JPH11353365A - Process control method and process control device - Google Patents

Abstract

(57) [Summary] [Problem] Detailed schedule of workers such as settings optimal for reducing the defect rate, settings for leveling the work of multiple workers, or settings according to the capabilities of the workers Make assignments. SOLUTION: For each work process, a method of assigning workers is selected from a "worker's ability priority" method, a "worker load leveling priority" method and a "worker's minimum defect rate priority" method. And assign the workers according to it. Highly competent work processes are assigned to skilled workers, and workers are assigned to a simple work process that can be performed by anyone so that the work load among each worker is averaged. Workers with a lower defect rate are assigned to work steps that require attention so that the defect rate does not increase.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a process management method and a process for automatically extracting an operator who assigns a schedule according to the purpose of a work in each work process of product manufacturing, and automatically generating an optimum production schedule. Regarding the management device.

[0002]

2. Description of the Related Art Conventionally, as a process management method and a process management device for allocating a worker to a schedule, a work type and a working time record of a certain period in the past are stored for each worker.
In some cases, the worker with the lowest work time record is assigned to the corresponding work based on the work type and the work time record, thereby leveling the worker record. Such a process control method is described in, for example,
No. 2,449,692.

[0003] Information on the gender, date of birth, and past experience of each worker (type of the work, number of the work,
Based on the defect rate, and the work start date and time and the end date and time of the work).
There is a process management method in which scheduling is performed in consideration of the ability of each worker by determining the priority of work assignment based on the worker level. Such a process control method is disclosed in, for example, Japanese Patent Application Laid-Open No. 7-56997. In this publication, the worker level refers to the work time of the first single work in the case of a person who has experienced the work. On the other hand, in the case of the inexperienced person of the work,
The process manager individually sets the worker level value for information such as the type of work, the number of work, the defect rate, and the work start date and time and the end date and time of the work, and the average value or membership function The obtained value is used as the worker level of the worker.

Further, as a process management apparatus for allocating schedules in consideration of the abilities and loads of the workers, a load equalization method for evenly searching a plurality of workers in a group when searching for a worker, or a worker. In some cases, one of the close-packing methods, which mainly searches for capable workers from among the groups, is performed for the entire system. Such an apparatus is disclosed in, for example,
No. 3,482,387. In the apparatus disclosed in this publication, in the close-packing method, workers can be allocated by a rotation method in which workers to be searched are switched every day.

[0005]

However, in the apparatus disclosed in the above-mentioned Japanese Patent Application Laid-Open No. Hei 7-244692, the schedules of the workers are assigned so that the load is leveled by referring to the actual work time for each worker. To be
This is effective when there is not much difference in the defect rate for each worker or when there is no need to consider the defect rate for each worker. When there is no operator, or when there are so many defects that cause a decrease in productivity, there is a drawback that an optimal operator schedule is not always allocated.

Further, in the process management method disclosed in Japanese Patent Application Laid-Open No. 7-56997, a worker is determined based on a worker level which is irrelevant to the past defect rate of the work and reflects only the size of work work time. Since the schedule allocation order is determined, there is a disadvantage that the schedule allocation does not take into account the defect rate of each worker regarding the work.

In the apparatus disclosed in Japanese Patent Application Laid-Open No. 9-73482, either the load equalizing method or the closest filling method is selected for the entire production system. There is a disadvantage that it is not possible to assign a detailed schedule according to the characteristics such as the difficulty of the work. For example, in a work process in which the difference in ability between workers is relatively small, the load is leveled, and in a work process in which the difference in ability between workers is relatively large, a setting emphasizing capability is set. It is impossible to make detailed settings.

SUMMARY OF THE INVENTION The present invention has been made in view of the above, and it has been proposed that a plurality of workers who are candidates for schedule assignment for each work process be provided with an optimum schedule of workers for reducing the defect rate. It is an object of the present invention to obtain a process management method and a process management device capable of performing assignment.

Further, the present invention provides a method for a plurality of workers who are candidates for schedule assignment for each work process.
A process management method and process capable of finely allocating workers' schedules, such as settings optimal for reducing the defect rate, settings for leveling the work of multiple workers, or settings according to the capabilities of the workers The purpose is to obtain a management device.

[0010]

In order to achieve the above object, the present invention obtains a past defect rate in a work process for all workers who can take charge of a certain work process, and obtains the obtained defect rate, A step of comparing with a marginal failure rate which is the maximum value of the allowable failure rate, and searching for the worker who is available at the earliest time among the workers whose failure rate is equal to or less than the marginal failure rate, Selecting a worker whose past failure rate is the smallest from the corresponding workers, and allocating the work to the worker.

According to the present invention, in the next production scheduling, a worker having a small defect rate is preferentially assigned in consideration of a defect rate generated in the past work for each worker in each work process.

