JP3255038B2 - Work simulation device - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION In a normal production line, a plurality of workers are located along a work transfer path such as a conveyor.
Each worker performs a work previously assigned to the worker on the conveyed work, thereby producing a product by a flow operation system or a division of labor system.
The assignment of work to each worker needs to be performed properly. If the work is improperly performed, the load is concentrated on a specific worker, or the tact or the cycle time is over. Also, the work assigned to each worker is usually a set of several elementary works, and the execution order of the elementary work must also be determined properly.
If this is improperly determined, what is in time for the cycle time may not be in time. In recent years, a plurality of types are often made separately on a single production line. For example, when products are produced in the order of A → B → C → A, the work is appropriately performed for each worker for each product type. It is necessary to allocate it definitely. That is, the so-called mixed production line is a production line in which a plurality of workers separately perform a plurality of types of products by performing work assigned to each worker for each type of production on a work to be conveyed. It turns out that. The present invention develops an apparatus for simulating the progress of work in this mixed production line, thereby facilitating accurate determination of work allocation, element work execution sequence, and the like.

[0002]

2. Description of the Related Art Japanese Unexamined Patent Publication No. 5-54017 discloses a technique for determining the order of execution of elemental work groups when the group of elementary work is temporarily allocated to each worker. According to the technology described in this publication, regarding the execution order of the element work assigned to one worker, an executable order is set as an order candidate. And for each order candidate,
Calculate the time required for the worker to walk, taking into account the movement position of the work when working in that order, and calculate the time required to complete the element work group assigned to one worker I do. And among the candidates for that order,
Find the order that minimizes the total work time described above. If this is completed within the cycle tom, the allocation is correct, and if the element work is performed in the determined order, it is understood that the work is completed within the cycle time. On the other hand, if there is no order that can be completed within the cycle time, it is determined that the work allocation is inappropriate, and the above processing is re-executed after reviewing the allocation, whereby an appropriate allocation is found.

[0003]

The above-described technique is based on the premise that the assigned work is completed within a cycle time for all the production types, and each worker puts the next work in his or her own work space. Only the situation of waiting for the next work to be transferred and starting work on the next work is considered. However, in the case of multi-product production or mixed production, even if the workload for a particular type is slightly high, it is feasible as a whole if the workload for the next type is low. ing. The prior art described above does not consider such a situation at all, and a simulation according to the actual situation has not been obtained. According to the present invention, the simulation from the end of the work on the previous work to the start of the work on the next work is included in the simulation target, so that a more realistic simulation can be performed. In addition, the order of production types during mixed production is also made a target that can be simulated, and the rationality of the order can be verified.

[0004]

SUMMARY OF THE INVENTION The present invention, in order to solve the above problems, a device for simulating the work progress of the mixing production line, each production type, each work
Memorize the work time required for work assigned to the worker
And means for storing the order of production types.
Work assigned to one worker for one work
Based on the work position or time when the work was completed,
Calculate the work start position or time for the ranked work
Means, means for calculating a walking prohibited area, and
Avoid the walk prohibited area from the start position and reach the walk end position
Walking route calculation means for calculating a walking route to perform.
Workers proceed with the assigned work according to the order of production type.
The situation to be continued continuously across multiple workpieces
Work simulation characterized by accumulating data
Provide equipment. This simulation device includes, from the end of the work on one work to the start of the work on the next work, in the simulation target. As a result of simulating the work for the type of the work later, it is possible to cumulatively simulate the work on the mixed production line, and a simulation result corresponding to the actual situation is obtained. In addition, this simulation
The motion device includes a means for calculating a walking prohibited area,
The trader avoids the walking prohibited area from the walking start position and ends walking.
Walking route calculation means for calculating the walking route to the end position
Have. According to this, for example, a worker
Even if you have to walk away
Simulation corresponding to the detour walking performed in
It becomes possible.

[0005]

DESCRIPTION OF THE PREFERRED EMBODIMENTS In this simulation apparatus,
The work start position for the next work, taking into account not only the position of the worker at the end of work for one work but also the work site at the end of work in that work and the work start site for the next work Alternatively, it is preferable to calculate time.
In this way, a simulation for a case where the worker must walk depending on the work site in one work, such as a large work, for example, the body of an automobile, is performed more accurately. In this simulation apparatus, it is preferable that an image display means for displaying the position of the workpiece and the worker being transported over time is added. According to this, the work status is visually displayed over time, and the analysis work is facilitated. Further, it is preferable that a means for detecting whether or not the work position or time when the work assigned to one worker for one work is completed is within an allowable value is added. According to this, the delay of the operation is detected by the simulation device, and the possibility of the delay is easily found. Further, it is preferable to add a means for detecting whether two or more workers work at the same position at the same time. according to this,
A situation in which workers cannot work due to interference with each other is likely to be found. Further, the walking route calculating means includes means for calculating two tangents passing through the walking start position and contacting the prohibited walking area and two tangents contacting the walking prohibited area and passing through the walking ending position. It is preferable to include means for calculating one walking route candidate, and means for setting a shorter walking distance from the two calculated candidates as a walking route. The walking route obtained in this way matches well with the detour walking route where the worker actually walks, and an accurate simulation can be performed.

