JP4655702B2 - Production management apparatus, production management method, and production management program - Google Patents

Description

  The present invention relates to a case where a product is once removed from the production line, such as when a product having a defect is ejected from the production line, the product is reworked and re-entered into the production line. The present invention also relates to a production management apparatus, a production management method, and a production management program for managing the presence / absence of the removed product and the removed time.

  In general, when a product is produced, a production plan is made in consideration of the production procedure of the product, the number of man-hours, the schedule, the procurement of parts, the delivery date of the product, and the like. Then, the production activity of the product is performed based on the production plan, while the progress of the production is managed to comply with the delivery date. Here, regarding management of production progress etc., for example, in Patent Document 1 below, for each of a plurality of work areas in the vehicle production process, the vehicle tracking data indicating the permutation state of the vehicles in the work area is used. An apparatus for correcting to match the actual permutation state is disclosed.

  The apparatus disclosed in the following Patent Document 1 is said to be at the exit based on the vehicle identification number actually obtained at the exit obtained from the detection means provided at the exit of the work area and the vehicle tracking data relating to the work area. If these identification numbers do not match, the vehicle identification number actually at the exit of the work area is extracted from the vehicle tracking data related to the work area where the identification number originally existed. Thus, the vehicle tracking data relating to the work area is moved to the beginning. With this configuration, it is possible to automatically correct the vehicle tracking data of a plurality of work areas in the vehicle production process so as to match the actual permutation state of the vehicles in those work areas.

  In addition to the following Patent Document 1, technologies relating to production management are disclosed in, for example, the following Patent Documents 2 to 4.

JP-A-6-144318 JP 2003-241819 A JP 2000-24848 A JP-A-8-174390

  By the way, if a defect such as a quality defect is found in each work area, for example, the product with the defective part is temporarily ejected out of the production line and repaired (hereinafter simply referred to as an operator). Are reworked, and after the defect is resolved, it is reintroduced into the production line.

  Here, when the defective product is ejected as described above, it is necessary to accurately detect whether or not the defective product is ejected in order to grasp which product has the defect. There is. Also, in order to prevent delays in the actions necessary for observing the delivery date (for example, priority work, overtaking production, overtaking correction, etc.), each defective product is ejected from the production line until it is re-introduced. You need to know exactly how long it took. That is, when a product is temporarily removed from the production line, which product is removed (whether or not the removed product is generated) and how long the product (removed product) is removed from the production line. It is necessary to know whether it was in a state (removal state time).

  However, in the apparatus disclosed in Patent Document 1, when the actual vehicle permutation state and the vehicle permutation state based on the vehicle tracking data are different, it is impossible to accurately grasp whether the factor is due to the generation of the removed product. It was. Moreover, even if the reason why the permutation state is different is only due to the generation of the removed product, for example, the repairing process from when the defective product pops out until it is re-introduced, that is, the removed product processing step that is once removed from the production line In the meantime, the rejected defective products are repaired in the order in which they are ejected, and are not necessarily re-entered into the production line in the order in which they are ejected. Therefore, it has not been possible to directly manage not only the occurrence of removal (splash occurrence) but also the removal state time (time during the rework process) for individual products during the rework process.

  In addition, when repairs are performed, information related to the time required for repairing each defective product (removal state time) is input to the production management device that manages the production line by the operator himself. It is also possible to directly manage the presence / absence of re-input (presence / absence of removed product) and the removal state time.

  However, for example, in a production line that produces a new product, there is a high possibility that a failure will occur. Therefore, it is often the case that a defective product is continuously present on the production line. In such a case, if the defective product is continuously ejected, the next defective product will be ejected during the input work related to the previous defective product, and the input work will not be able to catch up. Therefore, this input work is a heavy burden.

  In addition, if defective products are continuously splashed from one to the next, the input work related to the defective products is not performed because the input work cannot catch up or the operator concentrates on the rework work. Forgetful situations can occur. If such a situation occurs, after all, it will not be possible to accurately grasp the occurrence or non-existence of the defective product (removal occurrence) or the repair time of each defective product (removal state time). End up.

  In addition, due to the configuration of the production line, there may be a case where the space for installing the equipment for the operator to input the above information to the production management device cannot be secured near the reworking workplace. There may be a problem that it is difficult to execute the input work due to a problem in the installation space.

