Production management device, production management method, and production management program

Abstract

To provide a production management device, a production management method, and a production management program that make it possible to refine production plans and improve productivity by efficiently analyzing production plans and actual results.SOLUTION: A production management device includes a storage unit that stores a standard time as to working hours for each process included in the production plan, and a control unit that calculates the degree of deviation based on the standard time for each process, determines whether or not to change the standard time based on the calculated degree of deviation, and extracts the process determined to change the standard time as a target process.SELECTED DRAWING: Figure 1

Description

[Technical Field]

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

[0002] In order to realize efficient production of products, it is important to analyze the production plan and actual results for each process. A technology for analyzing the working time for each process is disclosed in, for example, Patent Document 1. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2005-157819 Summary of the Invention [Problem to be solved by the invention]

[0004] The production plan described above may include a large number of processes. In such cases, it is necessary to efficiently analyze the production plan and actual results.

[0005] The present disclosure has been made in consideration of the above, and aims to provide a production management device, a production management method, and a production management program that enable production plans and actual results to be analyzed efficiently, thereby enabling refinement of production plans and improvement of productivity. [Means for solving the problem]

[0006] The production management device according to the present disclosure includes a memory unit that stores the standard time for working time for each process included in a production plan, and a control unit that calculates a deviation for each process based on the standard time, determines whether to change the standard time based on the calculated deviation, and extracts the process for which it is determined that the standard time should be changed as a target process.

[0007] The production management method according to the present disclosure includes a deviation calculation step of calculating a deviation for each process included in a production plan based on a standard time for working time, a determination step of determining whether or not to change the standard time based on the calculated deviation, and an extraction step of extracting, as a target process, the process for which it has been determined that the standard time should be changed.

[0008] The production management program according to the present disclosure causes a computer to execute a deviation calculation process that calculates the deviation for each process included in a production plan based on the standard time of the working time for the process, a determination process that determines whether or not to change the standard time based on the calculated deviation, and an extraction process that extracts the process for which it has been determined that the standard time should be changed as a target process. [Effects of the Invention]

[0009] According to the present disclosure, by enabling efficient analysis of production plans and actual results, it is possible to refine production plans and improve productivity. [Brief explanation of the drawings]

[0010] [Figure 1] FIG. 1 is a block diagram showing the configuration of a production management device according to this embodiment. [Figure 2] FIG. 2 is a diagram showing an example of a process information setting screen. [Figure 3] FIG. 3 is a diagram showing an example of a setting screen for process mesh information. [Figure 4] FIG. 4 is a flowchart showing an example of a production management method. [Figure 5] FIG. 5 is a flowchart showing another example of the production management method. DETAILED DESCRIPTION OF THE INVENTION

[0011] Hereinafter, embodiments of a production management device, a production management method, and a production management program according to the present invention will be described with reference to the accompanying drawings. Note that the present invention is not limited to these embodiments. Furthermore, the components in the following embodiments include those that are easily replaceable by those skilled in the art, or those that are substantially identical.

[0012] Fig. 1 is a block diagram showing the configuration of a production management device according to this embodiment. The production management device 10 shown in Fig. 1 is an information processing device that analyzes work processes (hereinafter sometimes simply referred to as "processes") executed based on a production plan. The production management device 10 shown in Fig. 1 is connected to a production management system SYS, and manages the production plan based on work performance information and the like managed by the production management system SYS.

[0013] In this embodiment, a "production plan" refers to a plan that indicates which production facilities will be used to produce a product and its parts, when, and in what quantities. In this embodiment, a "product" refers to something that is produced through a process, and does not necessarily refer to a final product. In other words, the "product" described in this embodiment also includes parts that are incorporated into other products.

[0014] As shown in FIG. 1, the production management device 10 includes a display unit 11, an input unit 12, a communication unit 13, a medium reading unit 14, a control unit 15, and a storage unit 16.

[0015] The display unit 11 has a display device such as a liquid crystal panel or an organic electro-luminescence (EL) panel, and displays various information such as characters and figures based on control signals transmitted from the control unit 15. The input unit 12 has an input device such as a keyboard, and outputs to the control unit 15 a signal corresponding to an operation performed by a user on the input device.