[0006]

Next, an embodiment of the present invention will be described with reference to FIGS. First, the configuration of the main part of the work simulation apparatus will be described with reference to FIG. FIG. 1 is a block diagram illustrating a main part of a work simulation device 2 according to the present embodiment. FIG.
As shown in (1), the work simulation apparatus 2 of the present embodiment is mainly configured by a central processing unit (CPU) 4 and a storage device 20. The CPU 4, the storage device 20, and the keyboard 6, the mouse 8, the color display 1
0, a printer 12, a scanner 14, and an F / D (floppy disk) drive 16 are connected to each other by a bus 18 so that data can be transferred therebetween. In the storage device 20,
In addition to the program 22 that executes a series of processes described below,
RAM work area 24, work result data file 2
6, storage areas for the work interference data file 28 and the line stop data file 30 are secured.

Next, a specific example of a schematic diagram of a production line displayed on the screen of the color display 10 in the work simulation apparatus 2 of the present embodiment will be described with reference to FIG. As shown in FIG. 2, in the production line 32 on the screen in the present embodiment, a carry-in lifter 34 is displayed at the left end of the screen, and the production line center line 36
Extends straight to the carry-out lifter 50 at the right end. Vehicle bodies 38 to 38 serving as workpieces are arranged on the center line 36 at regular intervals. On both sides (up and down on the screen) of the production line 32, component shelves 44 to 44 are arranged everywhere. Further, two fixed facilities 46 and two automatic facilities 48 are arranged as automatic machines. For the automatic equipment 48, the movable range is displayed. Workers 40 to 40 are arranged along the center line 36 between these component shelves 44 to 44 and the like. In addition, fixed positions 42 to 42 drawn on the floor are displayed on the actual production line as a reference for the position of the work (car body) 38 to be conveyed. This fixed position line 42
Is the reference position of the work when the front wheel position of the vehicle body 38 is located at the front of the vehicle body 38. In FIG.
8 is in the reference position. In this screen, the position of the work 38 and the position of the worker 40 move based on the result of the simulation described later.

Next, the contents of data input prior to execution of a simulation in the work simulation apparatus 2 of the present embodiment will be described with reference to FIG. 2 and FIGS. First, a tact, a pitch, a work zone width, a walking speed of a worker, and a work allowance are input as data relating to the entire production line. The tact is a cycle in which the automobile body 38 as a work is transported, and is equal to a cycle time. The pitch is a distance between the car bodies 38 to be conveyed. The pitch divided by the tact is equal to the moving speed of the work. In the present embodiment, the pitch is equal. The work zone width is a distance from the center line 36 of the production line to the parts shelf 44, and is indicated by a symbol W in FIG. In addition, in this embodiment, the walking speed of the worker is the same for all workers, but a different value can be input for each worker. The work allowance is a distance at which the worker is allowed to start work before the vehicle body 38 reaches the reference position. For example, if the distance of “2 m” is set and the work on the preceding work is completed in a short time, the worker may start work on the next vehicle from 2 m before reaching the reference position. Allowed.

Next, FIG.
As shown in (A), a set, a process, and a process position are input. The set is the number of the team to which the worker belongs, and the process is the serial number of the process in charge of each worker in the team. Therefore, if a set and a process are specified, a certain worker will be specified. Also, the process position defines the position where each worker actually works, as shown in FIG. 3B, by the number of works from the end of the production line and the left and right with respect to the work transfer direction. It was done. For example,
“1-R” indicates a position on the right side of the work closest to the carry-in lifter 34, and “3-L” indicates a position on the left side of the third work from the carry-in lifter 34.

Next, data relating to the work is input for each of the workers whose data has been input as described above. FIG.
As shown in (A), the data related to the work includes a procedure number, a work name, a work time, a work part, a model correspondence, and an option code. The procedure number is a serial number of the work, the work name is the name of the work, and the work time indicates the time required for the work in seconds, and does not include the walking time, the waiting time, and the like. As shown in FIGS. 4 (B) and 4 (C), the work part defines a part for performing a work on the vehicle body by a code. FIG. 4B is a code showing a work site when the vehicle body is placed on the floor,
FIG. 4C is a code showing a work site when the vehicle body is in a suspended state. In addition, the parts shelf has the code "G
G ". The vehicle type correspondence is defined by a code for each vehicle type as to whether or not to always carry out the work. The model is indicated by 1, 2,..., K. If the code is “S”, the work is always performed for the model, and if the code is “N”, the work is not performed for the model.
In the case of the code "P", if the option is provided, it indicates that the work is performed. The option code indicates the number of the corresponding option for this option operation. FIG. 4 (A) shows a group of elementary tasks shared by each worker, and illustrates that the assignment is different for each production type.