  An object of the present invention is to provide a production management device, a production management method, and a production management program capable of solving the above-described problems and reliably managing the occurrence of removal of each product and the removal state time of each removed product. It is in.

  The production management device of the present invention acquires the passage time passing through two passage check points on the production line for each product flowing on the production line, and refers to the actual product passage time at each passage check point. A production order management device for managing the production progress status, wherein a passage order calculating means for calculating a passage order of each product at each passage check point from a passage time of each product at each passage check point, and each passage check Based on the order of passage of each product at the point, the removed product detection means for detecting the removed product once removed from the production line between the passage check points, and the detected removed product was once removed from the production line The removal state time is set to the upstream passage check point in each passage check point, the passage order of the removal product, and the downstream before the removal product. Among the products that have passed the passage check point, the passage order at the upstream passage check point of the latest non-removed product, the number of products that have passed the downstream passage check point between the non-removed product and the removed product, and Removal state time calculating means for calculating based on the tact time of the product in the production line.

  In a preferred aspect of the present invention, when the two passage check points include another production line that once diverges from the production line and merges again, the removed product detection means includes each passage Based on the passing order of each product at the check point, in addition to the removed product once removed from the production line between each check point, other line products that flowed to the other production line were also temporarily removed from the production line. The removal state time calculating means detects the staying time when the detected staying product has once deviated from the production line, and the order of passage of the staying product at the upstream passage check point among the passage check points. , The order of passage of the latest non-retained product at the upstream pass check point among the products that have passed through the downstream pass check point prior to the stay product, the non-retained product Calculated based on the number of products passing through the downstream passage check point and the tact time of the product on the production line, and the lead time on the other production line is calculated from the residence time. If the time value obtained by subtraction is positive, this time value may be calculated as the removal state time.

  Further, in another preferred aspect of the present invention, an over-advanced product that has passed through the downstream passage check point in an order earlier than the originally planned plan order based on the passage time of each product at each passage check point. An over-advanced product detection means for detecting; and an over-advanced product information exclusion means for excluding information relating to the detected over-advanced product; After the item is excluded, the passage order at each passage check point is calculated for each product that is not excluded.

  The present invention is typically realized by causing a computer to execute a program describing the functions of the respective means described above.

  According to the present invention, it is possible to automatically and accurately extract information on the presence / absence of products (removed products) once removed from the production line and the time when each removed product was removed from the production line. This information can be directly managed. Even if there is no space to install equipment such as a passage check device near the junction or junction between the production line and the removal product processing process due to the configuration of the production line, the passage check device is located upstream of the removal product processing step. It is only necessary to install them at arbitrary points on the downstream side, and there is an advantage that the problem of the conventional installation space is solved.

  First, the configuration of a production management system according to an embodiment of the present invention will be described with reference to FIG. FIG. 1 is a diagram showing a configuration of a production management system according to an embodiment of the present invention. In the following description, the product flowing on the production line is described as a vehicle, but the type of product is not limited to this.

  In the production management system according to the present embodiment, an upstream passage check device 20a at an arbitrary point (upstream check point) A located on the previous process side (upstream line side) from the branch point from the production line 10 to the removed product processing process. However, downstream passage check devices 20b are respectively provided at arbitrary points (downstream side check points) B located on the downstream side (downstream line side) from the joining point returning from the removed product processing step onto the production line 10. . The passage check devices 20a and 20b and the production management device 50 are connected to each other via a data communication network 40 such as an in-factory LAN (Local Area Network) so that data communication is possible.

  Each passing check device 20a, 20b acquires the passing time of each vehicle 30 as the product passing time at each check point A, B on the production line 10, and uses the acquired product passing time information for each vehicle 30 as a network. 40 to the production management device 50. In FIG. 1, the passage check device 20a acquires the product passage time (hereinafter referred to as upstream point passage time) of each vehicle 30 passing through the upstream side check point A and transmits it to the production management device 50. The passage check device 20b The product passing time of each vehicle 30 passing through the downstream check point B (hereinafter referred to as downstream point passing time) is acquired and transmitted to the production management device 50.