[0012] The next invention obtains the past defect rates of all the workers who can be in charge of a certain work step, and obtains the obtained defect rate and a limit defect which is the maximum allowable defect rate. A step of comparing with the rate, and search for the worker who is available at the earliest time among the workers whose failure rate is equal to or less than the marginal failure rate, from among the workers corresponding thereto, from a plurality of conditions. Selecting a worker who satisfies the selected specific condition, and allocating the work to the worker.

According to the present invention, a method of assigning workers is selected for each work process, and workers satisfying specific conditions are preferentially assigned according to the selected method.

In the next invention, the plurality of conditions include three conditions, of which the first condition is that the work ability is the highest, and the second condition is that the work load time accumulated in the past is accumulated. And the sum of the load time of the assigned work scheduled in the future is the smallest, and the third condition is that
It is characterized in that the past defect rate is minimum.

According to the present invention, a work process that requires a high ability is set based on the first condition with priority given to the ability, and a simple work process that anyone can work on is set according to the second condition. Based on the third condition, the priority is given to the load leveling based on the third condition, and the work process which requires attention so that the defect rate does not increase further is set based on the third condition.

The next invention obtains the past defect rates of all the workers who can be in charge of a certain work step, and obtains the obtained defect rate and a limit defect which is the maximum allowable defect rate. A defect rate comparison processing unit for comparing the defective rate with the defective rate is equal to or less than the limit defective rate. And a worker assignment processing unit for selecting a worker with the lowest defect rate and allocating the work to the worker.

According to the present invention, in the next production scheduling, a worker having a small defect rate is preferentially assigned in consideration of a defect rate generated in the past work for each worker in each work process.

[0018] The next invention obtains the past defect rates of all the workers who can take charge of a certain work step, and obtains the obtained defect rate and the limit defect which is the maximum allowable defect rate. A defect rate comparison processing unit that compares the rate with the defective rate, the defective rate is less than or equal to the limit defective rate, and searches for the worker who is available at the earliest time. A worker assignment processing unit that selects a worker that satisfies a specific condition selected from a plurality of conditions and allocates the work to the worker.

According to the present invention, a method of assigning workers is selected for each work process, and workers satisfying specific conditions are preferentially assigned according to the selected method.

In the next invention, the plurality of conditions include three conditions, of which the first condition is that the work ability is the highest, and the second condition is that the work load time accumulated in the past is obtained. And the sum of the load time of the assigned work scheduled in the future is the smallest, and the third condition is that
It is characterized in that the past defect rate is minimum.

According to the present invention, a work process requiring a high ability is set based on the first condition with priority given to the ability, and a simple work process in which anyone can work is performed under the second condition. Is set based on the load level, and the work process that requires attention so that the defect rate does not increase further is set based on the third condition based on the minimum defect rate.

[0022]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Embodiments of a process management method and a process management apparatus according to the present invention will be described below in detail with reference to the drawings.

Embodiment 1 FIG. 1 is a functional block diagram showing one configuration example of the process management device according to the present invention. The process management device 1 has a work record 2 for each worker in each work process.
Result input processing unit 11 for input processing, and a work result management unit 1 for storing the work results input by the work result input processing unit 11 for each work process and for each worker
2. It has a schedule processing unit 20 for calculating a production schedule based on work results stored in the work result management unit 12.

The work record 2 is input to the process control device 1 by an input device such as a keyboard connected to the process control device 1.

The schedule processing unit 20 includes a marginal failure rate setting unit 21 for setting a marginal failure rate, which is an allowable limit of the failure rate, in advance for each work process, and a work of an arbitrary work process during calculation of the production schedule. When there are a plurality of vacant workers that can be assigned to the same, the defect rate in the past work results in the work process for each of those workers is determined by the marginal defect rate preset in the marginal defect rate setting unit 21. Comparing, and based on the comparison result, a defect rate comparison processing unit 22 for extracting an operator smaller than the marginal defect rate, and when there is one or more workers extracted by the defect rate comparison processing unit 22,
One more worker is extracted from among them based on another priority (for example, the past defect rate is the smallest or the work ability is the highest), and the work is extracted in the work process. An operator assignment processing unit 23 for assigning the assigned workers is provided.

The schedule processing section 20 outputs an output 3 of a schedule result which can be taken out after all the schedule processing is completed, to a display device such as a monitor or a printing device such as a printer.

Each functional unit of the process management apparatus 1 having the above functions is realized by, for example, a microprocessor operating according to a process management program stored in an external storage device such as a ROM or a disk storage device.

FIG. 2 and FIG. 3 are flowcharts showing an example of the process management method according to the present invention. Here, as an example, in an arbitrary work process N, a worker 1, a worker 2,..., And a worker m are registered, and work 1, work 2,. Assume that it is assigned to workers. However, it is assumed that the marginal defective rate y of the work process N is set in advance by an operator who is a process manager. After extracting the workers whose defect rate is smaller than the marginal defect rate, the work is allocated to the worker having the smallest defect rate among the workers who are available at the earliest time at the time of the schedule planning. Shall be.

