined that the process for all workers has been completed (YES), the process ends.

[0098] Next, the process of generating the worker-specific mindset evaluation information 1207 in S070 of FIG. 10 will be described.

[0099] FIG. 12 is a diagram showing an example of a flowchart of the process for generating the worker-specific mindset evaluation information 1207.

[0100] First, the mind evaluation unit 1105 acquires the worker-specific work performance evaluation value 1206g from the worker-specific work performance evaluation information 1206 (S071).

[0101] Next, the mind evaluation unit 1105 acquires the work start date and time 1205e, the work end date and time 1205f, and the work result 1205g for each part of each worker from the production performance information 1205 (S072). Note that, hereinafter, it is assumed that the work start date and time 1205e and the work end date and time 1205f of the production performance information 1205 are included in the target period 1207b of the worker-specific mind evaluation information 1207.

[0102] Next, the mind evaluation unit 1105 calculates the difference between the work start date and time 1205e and the work end date and time 1205f for each row of the production result information 1205 as the actual work time, and calculates the work time variation and the learning time based on the actual work time (S073).

[0103] Furthermore, the mind evaluation unit 1105 calculates, as the work interval time, the difference between the work end date / time 1205f and the work start date / time 1205e of two consecutive rows in the production performance information 1205. The mind evaluation unit 1105 also calculates a failure rate 1207h based on the work results 1205g of the production performance information 1205. For example, the mind evaluation unit 1105 calculates, as the failure rate 1207h, the percentage of the proportion of "0" in the work results 1205g corresponding to each of the same product number 1205a, the same process ID 1205b, and the same worker ID 1205d in the target period 1207b.

[0104] The work time variation, learning time, and work interval time are calculated as follows.

[0105] Fig. 13(a) is a schematic diagram showing an example of the working status of a worker identified by the mind evaluation unit 1105 based on the production performance information 1205. The horizontal axis of Fig. 13(a) indicates the working date and time, and the vertical axis indicates whether or not the worker is currently working. In addition, here, the example shows a worker with a worker ID of "1."

[0106] 13(a), work start date and time 1301a corresponds to work start date and time 1205e in one row of production performance information 1205, and work end date and time 1301b corresponds to work end date and time 1205f in the same row. Work start date and time 1301d is the date and time when the next work started after the work was completed at work end date and time 1205f.

[0107] It is considered that the worker was in a working state during the period from the work start date and time 1301a to the work end date and time 1301b. Therefore, the mind evaluation unit 1105 calculates the difference between the work start date and time 1301a and the work end date and time 1301b as the actual working time 1301c.

[0108] Furthermore, the period from the task end date and time 1301b to the task start date and time 1301d is considered to be a period during which the worker was not working, and therefore the mind evaluation unit 1105 calculates this period as the actual task interval time 1301e.

[0109] 13(b) is a schematic diagram showing an example of a graph showing the distribution of calculated actual work times 1301c for each part. As shown in FIG. 13(b), even when the same worker handles the same part, there is variation in the actual work times 1301c. As an example, the mind evaluation unit 1105 calculates the standard deviation of the actual work times 1301c for each part and worker as the work time variation 1207i.

[0110] FIG. 13(c) is a schematic diagram showing an example of the time progression of the calculated actual work time 1301c. As shown in FIG. 13(c), the actual work time of the same worker for the same part tends to decrease with each iteration compared to the initial time when the worker started the work. This is because the worker becomes more proficient at the work as the number of iterations increases. Furthermore, if the worker is good at a task, the actual work time decreases more quickly as the number of iterations increases compared to a task that the worker is not good at. In this way, the strengths and weaknesses of the worker are reflected in the rate at which the actual work time decreases. Therefore, the mind evaluation unit 1105 calculates the proficiency time 1207j as the time from the first actual work time or the maximum actual work time to the work date and time at which the actual work time reaches a predetermined reduction rate.