  As this passage check device 20a, 20b, for example, by communicating with an RF (Radio Frequency) tag affixed to each vehicle 30, the vehicle 30 that has passed each check point A, B is identified, and its passage time is determined. There are devices to acquire. In this case, the RF tag attached to each vehicle 30 includes product identification information for identifying each vehicle 30 (in this embodiment, a vehicle ID number that is a product ID number) is used as an upstream check point. It is assumed that it has already been stored when passing A. In this embodiment, the passing time for each vehicle 30 is acquired by acquiring the vehicle ID number and the passing time. Here, the vehicle ID number in the present embodiment is an identification number assigned to the vehicle 30 in the order of passing through the upstream check point A, but is not limited thereto. In addition, as the passage check devices 20a and 20b, in addition to the devices described above, a human may manually input the product passage time.

  The production management device 50 in FIG. 1 includes a calculation unit 51, a communication control unit 52, an input unit 53, an output unit 54, and a storage device 55, which are connected to each other via an internal bus. The communication control unit 52 is connected to the passage check devices 20a and 20b, other computers (not shown) connected to the network 40, and the like via the network 40 so that data communication is possible. The input unit 53 is for a user to input a desired command to the production management device 50 such as a keyboard. The output unit 54 is for outputting information on the presence / absence of occurrence of a removed product and a removal state time extracted as described later, such as a display device and a printing device, to the outside of the production management device 50.

  The storage device 55 is for storing information for a predetermined period (for example, one day) of information on the product passage time for each vehicle 30 at both check points A and B for each vehicle 30. For example, FIG. A passing time table 55a having “vehicle ID number”, “upstream point passing time” and “downstream point passing time” as items 2 is stored. In addition, the storage device 55 stores information for a predetermined period (for example, one day) of information on the presence / absence of removal for each vehicle 30 and information on the removal state time (hereinafter referred to as removal information). Also, a removal information table 55b having items such as “downstream point passage order”, “vehicle ID number”, “upstream point passage order”, “removal occurrence flag”, and “removal state time” are also stored. In the present embodiment, the passage time table 55a and the removal information table 55b are stored in the same storage device 55, but the present invention is not limited to this and may be stored separately.

  The calculation unit 51 includes a passage time information registration unit 51a, a passage order calculation unit 51b, a removed product detection unit 51c, and a removal state time calculation unit 51d. Hereinafter, each part in the calculating part 51 is demonstrated.

  The passage time information registration unit 51a performs a process of storing the passage time information acquired from the passage check devices 20a and 20b in the storage device 55. Specifically, when information on passage times at both check points A and B for each vehicle 30 is acquired from the passage check devices 20a and 20b, the passage times at both check points A and B using the vehicle ID number as a key. A process of registering information for each vehicle 30 in the passage time table 55a in the storage device 55 is performed.

  The passing order calculation unit 51b obtains the passing order at both check points A and B of each vehicle 30 based on the data registered in the passing time table 55a as shown in FIG. Then, the vehicle ID numbers are registered in the “vehicle ID number” in the removal information table 55b in the storage device 55 in the order of passing through the downstream check point B, and the vehicle ID number is used as a key in the “vehicle ID number” in the removal information table 55b. The order of passing through the upstream check point A of each vehicle 30 is registered in “Upstream Point Passing Order”.

  The removed product detection unit 51c determines whether or not each vehicle 30 has been temporarily removed from the production line 10, that is, whether or not a removal has occurred, based on the registration information in the removal information table 55b as shown in FIG. A certain removed vehicle is detected. For example, the upstream point passing order of all vehicles that have passed the downstream check point B before the determination target vehicle is compared with the upstream point passing order of the determination target vehicle. If there is a vehicle that has passed the upstream check point A after the determination target vehicle among all the vehicles that have passed the downstream check point B prior to the determination target vehicle, the determination It is determined that the target vehicle has been once removed from the production line 10, and if it does not exist, it is determined that the determination target vehicle has not been removed. For the vehicle determined to be removed, the “removal occurrence flag” of the corresponding vehicle in the removal information table 55b is set to “1” (ON), and the upstream check point A on the production line 10 is not removed. As for a vehicle (direct vehicle) that is determined to have gone straight from to the downstream check point B, the “removal occurrence flag” of the vehicle in the removal information table 55b is set to “0” (OFF).

