JP3680716B2 - Worker assignment device at production site - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to an apparatus for assigning an operator to each operation at a production site where a product is manufactured by a plurality of operations having different degrees of difficulty.
[0002]
[Prior art]
In general, when a product is manufactured, the work is performed by dividing the product into several sub-assemblies. For example, when the spindle head 10 of a machine tool is assembled and manufactured in a plurality of operations shown in FIG. 1, the disc spring subassembly 10v shown in FIG. 2 is shown in FIG. The spindle sub-assembly 10s is assembled. In the spindle assembling operation 18s, as shown in FIG. 4, the disc spring subassembly 10v is inserted into the spindle subassembly 10s, and the spindle / disc spring subassembly 10sv is assembled. The cylinder subassembly 10c shown in FIG. 5 is assembled by the cylinder assembly operation 17c, and the housing subassembly 10h shown in FIG. 6 is assembled by the housing assembly operation 17h. In the housing assembly operation 18h, as shown in FIG. 7, the spindle / disc spring sub-assembly 10sv is fitted into the housing sub-assembly 10h, and the spindle unit sub-assembly 10svh is assembled. The main body subassembly 10m shown in FIG. 8 is assembled by the main body assembly operation 17m, and the spindle unit subassembly 10svh is inserted into the main body subassembly 10m as shown in FIG. 10 svhm is assembled. The rear subassembly 10r shown in FIG. 10 is assembled by the rear assembly operation 17r, and the cylinder subassembly 10c is fitted and fixed to the rear subassembly 10r as shown in FIGS. 11 and 12 by the rear assembly operation 18r, so that the rear cylinder subassembly 10rc. The rear cylinder subassembly 10rc is fitted and fixed to the rear end portion of the main body-equipped spindle unit subassembly 10svhm, and the spindle head 10 is assembled and manufactured.
[0003]
Assembling the parts to be assembled from the machining process etc. as the previous stage until the disc spring assembly work 17v, the spindle assembly work 17s, the cylinder assembly work 17c, the housing assembly work 17h, the main body assembly work 17m, and the rear assembly work 17r. Parts preparation work 11v, 11s, 11c, 11h, 11m, 11r collected at the assembly place where the work is performed, chamfering work 12v, 12s, 12c, 12h, 12m, 12r for chamfering the collected assembly parts, and chamfering were performed. Parts cleaning work 13v, 13s, 13c, 13h, 13r for cleaning parts and parts coated with rust-preventing oil in advance for assembling, the thickness of shims interposed between the parts to be assembled, etc. Assembly work 14v, 14s, 14c, 14h, 14m, 14r to be adjusted at the assembly, assembling purchased products from warehouses, etc. Purchases preparatory work 15v to collect the place to do business, 15s, 15c, 15h, 15m, 15r, packed Snoop work 16s press-fitting the packed Snoop to the end portion or the like of the drill hole of the oil passage, 16c, 16h are respectively carried out.
[0004]
Conventionally, one operator is in charge of all the series of operations until the spindle head 10 is assembled and manufactured, or one operator is in charge of a series of operations until each sub-assembly is assembled. The spindle head 10 was manufactured by six workers.
[0005]
[Problems to be solved by the invention]
Each of the above-mentioned series of work includes work that can be performed by a low-skilled worker and high-skilled work that can only be performed by a highly skilled worker. It was necessary to be able to perform work with a high degree of difficulty. In this case, there is a problem that a large number of highly skilled workers have to be input in order to perform work with low difficulty that increases as the production amount increases. In addition, there is a problem that the ratio of high-skilled workers performing work with low difficulty increases, and the skill of skilled workers cannot be fully utilized.
