Production management support system

Abstract

To improve productivity without lowering the operational rates of an operator and a facility which requires human support work.SOLUTION: A production management support system for supporting the management of a production process, in which an operation step by an operator and an operation step by a facility including human support work are mixed, comprises: a facility operation information acquisition unit for acquiring the facility operation information about the operational state of the facility; an operator's operation information acquisition unit for acquiring the operator's operation information about the operational state of the operator; a priority work determination unit for determining whether to give priority to the work in relation to the step by the operator or the support work, based on the facility operation information and the operator's operation information; and a notification unit for notifying the operator when the support work is determined to be given the priority.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to a production management support system.

Background Art

[0002] In a production line where there are mixed work processes of semi-automatic machines and workers, when the work of the semi-automatic machine is completed, the worker needs to perform auxiliary work such as collecting the processed work from the semi-automatic machine and supplying the work for the next operation. When the semi-automatic machine becomes a bottleneck, the worker performs the work without stopping or waiting for the semi-automatic machine. For this reason, interruptions occur in other processes that the worker is in charge of. When a process is interrupted, there is a risk of producing defective products because the work that should originally be carried out is not carried out.

[0003] On the other hand, in a production process where workers and automatic machines (robots) coexist, technologies have been proposed to calculate the progress of work and whether the work is proceeding as planned in the production plan, and to reorganize robot jobs and manual work instructions according to the work situation and progress (see Patent Document 1), and to determine whether the work is proceeding as planned in the production plan, and to call workers when the work is not proceeding as planned in the production plan (see Patent Document 2). However, when the semi-automatic machine is in a waiting state, no criteria are presented for the worker to choose whether to interrupt their own work and turn to assist the semi-automatic machine or continue their own work.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Patent Document 2

Summary of the Invention

Problems to be Solved by the Invention

[0005] This invention has been made in view of the above-mentioned problems, and aims to improve productivity by enabling production without reducing the utilization rate of equipment and workers that require human assistance. [Means for solving the problem]

[0006] The present invention, which solves the above problems, A production management support system that assists in managing production processes that involve a mix of processes performed by workers and processes performed by equipment, including auxiliary work by humans, Equipment operation information acquisition unit acquires equipment operation information regarding the operating status of the equipment, A worker work information acquisition unit acquires worker work information regarding the working status of workers, A priority work determination unit determines, based on the equipment operation information and the worker operation information, which of the work related to the process performed by the worker and the auxiliary work to prioritize. A notification unit that notifies the worker when it is determined that the aforementioned auxiliary work should be prioritized, It is characterized by having the following features.

[0007] According to this, in a production process that mixes processes performed by workers and processes performed by equipment, including manual assistance, the priority work determination unit determines whether to prioritize the worker's process-related work or the equipment's assistance work based on equipment operation information regarding the equipment's operating status and worker operation information regarding the workers' operating status. If it determines that the assistance work should be prioritized, the notification unit notifies the worker accordingly, thereby enabling production to continue without reducing the operating rate of both equipment and workers, and improving productivity.

[0008] Furthermore, in the present invention, Equipment production plan information acquisition unit acquires equipment production plan information, which is production plan information related to the aforementioned equipment. A worker production plan information acquisition unit acquires worker production plan information, which is production plan information relating to the aforementioned worker. A first evaluation index calculation unit calculates an equipment productivity evaluation index for evaluating the productivity of the equipment based on the equipment operation information and the equipment production plan information, A second evaluation index calculation unit calculates a worker productivity evaluation index for evaluating the productivity of the worker based on the worker operation information and the worker production plan information, Equipped with, The priority work determination unit may determine, based on the equipment productivity evaluation index and the worker productivity evaluation index, whether to prioritize the work related to the process performed by the worker or the auxiliary work.

[0009] According to this, the priority work determination unit can more accurately determine, taking into account the production plan, whether to prioritize process-related work or auxiliary work performed by workers, based on an equipment productivity evaluation index that evaluates the productivity of equipment based on equipment operation information and production plan information related to equipment, and a worker productivity evaluation index that evaluates the productivity of workers based on worker operation information and production plan information related to workers. As a result, production can be carried out without reducing the operating rate of equipment and workers, and productivity can be improved.

[0010] Furthermore, in the present invention, The priority work determination unit may determine whether to prioritize the work related to the process performed by the worker or the auxiliary work, based on the equipment productivity evaluation index and the worker productivity evaluation index during a predetermined time period close to the time of determination.

[0011] In this way, by determining whether to prioritize process-related work or auxiliary work performed by workers based on equipment productivity evaluation indicators and worker productivity evaluation indicators for a predetermined time period close to the time of decision-making, it is possible to make a more accurate decision even when there is no significant difference in operating rates when judged over a long period of time, but the operating rate has decreased in the most recent period. As a result, production can be carried out without reducing the operating rates of equipment and workers, and productivity can be improved.

[0012] Furthermore, in the present invention, The priority work determination unit may determine whether to prioritize the work related to the process performed by the worker or the auxiliary work, based on the equipment productivity evaluation index and the worker productivity evaluation index, which are weighted according to the time up to the determination.