The removal state time calculation unit 51d calculates the time (removal state time) once removed from the production line 10 for each removal vehicle for the removal vehicle detected by the removal product detection unit 51c. Here, the upstream point passing order X of the target vehicle (calculation target vehicle) for calculating the removal state time, the upstream point of the nearest direct vehicle among all the vehicles that have passed the downstream check point B before this calculation target vehicle Passing order Y, the number n of vehicles passing through the downstream check point B from the time when the nearest vehicle passes through the downstream check point B until the calculation target vehicle passes through the downstream check point B, and using the tact time t _a of the product at the production line 10 of the production management system calculates the removed state time T calculated target vehicle. Specifically, the above X, Y, determined from n to remove information table 55b, and a tact time t _a of the products previously determined and these values, the equation of T = (Y-X + n ) × t a By substituting, the removal state time T of the calculation target vehicle is calculated. Then, the calculated removal state time is registered in the “removal state time” of the vehicle in the removal information table 55b.

Figure 3 is intended as an example a cycle time t _a product and 50 seconds, was calculated to remove state time using the above equation for each removal product. For example, for the vehicle ID number “A0009”, since X = 9, Y = 13, and n = 0, the removal state time T = (13−9 + 0) × 50 = 200 seconds is calculated. For vehicle ID number “A0005”, since X = 5, Y = 14, and n = 3, the removal state time T = (14−5 + 3) × 50 = 600 seconds is calculated.

  Next, processing operations performed in the production management system configured as described above will be described.

[Processing during production line operation]
First, in a situation where the production line 10 is in operation in the production management system, each of the passage check devices 20a and 20b receives the vehicle ID number of each vehicle 30 that has passed through each of the check points A and B on the production line 10 and each vehicle 30. The passage time information is transmitted to the production management device 50 via the network 40. And the passage time information registration part 51a in the calculating part 51 memorize | stores the passage time information of each vehicle 30 received via the communication control part 52 from each passage check apparatus 20a, 20b by using vehicle ID number as a key. Each vehicle 30 is registered in the passage time table 55 a in the device 55. The above processing is repeatedly performed every time a passing vehicle is generated during the production line operation, and finally, the passing time table 55a in the storage device 55 stores the passing time for a predetermined period (for example, one day). Information is registered.

[Removal information extraction process]
Then, when the production line 10 is not in operation (for example, when the operation of the day is finished), the user inputs a command to extract removal information from the input unit 53 of the production management device 50, thereby producing In the calculation unit 51 of the management device 50, removal information extraction processing is performed in the procedure as shown in FIG.

  First, when the removal information extraction command is input from the input unit 53 (step S10), the passage order calculation unit 51b sets the vehicle 30 for a predetermined period (for example, one day) registered in the passage time table 55a. Based on the passing time information, the passing order at both check points A and B for each vehicle 30 is calculated (step S11). Then, the vehicle ID numbers are registered in the removal information table 55b in the storage device 55 in the order of passing through the point B, and the upstream point passing order of each vehicle 30 is registered using each vehicle ID number as a key.

  Subsequently, the removal product detection unit 51c pays attention to, for example, the upstream point passage order of each vehicle 30 from the registration information of the removal information table 55b registered in the passage order of the downstream check point B, for each vehicle 30 as described above. Whether or not removal has occurred is determined (step S12). At this time, for a removed vehicle that has been determined to have been removed from the production line 10, the “removal occurrence flag” of the vehicle in the removal information table 55 b is set to “1” (ON), and the production line 10 is not removed. For a straight vehicle determined to have gone straight up, the “removal occurrence flag” of the vehicle in the removal information table 55b is set to “0” (OFF). If it is determined by this determination that no removal has occurred, the removal information extraction process ends (step S13).

On the other hand, when it is determined that the removal has occurred in the removed product detection unit 51c, the removal state time calculation unit 51d calculates the removal state time for each of the removed vehicles thus detected (steps S13 and S14). Here, as described above, the upstream point passing order X of the target vehicle (calculation target vehicle) for which the removal state time is calculated, and the most recent direct among all the vehicles that have passed the downstream check point B before this calculation target vehicle. Passage order Y of the upstream point of the vehicle, a vehicle that has passed the downstream check point B after the latest direct vehicle passes the downstream check point B until the calculation target vehicle passes the downstream check point B the number n, and calculates the removed state time calculation target vehicle using a tact time t _a of the product at the production line 10 of the production control system. Further, the removal state time calculated in this way is registered in the “removal state time” of the vehicle in the removal information table 55b.

  The removal state time calculation process in step S14 is performed for all detected removed vehicles, and when the removal state time is calculated for all removed vehicles, the removal information extraction process ends (step S14, S15).