[0016] The communication unit 13 controls the transmission and reception of information to and from other devices such as the mobile terminal device 20 based on a predetermined communication protocol. The mobile terminal device 20 is an information processing terminal carried by a worker involved in the production of a product. The medium reading unit 14 reads programs and data from a storage medium such as a CD-ROM.

[0017] Control unit 15 includes CPU (Central Processing Unit) 17, which is a calculation means, and memory 18, which is a storage means, and realizes various functions by executing programs using these hardware resources. Specifically, control unit 15 reads out programs stored in storage unit 16, loads them into memory 18, and causes CPU 17 to execute instructions included in the programs loaded into memory 18. Then, according to the results of the execution of instructions by CPU 17, control unit 15 reads and writes data from memory 18 and storage unit 16, and controls the operation of communication unit 13, etc.

[0018] The storage unit 16 is a nonvolatile storage device such as a magnetic storage device or a semiconductor storage device, and stores various programs and data. The data stored in the storage unit 16 includes process information 21, process mesh setting information 22, and a production management program 23.

[0019] 1 may be stored in a storage medium readable by the medium reading unit 14. In addition, the programs and data stored in the storage unit 16 in FIG. 1 may be acquired in whole or in part from another device through communication by the communication unit 13.

[0020] The process information 21 holds information about the work performed in each process. FIG. 2 is a diagram showing an example of a setting screen P for setting the process information 21. The setting screen P is displayed on the display unit 11, for example. As shown in FIG. 2, the process information 21 has the following items: number, item number, job name, detailed class name, new standard time, current standard time, average actual time, and deviation. The process information 21 stores data for each process.

[0021] The number is a number that identifies the process. The item number is a number that identifies the item produced in each process. The job name indicates the name of the job performed in each process. The detailed class name indicates the name of the class (child job) included in each job. A class is defined as one process (job) in the settings. At the production site, because continuous processing of multiple classes is possible in NC programs, etc., multiple classes can be grouped together and set as one process (one job).

[0022] The current standard time indicates the currently set standard time. The standard time indicates the standard value for the work time for each process.

[0023] The new standard time (hereinafter referred to as new standard time) indicates the standard time that is newly set.

[0024] The average performance time indicates the average performance value (performance time) of the work time for each process.

[0025] The deviation indicates a value calculated based on the standard time. The deviation includes a first deviation, a second deviation, and a third deviation.

[0026] The first deviation is a value that quantifies the deviation between the average performance time for each process and the current standard time. The first deviation can be calculated, for example, based on the following formula: First deviation = (average actual time / standard time - 1) x 100

[0027] The second deviation is a value that quantifies the deviation between the average actual time for each process and the new standard time when a new standard time is set for the process (hereinafter referred to as the new standard time). The second deviation can be calculated, for example, using the following formula: Second deviation = (average actual time / new standard time - 1) x 100

[0028] When a new standard time is set for a process, the third deviation is a value that quantifies the deviation between the standard time that had been set up until then (hereinafter referred to as the old standard time) and the new standard time. The third deviation can be calculated, for example, using the following formula: Third deviation = (old standard time / new standard time-1) x 100

[0029] The setting screen P shown in FIG. 2 has an average time object P1, a calculated time object P2, and a current time object P3. The average time object P1 is an object for setting the average value of the actual times as the new standard time. The calculated time object P2 is an object for setting a candidate value for the standard time calculated by the control unit 15 as the new standard time. The current time object P3 is an object for setting the current standard time as the new standard time. The worker selects one of the average time object P1, calculated time object P2, and current time object P3 via the input unit 12, for example, and the new standard times of the selected content are set collectively for each process.

[0030] The process mesh setting information 22 is information for setting classes (child jobs) included in a job in each process. Fig. 3 is a diagram showing an example of a setting screen Q for the process mesh setting information 22. The setting screen Q is displayed on the display unit 11.