When the process management processing according to the present invention is started, first, assuming that a variable for counting the number of workers is j, the j is initialized to 1 (step S1 in FIG. 2). Here, the variable j also serves as a number unique to each worker (hereinafter, referred to as a worker identification number). That is, for example, a worker who may be in charge of the work related to the process
If there are people, they are worker 1, worker 2, worker 3 and worker 4.

Subsequently, it is determined whether or not the check of the defect rate of all the workers who can take charge of the work process N has been completed (FIG. 2).
Step S2). At this time, the defect rate is checked one by one in the order of the worker with the lowest worker identification number. As will be described later, each time one check is completed, the variable j is incremented by one, and then the worker identification number becomes one. Only move to the big worker check. Therefore, the values m and j of the maximum numbers among the worker identification numbers of all the workers registered for the work process N are compared, and when the value of j becomes larger, the failure of all the workers is determined. It is determined that the rate check has been completed.

Subsequently, for the worker having the worker identification number j, the failure rate in the past certain period in the work process N is compared with a preset marginal failure rate y, and the failure rate of the worker is determined to be the marginal failure rate y It is determined whether it is smaller than (Step S3 in FIG. 2). As a result, all the workers registered with respect to the work process N have 2
The group is divided into two groups, that is, a group having a smaller defective rate than the marginal defective rate y and a group having a larger defective rate.

For the worker whose failure rate is determined to be smaller than the marginal failure rate y in step S3, the worker identification number and the failure rate for a fixed period in the past are stored in an array of work assignment worker candidates (FIG. 2 step S4). Then, the value of the variable j also counting the number of workers is incremented by 1 (step S5 in FIG. 2). Step S3
For the operator determined that the defect rate is larger than the marginal defect rate y, the process skips step S4 and proceeds to step S5, where the value of the variable j is incremented by one.

Thereafter, following step S5, the process returns to step S2, and it is determined whether or not the defect rate check has been completed for all the workers. Thereafter, this series of processing is repeatedly performed until the defect rate check for all workers is completed. Then, when the defect rate check of all the workers is completed (step S2 in FIG. 2), it is determined whether or not there is stored data in the array of the work assignment worker candidates (step S2 in FIG. 2).
6). If it is determined that there is no saved data, an error process is performed when there is no work assignment worker candidate (step S7 in FIG. 2). On the other hand, if it is determined in step S6 that there is stored data, the process proceeds to step S8 in FIG.

Assuming that a variable for counting the number of works to be allocated is i, the i is initialized to 1 (step S8 in FIG. 3). Here, the variable i also serves as a number unique to each work (hereinafter, referred to as a work identification number). That is, when there are nine works related to the process management processing, for example, work 1, work 2, work 3, ..., work 8, and work 9 are performed.

Subsequently, it is determined whether or not the allocation of all the operations performed in the operation process N has been completed (step S in FIG. 3).
9). At this time, the work is assigned one by one in ascending order of the work identification number. As will be described later, each time the assignment of one work is completed, the variable i is incremented by one. Only move to a larger work assignment. Therefore, the value n of the maximum number among the work identification numbers for all the works in the work process N and the value of i are compared, and when the value of i becomes larger, it is determined that the allocation of all the works is completed. When the assignment of all the operations is completed, the process management process being executed is ended.

On the other hand, if all the work has not been allocated in step S9, the worker among the workers (stored in step S4 in FIG. 2) stored in the work allocation worker candidate array has the highest number. A worker who is available early is searched for (step S10 in FIG. 3).

Subsequently, as a result of the search performed in step S10, it is determined whether or not a plurality of workers are available at the earliest time (step S11 in FIG. 3). This is because, when two or more workers become available at the same time at the earliest time, it is necessary to determine to which worker the work i is to be assigned in a later process.

When there are a plurality of vacant workers to which the work i is to be allocated, a worker having the lowest defect rate in a past fixed period is selected from the plurality of vacant workers to be assigned to the work i. Allocate work i (Step S1 in FIG. 3)
2). On the other hand, if there is only one vacant worker, the work i is assigned to the only vacant worker (step S13 in FIG. 3).

When the assignment of the work i is completed, the value of the variable i also serving as a count of the number of work is incremented by 1 (step S14 in FIG. 3), and the process returns to step S9 again.
It is determined whether or not all work has been allocated. Thereafter, step S is performed until the assignment is completed for all the operations.
The series of processing from step 9 to step S14 is repeated, and when all the work has been allocated, the series of processing ends.