[0111] 13(d) is a schematic diagram showing an example of a graph showing the distribution of calculated actual task interval times 1301e for each part. As shown in FIG. 13(d), even when the same worker is working on the same part, the actual task interval time 1301e varies depending on the worker's state of mind. Therefore, the mind evaluation unit 1105 calculates the average actual task interval time 1301e for each part and worker as the task interval time 1207k. Furthermore, if a worker is good at working with a certain part, that worker will perform the work one after another, and therefore the actual task interval time 1301e corresponding to that part will be shorter than that for work that the worker is not good at.

[0112] In this way, the mind evaluation unit 1105 can calculate the work time variation 1207i, the learning time 1207j, and the work interval time 1207k based on the production performance information 1205.

[0113] Furthermore, the mind evaluation unit 1105 calculates the work time variation 1207i, the learning time 1207j, the work interval time 1207k, and the failure rate 1207h for a part that a certain worker has never handled, as follows.

[0114] FIG. 14 is a schematic diagram showing an example of a method for calculating the work time variation 1207i for parts that a worker has never handled.

[0115] The horizontal axis of FIG. 14 represents the worker-specific workability evaluation value E1 of the worker with the worker ID “1”. i The subscript "i" indicates the part ID that the worker with worker ID "1" has handled. The vertical axis of Fig. 14 represents the variation in work time for the worker with worker ID "1".

[0116] As shown in Fig. 14, there is a correlation between the work time variation and the worker-specific workability evaluation value. i and worker-specific workability evaluation value E1 i The mind evaluation unit 1105 then obtains an approximate expression 1401 that approximates the relationship between the workability evaluation value 1202g and the workability evaluation value 1202g. The mind evaluation unit 1105 then obtains the workability evaluation value 1202g of the part that the worker with the worker ID "1" has never handled from the process plan information 1202, and obtains the work time variance by substituting the workability evaluation value 1202g into the approximate expression 1401. The work time variance obtained in this way becomes an estimated value of the work time variance 1207i corresponding to the part that the worker has never handled. In this way, even if the part is one that the worker has never handled, the mind evaluation unit 1105 can estimate the work time variance 1207i of that part by using the approximate expression 1410.

[0117] Similarly, the mind evaluation unit 1105 can estimate each index such as the learning time 1207j, the operation interval time 1207k, and the failure rate 1207h for a part that the worker has never handled, based on the approximation formula 1401.

[0118] Referring again to Figure 12, the mind evaluation unit 1105 then calculates a mind evaluation value 1207f for each worker and each part based on the task time variation 1207i, familiarization time 1207j, task interval time 1207k, and failure rate 1207h (0S74). For example, as described above, the mind evaluation unit 1105 calculates the reciprocal of the square root of the sum of the squares of the task time variation 1207i, familiarization time 1207j, task interval time 1207k, and failure rate 1207h as the mind evaluation value 1207f.

[0119] Next, the mind evaluation unit 1105 determines whether or not the mind evaluation values ​​1207f have been calculated for all parts handled by all workers (S075).

[0120] If it is determined that the processing for all workers has not been completed (NO), the process returns to S074. On the other hand, if it is determined that the processing for all workers has been completed (YES), the process of this flow ends.

[0121] This completes the basic processing of the process planning method according to this embodiment.

[0122] FIG. 15 is a schematic diagram showing an example of a screen 1501 displayed on the display unit 1400 by the planning unit 1103 based on the process plan information 1204 regenerated in step S090.

[0123] As shown in FIG. 15, a screen 1501 has a selection field 1501a, a current process plan information display field 1501b, a changed process plan information display field 1501c, a production performance period display field 1501d, a performance work time display field 1501e, a performance consciousness state evaluation value display field 1501f, an estimated work time display field 1501g, and an estimated consciousness state evaluation value display field 1501h.

[0124] The selection column 1501a is a column where the user selects a product number. The current process plan information display column 1501b is a column where information corresponding to the product number in the selection column 1501a is displayed in the process plan information 1204 (see FIG. 5) used in the current production line. In this example, a process ID 1204b, a part ID 1204c, and a worker ID 1204d are displayed in the current process plan information display column 1501b.