[0006]
[Means for Solving the Problems]
In order to solve the above problems, the structural feature of the invention described in claim 1 is that the input / output means for inputting / outputting information and the difficulty of each of a plurality of operations for manufacturing a plurality of types of products. Level, level of proficiency of workers who can perform each work, storage means for registering all work schedules for each skill level of workers who can perform each work, and manufacturing products all work is listed in the model-specific all the work list for the type of product that has been instructed and the storage means are registered all work list each model that has been listed for each model, the production needed to Each work is searched in the all work list, and the work difficulty and the work time for each skill level class listed in the all work list are collected and posted for each work of the same type. Storage means for storing an aggregation table; The work of the lowest skill class among the workers of different skill classes that can perform each consolidation work is listed in the order of the process, each work aggregated the same type of work posted in the type work aggregation table who entered the skill class field is assigned to each aggregate operation, the same kind of work hours required when working the skill of class attached said split the work done by another the model constituting each aggregate work Storage means for storing a worker allocation table recorded for each of the aggregate tasks in the work time column, and a skill assigned to each aggregate task in the worker allocation table If the work time required for a worker of the second class to perform the aggregation work is a short time aggregation work with a predetermined time or less, the worker assigned to the aggregation work before or after the short time aggregation work Short time integration work A means for assigning the worker to the short-time aggregation work if it is a skill level class that can be performed, and a means for calculating the total work time of each aggregation work to which the workers of each skill class are assigned And means for calculating the input personnel of each skill class by dividing the value obtained by multiplying the respective work hours by the number of manufactured units within a predetermined period by the working hours of one worker within the predetermined period, According to the process sequence, the number of products being assembled at the same time is N units, and the free time of each worker is allocated to the work that can be performed from the process order in the work assigned to each worker. Create a schedule that displays the schedule for performing each aggregation work for assembling the 1st to Nth products together with the work time of each aggregation work and the skill level of the assigned worker under the conditions Means.
[0007]
[Operation and effect of the invention]
According to the invention according to claim 1 configured as described above, for each of a plurality of operations for manufacturing a plurality of types of products, the level of difficulty of the operation and the skill level of the worker who can perform each operation The work time for each skill level of the worker who can perform each work is registered in the all work list. All operations required to manufacture the product are listed for each model in the model-specific all operations list. Each work listed in the model-specific all work list for the model of the product for which manufacture is instructed is searched in the all work list, and the difficulty and skill level of the work described in the all work list are classified by class. The work hours are collected for each work of the same type and posted to the work summary table for each model. Then, each aggregated work in which the same type of work posted in the model-specific work aggregated table is aggregated is listed in the worker assignment table in the order of the processes, and the lowest among the workers of different skill levels that can perform each aggregated work When a worker of a higher skill class is assigned to each aggregate work and entered in the skill class column, and the same type of work constituting each aggregate work is performed by the assigned skill class worker The total work time read from the model-specific work aggregation table and totaled is recorded for each aggregated work in the work time column. When the work time required for the workers of the skill class assigned to each aggregated work in the worker assignment table to perform the aggregated work is a short-time aggregated work with a predetermined time or less, If the worker assigned to the post-aggregation work is a skill class that can perform the short-time aggregation work, the worker is assigned to the short-time aggregation work. The work hours of each aggregate work assigned to workers of each skill level are summed to calculate the work hours on hand, and the work within the time period is calculated by multiplying each work time by the number of production plans within the time period. Divided by the working hours of one person, the number of employees in each skill class is calculated. Each work is performed in accordance with the process order. At the same time, the number of products being assembled is N units, and the work assigned to each worker can be performed from the process order. The schedule for performing each aggregation work for assembling the first to Nth products is displayed together with the work time of each aggregation work and the skill level of the assigned worker. A schedule is created. Accordingly, it is possible to create a schedule table in which the respective aggregated operations in which the same types of operations performed in association with each of the plurality of sub-assembly assemblies are aggregated according to the process order.
[0008]
Embodiment
Embodiments of a worker assignment method in a production site according to the present invention and an apparatus for carrying out this method will be described below with reference to the drawings. In FIG. 13, reference numeral 20 denotes a hardware configuration of the worker assignment system at the production site according to the present invention. A production management computer 22 as a server installed in the production management room 21 and a plurality of assembly sites 23 for assembling the spindle head 10. And a computer 24 as a terminal installed respectively. The production management computer 22 and the computer 24 are connected to each other via an in-house LAN 25. FIG. 14 is a block diagram of the production management computer 22. The production management computer 22 includes a processing device 26 for performing various processes, an input device 27 for inputting various information, a display device 28 for displaying information, a printer 29 for printing out information, a storage device 30, and an external storage. A device 31, a communication device 32, and the like are connected to each other by a bus 33. The communication device 33 connects the processing device 26 to the in-house LAN 25 and inputs / outputs information to / from the production management computer 22. The storage device 30 stores an operating system OS, an application program AP for executing the system according to the present invention, and the like. Each computer 24 has the same configuration as the production management computer 22, but the processing speed is slower than that of the production management computer 22, and the capacity of the storage device may be small.