FIGS. 4 to 6 are tables for explaining an example of work assignment. Here, in the work process N, for example, work 1, work 2,..., Work 8 and work 9 are performed, and these nine works are registered by the work process N, for example, worker A , Worker B, worker C, and worker D are appropriately and sequentially allocated. In addition, each work 1, 2, ..., 9
It is assumed that the work time required to perform the above is calculated in advance by the following calculation formula, for example. That is, (working time) = (quantity) × (processing time per piece).

Further, the marginal defective rate of the work process N is set in advance by the operator, for example, 2% (0.
02). Also, each worker A, B, C,
The working time, break time, and transition time to the next work of D are not considered here.
Registered workers A, B, C, and D are not registered in other work processes, or are registered in other work processes but are not assigned work in that work process, that is, empty status. Assume that

FIG. 4 shows, for each of the workers A, B, C, and D, the work performance of each worker in a certain past period (for example, the past week), that is, the number of non-defective products in the work process N in that period. The number of defective products and the defective rate are shown. According to FIG. 4, the number of non-defective products, the number of defective products, and the defect rate of the worker A are 1,000, 15, and 1.48%, respectively, and the number of non-defective products, the number of defective products, and the defect rate of the worker B are 900, respectively. , 16 and 1.75%, and the number of non-defective products, the number of defective products, and the defective rate of the worker C are 120, respectively.
The number of non-defective products, the number of defective products, and the defective rate of the worker D are 900, 20, and 1.64%, respectively.
And 2.17%. Such past work results are managed by the work result management unit 12 of the process management device 1 shown in FIG. Note that the defect rate is obtained from the following formula. That is, (defective rate) = (number of defective products) / ((number of non-defective products) + (number of defective products)) × 100 [%].

FIG. 5 shows the information stored in the array of the work assignment worker candidates. Each of the workers A, B, C, and D is processed by the defect rate comparison processing unit 22 of the process management apparatus 1 shown in FIG.
As a result of comparing the past failure rate of D (see FIG. 4) with the marginal failure rate of 2%, the past failure rates of the workers A, B, and C are smaller than 2%. It is stored in the array with the value of each defect rate. However, the past defect rate of worker D is 2.17%,
Since the marginal defect rate exceeds 2%, it is not stored in the array of the work assignment worker candidates.

FIG. 6 shows an example of the result of work schedule assignment. This is performed for each of the workers A, B, and C stored in the work assignment worker candidate array by the worker assignment processing unit 23 of the process management apparatus 1 shown in FIG. Each work is sequentially allocated while checking the defect rate of a certain period in the past for each user. An operator can output the schedule result shown in FIG. 6 and display it on a display device, or can confirm the result by printing with a printing device.

The time chart shown in FIG. 6 will be described. At the planning start time t0 instructed by the operator, all of the workers A, B and C are vacant workers, and therefore, the worker A (FIG. 5, the first work 1 is assigned to the defective rate 1.48), and the second work 2 is assigned to the worker C (see FIG. 5, defective rate 1.64) having a small defective rate in the past fixed period. The third work 3 is assigned to the worker B (see FIG. 5, the defect rate 1.75) having the highest defect rate in the past fixed period.

Thereafter, the worker C finishes the work 2 at the earliest time t1 after the time t0 and becomes free, so that the next work 4 is allocated to the worker C at the time t1. Thereafter, since the worker B completes the work 3 at the earliest time t2 after the time t1, the work B is assigned to the next work 5 at the time t2. Then, since the worker A finishes the work 1 at the earliest time t3 after the time t2 and becomes free, the next work 6 is allocated to the worker A at the time t3. Subsequently, since the worker C finishes the work 4 at the earliest time t4 after the time t3 and becomes vacant, the time t4
, The next work 7 is assigned to the worker C.

In this state, at the earliest time t5 after the time t4, both the workers A and B complete the respective allocating works 6 and 5, and become vacant workers. Therefore, the next work 8 is assigned to the worker A because the defect rate of the worker A in the past fixed period is smaller than that of the worker B (see FIG. 5), while the next work 9 is assigned to the worker B. Can be Thus, the assignment of all the operations in the operation process N is completed.

According to this embodiment, in consideration of the defect rate generated in the past work for each worker in each work process, in the next production scheduling, the worker having a small defect rate is preferentially assigned. In situations where the occurrence of defects is unacceptable, such as when raw materials and parts are scarce or expensive, the possibility of occurrence of defects is further reduced, or the number of defective products is reduced when the number of defective products is low and productivity is low. Thus, productivity can be improved.

Embodiment 2 FIG. 7 is a functional block diagram showing another example of the configuration of the process management device according to the present invention.
Note that the same components as those of the device 1 shown in FIG. 1 are denoted by the same reference numerals, and description thereof will be omitted. This process management device 101
Are stored in the work result input processing unit 11, the work result management unit 12, the worker assignment method setting unit 113 for setting the method 104 for assigning a worker to the work of each work process, and the work result management unit 12. A schedule processing unit 120 is provided for calculating the production schedule based on the work results and the assignment method set by the operator assignment method setting unit 113.