[0125] The changed process plan information display field 1501c is a field that displays information corresponding to the product number in the selection field 1501a in the process plan information 1204 changed in step S090. As an example, a process ID 1204b, a part ID 1204c, and a worker ID 1204d are displayed in the changed process plan information display field 1501c.

[0126] The production performance period display field 1501d is a field that displays the target period 1207b used to calculate the mind evaluation value 1207f and the process plan information 1204.

[0127] The actual work time display field 1501e is a field that displays a bar graph showing the actual work time 1301c (see FIG. 13) for each worker ID. Here, the total value of the actual work time 1301c for each part handled by each worker is displayed as a bar graph. For example, the bar graph for worker ID "1" has four areas, and each area corresponds to the actual work time for part IDs "1," "2," "3," and "4."

[0128] The estimated work time display field 1501g is a field that displays, as a bar graph, the estimated work time for each worker ID when manufacturing a product according to the information displayed in the changed process plan information display field 1501c. The estimated work time for a given worker is calculated by multiplying the sum of all worker-specific workability evaluation values ​​1206g for the parts handled by that worker in a given process by a proportional constant. For example, according to the changed process plan information display field 1501c, a worker with worker ID "1" handles parts with part IDs "2," "5," "6," and "7" in the process with process ID "1." In this case, the estimated work time for worker ID "1" is calculated by multiplying the sum of worker-specific workability evaluation values ​​1206g for the process ID "1" and the part IDs "2," "5," "6," and "7" by a proportional constant. The bar graph for worker ID "1" has four areas, and the height of each area is proportional to the workability evaluation value for each of the part IDs "2," "5," "6," and "7" above.

[0129] The actual work time display field 1501e and the estimated work time display field 1501g each display a target time. The target time is the upper limit of the work time required to produce a number of products equal to or greater than the planned production volume. If the bar graphs of all workers do not exceed this target time, the planned production volume of products can be manufactured.

[0130] The actual consciousness state evaluation value display field 1501f is a field that displays a bar graph showing the actual consciousness state evaluation value for each worker ID. As described above, the consciousness state evaluation value of a certain worker is the total value obtained by adding up the mind evaluation values ​​1207f for all parts handled by that worker. Here, the consciousness state evaluation value of each worker is shown as a bar graph. For example, the bar graph for worker ID "1" has four areas, and each area corresponds to the mind evaluation value 1207f for each part ID "1," "2," "3," and "4."

[0131] The estimated consciousness state evaluation value display field 1501h is a field that displays, in a bar graph, the consciousness state evaluation value estimated for each worker ID when a product is manufactured in accordance with the information in the changed process plan information display field 1501c. Here, the consciousness state evaluation value for each worker ID calculated in step S090 is displayed in the estimated consciousness state evaluation value display field 1501h.

[0132] In this example, as shown in a current process plan information display field 1501b and a changed process plan information display field 1501c, the part IDs assigned to the worker with the worker ID "1" have been changed from "1," "2," "3," and "4" to "2," "5," "6," and "7." In an estimated consciousness state evaluation value display field 1501h, the four areas in the bar graph for the worker ID "1" correspond to the mind evaluation values ​​1207f for the changed part IDs "2," "5," "6," and "7."

[0133] By displaying such a screen 1501 on the display unit 1400, the user can visually understand how the working time or consciousness state evaluation value changes in accordance with the change in the process plan information 1204.

[0134] According to the present embodiment described above, the mind evaluation unit 1105 generates worker-specific mind evaluation information 1207 including a mind evaluation value 1207g based on indicators such as work time variation (step S070). If it is determined in step S080 that the mind evaluation value does not satisfy the criteria, the planner 1103 changes the process plan information 1204 to plan an assignment of work in which the mind evaluation value is expected to satisfy the criteria (step S090).