[0013] In this way, by determining whether to prioritize process-related work or auxiliary work performed by workers based on the equipment productivity evaluation index and worker productivity evaluation index weighted according to the time elapsed until the decision was made, it is possible to make a more accurate decision even when there is no significant difference in operating rates when judged over a long period of time, but the operating rate has decreased in the most recent period. As a result, production can be carried out without reducing the operating rates of equipment and workers, and productivity can be improved.

[0014] Furthermore, in the present invention, The aforementioned priority work determination unit, The equipment operation information may be modified to exclude the downtime of the equipment, and a decision may be made as to whether to prioritize the work performed by the worker on the process or the auxiliary work.

[0015] According to this, the operating rate will be underestimated in cases where equipment unexpectedly shuts down. Even in such cases, by excluding the downtime of the equipment and evaluating the operating status of the equipment, it is possible to accurately determine whether to prioritize the work related to the process performed by the workers or auxiliary work. This allows for production to be carried out without reducing the utilization rate of both the equipment and the workers, thereby improving productivity.

[0016] Furthermore, in the present invention, A first evaluation index calculation unit calculates an equipment productivity evaluation index for evaluating the productivity of the equipment based on the equipment operation information and production plan information related to the equipment, A second evaluation index calculation unit calculates a worker productivity evaluation index for evaluating the productivity of the worker based on the worker operation information and production plan information relating to the worker, A productivity decrease determination unit that determines whether or not the equipment productivity evaluation index and the operator productivity evaluation index satisfy a predetermined condition indicating a decrease in productivity; A manager notification unit that notifies a manager when it is determined that the predetermined condition is satisfied; It may be configured to include.

[0017] According to this, when the productivity of both the equipment and the operator decreases and there is a possibility that the planned quantity cannot be produced, the manager is notified by the manager notification unit, prompting appropriate countermeasures and preventing a situation where the planned quantity cannot be produced.

Effect of the Invention

[0018] According to the present invention, production can be carried out without reducing the operating rates of equipment and operators that require human assistance work, and productivity can be improved.

Brief Description of the Drawings

[0019] [Figure 1] It is a schematic configuration diagram of a production management support system according to an embodiment of the present invention. [Figure 2] It is a functional block diagram of a processing unit of a production management support system according to an embodiment of the present invention. [Figure 3] It is a diagram for explaining the work time measurement of an operator in a production management support system according to an embodiment of the present invention. [Figure 4] It is a graph for explaining the relationship between the target achievement rate of a semi-automatic machine and an operator and a threshold value according to an embodiment of the present invention.

Modes for Carrying Out the Invention

[0020] 〔Application Example〕[[ID=?]] Hereinafter, a production management support system 1 according to an application example of the present invention will be described with reference to the drawings. As shown in Figure 1, the production management support system 1 is a system that supports the management of production processes in cell line CL, where processes performed by workers W1 and W2 and processes performed by semi-automatic machine Eq, which requires auxiliary work such as preparing and collecting workpieces for worker W1, are mixed together.

[0021] The production management support system 1 consists of two main components: a configuration for the production line 10 and a configuration for the office 20. The production line 10 includes a semi-automatic machine data acquisition unit 13 that collects data from the cell line CL and semi-automatic machine Eq, a semi-automatic machine data provision unit 12 that provides data from the semi-automatic machine Eq to the semi-automatic machine data acquisition unit 13, an imaging unit 14, an image analysis unit 15, a processing unit 11, and a notification unit 16.

[0022] Office 20 is a workspace for managers such as line leaders and production engineers who manage production line 10, including cell line CL. Office 20 includes a processing unit 21 and a notification unit 22, which are connected to the processing unit 11 of production line 10 by a network.

[0023] The processing unit 11 is composed of a general computer device and has the functional units shown in Figure 2. The processing unit 11 includes a semi-automatic machine operating rate calculation unit 111, a semi-automatic machine production plan information acquisition unit 112, a semi-automatic machine target achievement rate calculation unit 113, a worker operating rate calculation unit 114, a worker production plan information acquisition unit 115, a worker target achievement rate calculation unit 116, and a judgment unit 117.

[0024] The semi-automatic machine utilization rate calculation unit 111 calculates the actual utilization rate of the semi-automatic machine Eq from the information on the operation of the semi-automatic machine Eq collected by the semi-automatic machine data collection unit 13. The semi-automatic machine target achievement rate calculation unit 113 calculates the target achievement rate of the semi-automatic machine Eq from the actual utilization rate of the semi-automatic machine Eq calculated by the semi-automatic machine utilization rate calculation unit 111 and the target utilization rate of the semi-automatic machine Eq obtained from the semi-automatic machine production plan information acquisition unit 112.

[0025] The worker utilization rate calculation unit 114 calculates the actual utilization rate of worker W1 (and W2) from the working time (actual time) and actual production quantity of worker W1 (and W2) detected by the image analysis unit 15 analyzing the image data from the imaging unit 14. The worker target achievement rate calculation unit 116 calculates the target achievement rate of worker W1 from the actual utilization rate of worker W1 calculated by the worker utilization rate calculation unit 114 and the target utilization rate of worker W1 obtained from the worker production plan information acquisition unit 115.