The worker allocation method 104 is not particularly limited when extracting the workers to be assigned to the work of each work process. For example, a method that prioritizes the ability of the worker, a method that prioritizes the leveling of the load, In addition, there is a method of giving priority to a worker having the smallest past defect rate for the target work, and these are alternatively selected. The work record 2 and the worker assignment method 104 are input to the process management device 101 by an input device such as a keyboard and a mouse connected to the process management device 101.

The schedule processing unit 120 determines whether the marginal failure rate setting unit 21, the failure rate comparison processing unit 22, and one or more workers extracted by the failure rate comparison processing unit 22 have one or more workers.
A worker assignment process for extracting one more worker from among them based on the assignment method set by the worker assignment method setting unit 113 and assigning the extracted worker to work in the work process. The unit 123 is provided.

The schedule processing section 120 outputs a schedule result output 3 which can be taken out after all the schedule processing is completed, to a display device such as a monitor or a printing device such as a printer.

When extracting a specific worker from a plurality of workers, a worker assignment processing unit 123 assigns a priority to the worker with a higher ability to assign a schedule. Leveling priority allocation processing 125 for allocating a schedule so as to level the load of the work, and a minimum defect rate priority allocation processing for allocating a schedule to a worker who has the lowest past defect rate for the work to be allocated in the work process. 126 is executed.

Each functional unit of the process management apparatus 101 having the above functions is realized by, for example, a microprocessor operating according to a process management program stored in an external storage device such as a ROM or a disk storage device.

FIG. 8 is a flowchart showing a part of another example of the process management method according to the present invention, and shows a routine for performing a work assignment process. Here, as an example,
In an arbitrary work process N, worker 1, worker 2,...
, And the worker m are registered, and when the work 1, the work 2,..., And the work n are sequentially assigned to each worker, the failure rate is set to a marginal failure rate y (preset by the operator. After the extraction of the workers smaller than), each of the workers is assigned to each worker based on the assignment method set by the worker assignment method setting unit 113 shown in FIG. I do.

Therefore, in the process management method according to the second embodiment, the main flow of the process management method according to the flowcharts shown in FIGS.
Steps S12, S13, and S14 are the same, and the description thereof will be omitted. Step S12 in the flowcharts shown in FIGS. 2 and 3 will be referred to as "execution of a work assignment routine". What is necessary is just to execute a "work assignment routine".

When there are a plurality of vacant workers to be assigned the work i in step S11 shown in FIG. 3, the work assignment routine shown in FIG. 8 is started. When this subroutine is started, first, an operator assignment method previously input and set by the operator is obtained from the operator assignment method setting unit 113 shown in FIG. 7 (step S1).
21).

Whether the acquired worker allocation method is prioritized for the ability of the worker (step S122) or not is prioritized for leveling the load of the worker (step S12).
3) It is determined whether or not the priority is given to the minimum defect rate of the worker (step S124). Step S12
In the case where the priority is given to the worker in 2, the work i is assigned to the worker having the highest ability in the work process N among the idle workers. If priority is given to the worker's load leveling at step S123, the work i is assigned to the worker who has the smallest sum of the past cumulative work actual load time and the scheduled load time from now on among the idle workers. Assign Alternatively, if the minimum defect rate of the worker is prioritized in step S124, the work i is assigned to the worker having the smallest past defect rate in the work process N among the vacant workers.

Then, it conforms to any of the allocation methods in steps S122 to S124, and
7, when the work i is allocated, the process returns to the main routine shown in FIGS. Step S12
If it does not conform to any of the allocation methods of 2 to S124, error processing is performed when the operator allocation method is other than the predetermined method.

FIGS. 9 and 10 are charts for explaining an example of work assignment when the worker assignment method is “employee priority of worker”. In this example, similarly to the first embodiment, for example, nine works 1, 2,..., 9 in the work process N are assigned to the four registered workers A, B, C, D in the work process N. It is assumed that they are allocated appropriately and sequentially. It is assumed that the work results of the registered workers A, B, C, and D in the work process N in the past fixed period, that is, the number of non-defective products, the number of defective products, and the defect rate are the same as the respective numerical values shown in FIG. Further, the marginal defective rate is, for example, 2%, and the work time, the break time, the transition time to the next work, etc. of each of the workers A, B, C, and D, and the registration in the other work process are performed as described above. The same as in the first mode.

FIG. 9 shows the abilities of the workers A, B, C, and D in the work process N. Here, as for the abilities of each worker in the work process N, it is assumed that the operator sets an arbitrary numerical value in consideration of the work speed, the work experience time, and the like, and it is assumed that the higher the numerical value, the higher the ability. According to FIG. 9, the capability of the worker A is 10
The abilities of the worker B are 90, and the abilities of the workers C and D are both 80.