Next, data relating to the vehicle type is input.
As shown in FIG. 5A, the data relating to the vehicle type includes a vehicle type number, a picture code, and the number of products produced. The model number is a serial number assigned to each vehicle type, and the picture code is a picture code of a car displayed on the screen corresponding to the model number. The production volume is the number of vehicles produced in a certain period for each vehicle type. As the picture code data, as shown in FIG. 5B, there are data on the overall length, the full width, and the front wheel position of the car. The data of this picture code is
It is used as data indicating a walking prohibited area described later.

Next, data relating to the option is input. As shown in FIG. 6, data relating to options include an option number, an option name, the presence or absence of an option for each model, and the number of options produced.
The option number is a serial number of the option and corresponds to the option code in FIG. The presence or absence of an option for each model is defined by a code as to whether or not the option is normally attached to the model. If the code is "S", the option is always attached to the model and the code "N""Indicates that the option is not available for that model. Further, the code "P" indicates that there is a car with an option and a car with no option for that model. In other words, it means that the option is available with a certain probability for the model. The number of options produced is the sum of the number of vehicles to which the option is attached for all types of vehicles over a certain period. The order of the types to be produced on the production line is determined by the number of production units, and the higher the number of production units, the higher the frequency of production. To explain with a simple example, when 20 units of type 1 and 10 units of type 2 are produced, the cycle of 1 → 1 → 2 is repeated. Instead of inputting the production order by the number of production units, the production order can be directly input.

Now, with the various data shown in FIGS. 3 to 6 being input, a simulation is performed by the work simulation apparatus 2 of the present embodiment. Next, the details of the processing in the work simulation apparatus 2 of the present embodiment will be described with reference to the flowcharts of FIGS. First, the overall processing procedure will be described with reference to the flowchart in FIG.
When the process is started in step S2 of FIG. 7, first, each worker and each work (vehicle) on the screen are respectively shown in FIG.
2, the coordinates (Xn,
(Yn) (Step S4). Then, the value of (Xn, Yn) is substituted as a new value of the coordinates (X, Y) indicating the position of each worker and each work (step S6). Subsequently, in the subroutine of step S8, the next stage of coordinates (Xn, Yn), various states, and other calculations are executed for each worker and each work.

The specific contents of this subroutine are shown in the following flowcharts. The calculation for the worker (step S10), the calculation for the work (step S12), and the check for work interference (step S10)
14), a line stop check (step S16). These steps S1 included in step S8
0, step S12, step S14, step S16
After all of the subroutines have been executed, it is determined whether to stop the simulation (step S1).
8). If this determination is YES, the simulation is stopped and the process ends (step S20). If this determination is NO, to continue the simulation,
After one second has elapsed, the process returns to step S4. As described above, the arithmetic processing in the present embodiment is executed in units of one second. That is, the position and the state of the worker and the work are calculated every one second.

Next, the overall flow of the calculation (step S10) for the operator in the subroutine will be described with reference to FIG. When the process is started in step S22 in FIG. 8, it is first determined whether or not the work is delayed somewhere on the production line. That is, it is determined whether any of the assembled vehicles exceeds the downstream limit (step S24). In this embodiment, the state in which the front wheel position of the vehicle body 38 has reached the home position line 42 in the next process is defined as the downstream limit. If this determination is YES,
After passing through a "line stop occurrence subroutine" (step S26) whose specific contents are shown in FIG.
The process proceeds to step S28, and if the determination is NO, the process directly proceeds to step S28. In step S28, it is determined what the value of the “state” that is a variable related to the worker is currently. The values of this "state" include "work", "standby",
There are three types of "walking". Depending on the value of this "state",
From step S28, "walking subroutine" (step S28)
30), "standby subroutine" (step S32),
The process proceeds to any one of the “work subroutine” (step S34). Thereafter, the process returns to step S18 in FIG. 7 (step S36).

Although FIG. 8 shows that the subroutine "work", "standby" or "walk" is executed only once according to the value of "state", the routine returns. Actually, as described below, since each subroutine includes another subroutine, the process returns to step S18 in FIG. 7 after following a complicated path. On the other hand, if the value of the “state” is other than “work”, “standby”, and “walking” in step S28, it is determined that an abnormality has occurred and an error message is output (step S38), and the simulation is stopped (step S38). S40).