  Further, the data in the removal information table 55b as shown in FIG. 3 obtained by the above-described removal state time calculation process is input by the user from the input unit 53 of the production management device 50 to output the removal information table data. Is output from the output unit 54. Thereby, the user of the production management device 50 can accurately grasp the removed vehicle and its removal state time by referring to the output removal information table data.

  As described above, according to the production management apparatus 50 in the present embodiment, removal information can be extracted automatically and accurately, and direct management can be realized. Further, due to the configuration of the production line 10, even if there is no space for installing devices such as the passage check devices 20a and 20b near the junction or junction between the production line 10 and the removed product processing step, the passage check devices 20a and 20b. There is also an advantage that the problem on the installation space of the device can be solved, because it is only necessary to install at the arbitrary point on the upstream side and the arbitrary point on the downstream side of the removal product processing step.

[Second Embodiment]
By the way, in terms of equipment installation space, for example, as shown in FIG. 5, not only the removal product processing process between the passage check devices 20a and 20b but also other production processes (options) branch from the production line 10. Each passage check device 20a, 20b may be installed so that a production line (optional production line) for performing (process) is included. However, when the optional production line is included between the passage check devices 20a and 20b as described above, if the removal information extraction process similar to that of the above-described embodiment is performed, a vehicle passing through the optional production line is mistaken as a removed vehicle. . Therefore, in order to prevent this misidentification, the lead time of the optional process is stored in advance in the production management device 50 (for example, the storage device 55), and the removal information is extracted using the lead time of the optional process. I will do it. Hereinafter, the removal information extraction process in the case where the optional process is included between the passage check devices 20a and 20b will be described with reference to FIG.

  In FIG. 6, the process from step S20 to S22 is the same as the process from step S10 to S12 of FIG. 4 in the first embodiment. However, in step S22, the type of vehicle detected is different from that of the first embodiment. That is, in the first embodiment, as a staying product that stays between check points by being removed from the production line 10 or the like (when the product is a vehicle as described in this description), Since the occurrence of stagnation is caused only by the removed product processing step, there is only a removed vehicle once removed from the production line 10. However, in this embodiment, in addition to the removed vehicle that has passed through the removed product processing step, the vehicle that has passed through the optional step is also detected as a staying vehicle. Therefore, in the present embodiment, the processing procedure is such that a staying vehicle is first detected in step S22, and a removal vehicle is detected from the staying vehicle in the subsequent steps.

  As a result of the determination in step S22, when it is determined that there is no staying vehicle, the removal information extraction process ends (step S23). On the other hand, when it is determined that there is a staying vehicle, processing is performed for each staying vehicle in the following procedure.

First, the removal state time calculation unit 51d calculates a residence time (time spent in the removal product processing step or the optional step) by the same method as in step S14 of FIG. 4 in the first embodiment. Specifically, the upstream point passing order X of the target vehicle (calculation target vehicle) for calculating the dwell time, the upstream of the nearest direct vehicle among all the vehicles that have passed the downstream check point B earlier than the calculation target vehicle. Point passing order Y, the number n of vehicles passing through the downstream check point B from the time when the nearest vehicle passes through the downstream check point B until the calculation target vehicle passes through the downstream check point B , and using a cycle time t _a of the product at the production line 10 of the production management system, calculates the residence time T ₁ of the calculated target vehicle by substituting them into equation _{T 1 = (Y-X +} n) × t a To do. Then, the lead time of the optional process is subtracted from the calculated residence time (step S24).

  Here, if the calculated value (time) is 0 or more, it is determined that this time value corresponds to the removal state time staying in the removal product processing step, and this time value is set as the removal state time of the staying vehicle. As “removed state time” of the corresponding vehicle in the removal information table 55b. Upon receipt of this calculation result, the removed product detection unit 51c determines that the staying vehicle has been once removed, and sets the “removal occurrence flag” of the vehicle in the removal information table 55b to “1” (ON). (Steps S25 and S26). On the other hand, if the obtained value (time) is a negative value, the removal product detection unit 51c receives this calculation result and determines that the staying vehicle has not been once removed, and the removal information table 55b The “removal occurrence flag” of the vehicle is set to “0” (OFF) (steps S25 and S27).

  The removal state time calculation process after step S24 is performed for all the staying vehicles, and when the removal state time is calculated and the removal vehicle is detected for all staying vehicles, the removal information extraction process ends ( Steps S24 to S28).