[0031] As shown in Fig. 3, the process mesh setting information 22 has the following fields: number, item number, job name, and class name. The setting screen Q shown in Fig. 3 is provided with an add object Q1 for adding a class, a delete object Q2 for deleting a class, and a save object Q3 for saving the settings. On the setting screen Q, the worker can add or delete classes included in the job for each process by selecting each of the objects Q1, Q2, and Q3 via the input unit 12. In addition, by saving the settings, the settings are reflected in the setting screen P shown in Fig. 2.

[0032] The production management program 2323 provides a function for formulating an appropriate production plan. The production management program 2323 includes a deviation calculation unit 31, a determination unit 32, an extraction unit 33, a process mesh setting unit 34, and an output unit 35.

[0033] The deviation calculation unit 31 calculates the above-mentioned deviations (first deviation, second deviation, and third deviation) for each process.

[0034] The determination unit 32 determines that the standard time should be changed if the absolute value of the calculated deviation exceeds a predetermined value. In other words, the determination unit 32 determines that the standard time should not be changed if the absolute value of the calculated deviation is equal to or less than a predetermined value. The predetermined value can be set in advance.

[0035] The extraction unit 33 extracts, as a target process, a process for which the absolute value of the deviation calculated by the determination unit 32 is determined to exceed a predetermined value.

[0036] The process mesh setting unit 34 groups together a plurality of processes (classes, child jobs) and sets them as one process (job) based on input from the worker.

[0037] The output unit 35 outputs the deviation calculation results, the target process extraction results, and the process mesh setting results to the display unit 11. The output unit 35 outputs the results as a table on a setting screen of a spreadsheet application, for example, as in setting screen P shown in Fig. 2 and setting screen Q shown in Fig. 3. The output unit 35 can sort and display each process of the process information 21 displayed on setting screen P in ascending or descending order according to the magnitude of the deviation, for example, based on an input by the operator.

[0038] Next, the steps of the production management method executed by the production management device 10 will be described. FIG. 4 is a flowchart showing an example of the production management method according to this embodiment. As shown in FIG. 4, the control unit 15 calculates a deviation based on the standard working time for each process included in the production plan, using the deviation calculation unit 31 of the production management program 23 (step S101). When calculating the deviation for the first time, the control unit 15 can calculate, for example, the first deviation out of the three types of deviation. When calculating the deviation for the second time or later, the control unit 15 can calculate, for example, the second and third deviation out of the three types of deviation.

[0039] Next, the control unit 15 determines whether or not to change the standard time based on the calculated deviation, that is, whether or not the deviation exceeds a predetermined value, using the determination unit 32 of the production management program 23. The determination in step S102 may be made based on any one of the three types of deviation, the first deviation, the second deviation, and the third deviation, or may be made based on a combination of two or more types of deviation among the above three types of deviation.

[0040] Next, if there is a process determined to change the standard time based on the extraction unit 33 of the production management program 23 (Yes in step S103), the control unit 15 extracts the process as a target process (step S104).

[0041] Next, the control unit 15 outputs the deviation calculation results and the target process extraction results as a table on a setting screen of a spreadsheet application, such as the setting screen P shown in Figure 2, based on the output unit 35 of the production management program 23 (step S105).

[0042] The worker can input the new standard time for each process while referring to the calculated deviation on the output setting screen P. In this case, by selecting the average time object P1, the calculated time object P2, and the current time object P3, the new standard time can be set for all the target processes at once.

[0043] If the new standard time has been set (Yes in step S106), the control unit 15 causes the processes from step S101 onwards to be repeated. Furthermore, the control unit 15 repeatedly makes the determination in step S106 until the new standard time is set (No in step S106). In step S106, the control unit 15 may determine that the new standard time has been set when the new standard time has been set for some of the target processes that have been set in advance, for example, when the new standard time has been set for 10% or more of the target processes whose actual times have been acquired. In this way, the control unit 15 can determine that the new standard time has been set in step S106 even if the new standard time has not been set for some of the target processes.