[0009]
As shown in FIG. 1, all the operations for assembling and manufacturing the spindle head 10 as a product are identified, and all the operations are aggregated for each type, and a component preparation operation 11, a chamfering operation 12, a component cleaning operation 13. , Current work 14, purchased product preparation work 15, plugging work 16, assembly work 17, and assembly work 18. For example, the parts preparation work 11 is the same kind of parts performed in relation to the disc spring assembly work 17v, the spindle assembly work 17s, the cylinder assembly work 17c, the housing assembly work 17h, the main body assembly work 17m, and the rear assembly work 17r. The preparatory operations 11v, 11s, 11c, 11h, 11m, and 11r are integrated, and the assembly operation 17 includes the same type of disc spring assembly operation 17v, the assembly assembly operation 17s, the cylinder assembly operation 17c, and the housing assembly. The operation 17h, the main body assembly operation 17m, and the rear assembly operation 17r are integrated.
[0010]
In the external storage device 31, as shown in FIG. 15, all work for assembling the six types of spindle heads 10 is registered in the all work list 35. For example, in relation to the disc spring assembly work, six types of parts preparation work 1 to 6 are prepared corresponding to the models 1 to 6, respectively. Are the same, so five types are prepared. All operations for assembling and manufacturing six types of spindle heads are divided into a plurality of levels A, B, and C according to the degree of difficulty, and the levels A, B, and C attached to each operation are a list of all operations. Each task is registered in the difficulty column of Table 35. The workers are divided into a plurality of skill classes, advanced, intermediate, and beginner classes according to the level of difficulty of work that can be performed. Workers with skill level “advanced” are all tasks with difficulty levels A, B, C. Workers with skill level “intermediate” are tasks with difficulty level B, C, with skills class “beginner” It is registered in the external storage device 31 that the worker can perform work with difficulty C. That is, the difficulty level of the work that can be performed by the worker is stored for each skill level class assigned to the worker. Also, the work time required for each skill level worker to perform each work is set according to the skill class advanced, intermediate, and beginner level, and is registered in the work time column of the total work list 35 for each work. Yes. All the operations necessary for assembling and manufacturing the spindle head 10 of each model are identified and listed for each model, and are registered in the model-specific all operations list 37 shown in FIG.
[0011]
Next, when assembling and manufacturing the spindle head 10 of the model 1, an example of the operator assignment method and the operation of the apparatus at the production site will be described based on the program flowcharts shown in FIGS. Here, the worker does not indicate an individual worker, but means an abstract worker having the skill level of each class, and also has a meaning close to the skill level of the worker to whom the work is assigned. . When the production manager instructs assembly of the spindle head 10 of the model 1, the production management computer 12 executes the worker assignment program 50 and reads the model-specific total work list 37 for the model 1 (step 51). . Each work listed in this model-specific all work list 37 is searched in the all work list 35, and the work time according to the difficulty level and skill level of the work described in the all work list 35 is shown for each work. posted, each model working aggregate table 38 shown in collected et al is in Figure 19 for each same type of work is created for each (step 52).
[0012]
The operations of the same type are summarized as the component preparation operation 11, the chamfering operation 12, the component cleaning operation 13, the current assembly operation 14, the purchased product preparation operation 15, the plugging operation 16, the assembly operation 17, and the assembly operation 18. As shown in FIG. 20 , the worker assignment table 39 shown in FIG. 20 is created (step 53). Each aggregated work is assigned a worker of the lowest skill level class that can perform each work, and the skill level of the assigned worker is entered in the skill level class column for each aggregated work. The work time required when the workers of the skill class assigned the same kind of work constituting each aggregated work is read and totaled by the model-specific work aggregation table 38, and this total time is aggregated for each. The work time is recorded in the work time column of the worker assignment table 39.
[0013]
The number n indicating the order of the work described in the worker assignment table 39 is set to 1 (step 54), the first part preparation work 11 is read (step 55), and the work time is a predetermined time, for example, 3 hours. If not (step 56), if not, it is checked whether or not all the operations listed in the worker allocation table 39 have been executed (step 57). Are sequentially added (step 58), and the same steps are repeated up to the eighth assembly operation 18.
[0014]
The fifth purchase preparation work 15 is 3.8 hours in the worker assignment table, but if it is a short work with a work time of 2 hours, it becomes Yes in step 56, and it is skilled. The skill level class of the worker entered in the degree class column is compared between the fifth purchased product preparation work 15 and the previous fourth current joint work 14 (step 59). As for the skill level of the assigned worker, the current work 14 is “advanced”, the purchase preparation work is “beginning”, and the current work 14 is higher, so the purchase work preparation work 15 is advanced. Are gathered as work performed at the same time as the current work 14 (step 60).