Next, the contents of the "line stop occurrence subroutine" shown in step S26 of FIG. 8 will be described with reference to FIG.
This will be described with reference to FIG. When the process is started in step S42 of FIG. 9, it is first determined whether or not the production line is currently stopped. This determination is based on whether the "state" which is a variable for the production line is "stopping" (step S44). If this determination is YES, the stoppage of the production line due to the work delay (step S24 in FIG. 8) is not the current stage but has already occurred at the previous stage, so no processing is performed. The process directly returns to step S28 in FIG. 8 (step S54). On the other hand, if the determination in step S44 is NO, since the stop of the production line has occurred at the present stage, the "state" of the production line is set to "stopping" (step S46). Then, the current time is recorded as the line stop occurrence time in the line stop data file 30 of FIG. 1 (step S48). Further, the "set" and "process" of the corresponding worker are recorded in the line stop data file 30 of FIG. 1 as the cause of the line stop (Step S).
50), the line stop time is set to 1 second (step S52), and the process returns (step S54).

Next, the contents of the "walking subroutine" shown in step S30 of FIG. 8 will be described with reference to FIG. When the process is started in step S56 in FIG. 10, it is first determined whether or not the worker has arrived at the destination (ie, the walking end position). This judgment is
The current coordinates (X, Y) of the worker are the coordinates of the destination (X, Y).
Y) is performed based on whether or not it matches. The coordinates (X, Y) of the destination are obtained as a function f1 of the “target” and the work position of the current work, and the “target” is a function f2 of the car currently being worked and the work position of the current work. (Step S58). The “target” may be a component shelf. The coordinates (X, Y) of the destination are shown in FIG.
2, it may be obtained. In FIG. 22, t
0 indicates the end of the work in the part R1, and t1 indicates the start of the work in the part R4. At this time, t1
Is determined by a function of t0, the previous work site, the current work site, the transfer speed of the work, and the walking speed of the worker.
The coordinates of the destination that should have arrived at 1 are also determined. Similarly, t2 indicates the end of the work on one work, and t3 indicates the start of the work on the next work. In this case as well, the coordinates of the destination are determined. In this case, the pitch between the works is used for the calculation. If the determination in step S58 of FIG. 10 is YES, the worker has arrived at the destination, and the "walking end subroutine" (step S66) whose contents are shown in FIG. 11 is executed. Subsequently, a "waiting subroutine" whose contents are shown in FIG.
After the execution of (Step S68), the process returns from Step S36 in FIG. 8 to Step S18 in FIG. 7 (Step S64). On the other hand, if the determination in step S58 is NO, the worker has not arrived at the destination,
You need to continue walking. Therefore, "walking time"
Is added (step S60), and the walking time data is stored in the work result data file 26 of FIG. Then, the contents are shown in FIG.
After the "Y) subroutine" (step S62) is executed, the process returns from step S36 in FIG. 8 to step S18 in FIG. 7 (step S64).

Next, the contents of the "walking end subroutine" shown in step S66 of FIG. 10 will be described with reference to FIG. When the process is started in step S70 of FIG. 11, it is first determined whether or not work interference has occurred. That is, the coordinates (X,
It is determined whether there is another worker having the same coordinates (X, Y) as (Y) (step S72). As described above, since a worker who can afford can start the work quickly within the work allowance distance, the workers may interfere with each other in position. If this determination is YES, the "state" of this interference is set to "ongoing" (step S74), and the interference time is set to 1 second (step S76). Further, the data of the interference occurrence time, the interference location, the interference vehicle type, and the set, process, procedure, and work name of each interference work are recorded in the work interference data file 28 of FIG.
78), the “state” of the worker is set to “standby” (step S80), and the process returns to step S68 of FIG. 10 (step S82). On the other hand, if the determination in step S72 is NO, the process directly proceeds to step S80, where the "state" is set to "standby" and the process returns (step S8).
2).