[0026] The decision unit 117 compares the target achievement rate of the semi-automatic machine Eq with the target achievement rate of worker W1. If the target achievement rate of the semi-automatic machine Eq is higher than that of worker W1, the decision unit 117 determines that worker W1 should prioritize improving their own work efficiency and proceed to the next step in their own work process without returning to the semi-automatic machine Eq. If the target achievement rate of the semi-automatic machine Eq is lower than that of worker W1, the decision unit 117 determines that worker W1 should prioritize improving the work efficiency of the semi-automatic machine Eq and perform auxiliary work on the semi-automatic machine Eq without making it wait, and notifies worker W1 via the notification unit 16 to take over the auxiliary work on the semi-automatic machine Eq.

[0027] Furthermore, if the target achievement rate of the semi-automatic machine Eq falls below a predetermined threshold Th1, and the target achievement rate of the worker W1 also falls below a predetermined threshold Th2, the judgment unit 117 determines that there is an abnormality and the notification unit 22 notifies the line leader or other personnel working in the office accordingly.

[0028] Thus, according to the production management support system 1, in order to avoid reducing the operating rate of the semi-automatic machine Eq and worker W1, worker W1 is notified whether to proceed with their own work or to assist the semi-automatic machine Eq. If it is necessary to assist the semi-automatic machine Eq, worker W1 is notified accordingly. As a result, production can be carried out without reducing the operating rate of the semi-automatic machine Eq and worker W1, and productivity can be improved.

[0029] [Example 1] The configuration of the production management support system 1 according to Embodiment 1 of the present invention will be described below with reference to the drawings. However, the configuration of the device described in this embodiment should be modified as appropriate depending on various conditions. In other words, the scope of this invention is not intended to be limited to the following embodiment.

[0030] Figure 1 shows the overall configuration of production management support system 1. The production management support system 1 includes the configuration for the production line 10 and the configuration for the office 20. Production line 19 is carried out by a cell line CL which includes workbenches where workers W1 and W2 work and a semi-automatic machine Eq. Production line 10 includes a semi-automatic machine data provision unit 12 which includes sensors installed on the semi-automatic machine Eq, a semi-automatic machine data collection unit 13 which collects data from the semi-automatic machine data provision unit 12, an image analysis unit 15 which performs image analysis such as detecting the movement of workers W1 and W2 working on the cell line CL based on imaging information from the imaging unit 14, and a semi-automatic machine data The system includes a processing unit 11 that performs processing described later based on data collected by the data collection unit 13 and information regarding the working status of workers W1 and W2 detected by the image analysis unit 15, and a notification unit 16 that notifies workers W1 and W2 working on the cell line CL of the information output based on the processing in the processing unit 11. The semi-automatic machine data collection unit 13, the image analysis unit 15, and the processing unit 11 are connected via a network to a processing unit 21 installed in the office 20. The office 20 is equipped with a notification unit 22 that provides information to the processing unit 21 and managers LL such as line leaders (production technology personnel) working in the office 20. Here, the semi-automatic machine Eq corresponds to the equipment of the present invention. The semi-automatic machine data provision unit 12, the semi-automatic machine data collection unit 13, and the semi-automatic machine operating rate calculation unit 111 described later correspond to the equipment operating information acquisition unit of the present invention. The imaging unit 14, the image analysis unit 15, and the worker operating rate calculation unit 114 described later correspond to the worker operating information acquisition unit of the present invention.

[0031] The semi-automatic machine data provision unit 12 is composed of, for example, an OCR (Optical Character Reader), a BCR (Barcode Reader), switches, photoelectric sensors, image sensors, etc. The semi-automatic machine data provision unit 12 may also include a PLC (Programmable Logic Controller) that controls the semi-automatic machine Eq, and depending on the configuration, the BCR, switches, photoelectric sensors, etc. It may also be connected via a rail terminal or similar.

[0032] The image analysis unit 15 generates information regarding the working status of worker W1 by analyzing imaging information captured by, for example, an imaging unit 14 such as a camera to detect the movement of workers W1 and W2, and to detect the number of items produced by workers W1 and W2. The movement of workers W1 and W2 may also be detected by RFID tags carried by workers W1 and W2, and any appropriate detection means can be used.

[0033] For example, cell line CL is configured as shown in Figure 3. Here, cell line CL consists of five workbenches WB1 to WB5. Worker W1 works at workbenches WB1 and WB2. A semi-automatic machine Eq is installed at workbench WB3. Worker W2 works at workbenches WB4 and WB5. Work areas WA1, WA2, WA3, WA4, and WA5 are set up in front of workbenches WB1, WB2, WB3, WB4, and WB5, respectively. The product (also called workpiece) PD moves from workbench WB1 to workbench WB5 following the arrow FL, and the production process progresses. Worker W1 moves from workbench WB1 to workbench WB2, and then to workbench WB3 to perform auxiliary work for the semi-automatic machine Eq, depending on the work process. At this time, worker W1 moves between work areas WA1, WA2, and WA3 according to the task, as indicated by arrow R1. Similarly, worker W2 moves from workbench WB4 to workbench WB5 according to the work process. At this time, worker W2 moves between work areas WA4 and WA5 according to the task, as indicated by arrow R2.