[0015]
If the proficiency level column contains “beginning” for the current work 14, “intermediate” for the pre-purchase work 15, and “advanced” for the stuffing work, it is judged as NO in step 59. The skill level class of the worker entered in the skill level class column is compared between the fifth purchased product preparation work 15 and the next sixth stuffing work 16 (step 61). Here, since the skill level of the worker is assumed to be higher in the stuffing work 16, the purchase preparation work 15 is performed at the same time as the stuffing work 16 by an advanced skill class worker. It will be compiled as work (step 62).
[0016]
If the above steps 54 to 62 are short-time work of a predetermined time or less when the work of the lowest skill level class capable of performing the work 11 to 18 is performed, the short time If the worker assigned to the work before or after the work is a skill class capable of performing the short-time work, a means 40 for assigning the worker to the short-time work is configured.
[0017]
If the process assigned to the worker in the previous process or the subsequent process is executed for all the work listed in the worker assignment table 39 if a short time work is possible, the result is Yes in step 57 and assigned to each worker. The work time of the selected work is totaled for each worker, and the on-hand work time is calculated for each skill class (step 63). Next, the total number of days required for manufacturing is calculated for each skill class by multiplying each work time by the planned number of spindle heads 10 manufactured for a predetermined period, for example, one month, and this total number of manufacturing times is calculated for one worker. It is checked whether it is longer than a predetermined period, for example, one month of working time (step 64). When all skill levels are small, the planned number of spindle heads 10 can be manufactured by one worker in each skill class, and a schedule is created. If it is larger, the total production days of the corresponding skill class are divided by the working hours, and the number of workers of the skill class is calculated by rounding up the fraction (quotient) (step 65). Each worker is assigned a work time obtained by dividing the total number of days of production in the skill class by the number of input personnel (step 66), and a schedule is created (step 70). Usually, since a plurality of spindle heads 10 are assembled and manufactured at the same time, each worker can perform each assigned work on any of the spindle heads 10 being assembled so as not to have play time. An itinerary is created so that you can.
[0018]
Then, itinerary for performing the tasks stored in the worker allocation table 39 in accordance with the process sequence is created by itinerary creation program 70 shown in FIG. 18. (1) Each operation is performed according to the process order. (2) The number of units being assembled at the same time is N units, for example, 3 units. (3) All workers' idle time is assigned to the work assigned to each worker, which can be performed in the process order. Under the above three conditions, each work for assembling the first to N-th spindle heads 10, that is, part preparation work 11, chamfering work 12, part cleaning work 13, current joint work 14, purchase product preparation The work 15, the plugging work 16, the assembling work 17, and the assembling work 18 are displayed as a schedule table pattern as shown in FIG. 21 together with the skill level of the worker assigned to each work (step 71). As an example of a different schedule table pattern, an operator of the skill class “beginner” can perform the first stuffing operation 16 from the fourth day to the fifth day in FIG. As shown by the broken line in the column, it is also possible to perform the third component preparation work 11. The belt-like body 44 includes parts preparation work 11, parts washing work 13, purchased goods preparation work 15, and plugging work 16 that are assigned to workers of skill level “beginning” to assemble the first spindle head 10. The length represents each working time, and the letter “beginning” written in the band 44 indicates the skill level “beginning”. The band 45 indicates the chamfering work 12 and the assembling work 18 assigned to the workers of the skill level class “intermediate”, and the length indicates each work time, and the characters written in the band 45 “Medium” indicates a “intermediate” skill level. The belt-like body 46 indicates the current work 14 and the assembly work 17 assigned to the workers of the skill level “advanced”. The length represents each work time, and the characters written in the belt-like body 46 are shown. “Up” indicates a skill level of “advanced”. Similarly, the strips displayed in the second and subsequent columns also indicate the work assigned to the workers of each skill level and the work time. For each of a plurality of created schedule tables patterns, the free times up to the Nth of all workers are calculated and totaled, and the schedule table pattern with the minimum free time, for example, the one shown by the solid line in FIG. Adopted as Table 48 (step 72). When the schedule table 48 is determined, a specific worker of the corresponding skill level class may be assigned to the worker of each skill level class in the table. The example shown in FIG. 21 is a case where there is one worker in each skill level class, but in all skill classes, the total number of days of production within a predetermined period is twice the working time of one person, When two workers are input in the degree class, one set of schedules similar to the schedule in FIG. 21 is added .
[Brief description of the drawings]
FIG. 1 is a view showing all the operations for assembling and manufacturing a spindle head.