Next, the contents of the "next (X, Y) subroutine" shown in step S62 of FIG.
This will be described with reference to FIG. When the process is started in step S84 of FIG. 12, first, coordinates (X, Y) of the destination are calculated (step S86). Destination coordinates (X,
Y) is obtained as a function f1 of the “target” and the work position of the current work, and “target” is obtained as a function f2 of the car currently being worked and the work position of the current work.
The “target” may be a component shelf. In the case illustrated in FIG. 22, the timing t1 at which the worker reaches the work site R4 is obtained from the time t0, the previous work site R1, the current work site R4, the work transport speed, and the worker's walking speed.
Is determined, and at the timing t1, the work site R
The position (X, Y) where 4 is located is determined. This is set as the coordinates (X, Y) of the destination. In the case of the present embodiment, since the work is moving at the same speed, the work position is known if the timing is known, and the timing is known if the work position is known. That is, the position and time of the work are 1: 1.
Is associated with. Subsequently, the movement amount (dx, dy)
Is calculated. The movement amount (dx, dy) is obtained as a function f3 of the coordinates of the destination, the speed of the target, and the walking speed. Then, by adding the calculated movement amount (dx, dy) to the coordinates (X, Y) of the position of the worker, the coordinates (Xn, Yn) of the next position are obtained (step S).
88). That is, Xn = X + dx and Yn = Y + dy. Further, since the walking distance accompanying this movement is obtained as the square root of the value of (dx ² + dy ² ), this walking distance is added to the previous walking distance and stored in the work result data file 26 of FIG. (Step S90).
Then, the process returns to step S64 in FIG. 10 (step S92), and returns from step S36 in FIG. 8 to step S18 in FIG.

Next, the contents of the "standby subroutine" shown in step S68 of FIG. 10 will be described with reference to FIG. When the process is started in step S94 of FIG. 13, it is first determined whether or not a work start condition is satisfied. This determination is made based on whether or not the vehicle has passed the work startable point (step S96). Here, the work start possible point means that the work is located on the left side of the work allowance distance from the reference position shown in FIG. 2, and the work start condition is set when the front wheel position of the vehicle body 38 reaches this work start possible point. Holds. NO in step S96
If the work start condition is not satisfied,
One second is added to the waiting time (step S98), and the data of this waiting time is stored in the work result data file 26 of FIG. Subsequently, the “next (X, Y)” shown in FIG.
A "subroutine" is executed (step S100). Thereafter, the process returns to step S64 in FIG. 10 (step S102), and further returns from step S36 in FIG. 8 to step S18 in FIG.

On the other hand, if the determination in step S96 is YES, the work time, which is the input data shown in FIG. 4A, is substituted into the variable TC (time counter) from that of the procedure number 1 (step S104). ). Subsequently, the "state" of the worker is set to "work" (step S106), and FIG.
4 is executed (step S108). Thereafter, the process returns to step S64 in FIG. 10 (step S102), and further returns from step S36 in FIG. 8 to step S18 in FIG.

Next, the contents of the "work subroutine" shown in step S108 of FIG. 13 will be described with reference to FIG. When the process is started in step S110 of FIG. 14, it is first determined whether or not a variable TC (time counter) is zero (step S112). TC = 0
If this is the case, one operation has been completed.
A "work end subroutine" whose contents are indicated in (1) is executed (step S122). Thereafter, a “walking subroutine” whose contents are shown in FIG. 10 is executed (step S
124), the process proceeds from step S102 in FIG.
0, and the process returns from step S36 in FIG. 8 to step S18 in FIG. 7 (step S120). On the other hand, if the determination in step S112 is NO, that work is still being executed, so a value obtained by subtracting one second from the variable TC is substituted for TC (step S11).
4) Add 1 second to the work time (step S11)
6), this work time data is stored in the work result data file 26 of FIG. After that, the "next (X, Y) subroutine" whose contents are shown in FIG. 12 is executed (step S118), and then the steps S102 and S102 in FIG.
Step S64 in FIG. 10 and step S36 in FIG.
Is returned to step S18 in FIG. 7 (step S120).

Next, the contents of the "work end subroutine" shown in step S122 of FIG. 14 will be described with reference to FIG. This work end subroutine is shown in FIG.
It is executed every time the element work indicated by the procedure number (A) ends. When the process is started in step S126 in FIG. 15, it is first determined whether or not there is a next element work in the vehicle (step S128). This judgment is YES
If so, the work content shifts to that of the next procedure number in FIG. 4A (step S130), and the "state" of the worker is set to "walk" (step S132). Then, the process returns to step S124 of FIG. 14 (step S13).
4). On the other hand, if the determination in step S128 is NO, it means that the work in the car has been completed, and the assembly target of the worker is shifted to the next car (step S136).
The determination in step S128 is performed for this new car.
Normally, this determination is YES, and the processing from step S130 is performed.

Next, the contents of the "vehicle calculation subroutine" shown in step S12 of FIG. 7 will be described with reference to FIG. When the process is started in step S138 of FIG. 16, it is first determined whether or not the production line is operating (step S140). This determination is made based on whether or not the “state” of the production line described in FIG. 9 is “stopped”. If this determination is YES, (X +) is set as Xn of the next coordinate (Xn, Yn) for the car.
(Pitch / tact). As shown in FIG. 2, since the production line 32 is conveyed horizontally on the screen, the value of Yn is always constant for a vehicle.
Then, the process returns to step S12 of FIG. 7 (step S144). On the other hand, if the determination in step S140 is NO
In the case of, since the production line is stopped and the car on the screen does not move, the process returns to step S18 in FIG. 7 (step S144).

