JP7791043B2 - Process planning device, process planning system, and process planning method - Google Patents

Description

The present invention relates to a process planning device, a process planning system, and a process planning method.

On a production line that produces a product, process plan information is created that assigns multiple workers to multiple tasks based on the amount of time required for tasks such as assembling and inspecting the multiple parts that make up the product. To maximize throughput and improve production line productivity, it is necessary to accurately predict the amount of time each worker will spend working, assign workers so that the difference in total work time between each worker is minimized, and eliminate waste on the production line.

On the other hand, as the workforce becomes more diverse, differences in work ability arise between workers, and the actual work time may differ for each worker even when performing the same work content. This reduces the accuracy of work time predictions, and may result in the expected production efficiency not being achieved. In order to address these differences in work ability between workers, Patent Document 1 discloses a method for predicting the work time of each worker based on production results.

JP 2010-79533 A

However, the method of Patent Document 1 does not take into account the aptitude of each worker, such as which tasks they are good at or bad at. Furthermore, the method of Patent Document 1 does not take into account changes over time, such as fatigue or boredom. As a result, the method of Patent Document 1 does not take into account the worker's state of mind, where motivation, enthusiasm, satisfaction, etc. decline over time. This state of mind can lead to a decline in product quality and an increase in worker stress, resulting in a decline in long-term labor productivity.

The present invention was developed in light of these circumstances, and aims to maintain a good state of consciousness for workers and maintain production efficiency.

This application includes multiple means for solving at least some of the above problems, examples of which are as follows:

To solve the above problem, a process planning device according to one aspect of the present invention has a mind evaluation unit that evaluates a mind evaluation value that indicates the worker's state of consciousness when performing a task based on an index that indicates the worker's work performance, and a planning unit that, if the mind evaluation value does not satisfy a criterion, plans the allocation of tasks to each worker based on the mind evaluation value that is expected to satisfy the criterion.

This invention makes it possible to maintain a good state of consciousness for workers and maintain production efficiency.

FIG. 1 is a schematic diagram showing an example of the schematic configuration of a process planning system according to this embodiment. FIG. 2 is a schematic diagram showing an example of product information. FIG. 3 is a schematic diagram showing an example of process plan information. FIG. 4 is a schematic diagram illustrating an example of production plan information. FIG. 5 is a diagram illustrating an example of the process plan information. FIG. 6 is a schematic diagram showing an example of production performance information. FIG. 7 is a schematic diagram showing an example of worker-specific work performance evaluation information. FIG. 8 is a diagram showing an example of worker-specific mindset evaluation information. FIG. 9 is a schematic diagram showing an example of workability evaluation value information. FIG. 10 is a diagram showing an example of a flowchart of the process planning method according to this embodiment. FIG. 11 is a diagram illustrating an example of a flowchart of a process for generating worker-specific work performance evaluation information. FIG. 12 is a diagram illustrating an example of a flowchart of a process for generating worker-specific mindset evaluation information. FIG. 13( a) is a schematic diagram showing an example of the working state of a worker identified by the mind evaluation unit based on production performance information, FIG. 13( b) is a schematic diagram showing an example of a graph showing the distribution of calculated actual working times for each part, FIG. 13( c) is a schematic diagram showing an example of the time progression of calculated actual working times, and FIG. 13( d) is a schematic diagram showing an example of a graph showing the distribution of calculated actual working interval times 1301 e for each part. FIG. 14 is a schematic diagram showing an example of a method for calculating the variation in work time for a part that a worker has never handled before. FIG. 15 is a schematic diagram showing an example of a screen displayed on the display unit by the planning unit. FIG. 16 is a diagram illustrating an example of a hardware configuration of a process planning apparatus according to this embodiment.

An embodiment of the present invention will be described below with reference to the drawings. In all drawings used to explain the embodiment, identical components will generally be given the same reference numerals, and repeated explanations will be omitted where appropriate. It goes without saying that, in the following embodiments, the components (including element steps, etc.) are not necessarily essential, unless expressly stated otherwise or clearly considered essential in principle. It goes without saying that when words such as "consist of A," "composed of A," "having A," or "including A" are used, they do not exclude other elements, unless expressly stated to include only that element. Similarly, in the following embodiments, when referring to the shape, positional relationship, etc. of components, etc., this includes those that are substantially similar or similar to that shape, etc., unless expressly stated otherwise or clearly considered otherwise in principle.

<Present Embodiment>
1 is a schematic diagram showing an example of the overall configuration of a process planning system according to this embodiment. The process planning system is a system that plans the allocation of tasks to each of a plurality of workers. As an example, the process planning system includes a process planning device 1000 and an external device 2000 that are connected to each other via a network N.

The network N may be, for example, a public network such as the Internet, a local area network (LAN), or a wide area network (WAN). The external device 2000 is a control device that instructs the production line to execute production.

The process planning device 1000 is a server that plans task allocation, or a computer such as a PC (Personal Computer). As an example, the process planning device 1000 has a processing unit 1100, a memory unit 1200, an input unit 1300, a display unit 1400, and a communication unit 1500.

The input unit 1300 is an input device such as a keyboard or mouse that allows a user to input various data into the process planning device 1000. The display unit 1400 is a display device such as a liquid crystal display or organic EL (Electro Luminescence) display that displays the process plan created by the process planning device 1000. The communication unit 1500 is a communication interface that connects the process planning device 1000 to the network N.

The processing unit 1100 is a functional unit that executes various processes of the process planning device 1000. In this example, the processing unit 1100 includes a process plan calculation unit 1101, a workability evaluation value calculation unit 1102, a planning unit 1103, a workability evaluation unit 1104, and a mind evaluation unit 1105.