[0034] The image analysis unit 15 analyzes the image data from the imaging unit 14 to detect when workers W1 and W2 enter and exit their respective work areas WA1, calculates the operating time for each work process, and generates information regarding the operating status of workers W1 and W2, such as the number of items produced.

[0035] The processing unit 11 can be composed of a general computer device including a CPU, memory, input device, output device, and communication interface. Figure 2 shows a functional block diagram of the processing unit 11. The processing unit 11 includes a semi-automatic machine utilization rate calculation unit 111, a semi-automatic machine production plan information acquisition unit 112, a semi-automatic machine target achievement rate calculation unit 113, a worker utilization rate calculation unit 114, a worker production plan information acquisition unit 115, a worker target achievement rate calculation unit 116, and a judgment unit 117. Each of these functions is realized by executing a program stored in memory on the CPU. The functions of each functional unit will be described later.

[0036] The notification unit 16 uses HMI (Human Machine Interface) such as touch panels and tablets. It can be configured with appropriate means to notify the worker W1 performing work on the cell line, such as a terminal, indicator light, or buzzer. In this case, the notification unit 16 corresponds to the notification unit of the present invention.

[0037] The processing unit 21 can be composed of a general computer device including a CPU, memory, input device, output device, and communication interface.

[0038] The notification unit 22 can be configured with appropriate means to notify managers such as line leaders or production engineers working in the office, such as PCs or tablet devices. The notification unit 22 is connected to the processing unit 21 by appropriate communication means such as Ethernet® or Wi-Fi®. In this case, the notification unit 22 corresponds to the manager notification unit of the present invention.

[0039] (Processing in the processing unit 11 to determine the priority of worker W1's tasks) The following describes the process performed in processing unit 11 to determine how to deal with worker W1.

[0040] The semi-automatic machine target achievement rate calculation unit 113 of the processing unit 11 calculates the target achievement rate of the semi-automatic machine Eq. Here, the semi-automatic machine target achievement rate calculation unit 113 corresponds to the first evaluation index calculation unit of the present invention, and the target achievement rate of the semi-automatic machine Eq corresponds to the equipment productivity evaluation index of the present invention. The target achievement rate of the semi-automatic machine Eq is calculated by the following equation (1). Target achievement rate = (Actual operating rate of semi-automatic machine Eq) / (Target operating rate of semi-automatic machine Eq) ... (1) Here, the target operating rate of the semi-automatic machine is calculated by the semi-automatic machine production plan information acquisition unit 112 using the following equation (2), and the actual operating rate of the semi-automatic machine Eq is calculated by the semi-automatic machine operating rate calculation unit 111 using the following equation (3). Target operating rate for semi-automatic machine Eq = Target production time / Planned operating time ... (2) Actual operating rate of semi-automatic machine Eq = Actual production time / Actual operating time ... (3) Furthermore, the target production time is calculated by the semi-automatic machine production plan information acquisition unit 112 using the following formula (4), and the actual production time is calculated by the semi-automatic machine operating rate calculation unit 111 using the following formula (5). Target production time = Target production quantity × Processing time of semi-automatic machine Eq ... (4) Actual production time = Actual production quantity × Processing time of semi-automatic machine Eq ... (5) Here, the target operating rate, target production time, planned operating time, target production quantity, and processing time of the semi-automatic machine Eq correspond to the equipment production planning information of the present invention, and the semi-automatic machine production planning information acquisition unit 112 corresponds to the equipment production planning information acquisition unit of the present invention. In addition, the actual operating rate, actual production time, actual operating time, and actual production quantity of the semi-automatic machine Eq correspond to the equipment operation information of the present invention.

[0041] Similarly, the worker target achievement rate calculation unit 116 of the processing unit 11 calculates the target achievement rate of worker W1 using the following equation (6). Here, the worker target achievement rate calculation unit 116 corresponds to the second evaluation index calculation unit of the present invention, and the target achievement rate of worker W1 corresponds to the worker productivity evaluation index of the present invention. Target achievement rate = (Actual utilization rate of worker W1) / (Target utilization rate of worker W1) ... (6) Here, the target utilization rate of worker W1 is calculated by the worker production plan information acquisition unit 115 using the following formula (7), and the actual utilization rate of worker W1 is calculated by the worker utilization rate calculation unit 114 using the following formula (8). Target utilization rate for worker W1 = (Standard time × Target production quantity) / Planned operating time ... (7) Actual utilization rate of worker W1 = Actual production time / Actual working time ... (8) Here, the target operating rate, standard time, planned operating time, and target production quantity of worker W1 are defined in the present invention. This corresponds to worker production plan information, and the worker production plan information acquisition unit 115 corresponds to the worker production plan information acquisition unit of the present invention. In addition, the actual operating rate, actual production time, and actual operating time of worker W1 correspond to the equipment operation information of the present invention.