[0135] The mind evaluation value indicates whether a worker is in a state of mind that is effective for improving product productivity, such as not feeling stressed or concentrating on their work. By planning the allocation of work so that the mind evaluation value meets the standard, it is possible to create an environment in which workers can concentrate on their work and reduce stress. As a result, it is possible to maintain a good state of mind for workers on the production line and maintain product production efficiency.

[0136] <Hardware configuration> FIG. 16 is a diagram illustrating an example of a hardware configuration of a process planning apparatus 1000 according to this embodiment.

[0137] 16, the process planning apparatus 1000 includes a processor 1001, a memory 1002, a storage device 1003, a communication device 1004, a display device 1005, an input device 1006, and a reading device 1007. These components are connected to each other by a bus 1009.

[0138] The storage device 1003 is a non-volatile storage device such as an HDD (Hard Disk Drive) or an SSD (Solid State Drive), and stores the process planning program according to this embodiment.

[0139] The process planning program may be recorded on a computer-readable recording medium 1008 , and the processor 1001 may read the process planning program from the recording medium 1008 .

[0140] The recording medium 1008 may be a physically portable recording medium such as a CD-ROM (Compact Disc - Read Only Memory), a DVD (Digital Versatile Disc), or a USB (Universal Serial Bus) memory. A semiconductor memory such as a flash memory or a hard disk drive may also be used as the recording medium 1008.

[0141] The process planning program may be stored in a device connected to a public line, the Internet, a LAN (Local Area Network), etc. In this case, the processor 1001 may read and execute the process planning program.

[0142] The memory 1002 is hardware that temporarily stores data, such as a DRAM (Dynamic Random Access Memory), and the process planning program is developed on it.

[0143] The processor 1001 is a CPU (Central Processing Unit) or a GPU (Graphical Processing Unit) that controls each part of the process planning apparatus 1000. The processor 1001 executes a process planning program in cooperation with the memory 1002, thereby realizing the processing unit 1100 in FIG.

[0144] 1 is realized by a storage device 1003 and a memory 1002. A communication device 1004 is hardware such as a network interface card (NIC) for connecting the process planning apparatus 1000 to a network N. The communication device 1004 realizes a communication unit 1500 in FIG.

[0145] The display device 1005 is hardware such as a liquid crystal display or an organic EL display for realizing the display unit 1400 in Fig. 1. The input device 1006 is hardware such as a keyboard or a mouse for realizing the input unit 1300 in Fig. 1.

[0146] The reading device 1007 is hardware such as a CD drive for reading data recorded on the recording medium 1008 .

[0147] The effects described in this specification are merely examples and are not limiting, and other effects may also be present.

[0148] The present invention is not limited to the above-described embodiments and includes various modifications. For example, the above-described embodiments have been described in detail to clearly explain the present invention, and the present invention is not necessarily limited to an embodiment including all of the described components. Furthermore, part of the configuration of one embodiment can be replaced with the configuration of another embodiment, and the configuration of another embodiment can be added to the configuration of one embodiment. Furthermore, part of the configuration of each embodiment can be added to, deleted from, or replaced with another configuration.

[0149] Furthermore, the above-described configurations, functions, processing units, processing means, etc. may be partially or entirely implemented in hardware, for example, by designing them as integrated circuits. Furthermore, the above-described configurations, functions, etc. may be implemented in software by a processor interpreting and executing a program that implements each function. Information such as the program, decision table, and files that implement each function can be stored in memory, a storage device such as an HDD or SSD, or a recording medium such as an IC (Integrated Circuit) card, an SD (Secure Digital) card, or a DVD (Digital Versatile Disc). Furthermore, the control lines and information lines shown are those considered necessary for explanation, and do not necessarily represent all control lines and information lines in the product. In reality, it can be assumed that almost all components are interconnected. [Explanation of symbols]

[0150] 1000...process planning device, 1001...processor, 1002...memory, 1003...storage device, 1004...communication device, 1005...display device, 1006...input device, 1007...reading device, 1008...recording medium, 1009...bus, 1100...processing unit, 1101...process plan calculation unit, 1102...workability evaluation value calculation unit, 1103...planning unit, 1104...workability evaluation unit, 1105...main evaluation unit, 1200...storage unit, 1201...product information, 1202...process plan information, 1203...production plan information, 1204...process plan information, 1205...production performance information, 1206...worker-specific workability evaluation information, 1207...worker-specific mind evaluation information, 1208...workability evaluation value information, 1300...input unit, 1400...display unit, 1500...communication unit, 1501...screen, 2000...external device.