  As described above, even when each pass check device 20a, 20b is installed so as to include the optional process between the pass check devices 20a, 20b, the production management device 50 can automatically and accurately extract the removal information. , Direct management can be realized.

  In the second embodiment, one option process is included between the passage check devices 20a and 20b. However, a plurality of option processes may be included between the passage check devices 20a and 20b. However, when a plurality of optional processes are included, the total lead time of the plurality of optional processes is subtracted from the residence time in the process in step S24.

[Third embodiment]
Also, depending on the production line, as shown in FIG. 7, the equipment (storage) for correcting the order of products that are out of order due to the generation of removed products and differed from the original planned order to the next process before flowing to the next process. ) 60 may be provided. For example, between the painting process and the assembling process of the vehicle, the PBS (flowing to the assembling process) is corrected by temporarily removing the order from the production line 10 for reasons such as reworking between the painting processes, and flowing the vehicle to the assembling process. Painted Body Storage). In such a production line, due to a problem in the installation space of equipment, each passage check is performed in a state where not only the removal product processing step but also the storage 60 is included between the passage check devices 20a and 20b as shown in FIG. Devices 20a and 20b can also be installed.

  Then, the removal information extraction process in such a case is normally performed in place of the lead time of the optional process in the second embodiment described above, and the lead time of the process in the storage 60 (from the time when the vehicle 30 enters the storage 60 to the time of exit. The removal information can be extracted by performing the same procedure as in the second embodiment described above.

  However, in such a production line including the storage 60, for example, due to a strong request from a customer, a product requested by the customer is intentionally taken out of the storage 60 earlier than the planned order, and the customer requests. Products may be produced earlier than planned. In such a case, if a product moved forward in the order earlier than the planned order (over-advanced product) occurs, the normal direct product order will be delayed from the original planned order due to the over-progress product occurrence. This causes a problem that the direct product of the product is erroneously recognized as a stay product. Therefore, the calculation unit 51 of the production management apparatus 50 is newly provided with a product information exclusion unit 51e so as to prevent such erroneous recognition.

  In the present embodiment, the excessively advanced product information exclusion unit 51e detects a vehicle that is an excessively advanced product (an excessively advanced vehicle), and performs a process of excluding excessively advanced vehicle data from the target of the removal information extraction process. According to this, since the passing order is specified for the remaining vehicles excluding the vehicles that have advanced too much, and the removal information extraction process is performed based on the passing order, it is possible to prevent such erroneous recognition as described above. It becomes. In the present embodiment, the over-advanced product information exclusion unit 51e performs the over-advanced vehicle detection process and the over-advanced product information exclusion process. These processes are performed by separate processing units. You may be made to be. In other words, an over-advanced product detection unit (not shown) is provided, the over-advanced product detection unit detects an over-advanced product, and the over-advanced product information exclusion unit 51e only excludes information on over-advanced products. You may do it. Hereinafter, the process performed by the excessively advanced product information exclusion unit 51e will be described.

  The time required for the direct vehicle to pass through the upstream check point A and the downstream check point B (direct direct lead time) is almost the same for any direct vehicle if it is produced according to the planned sequence. Become. On the other hand, the passing lead time from the upstream check point A to the downstream check point B that the vehicle needs to travel too much should be clearly shorter than the direct passing lead time. Therefore, in the excessively advanced product information exclusion unit 51e, first, from the upstream point passing time and the downstream point passing time of each vehicle in the passing time table 55a in the storage device 55, the downstream side from the upstream check point A required for each vehicle 30. The passing lead time to the check point B is calculated, and the passing lead times of the obtained vehicles 30 are compared to detect vehicles that have traveled too much.

  Specifically, in consideration of the fact that in the actual production line, there is a slight delay in the flow of the production line with respect to the initial plan, the moving average of the passing lead time of each vehicle 30 is calculated, and the average In contrast, a vehicle whose transit lead time is shorter than a predetermined time is determined to be an excessively advanced vehicle. For example, if a graph showing a vehicle ID number, a passing lead time of each vehicle 30, a moving average line, and an allowable range that can be determined as a straight vehicle is created, and this graph has a relationship as shown in FIG. The vehicle with the number “A0003” is determined to be an excessively advanced vehicle. The allowable range based on the moving average line may be set, for example, ± 5% of the moving average value, ± 10 minutes based on the moving average value, etc. It can be adjusted. From this graph, it is also possible to determine that the vehicle with the vehicle ID number “A0007” is likely to be a removed vehicle.

