Production System Operator Restriction for Productivity
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Solution Overview
Problem
Existing production systems only apply performance restrictions retrospectively after productivity issues occur, leading to repeated inefficiencies and decreased productivity due to unsuitable operator work assignments before production.
Innovation Solution
A production system that includes a memorizing device for operator performance information, a detecting device for lowered productivity, and a restricting device that applies performance restrictions proactively to prevent repeated inefficiencies by identifying and restricting operators who consistently lower productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If performance restrictions are applied retrospectively after trouble occurs, then operators with insufficient experience are prevented from performing difficult recovery work, but the same operators may repeatedly perform unsuitable work before production causing repeated productivity drops
Solution Approach 1:
The system performs preliminary evaluation of operator work appropriateness before production occurs. The evaluating device assesses whether operator work contents are suitable for their experience level in advance, and the restricting device prevents operators from performing work that would likely cause productivity drops, rather than waiting for problems to occur after the fact.
Solution Approach 2:
The system implements continuous feedback by detecting actual productivity data during production, comparing it against expected standards, and using this information to identify operators whose work is causing productivity drops. This feedback loop enables the system to dynamically adjust performance restrictions based on real-time performance data.
2Ease of operation
If operators are allowed to perform all work without restrictions, then operational flexibility is maintained, but productivity drops due to unsuitable operator-work matching
Solution Approach 1:
The performance restriction system is dynamic rather than static. Restrictions are not permanently assigned to operators but are temporarily applied based on real-time detection of productivity drops and ongoing evaluation of work appropriateness. The system can adjust and remove restrictions as operators demonstrate improved performance or gain relevant experience.
Solution Approach 2:
The system changes the parameter of operator work authorization based on detected productivity patterns. When productivity drops are detected and linked to specific operators through the memorizing device, the restricting device modifies the authorization parameters for those operators, limiting their ability to perform similar work until the underlying issues are resolved.
Data Source
AI summary
The management computer of a mounting system, when productivity is lowered, identifies an operator and work type from a work history, retrieves a management value P for the identified work type for the identified operator, and increases the management value P by an increment of “1.” Then, the management computer of the mounting system, when judging that management value P is at least second threshold value P2, applies a performance restriction on the identified operator for the work of the identified work type. Thus, it is possible to curtail lowered productivity due to the same work by the same operator being repeated.