Next, the contents of the "interference check subroutine" shown in step S14 of FIG. 7 will be described with reference to FIG.
This will be described with reference to FIG. When the process is started in step S146 of FIG. 17, it is first determined whether or not there is any interference (step S148). This determination is made based on whether or not there is an interference whose “state” is “ongoing” described with reference to FIG. This judgment is YE
If S, it is determined whether or not the interference still continues (step S150). This determination is made based on whether or not (X, Y) of two or more interfering workers is the same even at present. If the determination is YES, one second is added to the interference time of the interference (step S152), and the data of the interference time is stored in the work interference data file 28 of FIG. Thereafter, the process returns to step S18 in FIG. 7 (step S154). On the other hand, step S150
Is NO, the "state" of the interference is set to "end" (step S156), and the process returns to step S18 in FIG. 7 (step S154). Also,
If the determination in step S148 is NO, there is no interference, and the process directly returns to step S18 in FIG. 7 (step S154).

Next, the contents of the "line stop check subroutine" shown in step S16 of FIG.
This will be described with reference to FIG. Step S158 in FIG.
Is started, it is first determined whether or not the line is currently stopped (step S160). This determination is made based on whether or not the “state” of the production line described in FIG. 9 is “stopped”. This judgment is YES
If so, it is determined whether or not the line stop is still continued (step S162). This determination is made based on whether or not the vehicle installed by the worker causing the stop exceeds the downstream limit. If the determination is YES, one second is added to the stop time of the line stop (step S164), and the data of the stop time is stored in the line stop data file 30 of FIG. Thereafter, the process returns to step S18 in FIG. 7 (step S16).
6).

On the other hand, if the determination in step S162 is NO, the worker who caused the line stop is recorded in the line stop data file 30 of FIG. 1 by "set" and "process" (step S168). . Thereafter, the “state” of the production line is set to “in operation” (step S170), and the process returns to step S18 in FIG. 7 (step S166). If the determination in step S160 is NO, the line is in operation, and the process returns to step S18 in FIG. 7 (step S160).
166).

Now, specific examples of simulation results obtained by the processing performed according to the flowcharts of FIGS. 7 to 18 will be described with reference to FIGS.
This will be described with reference to FIG. FIGS. 19 to 21 are tables showing specific simulation results in the work simulation apparatus 2 of the present embodiment. First, FIG.
The data obtained for each worker is shown. As described above, one worker is specified by the “set” and the “process”. In FIG. 19, the walking distance, walking time, working time,
Each data of the waiting time is shown. For example, for a worker of 311 sets and one process, 4
000 seconds, walking distance 1523, walking time 108
It can be seen that 0 seconds, work time was 2888 seconds, and wait time was 32 seconds. Of these data, the walking distance is shown in FIG.
Step S90, the walking time is the same as step S6 in FIG.
0, the working time is obtained in each process of step S116 in FIG. 14, and the waiting time is obtained in each process of step S98 in FIG.
Is stored in the work result data file 26.

Next, FIG. 20 shows data obtained for the line stop. FIG. 20 shows the data of the occurrence time, the stop time, and the cause of the stop obtained for each line stop that has occurred. For example, the first line stoppage occurs 115 seconds after the start of the simulation, and the time during which the line stoppage is continued is 12 seconds. It can be seen that the cause of the stoppage is the 311 group and 5 process workers. Among these data, the occurrence time is obtained in step S48 in FIG. 9, the stop time is obtained in step S164 in FIG. 18, the cause of the stop is obtained in each process in step S168 in FIG. 18, and stored in the line stop data file 30 in FIG. It is a thing.

Next, FIG. 21 shows data obtained on work interference. FIG. 21 shows the data of the interference occurrence time, the interference time, the interference location, the interference vehicle type, and the interference work obtained for each of the generated work interferences. For example, the first interference occurs 108 seconds after the start of the simulation, the duration of the interference is 3 seconds, and the work position where the interference occurs is R2 in FIG. 4B. In addition, the number of the vehicle models in which the interference occurred was 2, and the work of “installation of right Fr door W / H” in procedure 5 of 312 sets and the procedure of “right Fr door striker” in procedure 7 of 6 steps of 312 sets were performed.
It can be seen that this work interfered. Among these data, the interference occurrence time, the interference location, the interference vehicle type, and the interference work are shown in step S78 in FIG. 11, and the interference time is shown in step S78 in FIG.
152, and are stored in the work interference data file 28 of FIG.