FIG. 2 is a view showing a disc spring sub-assembly.
FIG. 3 is a diagram showing a spindle sub-assembly.
FIG. 4 is a diagram showing a spindle / disc spring sub-assembly.
FIG. 5 is a view showing a cylinder sub-assembly.
FIG. 6 is a view showing a housing sub-assembly.
FIG. 7 is a diagram showing a spindle unit sub-assembly.
FIG. 8 is a view showing a main body sub-assembly.
FIG. 9 is a view showing a spindle unit sub-assembly with a main body.
FIG. 10 is a view showing a rear sub-assembly.
FIG. 11 is a view showing a rear cylinder sub-assembly.
FIG. 12 is a diagram showing an assembled state of the spindle head.
FIG. 13 is a diagram showing a hardware configuration of an operator assignment system at a production site according to the present invention.
FIG. 14 is a block diagram of a production management computer.
FIG. 15 is a diagram showing an all work list in which all works for assembling a plurality of types of spindle heads are registered.
FIG. 16 is a diagram showing a list of all types of work.
FIG. 17 is a flowchart of an operator assignment program.
FIG. 18 is a flowchart of a schedule table creation program.
FIG. 19 is a diagram showing a model-specific work summary table.
FIG. 20 is a diagram showing an operator assignment table.
FIG. 21 is a diagram showing a schedule table pattern.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 10 ... Spindle head, 10v ... Belleville spring subassembly, 10s ... Spindle subassembly, 10c ... Cylinder subassembly, 10h ... Housing subassembly, 10m ... Main body subassembly, 10r ... Rear subassembly, 10sv ... Spindle, disk spring subassembly, 10svh ... Spindle unit Sub-assembly, 10 svhm ... Spindle unit sub-assembly with main body, 10 rc ... Rear cylinder sub-assembly, 11 ... Parts preparation work, 12 ... Chamfering work, 13 ... Parts cleaning work, 14 ... On-site work, 15 ... Purchased goods preparation work, 16 ... Packing work, 17 ... Assembly work, 18 ... Assembly work, 22 ... Production management computer, 24 ... Computer, 31 ... External storage device, 35 ... All work list, 37 ... All work list by model, 38 ... Model-specific work aggregation table, 39 ... Worker assignment table, 4 ... means assigning a worker in a short period of time work, 48 ... calendar, 50 ... worker assignment program, 70 ... schedule table creation program.

Claims (1)

Input / output means for inputting / outputting information;
The level of difficulty of work for each of a plurality of works for manufacturing multiple types of products, the skill level of workers who can perform each work, and the work time for each skill class of workers who can perform each work A storage means for which all registered work lists are registered;
A storage means in which a list of all work required for each model in which all work necessary for manufacturing a product is listed for each model is registered;
The search for the type of product you are instructed to manufacture each of the work that has been listed in the model-specific all the work list in the whole work list, degree of difficulty of the tasks described in該全work list, proficiency A storage means for storing a model-specific work aggregation table in which work times by class are collected and posted for each work of the same type;
Each aggregated work in which the same type of work posted in the model-specific work aggregated table is aggregated is listed in the order of the processes, and the lowest skill class among workers of different skill classes that can perform each aggregated work Are assigned to each aggregated work and entered in the skill class column, and the work time required when the assigned skill level workers perform the same kind of work constituting each aggregated work is Storage means for storing a worker allocation table recorded for each of the aggregate work in the work time column, the total time read and summed from the model-specific work aggregation table;
When the work time required for an operator of the skill class assigned to each aggregate work in the worker assignment table to perform the aggregate work is a short time aggregate work of a predetermined time or less, the preceding process of the short time aggregate work Or means for assigning the worker to the short-time aggregate work if the worker assigned to the post-process aggregate work is a skill class capable of performing the short-time aggregate work;
Means for calculating the work on-hand time by summing up the work time of each aggregate work assigned workers of each skill level;
Means for calculating the input personnel of each skill class by dividing the value obtained by multiplying the number of manufactured work within a predetermined period by the working time of each work by the working time of one worker within the predetermined period;
Each work is performed in accordance with the process order, and the number of products being assembled at the same time is N units, and the idle time of each worker is allocated to the work that can be performed in the process order in the work assigned to each worker. A schedule for displaying the schedule for performing each aggregate work for assembling the first to Nth products together with the work time of each aggregate work and the skill level of the assigned worker under the condition of attaching And a means to create
A worker assignment device at a production site characterized by comprising:

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