[0042] Then, the determination unit 117 of the processing unit 11, Achievement rate of worker W1 < Achievement rate of semi-automatic machine Eq ... (9) If this condition is met, the priority will be to improve the productivity of worker W1, and it will be determined that worker W1 should proceed to their next process rather than returning to the semi-automated machine Eq to handle the situation. On the other hand, the determination unit 117 of the processing unit 11, Operator W1's target achievement rate > Semi-automatic machine Eq's target achievement rate... (10) If this condition is met, it is determined that priority should be given to improving the operation of the semi-automatic machine Eq, and that worker W1 should return to the semi-automatic machine Eq to collect the workpieces that have been processed by the semi-automatic machine Eq and perform auxiliary tasks such as preparing the workpieces for the next operation. In this case, the determination unit 117 corresponds to the priority work determination unit of the present invention.

[0043] The decisions made using the above formulas will be explained using specific numerical examples. Here, the planned values ​​are: The planned operating time is 6 hours = 21,600 seconds. The target production quantity is 200 units. The processing time per unit is 90 seconds. The standard worker time per item is 80 seconds. Furthermore, as actual data, for half a day (3 hours), The number of semi-automatic machines produced was 80. The number of units produced by the worker was 90. The actual time taken by the worker (per item) will be 90 seconds.

[0044] Based on the numerical examples above, The target operating rate for the semi-automatic machine Eq = 90 × 200 / 21600 = 83%. Target utilization rate for worker W1 = 80 × 200 / 21600 = 74% Actual operating rate of semi-automatic machine Eq = 90 × 80 / 10800 = 66% Actual utilization rate of worker W1 = 90 × 90 / 10800 = 75% This is the result.

[0045] Substituting the above-mentioned target operating rate and actual operating rate into equations (1) and (6), respectively, the target achievement rates for the semi-automatic machine Eq and the operator W1 are calculated as follows: The target achievement rate for the semi-automatic machine Eq is 0.66 / 0.83 = 79%. Worker W1's target achievement rate = 0.75 / 0.74 = 101% This is the result. Here, the target achievement rate of worker W1 is greater than the target achievement rate of the semi-automatic machine Eq, and the inequality in equation (10) holds true. Therefore, prioritizing the improvement of the semi-automatic machine Eq's operation, the decision unit 117 of the processing unit 11 returns to the semi-automatic machine Eq via the notification unit 16 and notifies worker W1 not to keep the semi-automatic machine Eq waiting. Following this notification, worker W1 returns to the semi-automatic machine Eq to perform auxiliary work instead of proceeding to the next process, thereby improving the operating rate of the semi-automatic machine Eq. This allows production to proceed without reducing the operating rates of both the semi-automatic machine Eq and worker W1, and thus improves productivity.

[0046] [Example 2] The following describes the production management support system 1 according to Embodiment 2 of the present invention. For components similar to those in Embodiment 1, the same reference numerals are used, and detailed explanations are omitted. The device configuration of the production management support system 1 according to Embodiment 2 is the same as that of the production management support system according to Embodiment 1. In the production management support system 1 according to Example 2, the method of determining the priority of worker W1 in the processing unit 11 differs from that of the production management support system 1 according to Example 1.

[0047] In Example 1, the decision of whether to improve the operation of the semi-automatic machine Eq or worker W1, specifically whether worker W1 should proceed to the next process or return to the semi-automatic machine Eq, is made using the respective target achievement rates of the semi-automatic machine Eq and worker W1. In this case, even if the operating rates are the same, if the operating rate has decreased in the most recent time, it is necessary to increase the operating rate. Therefore, in Example 2, the decision of which operation to prioritize, the semi-automatic machine Eq or worker W1, is made using the most recent target achievement rate at the time of the decision.

[0048] In other words, at the most recent time at the time of the decision, Operator W1's target achievement rate < Semi-automatic machine Eq's target achievement rate ... (11) If this condition is met, the decision unit 117 of the processing unit 11 prioritizes improving the work efficiency of worker W1 and determines that worker W1 should proceed to their next process rather than returning to the semi-automatic machine Eq to handle the situation. Meanwhile, in the most recent time, Operator W1's target achievement rate > Semi-automatic machine Eq's target achievement rate... (12) If this condition is met, the determination unit 117 of the processing unit 11 decides that the operator W1 should return to the semi-automatic machine Eq in order to prioritize improving the operation of the semi-automatic machine Eq.

[0049] The judgment based on the above formula will be explained using a specific numerical example. Here, similar to Example 1, the planned value is: The planned operating time is 6 hours = 21,600 seconds. The target production quantity is 200 units. The processing time per unit is 90 seconds. The standard worker time per item is 80 seconds. Furthermore, as actual data, for half a day (3 hours), The semi-automatic machine produced 40 units in the first hour and 60 units in the remaining two hours. The worker's actual production figures were 40 units in the first hour and 65 units in the remaining two hours. The actual time taken by the worker (per item) will be 90 seconds.