[0044] Furthermore, in step S103, if there is no process determined to change the standard time (No in step S103), the control unit 15 ends the process.

[0045] Fig. 5 is a flowchart showing another example of the production management method according to this embodiment. As shown in Fig. 5, when a predetermined input to set a process mesh is made by an operator, the control unit 15 outputs a setting screen Q based on the output unit 35 of the production management program 23 (step S201).

[0046] When the worker changes the process mesh for each process and the changes are saved (Yes in step S202), the control unit 15 reflects the changes in the process information 21 based on the process mesh setting unit 34 of the production management program 23 (step S203).

[0047] On the other hand, if the operator does not change the process mesh for each process, or if the changes are not saved (No in step S202), the process ends.

[0048] As described above, the production management device 10 according to this embodiment includes a memory unit 16 that stores the standard time for work time for each process included in the production plan, and a control unit 15 that calculates the deviation for each process based on the standard time, determines whether or not to change the standard time based on the calculated deviation, and extracts processes for which it has been determined that the standard time should be changed as target processes.

[0049] In addition, the production management method according to this embodiment includes a deviation calculation step of calculating the deviation for each process included in the production plan based on the standard time of the working time, a determination step of determining whether or not to change the standard time based on the calculated deviation, and an extraction step of extracting, as target processes, those processes for which it has been determined that the standard time should be changed.

[0050] In addition, the production management program according to this embodiment causes a computer to execute a deviation calculation process that calculates the deviation for each process included in the production plan based on the standard time for working hours, a determination process that determines whether or not to change the standard time based on the calculated deviation, and an extraction process that extracts processes for which it has been determined that the standard time should be changed as target processes.

[0051] Therefore, with the above configuration, it is possible to automatically extract target processes for which the standard time should be changed based on the concept of deviation, and by reviewing the standard time for the extracted target processes, it is possible to efficiently analyze the production plan and actual results, thereby enabling the refinement of the production plan and improvement of productivity.

[0052] In the production management device 10 according to this embodiment, the control unit 15 calculates a first deviation degree that quantifies the deviation between the average performance time for each process and the standard time. Therefore, it is possible to accurately detect a target process for which the standard time is to be changed, and therefore it is possible to analyze the production plan and the performance with high accuracy.

[0053] In the production management device 10 according to this embodiment, when a new standard time is set for a process, the control unit 15 calculates a second deviation degree that quantifies the deviation between the average performance time for each process and the newly set standard time. Therefore, it is possible to accurately detect a process for which the standard time is to be changed, and therefore it is possible to accurately analyze the production plan and the performance.

[0054] In the production management device 10 according to this embodiment, when a new standard time is set for a process, the control unit 15 calculates a third deviation degree that quantifies the deviation between the standard time and the newly set standard time as the deviation degree. Therefore, it is possible to detect with high accuracy the process for which the standard time is to be changed, and therefore it is possible to analyze the production plan and actual results with high accuracy.

[0055] In the production management device 10 according to this embodiment, the control unit 15 sets the new standard time for each process to one of the average performance time, a candidate value for the standard time calculated by the control unit 15, or the standard time set at the time the control unit 15 extracted the process. Therefore, new standard times can be set for all the extracted target processes at once. This reduces the effort required to set new standard times.

[0056] In the production management device 10 according to this embodiment, the control unit 15 can set a plurality of processes as one process. Therefore, a new standard time can be appropriately set for the one process that is a combination of a plurality of processes.

[0057] In the production management device 10 according to this embodiment, the control unit 15 outputs the deviation calculation results and the target process extraction results as a table on the settings screen of a spreadsheet application. Therefore, the deviation calculation results and the target process extraction results can be easily understood, and a new standard time can be set efficiently.

[0058] The aspects of the present disclosure described in the above embodiments can be modified as desired without departing from the spirit of the present disclosure. For example, the programs described in the above embodiments can be divided into multiple modules or integrated with other programs.