FIG. 10 shows an example of the result of assigning work schedules in the “worker's ability priority” method based on the ability of each worker shown in FIG. FIG.
The time chart shown in FIG. At the planning start time t0 instructed by the operator, the worker A and the worker B
And the worker C are both vacant workers. The worker D is not included in the work assignment because the past failure rate (2.17%) exceeds the marginal failure rate (2%).

At t0, the first work 1 is assigned to the worker A (the ability 100, see FIG. 9) having the highest ability among the workers A, B, and C, and then the ability is the second highest. The second work 2 is assigned to the worker B (see FIG. 9, ability 90), and the third work 3 is assigned to the worker C (see FIG. 9, ability 80) with the lowest ability.

Thereafter, since the worker B finishes the work 2 at the earliest time t11 after t0 and becomes free, the next work 4 is allocated to the worker B at t11. Thereafter, since the worker C finishes the work 3 at the earliest time t12 after the time t11 and becomes vacant, the worker C is given the next work 5 at the time t12.
Is assigned. Then, since the worker A finishes the work 1 at the earliest time t13 after the time t12 and becomes free, the next work 6 is allocated to the worker A at the time t13. Subsequently, since the worker B finishes the work 4 at the earliest time t14 after the time t13 and becomes empty, the next work 7 is allocated to the worker B at the time t14.

In this state, the earliest time t15 after t14
In the above, both the workers A and C complete the respective allocating operations 6 and 5, and become vacant workers. Therefore, since the worker A has a higher ability than the worker C (see FIG. 9), the next work 8 is assigned to the worker A, while the next work 9 is assigned to the worker C. Thus, the assignment of all the work in the work process N by the "worker's ability priority" method is completed.

FIGS. 11 to 13 are tables for explaining an example of work assignment when the worker assignment method is “worker load leveling priority”. In this example, similarly to the first embodiment, for example, 9
.., 9 are assigned to the four registered workers A, B, C, D of the work process N in an appropriate order. Registered workers A, B, in work process N
The work results of C and D in the past fixed period, that is, the number of non-defective products, the number of defective products, and the defect rate are the same as the respective numerical values shown in FIG. The marginal defective rate is, for example, 2%, and each worker A, B,
The registration time in the other work processes, such as the working time of C and D, the break time, the transition time to the next work, and the like, are the same as those in the first embodiment.

FIG. 11 shows the cumulative actual work load time of each of the workers A, B, C, and D during the past fixed period. According to FIG. 11, the cumulative work actual load time of the worker A in the past fixed period is 100 hours, the cumulative work actual load time of the worker B in the past fixed period is 95 hours, and the workers C and Worker D
Are 90 hours in both cases.

FIG. 12 shows the standard work time for each work in the work process N. According to FIG. 12, the standard operation time of each of the work 1, the work 3, the work 6, and the work 8 is 2
The standard work time of each of work 2, work 5, work 7 and work 9 is 1 hour, and the standard work time of work 4 is 3 hours. It is assumed that the standard work time is calculated in advance by the following formula, for example. That is, (standard operation time) = (quantity) × (processing time per piece).

FIG. 13 shows a “worker load leveling priority” method based on the cumulative actual work load time of each worker in the past fixed period shown in FIG. 11 and the standard time of each work shown in FIG. An example of the result of work schedule assignment is shown. The time chart shown in FIG. 13 will be described. At the planning start time t0 instructed by the operator, all of the workers A, B and C are idle workers. The worker D is not included in the work assignment because the past failure rate (2.17%) exceeds the marginal failure rate (2%).

At t0, of the workers A, B and C, the first work 1 is given to the worker C (90 hours, see FIG. 11) with the smallest cumulative work load time in the past fixed period. Is assigned, and then the worker B who has a small cumulative work result load time in the past fixed period
(See FIG. 11, 95 hours), the second work 2 is allocated, and the third work 3 is allocated to the worker A (see, FIG. 11, 100 hours) having the largest cumulative work load time in the past fixed period. Can be

Thereafter, the worker B finishes the work 2 at the earliest time t21 after the time t0 and becomes free, so that the next work 4 is allocated to the worker B at the time t21. Thereafter, both the worker A and the worker C complete the work 3 and the work 1 respectively at the earliest time t22 after t21, and become vacant workers. Therefore, the worker A and the worker B compare the sum of the cumulative actual work load time in the past fixed period and the standard work time of the work already allocated in the current work allocation.

For the worker A, the cumulative actual work load time in the past fixed period is 100 hours (see FIG. 11).
Since the standard work time of the work 3 already allocated this time is 2 hours (see FIG. 12), the total of them is 1
02 hours. On the other hand, for the worker C, the cumulative work load time during the past fixed period is 90 hours (FIG. 11).
Since the standard work time of the work 1 already assigned this time is 2 hours (see FIG. 12), the total of them is 92 hours. Therefore, at t22, the next work 5 is assigned to the worker C whose total work time is smaller, and the next work 6 is assigned to the worker A.