[0050] Based on the numerical examples above, The target operating rate for the semi-automatic machine Eq = 90 × 200 / 21600 = 83%. Target utilization rate for worker W1 = 80 × 200 / 21600 = 74% This is the result. At this time, for half a day (3 hours), Actual operating rate of the semi-automatic machine Eq = 90 × 100 / 10800 = 83%. Actual utilization rate of worker W1 = 90 × 105 / 10800 = 87% Therefore, looking at the entire 3-hour period, both the semi-automatic machine Eq and the operator W1 achieved their target operating rates.

[0051] However, looking at the last two hours, Actual operating rate of semi-automatic machine Eq = 90 × 60 / 7200 = 75% Actual utilization rate of worker W1 = 90 × 65 / 7200 = 81% As a result, the utilization rate of the semi-automatic machine Eq decreases in the last two hours.

[0052] Therefore, the target achievement rates of the semi-automatic machine Eq and the operator W1 in the most recent time, i.e., the last two hours, are calculated using equations (1) and (6). In the last two hours, The target achievement rate for the semi-automatic machine Eq is 0.75 / 0.83 = 90%. Worker W1's target achievement rate = 0.81 / 0.74 = 109% This is the result. In this case, the latter two hours correspond to a predetermined time period close to the time of the determination of the present invention. The length of the predetermined time period can be set as appropriate. At this time, since the inequality in equation (12) holds, the decision unit 117 of the processing unit 11 prioritizes improving the operation of the semi-automatic machine Eq and notifies the worker W1 via the notification unit 16 to return to the semi-automatic machine Eq and notify the worker W1 not to keep the semi-automatic machine Eq waiting. By returning to the semi-automatic machine Eq in accordance with this notification, instead of proceeding to the next process, the operating rate of the semi-automatic machine Eq is improved, so production can be carried out without reducing the operating rates of the semi-automatic machine Eq and the worker W1, thereby improving productivity.

[0053] [Example 3] The following describes the production management support system 1 according to Embodiment 3 of the present invention. For components similar to those in Embodiments 1 and 2, the same reference numerals are used and detailed explanations are omitted. The device configuration of the production management support system 1 according to Embodiment 3 is the same as that of the production management support system 1 according to Embodiments 1 and 2. In the production management support system 1 according to Embodiment 3, the method of determining the priority of worker W1 in the processing unit 11 differs from that of the production management support system 1 according to Embodiments 1 and 2.

[0054] In Example 2, even if the utilization rate is the same, if the utilization rate has decreased in the most recent time at the time of the decision, it is necessary to increase the utilization rate. Therefore, the most recent target achievement rate was used to determine which operation to prioritize, the semi-automatic machine Eq or the worker W1. In Example 3, similarly, even if the utilization rate is the same, if the utilization rate has decreased in the most recent time at the time of the decision, it is necessary to increase the utilization rate. Therefore, the target achievement rate was weighted and averaged to determine which operation to prioritize, the semi-automatic machine Eq or the worker W1.

[0055] In Embodiment 3, the determination unit 117 of the processing unit 11 determines which operation to prioritize, the semi-automatic machine Eq or the worker W1, based on whether either inequality (9) or (10) holds true for the respective target achievement rates of the semi-automatic machine Eq and the worker W1.

[0056] Here, let's assume that at 11:30, the decision unit 117 of the processing unit 11 decides whether to prioritize the operation of the semi-automatic machine Eq or the worker W1, and that the target achievement rates of worker W1 and the semi-automatic machine Eq for each 30-minute time period from 9:00 to 11:30 are as shown in Table 1 below. [Table 1]

[0057] At this time, the target achievement rate of worker W1 and the target achievement rate of the semi-automatic machine Eq are calculated using a weighted moving average, where the weight of the value for the most recent time period is increased. That is, the weights for the target achievement rates of the time periods 0:90-09:30, 09:30-10:00, 10:00-10:30, 10:30-11:00, and 11:00-11:30 are set to 1, 2, and 3, respectively. The weight is increased for more recent time periods, such as 4, 5, and so on. The target achievement rates of worker W1 and semi-automatic machine Eq, calculated using a weighted moving average with the weights set in this manner, are expressed by the following formulas. Here, the weighted moving average with the set weights corresponds to weighting according to the time up to the decision-making stage of the present invention. Target achievement rate of worker W1 =(90+90×2+70×3+60×4+60×5) / (1+2+3+4+5) =68(%) Target achievement rate of semi-automatic machine Eq =(90+90×2+80×3+80×4+75×5) / (1+2+3+4+5) =80(%)

[0058] At this point, the target achievement rate of worker W1 is less than the target achievement rate of the semi-automatic machine Eq, and the inequality in equation (9) holds. Therefore, prioritizing the improvement of worker W1's work rate, the decision unit 117 of the processing unit 11 decides that worker W1 should proceed to the next process without returning to the semi-automatic machine Eq. The decision unit 117 of the processing unit 11 may notify worker W1 through the notification unit 16 to proceed to the next process without returning to the semi-automatic machine Eq, but worker W1 will proceed to the next process unless there is a problem, so notification is not necessary. In this way, by having worker W1 proceed to the next process, the work rate of worker W1 is improved, so production can be carried out without reducing the work rates of the semi-automatic machine Eq and worker W1, and productivity can be improved.