  When a vehicle that has traveled too far is detected as described above, the vehicle ID number is used as a key to exclude information relating to all vehicles that have traveled too much, and the vehicle passes through both check points A and B for each vehicle 30 other than the vehicle that travels too much. The order may be calculated, and thereafter the same processing as in the first or second embodiment may be performed. For example, after passing (or deleting) the passing time information of the over-traveling vehicle, the passing order at both check points A and B for each vehicle other than the over-traveling vehicle may be calculated. According to the above processing, since the removal information is started after removing the excessively advanced vehicle, the removal information is automatically detected without erroneously recognizing the normal direct vehicle as the staying vehicle due to the excessively advanced vehicle. And accurately.

  Note that the production management apparatus in each of the above embodiments is typically realized by causing a computer system to execute a program that describes the functions and processing operations of each apparatus described above.

It is a figure which shows the structure of the production management system in 1st embodiment of this invention. It is a figure which shows an example of a structure of the passage time table of FIG. It is a figure which shows an example of a structure of the removal information table of FIG. It is a flowchart which shows the procedure of the removal information extraction process by the production management apparatus in 1st embodiment of this invention. It is a figure which shows the structure of the production management system in 2nd embodiment of this invention. It is a flowchart which shows the procedure of the removal information extraction process by the production management apparatus in 2nd embodiment of this invention. It is a figure which shows the structure of the production management system in 3rd embodiment of this invention. It is a figure for demonstrating the method of the excessive vehicle detection process by the production management apparatus in 3rd embodiment of this invention.

Explanation of symbols

  DESCRIPTION OF SYMBOLS 10 Production line, 20a, 20b Passing check apparatus, 30 Vehicle, 40 Network, 50 Production management apparatus, 51 Calculation part, 51a Passing time information registration part, 51b Passing order calculation part, 51c Removal product detection part, 51d Removal state time calculation 51e, too much product information exclusion unit, 52 communication control unit, 53 input unit, 54 output unit, 55 storage device, 55a passage time table, 55b removal information table, 60 storage.

Claims (9)