[0059] In the above embodiment, the production management device 10 displays various screens on the display unit 11 provided in the production management device 10. However, the production management device 10 may display various screens on the display unit of another device. In this case, for example, the screens are transmitted from the production management device 10 to the other device in HTML (HyperText Markup Language) format. Information is exchanged between the production management device 10 and the other device based on HTTP (HyperText Transfer Protocol). [Explanation of symbols]

[0060] 10 Production control equipment 11 Display section 12 Input section 13 Communications Department 14 Media reading unit 15 Control Unit 16 Memory section 17 CPU 18 Memory 20 Portable terminal device 21 Process information 22 Process mesh setting information 23,2323 Production Management Program 31 Deviation calculation section 32 Judgment section 33 Extraction part 34 Process mesh setting section 35 Output section P,Q setting screen P1 Average Time Object P2 Calculated Time Object P3 Current Time Object Q1 Additional Objects Q2 Deleted Objects Q3 Saved Objects SYS Production Management System

Claims

1. a storage unit that stores standard work times for each process included in the production plan; a control unit that calculates a deviation based on the standard time for each process, determines whether or not to change the standard time based on the calculated deviation, extracts the process for which it has been determined that the standard time should be changed as a target process, outputs the calculation result of the deviation and the extraction result of the target process, determines whether or not a new standard time has been set for the target process, determines that the new standard time has been set for the target process when new standard times have been set for some of the target processes that have been set in advance, calculates the deviation based on the new standard time when it has been determined that the new standard time has been set for the target process, and completes the processing when there is no process for which it has been determined that the standard time should be changed in the determination of whether or not to change the standard time; A production management device comprising:

2. The control unit calculates, as the degree of deviation, a first degree of deviation that quantifies the deviation between the average value of the actual time for each process and the standard time. The production management device according to claim 1.

3. When the standard time is newly set for the process, the control unit calculates, as the deviation degree, a second deviation degree that quantifies the deviation between the average value of the actual time for each process and the newly set standard time. The production management device according to claim 1 or 2.

4. When the standard time is newly set for the process, the control unit calculates, as the deviation degree, a third deviation degree that quantifies the deviation between the standard time and the newly set standard time. The production management device according to any one of claims 1 to 3.

5. The control unit sets, as a new standard time for each of the processes, one of the average value of the actual time for each of the processes, the candidate value for the standard time calculated by the control unit, and the standard time set at the time when the control unit extracted the process. The production management device according to any one of claims 1 to 4.

6. The control unit can set a plurality of the steps as one step. The production management device according to any one of claims 1 to 5.

7. The control unit outputs the calculation result of the deviation degree and the extraction result of the target process as a table on a setting screen of a spreadsheet application. The production management device according to any one of claims 1 to 6.

8. a deviation calculation step of calculating a deviation for each process included in the production plan based on a standard time for the operation time for the process; a determination step of determining whether or not to change the standard time based on the calculated deviation; an extraction step of extracting the process determined to require a change in the standard time as a target process; an output step of outputting the calculation result of the deviation degree and the extraction result of the target process; a setting confirmation step of determining whether a new standard time has been set for the target process; Including, In the setting confirmation step, when new standard times are set for some of the target processes that have been previously set, it is determined that the new standard times have been set for the target processes; When it is determined in the setting confirmation step that a new standard time has been set for the target process, the deviation calculation step is performed based on the new standard time; If it is determined in the determination step that there is no process determined to change the standard time, the process is completed. Production management methods.

9. a deviation calculation process for calculating a deviation for each process included in the production plan based on a standard time for the operation time for the process; a determination process of determining whether or not to change the standard time based on the calculated deviation; an extraction process of extracting the process determined to require a change in the standard time as a target process; an output process for outputting the calculation result of the deviation degree and the extraction result of the target process; a setting confirmation process for determining whether a new standard time has been set for the target process; on the computer, In the setting confirmation process, when new standard times are set for some of the target processes that have been previously set, it is determined that new standard times have been set for the target processes; When it is determined in the setting confirmation process that a new standard time has been set for the target process, the deviation calculation process is performed based on the new standard time; If it is determined in the determination process that there is no process determined to change the standard time, the process is completed. Production management program.

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