[0059] [Example 4] The following describes the production management support system 1 according to Embodiment 4 of the present invention. For components similar to those in Embodiments 1 to 3, the same reference numerals are used and detailed explanations are omitted. The device configuration of the production management support system 1 according to Embodiment 4 is the same as that of the production management support system 1 according to Embodiment 1. In the production management support system 1 according to Embodiment 4, the method of determining priority work for worker W1 in the determination unit 117 of the processing unit 11 differs from that of the production management support system according to Embodiment 1.

[0060] In Embodiment 4, if the target achievement rate of the semi-automatic machine Eq and the worker W1 decreases, it may become impossible to produce the planned quantity. Therefore, when the target achievement rate of the semi-automatic machine Eq and the worker W1 falls below their respective thresholds, the processing unit 11 issues an error to the notification unit 22 via the processing unit 21, and notifies the manager LL, such as the line leader. Specifically, a threshold Th1 is set for the target achievement rate of the semi-automatic machine Eq, and a threshold Th2 is set for the target achievement rate of worker W1. Figure 3(A) is a graph showing the change in the target achievement rate of the semi-automatic machine Eq, with time on the horizontal axis and the target achievement rate on the vertical axis. Figure 3(B) is a graph showing the change in the target achievement rate of worker W1, similarly with time on the horizontal axis and the target achievement rate on the vertical axis. As shown in Figure 3(A), at times T3 and T4, the target achievement rate of the semi-automatic machine Eq is below the threshold Th1. As shown in Figure 3(B), at times T3 and T4, similarly, the target achievement rate of worker W1 is also below the threshold Th2. For example, as shown in Figures 3(A) and 3(B), when the target achievement rates of both the semi-automatic machine Eq and the worker W1 fall below their respective thresholds Th1 and Th2 at two consecutive timings, the judgment unit 117 of the processing unit 11 notifies the manager LL, such as a line leader working in the office 20, that an error has occurred by displaying this information on the display of the PC constituting the notification unit 22, or by similarly lighting or flashing the stacked indicator lights constituting the notification unit 22. This allows the manager LL to recognize the abnormality of the cell line CL and implement the necessary countermeasures for producing the planned number of units. The judgment unit 117 corresponds to the productivity reduction judgment unit of the present invention. Here, whether the target achievement rates of both the semi-automatic machine Eq and the operator W1 fall below the respective thresholds Th1 and Th2 at two consecutive timings corresponds to whether the predetermined conditions indicating a decrease in productivity of the present invention are met.

[0061] [Example 5] The following describes the production management support system 1 according to Embodiment 5 of the present invention. For components similar to those in Embodiments 1 to 4, the same reference numerals are used and detailed explanations are omitted. The device configuration of the production management support system 1 according to Embodiment 5 is the same as that of the production management support system 1 according to Embodiment 1. In the production management support system 1 according to Embodiment 5, the method of determining priority work for worker W1 in the determination unit 117 of the processing unit 11 differs from that of the production management support system 1 according to Embodiment 1.

[0062] In light of the fact that sudden stoppages, such as the shutdown of the semi-automatic machine Eq, can lead to an underestimation of the operating rate, the time during which the sudden stoppage occurred is excluded from the calculation of the target achievement rate. Based on the target achievement rate calculated in this way, the decision unit 117 of the processing unit 11 determines whether the operation of the semi-automatic machine Eq or the operator W1 should be improved. When the semi-automatic machine Eq suddenly stops, an abnormal signal is emitted from the semi-automatic machine Eq, and the processing unit 11 can recognize the sudden stoppage of the semi-automatic machine Eq by receiving this abnormal signal through the semi-automatic machine data provision unit 12 and the semi-automatic machine data collection unit 13.

[0063] The following will explain using specific numerical examples. Here, similar to Example 1, the planned value is: The planned operating time is 6 hours = 21,600 seconds. The target production quantity is 200 units. The processing time per unit is 90 seconds. The standard worker time per item is 80 seconds. Also, regarding actual data, for half a day (3 hours), The semi-automatic machine Eq was stopped for the first 30 minutes, and then produced 90 units in the following 2.5 hours. The number of units produced by the worker was 80. The actual time taken by the worker (per item) will be 90 seconds. In this case, the first 30 minutes correspond to the downtime of the equipment of the present invention.

[0064] Based on the figures above, Target operating rate for semi-automatic machine Eq = 83% Target utilization rate for worker W1 = 74% This is the result. At this time, for half a day (3 hours), Actual operating rate of semi-automatic machine Eq = 90 × 90 / 10800 = 75% Actual utilization rate of worker W1 = 90 × 80 / 10800 = 66% This is the result. Here, since the semi-automatic machine Eq is stopped for the first 30 minutes of its half-day (3 hours), excluding these 30 minutes, we can calculate the actual utilization rate for the 2.5 hours (9000 seconds) it was actually operating. Actual operating rate of semi-automatic machine Eq = 90 × 90 / 9000 = 90% The actual utilization rate of worker W1 remains unchanged at 66%.