Based on the simulation results shown in FIGS. 19 to 21, the operator can prevent the line stop and the work interference from occurring, and can determine the walking distance,
The next simulation is performed by updating the input data so that the walking time is as short as possible and the waiting time is as short as possible within a range in which the cycle time does not occur. Specifically, as a measure to prevent the line stoppage, it is conceivable to transfer a part of the work of the worker who caused the line stoppage to another worker (a person who has a long waiting time). Further, as a measure for preventing work interference, it is conceivable to replace one work procedure of the work that has interfered. Or change the order of the types to produce.

As described above, in the work simulation apparatus 2 of the present embodiment, a simulation is executed according to the processing procedures shown in FIGS. 7 to 18 based on the input data shown in FIGS. Through FIG.
A simulation result as shown in FIG. That is, according to the flowchart of FIG. 8 whose specific contents are shown in FIGS. 9 to 15, the arithmetic processing for the walking, standby, and work of the worker is performed, and simulation data of the work result whose example is shown in FIG. 19 is obtained. Can be Also,
According to the flowchart of FIG. 16, the calculation processing of the movement of the vehicle, which is the work, is performed. Further, a calculation process for work interference is performed according to the flowcharts of FIGS. 11 and 17, and simulation data of work interference whose example is shown in FIG. 21 is obtained. In addition, the arithmetic processing for the line stop is performed according to the flowcharts of FIGS. 9 and 18, and simulation data of the line stop, an example of which is shown in FIG.

Next, an embodiment in which the above embodiment is improved will be described. In this embodiment, the target position (walking end position) is obtained by the method described with reference to FIG. In this case, a simulation result is obtained in which an operator sometimes moves across a workpiece on the drawing. Therefore, the embodiment described below is improved so that the simulation can be performed in accordance with the detour walking actually performed by the operator. FIG. 24 shows an example of the walking prohibited area. The walking prohibited area is determined based on, for example, the size and shape of a work, equipment, and the like, and is offset outward by a half width of the worker's body. For example, regarding the item point P4, since the actual work item point is P4 ′, it indicates that the worker cannot walk inside the item point P4. FIG. 23 shows a process obtained by improving the process of FIG.
S232 has been added. Note that the same processes as those in FIG. 15 are denoted by the same step numbers, and redundant description is omitted. In step S230, it is determined whether or not a line (DL in FIG. 24) that linearly connects the current position of the worker and the destination is within the walking prohibited area PW. If not, detour walking is not necessary, and as in the previous embodiment, step S
Proceed to 134. When one is present, the avoidance points are stored in order for detour walking (S232). The avoidance points are sequentially stored as follows. First, as shown in FIG. 24, two tangent lines L1 and L2 that pass through the current worker position and contact the walking prohibited area PW are obtained. At this time, if the walking prohibited area PW is a polygon, the line connecting the current position and each item point and having the largest angle from the direct line DL described above is defined as a tangent. Next, the walking prohibited area PW
Tangent lines L passing through the destination (walking end position) in contact with
3, L4 is obtained. As a result, two alternative walking route candidates are obtained. In other words, a route detouring clockwise from L1 to L4 and a route detouring counterclockwise from L2 to L3 are obtained as candidates. The route between the tangents is a route along the walking prohibited area PW.
Now, the total length of each of the two candidates thus obtained is obtained, and the shorter one is set as the detour walking route.
In the case of FIG. 24, the detour route in the counterclockwise direction is shorter, goes to the point P5 along the tangent line L2, and moves from the point P5 to the point P.
4, a route from P3 to the destination along the tangent line L3 is defined as a detour route. In step S232 in FIG. 23, the avoidance points thus obtained are stored in order. In the case illustrated in FIG. 23, the avoidance point is P5.
P4 and P3 are stored in this order. FIG. 25 shows a process in which the process of FIG. 12 is improved for a simulation for detour walking. Step S248 is for determining whether or not the avoidance point is stored. If the avoidance point is not stored (this corresponds to the case where the worker can go straight without bypassing), the process of FIG. The processing is exactly the same. On the other hand, when the avoidance point is stored, a process (S250 to S254) of simulating a state of walking toward the avoidance point is added. In step S250, it is determined whether or not the vehicle has arrived at the avoidance point, and the coordinates of the worker are updated so that the worker moves toward the avoidance point until the vehicle arrives at the avoidance point (S250).
254). When reaching the avoidance point, the avoidance point is erased from the storage, and the next avoidance point stored is set as the first avoidance point (S252). Thereafter, the process returns to step S248.
As a result of the above processing, when it is necessary for the worker to make a detour, the worker moves the coordinates while making a detour through the avoidance point, and the actual work and the simulation match very well. As a result, the accuracy of the simulation is improved as a whole, and the presence or absence of interference, the presence or absence of a line stop, and the like can be more accurately simulated. The values of input data such as work content, work time, work position, and the like, and output data values such as walk distance, walk time, work time, and waiting time in the present embodiment are merely examples. However, the present invention is not limited to this. The configuration, function, number, connection relationship, and the like of other parts of the work simulation device are not limited to the present embodiment. Further, in this embodiment, the work allowance is set on the left side of FIG. 2 to allow the work to be started earlier, but the work allowance is set to the right to allow the work to be delayed within a certain range. Is also good. Work margins may be provided on both the left and right sides.