For each product that flows on the production line, obtain the passage time that passes through two passage check points on the production line, and manage the production progress by referring to the actual product passage time at each passage check point A management device,
From the passage time of each product at each passage check point, passage order calculating means for calculating the passage order of each product at each passage check point;
Based on the passing order of each product at each passing check point, a removed product detecting means for detecting a removed product once removed from the production line between each passing check point;
The detected removal product once removed from the production line, the removal order time of the removal product at the upstream passage check point in each passage check point, the downstream passage check point before the removal product Of the products that have passed through the upstream pass check point of the most recent non-removed product, the number of products that have passed through the downstream pass check point between the non-removed product and the removed product, and the production line Removal state time calculating means for calculating based on the tact time of the product,
A production management device comprising: The production management device according to claim 1,
When another production line that once branches from the production line and joins again is included between the two passage check points,
The removed product detection means is based on the order of passage of each product at each passage check point, in addition to the removed product once removed from the production line between the passage check points, another line product that has flowed to the other production line Are detected as stagnant products once off the production line,
The removal state time calculating means calculates the stay time that the detected stay product has once deviated from the production line, the passage order of the stay product at the upstream pass check point of each pass check point, and the stay product before the stay product. Among the products that have passed through the downstream pass check point, the passage order of the latest non-retained product at the upstream pass check point, and the product that has passed through the downstream pass check point between the non-retained product and the stayed product. Calculate based on the number of products and the tact time of the product on the production line, and further subtract the lead time on the other production line from the dwell time. If the obtained time value is positive, this time value is removed. Calculate as state time,
Production management device characterized by that. In the production management device according to claim 1 or 2,
Based on the passing time of each product at each passing check point, an over-advanced product detecting means for detecting an excessively advanced product that has passed through the downstream passing check point in an order earlier than the originally planned plan order;
Excessive product information excluding means for excluding information about detected excessively advanced products,
With
The passing order calculation means calculates the passing order at each passing check point for each product that is not excluded after the information regarding the excessively advanced product is excluded by the excessively advanced product information exclusion means.
Production management device characterized by that. For each product flowing on the production line, obtain the passage time passing through two passage check points on the production line, and manage the production progress status by computer by referring to the actual product passage time at each passage check point A production management method, wherein the computing unit of the computer comprises:
From a passage time of each product at each passage check point, a passage order calculation step for calculating a passage order at each passage check point of each product,
A removal product detection step of detecting a removal product once removed from the production line between the passage check points based on the passage order of the products at each passage check point;
The detected removal product once removed from the production line, the removal order time of the removal product at the upstream passage check point in each passage check point, the downstream passage check point before the removal product Of the products that have passed through the upstream pass check point of the most recent non-removed product, the number of products that have passed through the downstream pass check point between the non-removed product and the removed product, and the production line A removal state time calculating step for calculating based on the tact time of the product,
The production management method characterized by performing . 5. The production management method according to claim 4, wherein the computing unit of the computer includes:
When another production line that once branches from the production line and joins again is included between the two passage check points,
In the removed product detection step, in addition to the removed product once removed from the production line between the passage check points based on the order of passage of the products at the passage check points, another line product that has flowed to the other production line Are detected as stagnant products once off the production line,
In the removal state time calculating step, the stay time in which the detected staying product has once deviated from the production line is set as the passage order of the staying product at the upstream passage check point in each passage check point, before the staying product. Among the products that have passed through the downstream pass check point, the passage order of the latest non-retained product at the upstream pass check point, and the product that has passed through the downstream pass check point between the non-retained product and the stayed product. Calculate based on the number of products and the tact time of the product on the production line, and further subtract the lead time on the other production line from the dwell time. If the obtained time value is positive, this time value is removed. Calculate as state time,
A production management method characterized by that. The production management method according to claim 4 or 5, wherein the computing unit of the computer includes:
Based on the passage time of each product at each passage check point, an over-advanced product detection step of detecting an over-advanced product that has passed through the downstream passage check point in an order earlier than the originally planned plan order;
An over-progress product information excluding process for excluding information about detected over-progress products;
Run
In the passing order calculation step, after the information on the excessively advanced product is excluded by the excessively advanced product information exclusion step, the passing order at each passing check point is calculated for each product that is not excluded.
A production management method characterized by that. To acquire the passage time that passes through two passage check points on the production line for each product flowing on the production line, and to manage the production progress with reference to the actual product passage time at each passage check point Production management program
On the computer,
From the passage time of each product at each passage check point, a passage order calculation step for calculating the passage order of each product at each passage check point;
A removed product detection step for detecting a removed product once removed from the production line between each of the passage check points based on the passage order of each product at each passage check point;
The detected removal product once removed from the production line, the removal order time of the removal product at the upstream passage check point in each passage check point, the downstream passage check point before the removal product Of the products that have passed through the upstream pass check point of the most recent non-removed product, the number of products that have passed through the downstream pass check point between the non-removed product and the removed product, and the production line A removal state time calculating step for calculating based on the tact time of the product,
Production management program for running. In the production management program according to claim 7,
When another production line that once branches from the production line and joins again is included between the two passage check points,
In the removed product detection step, in addition to the removed product once removed from the production line between the passage check points based on the order of passage of the products at each passage check point, another line product that has flowed to the other production line Are detected as stagnant products once off the production line,
In the removal state time calculating step, the staying time in which the detected staying product has once deviated from the production line is set as the passage order of the staying product at the upstream passage check point in each passage check point, before the staying product. Among the products that have passed through the downstream pass check point, the passage order of the latest non-retained product at the upstream pass check point, and the product that has passed through the downstream pass check point between the non-retained product and the stayed product. Calculate based on the number of products and the tact time of the product on the production line, and further subtract the lead time on the other production line from the dwell time. If the obtained time value is positive, this time value is removed. Calculate as state time,
A production management program that causes a computer to execute processing. In the production management program according to claim 7 or 8,
Based on the passage time of each product at each passage check point, an over-advanced product detection step for detecting an over-advanced product that has passed through the downstream passage check point in an order earlier than the originally planned plan order;
An over-progress product information exclusion step for excluding information about detected over-progress products;
Have
In the passing order calculation step, after the information regarding the excessively advanced product is excluded by the excessively advanced product information exclusion step, the passing order at each passing check point is calculated for each product that is not excluded.
A production management program that causes a computer to execute processing.

Images