Claims

1. a mind evaluation unit that calculates a mind evaluation value that indicates the state of consciousness of the worker when the worker performed the work, based on an index that indicates the performance of the work performed by the worker; a planning unit that, when planning work allocation, if the mind evaluation value calculated when the worker is assigned to a process plan does not satisfy a criterion, changes the process plan to a process plan whose calculated mind evaluation value satisfies the criterion, and plans work allocation; a workability evaluation unit that evaluates a workability evaluation value indicating the work efficiency of an executed work for each part and each worker handled in the work, The mind evaluation unit determining an approximate expression that approximates the relationship between the index and the workability evaluation value for a certain worker; When the assignment includes an operation relating to a part that the worker has never handled, the workability evaluation value relating to the part that the worker has never handled is substituted into the approximation formula to estimate the index relating to the part that the worker has never handled; the planning unit changes the process plan so that the mind evaluation value calculated based on the estimated index satisfies the criterion. Process planning device.

2. The process planning system according to claim 1, The index is at least one of a failure rate of the task, a variation in task time, a learning time for the task, and a task interval time. Process planning device.

3. The process planning system according to claim 1, the planning unit plans the allocation of the work using the process plan in which the calculated mind evaluation value satisfies the criterion under the condition that the number of products produced in the work is equal to or greater than a planned production volume; Process planning device.

4. The process planning system according to claim 1, the planning unit repeatedly determines whether the mind evaluation value satisfies the criterion while the worker is performing the work based on the plan, and re-plans the allocation of the work every time it is determined that the mind evaluation value does not satisfy the criterion; Process planning device.

5. a mind evaluation unit that calculates a mind evaluation value that indicates the state of consciousness of the worker when the worker performed the work, based on an index that indicates the performance of the work performed by the worker; a planning unit that, when planning work allocation, if the mind evaluation value calculated when the worker is assigned to a process plan does not satisfy a criterion, changes the process plan to a process plan whose calculated mind evaluation value satisfies the criterion, and plans work allocation; a workability evaluation unit that evaluates a workability evaluation value indicating the work efficiency of an executed work for each part and each worker handled in the work, The mind evaluation unit determining an approximate expression that approximates the relationship between the index and the workability evaluation value for a certain worker; When the assignment includes an operation relating to a part that the worker has never handled, the workability evaluation value relating to the part that the worker has never handled is substituted into the approximation formula to estimate the index relating to the part that the worker has never handled; the planning unit changes the process plan so that the mind evaluation value calculated based on the estimated index satisfies the criterion. Process planning system.

6. The computer calculating a mind evaluation value indicating the state of consciousness of the worker when the worker performed the work based on an index indicating the performance of the work performed by the worker; When planning work allocation, if the mind evaluation value calculated when the worker is assigned to a process plan does not satisfy a criterion, changing the process plan to one in which the calculated mind evaluation value satisfies the criterion, and planning work allocation; evaluating a workability evaluation value indicating the work efficiency of the performed work for each part and each worker handled in the work, In the step of calculating the mind evaluation value, An approximate expression that approximates the relationship between the index and the workability evaluation value is obtained for a certain worker; When the assignment includes an operation relating to a part that the worker has never handled, the index relating to the part that the worker has never handled is estimated by substituting a workability evaluation value relating to the part that the worker has never handled into the approximation formula; In the step of planning the allocation of work, the mind evaluation value calculated based on the estimated index is changed to the process plan that satisfies the criterion. Process planning methods.

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