[0035]

According to the present invention, a more accurate simulation can be performed by taking into account the type of work that has been performed immediately before in each process.

[Brief description of the drawings]

FIG. 1 is a block diagram showing a configuration of a main part of an embodiment of a work simulation apparatus according to the present invention.

FIG. 2 is a diagram showing specific work contents in an embodiment of the work simulation apparatus.

FIG. 3 is a diagram showing an example of input data in an embodiment of the work simulation apparatus.

FIG. 4 is a diagram showing an example of input data in an embodiment of the work simulation apparatus.

FIG. 5 is a diagram illustrating an example of input data in an embodiment of the work simulation apparatus.

FIG. 6 is a diagram illustrating an example of input data in an embodiment of the work simulation apparatus.

FIG. 7 is a flowchart illustrating a procedure of processing performed in an embodiment of the work simulation apparatus.

FIG. 8 is a flowchart illustrating a procedure of processing performed in an embodiment of the work simulation apparatus.

FIG. 9 is a flowchart illustrating a procedure of a process performed in an embodiment of the work simulation apparatus.

FIG. 10 is a flowchart illustrating a procedure of a process performed in an embodiment of the work simulation apparatus.

FIG. 11 is a flowchart illustrating a procedure of processing performed in an embodiment of the work simulation apparatus.

FIG. 12 is a flowchart illustrating a procedure of processing performed in an embodiment of the work simulation apparatus.

FIG. 13 is a flowchart illustrating a procedure of processing performed in an embodiment of the work simulation apparatus.

FIG. 14 is a flowchart illustrating a procedure of processing performed in an embodiment of the work simulation apparatus.

FIG. 15 is a flowchart illustrating a procedure of a process performed in one embodiment of the work simulation apparatus.

FIG. 16 is a flowchart illustrating a procedure of processing performed in an embodiment of the work simulation apparatus.

FIG. 17 is a flowchart illustrating a procedure of processing performed in an embodiment of the work simulation apparatus.

FIG. 18 is a flowchart illustrating a procedure of processing performed in an embodiment of the work simulation apparatus.

FIG. 19 is a diagram showing a specific example of a result of processing in one embodiment of the work simulation apparatus.

FIG. 20 is a diagram illustrating a specific example of a result of processing in one embodiment of the work simulation apparatus.

FIG. 21 is a diagram showing a specific example of a result of processing in one embodiment of the work simulation apparatus.

FIG. 22 is a diagram schematically showing a relationship between a work end position and a work start position.

FIG. 23 is a diagram showing a processing procedure obtained by improving the processing of FIG. 15 in consideration of detour walking.

FIG. 24 is a diagram showing a relationship between a detour route and a walking prohibited area.

FIG. 25 is a diagram showing a processing procedure corresponding to the processing of FIG. 12 improved so as to be able to simulate a situation during detour walking.

[Explanation of symbols]

 2 Work simulation device 32 Production line 38-38 Work 40-40 Worker

──────────────────────────────────────────────────続 き Continued on the front page (58) Field surveyed (Int. Cl. ⁷ , DB name) B23P 21/00 307 B23Q 41/08

Claims (2)

(57) [Claims] A plurality of workers are provided on a workpiece to be transported.
However, the work assigned to each worker for each production type
By doing this, you can make multiple types of products
Equipment that simulates work progress on the production line
, And the requirements for each production type, the work that is allocated to each worker
Means for storing the working time to be performed, means for storing the order of the production type, and means assigned to one worker for one work.
Based on the work position or time when the work is completed,
Calculate the work start position or time for the next work
Means for calculating a prohibited walking area, and means for allowing a worker to walk while avoiding the prohibited walking area from the walking start position.
Walking route calculation means for calculating a walking route reaching the end position
And the work assigned by the workers according to the order of the production type.
Continuous progress over multiple workpieces
Work simulation characterized by cumulative accumulation
Device. 2. The work simulation according to claim 1.
In the apparatus, the walking route calculating means may include a walking start position.
Tangent line and ban area that touch the ban area through
For calculating two tangents passing through the walking end position in contact with the area
Steps and two walking route candidates including the calculated tangent are calculated.
And a short walking distance from the calculated two candidates.
Work including means for setting the walking path to
Simulation device.