Thereafter, since the worker C finishes the work 5 at the earliest time t23 after the time t22 and becomes empty, the next work 7 is allocated to the worker C at the time t23. afterwards,
At the earliest time t24 after t23, the workers A, B, and C complete the work 6, the work 4, and the work 7, respectively, and become vacant workers. Therefore, the sum of the accumulated actual work load time in the past fixed period and the standard work time of the work already allocated in the current work allocation is compared between the worker A, the worker B, and the worker C.

For the worker A, the cumulative actual work load time in the past fixed period is 100 hours (see FIG. 11).
Since the standard work times of the work 3 and the work 6 already assigned this time are each 2 hours (see FIG. 12), the total of them is 104 hours. For the worker B, the accumulated actual work load time in the past fixed period is 95 hours (see FIG. 11), and the standard work times of the work 2 and the work 4 already allocated this time are 1 hour and 3 hours, respectively (see FIG. 11). 12), so their sum is 99 hours. As for the worker C, the cumulative actual work load time in the past fixed period is 90 hours (see FIG. 11), and the standard work times of the work 1, the work 5 and the work 7 already allocated this time are 2 hours and 1 hour, respectively. Since the time is one hour and one hour (see FIG. 12), the sum of them is 94 hours.

Therefore, at t24, the next work 8 is assigned to the worker C with the smallest total working time, and the next work 9 is assigned to the worker B with the smallest total working time. As described above, the assignment of all the work in the work process N by the “worker load leveling priority” method is completed.

The case where the worker allocation method is “priority to the minimum defect rate of the worker” is the same as that described in the first embodiment with reference to FIGS. .

According to this embodiment, the method of assigning the worker for each work process is the “worker's ability priority” method,
Choose from the "worker load leveling priority" method and the "worker's minimum defect rate priority" method, and assign workers according to the selected method. Workers with the ability can be assigned, and in a simple work process where anyone can work, the workers can be assigned so that the workload among each worker is averaged, and the defect rate is further reduced. In a work process in which care must be taken so as not to be high, an operator with a lower defect rate can be assigned. In other words, since the assignment method of the workers can be appropriately selected and set according to the work content and the degree of difficulty in each work process, it is possible to perform a wide range of worker assignment according to the request and situation at that time, The load on an operator who performs production scheduling can be reduced.

The worker allocation method is not limited to the “worker's ability priority” method, the “worker load leveling priority” method, and the “worker's minimum defect rate priority” method. It can be appropriately selected according to the contents.

As described above, in the present invention, the process control apparatus is not limited to the above description and examples shown in the drawings, and it goes without saying that various design changes can be made. Alternatively, by applying the present invention to a machine tool or the like instead of an operator, the present invention can also be applied to a case where a machine having the smallest past defect rate is assigned to each work process.

[0080]

As described above, according to the process management method of the present invention, the defect rate in the next production scheduling is considered in consideration of the defect rate generated in the past work for each worker in each work process. Priority is given to workers with small defects, so the possibility of occurrence of defects is further reduced in situations where the occurrence of defects is unacceptable, such as when raw materials and parts are scarce or expensive, or when there are many defective products, When the performance is reduced, the effect is obtained that the number of defective products can be reduced and the productivity can be improved.

According to the process management method of the next invention,
Select the method of assigning workers for each work process and assign priority to workers who meet specific conditions according to the selected method.Assignment of workers according to the work content and difficulty in each work process Since the method can be selected and set as appropriate, a wide range of worker assignment can be performed according to the request and situation at that time, and the effect of reducing the load on the operator who performs production scheduling can be obtained.

According to the process management method of the next invention,
By assigning priority to work processes that require high skills, it is possible to assign skilled workers, and for simple work processes where anyone can work, priority is given to load leveling. By doing so, the work load among each worker can be averaged, and the work process that needs to be careful so that the defect rate does not become Can be further reduced.

According to the process management apparatus of the next invention,
For each worker in each work process, the defect rate generated in the past work is taken into consideration, and in the next production scheduling, the worker with a low defect rate is assigned preferentially, so when raw materials and parts are small or expensive In a situation where the occurrence of defects is not acceptable, the possibility of occurrence of defects is further reduced, and when the number of defective products is low and the productivity is reduced, the number of defective products is reduced and the productivity is improved. Is obtained.

According to the process management apparatus of the next invention,
A worker assignment method is selected for each work process, and workers who meet specific conditions are preferentially assigned in accordance with the selected method.Therefore, workers are assigned according to the work content and difficulty in each work process. Is appropriately selected and set, so that a wide range of worker assignment is performed according to the demands and situations at that time, and the effect of reducing the load on the operator who performs production scheduling is obtained.