[0065] When calculating the target achievement rate after the semi-automatic machine Eq has stopped and resumed operation, The target achievement rate for the semi-automatic machine Eq is 0.90 / 0.83 = 108%. Worker W1's target achievement rate = 0.66 / 0.74 = 89% This is the result. At this point, since the inequality in equation (9) holds, the decision unit 117 of the processing unit 11 decides that prioritizing the improvement of worker W1's work efficiency, worker W1 should proceed to their next process rather than returning to the semi-automatic machine Eq to handle the situation. The decision unit 117 of the processing unit 11 communicates through the notification unit 16, The operator W1 may be notified to proceed to the next process without returning to the semi-automatic machine Eq, but operator W1 will proceed to the next process unless there is a problem, so notification is not necessary. In this way, operator W1's work rate is improved by proceeding to the next process, so production can be carried out without reducing the operating rate of the semi-automatic machine Eq and operator W1, thereby improving productivity.

[0066] [Variation] In the above embodiment, the target operating rate for worker W1 changes depending on the skill level of worker W1. Therefore, a target operating rate may be set for each worker W1, and based on this, the determination unit 117 of the processing unit 11 may calculate the target achievement rate for the semi-automatic machine Eq and worker W1 to determine which operation should be prioritized. Furthermore, since the target utilization rate changes when the product type or model of the product development plan (PD) is changed, it may be advisable to calculate the target achievement rate for each type or model. Alternatively, past target achievement rates for the previous day or the day before that may be stored, and these may be used to predict the target achievement rate for the current day. The predicted target achievement rate may then be used as the threshold for notification in Example 4.

[0067] <Note 1> A production management support system (1) that supports the management of a production process in which processes performed by workers (W1) and processes performed by equipment (Eq) including auxiliary work by humans coexist, Equipment operation information acquisition unit (12,13,111) acquires equipment operation information regarding the operating status of equipment (Eq), A worker operation information acquisition unit (14, 15, 114) acquires worker operation information regarding the working status of the worker (W1), Based on the equipment operation information and the worker operation information, a priority work determination unit (117) determines whether to prioritize the work related to the process performed by the worker or the auxiliary work, A production management support system (1) is characterized by comprising a notification unit (16) that notifies the worker when it is determined that the aforementioned auxiliary work should be prioritized. [Explanation of symbols]

[0068] 1. Production Management Support System 12 Semi-automatic machine data provision department 13. Semi-automatic machine data acquisition unit 14 Imaging Unit 15 Image Analysis Department 111 Semi-automatic machine operating rate calculation unit 114 Worker utilization rate calculation unit Eq semi-automatic machine W1 Worker

Claims

1. A production management support system that assists in managing production processes that involve a mix of processes performed by workers and processes performed by equipment, including auxiliary work by humans, Equipment operation information acquisition unit acquires equipment operation information regarding the operating status of the equipment, A worker operation information acquisition unit acquires worker operation information regarding the working status of workers, Equipment production plan information acquisition unit acquires equipment production plan information, which is production plan information related to the aforementioned equipment. A worker production plan information acquisition unit acquires worker production plan information, which is production plan information relating to the aforementioned worker. A first evaluation index calculation unit calculates an equipment productivity evaluation index for evaluating the productivity of the equipment based on the equipment operation information and the equipment production plan information, A second evaluation index calculation unit calculates a worker productivity evaluation index for evaluating the productivity of the worker based on the worker operation information and the worker production plan information, A priority work determination unit determines, based on the equipment operation information and the worker operation information, which of the work related to the process performed by the worker and the auxiliary work to prioritize. A notification unit that notifies the worker when it is determined that the aforementioned auxiliary work should be prioritized, Equipped with, The production management support system is characterized in that the priority work determination unit determines whether to prioritize the work related to the process performed by the worker or the auxiliary work, based on the equipment productivity evaluation index and the worker productivity evaluation index.

2. The production management support system according to claim 1, characterized in that the priority work determination unit determines whether to prioritize the work related to the process performed by the worker or the auxiliary work based on the equipment productivity evaluation index and the worker productivity evaluation index in a predetermined time period close to the time of determination.

3. The production management according to claim 1, characterized in that the priority work determination unit determines whether to prioritize the work related to the process performed by the worker or the auxiliary work, based on the equipment productivity evaluation index and the worker productivity evaluation index weighted according to the time up to the determination. Support system.

4. The aforementioned priority work determination unit, A production management support system according to any one of claims 1 to 3, characterized in that it determines whether to prioritize the work related to the process performed by the worker or the auxiliary work, by excluding the sudden downtime of the equipment from the equipment operation information.

5. A productivity decline determination unit that determines whether the equipment productivity evaluation index and the worker productivity evaluation index meet predetermined conditions indicating a decline in productivity, An administrator notification unit that notifies the administrator when it is determined that the aforementioned predetermined conditions are met, The production management support system according to claim 1, characterized by comprising the following features.

Images