According to the process management apparatus of the next invention,
Work processes that require high abilities are set to prioritize abilities, so that capable workers are assigned,
In addition, it is necessary to pay attention to the level of priority for load leveling for simple work processes that can be performed by anyone, so that the work load among each worker is averaged and the defect rate does not increase. The work process is set to give priority to the minimum defect rate, thereby further reducing the possibility of occurrence of defects.

[Brief description of the drawings]

FIG. 1 is a functional block diagram showing one configuration example of a process management device according to the present invention.

FIG. 2 is a flowchart illustrating a first half of an example of a process management method according to the present invention.

FIG. 3 is a flowchart showing a latter half of an example of the process management method according to the present invention.

FIG. 4 is a chart for explaining an example of work assignment by a process management method according to the present invention.

FIG. 5 is a chart for explaining an example of work assignment by a process management method according to the present invention.

FIG. 6 is a chart for explaining an example of work assignment by a process management method according to the present invention.

FIG. 7 is a functional block diagram illustrating another configuration example of the process management device according to the present invention.

FIG. 8 is a flowchart showing a work assignment routine that forms part of another example of the process management method according to the present invention.

FIG. 9 is a chart for explaining an example of work assignment when the worker assignment method is “employee's ability priority” in the process management method according to the present invention.

FIG. 10 is a chart for explaining an example of work assignment when the worker assignment method is “employee's ability priority” in the process management method according to the present invention.

FIG. 11 is a table for explaining an example of work assignment when the worker assignment method is “priority for load leveling of workers” in the process management method according to the present invention.

FIG. 12 is a table for explaining an example of work assignment when the worker assignment method is “priority for load leveling of workers” in the process management method according to the present invention.

FIG. 13 is a chart for explaining an example of work assignment when the worker assignment method is “prioritize worker load leveling” in the process management method according to the present invention.

[Explanation of symbols]

1, 101 process management device, 11 work result input processing unit, 113 worker assignment method setting unit, 12 work result management unit, 20, 120 schedule processing unit, 21
Marginal failure rate setting unit, 22 failure rate comparison processing unit, 23, 1
23 worker allocation processing section, 124 ability priority allocation processing, 125 load leveling priority allocation processing, 126
Minimum defect rate priority allocation processing, input of work results,
3 Output of schedule result, 104 Input of worker assignment method.

Claims (6)

[Claims] 1. A past defect rate in a work process for all workers who can be in charge of a certain work process is acquired, and the obtained failure rate and a limit failure rate which is a maximum allowable defect rate are obtained. A step of performing a comparison, and searching for an operator who is available at the earliest time among the workers whose failure rate is equal to or less than the marginal failure rate, and the past failure rate is the minimum among the workers corresponding to this. Selecting a worker and assigning the work to the worker. 2. Obtain past defect rates in the work process for all workers who can take charge of a certain work process, and calculate the obtained defect rate and a limit defect rate which is a maximum allowable defect rate. A step of performing a comparison, searching for the worker who is available at the earliest time among the workers whose failure rate is equal to or less than the marginal failure rate, and selected from a plurality of conditions from among the workers corresponding thereto; Selecting a worker who satisfies a specific condition, and allocating the work to the worker. 3. The plurality of conditions include three conditions, of which the first condition is that the work ability is the highest, and the second condition is that the work load time accumulated in the past and the future work load time are 3. The process management method according to claim 2, wherein the total of the assigned load times of the assigned work is the smallest, and the third condition is that the past failure rate is the minimum. 4. Obtaining past defect rates in all the work processes for all workers who can take charge of a certain work process, and calculating the obtained defect rate and a limit defect rate which is a maximum allowable defect rate. A defect rate comparison processing unit that performs comparison, and searches for an operator who is available at the earliest time among the workers whose defect rate is equal to or less than the marginal defect rate, and selects a past defect rate from the workers corresponding to the defect rate. A worker assignment processing unit for selecting a worker having the smallest number and assigning the work to the worker. 5. A past defect rate in a work process is acquired for all workers who can take charge of a certain work process, and the obtained failure rate and a limit failure rate which is a maximum allowable defect rate are obtained. A defect rate comparison processing unit that performs comparison, and searches for an operator who is available at the earliest time among the workers whose defect rate is equal to or less than the marginal defect rate, and among the workers corresponding to the defect rate, a plurality of conditions A worker assignment processing unit that selects a worker who satisfies a specific condition selected from the above, and assigns the work to the worker. 6. The plurality of conditions include three conditions, of which the first condition is that the work ability is the highest, and the second condition is that the work load time accumulated in the past and the future work load time 6. The process management apparatus according to claim 5, wherein the total of the assigned load times of the assigned work is the smallest, and the third condition is that the past failure rate is the minimum.