The process plan calculation unit 1101 calculates multiple process plans that include the work sequence and work content for multiple parts that make up the product.

The workability evaluation value calculation unit 1102 calculates a workability evaluation value that indicates the work efficiency of each task included in the process plan calculated by the process plan calculation unit 1101.

The planning unit 1103 creates a process plan for allocating workers to tasks so that the number of products produced is equal to or greater than the planned production volume, based on the multiple process plans calculated by the process plan calculation unit 1101 and the production plan information 1203 described below. When planning, the planning unit 1103 allocates workers to tasks so that each worker's state of mind is good, based on the mind evaluation value (described below) that indicates the worker's state of mind.

The workability evaluation unit 1104 calculates a workability evaluation value for each worker and each part based on the workability evaluation value calculated by the workability evaluation value calculation unit 1102 and the production performance information 1205 for each worker (described below).

The mind evaluation unit 1105 evaluates the mind evaluation value, which indicates the worker's state of consciousness, for each worker based on the workability evaluation value for each worker and the production performance information 1205.

The memory unit 1200 is a functional unit that stores various information. As an example, the memory unit 1200 stores product information 1201, process plan information 1202, production plan information 1203, process plan information 1204, production performance information 1205, worker-specific workability evaluation information 1206, worker-specific mindset evaluation information 1207, and workability evaluation value information 1208.

Figure 2 is a schematic diagram showing an example of product information 1201. Product information 1201 is information about the parts that make up a product, and is information that associates a product number 1201a, part ID 1201b, part number 1201c, and part name 1201d with each other.

Product number 1201a is a string that uniquely identifies a product. Part ID 1201b is a string that is assigned to each of multiple parts included in a product, with no duplication allowed. Part number 1201c is a string that uniquely identifies multiple parts. Part name 1201d is the name of each part.

Figure 3 is a schematic diagram showing an example of process plan information 1202. Process plan information 1202 is information that indicates multiple process plans.

As an example, the process plan information 1202 is information that associates a product number 1202a, a candidate ID 1202b, a process ID 1202c, a work content 1202d, a part ID 1202e, a workability evaluation element 1202f, and a workability evaluation value 1202g.

Product number 1202a is information corresponding to product number 1201a in product information 1201. Candidate ID 1202b is information that uniquely identifies multiple process plan candidates. For example, a row where candidate ID 1202b is "1" is a candidate for one process plan.

Process ID 1202c is an integer value that uniquely identifies multiple processes in a candidate. For example, a candidate with candidate ID 1202b of "1" contains process IDs 1202c of "1," "2," and "3." Therefore, a candidate with candidate ID 1202b of "1" consists of three processes identified by process IDs 1202c of "1," "2," and "3." In this example, the integer value of the process ID indicates the order of the processes. As an example, the smaller the process ID value, the earlier the process is performed. Furthermore, if the process plan information 1202 contains multiple rows with the same process ID 1202c, the order of work in those processes is indicated by the order of the rows. For example, a candidate with candidate ID 1202b of "1" contains four rows with process ID 1202c of "1." In this case, the work in the top row with part ID 1202e of "1" is performed first, followed by the work in the second row.

Work content 1202d is information indicating the work content of each process. For example, the work content of the process identified by process ID 1202c "1" is "case assembly."

Part ID 1202e is information corresponding to part ID 1201b in product information 1201. Workability evaluation element 1202f is the work content for each part. For example, if process ID 1202c is "1" and part ID 1202e corresponds to "1", the workability evaluation element 1202f is "installation". According to Figure 2, the part corresponding to part ID 1202e "1" is a "plate", so this indicates the work content of "installing a plate".

In the following, when we simply refer to work, it refers to the work indicated by the workability assessment element 1202f. The workability assessment element 1202f is uniquely determined by the process ID 1202c and the part ID 1202e. Therefore, work can be identified by the combination of a process and a part.

The workability evaluation value 1202g is a value that indicates the work efficiency of the work indicated by the workability evaluation element. In this example, work efficiency is evaluated based on the work time required for the work, with shorter work times indicating better work efficiency. The workability evaluation value 1202g is then a value proportional to the past performance of the work time. For example, if the workability evaluation element 1202f is "installation" and the average work time taken by multiple workers to perform the "installation" work in the past is 10 seconds, the workability evaluation value is calculated by multiplying this average by a proportionality constant of 0.1 (1.0). This proportionality constant is the same for all workability evaluation elements 1202f. For example, if the workability evaluation element 1202f is "positioning" and the average work time taken by multiple workers to perform the "positioning" work in the past is 11 seconds, the workability evaluation value for "positioning" is calculated by multiplying this average by 0.1 (1.1).

Figure 4 is a schematic diagram showing an example of production plan information 1203. Production plan information 1203 is information that indicates the planned production volume of each product to be produced in the factory in the future. As an example, production plan information 1203 is information that associates product number 1203a, production month 1203b, and quantity 1203c.

Product number 1203a is information corresponding to product number 1201a in product information 1201. Production month is the month in which the product is produced. Quantity 1203c is the planned production volume of the product to be produced in the production month. For example, 200 units of a product with product number "PR001" are scheduled to be produced in February 2022.

Figure 5 is a diagram showing an example of process plan information 1204. Process plan information 1204 is information in which a worker is assigned to one of multiple process plans identified by process ID 1202b in process plan information 1202. Here, of the multiple process plans, when the production volume per product production month 1203b is calculated based on workability evaluation value 1202g in process plan information 1202, a worker is assigned to the process plan whose production volume is equal to or greater than quantity 1203c in production plan information 1203.

As mentioned above, the workability evaluation value 1202g is proportional to the time required to handle a certain part in a certain process, and therefore the total workability evaluation value 1202g of all parts handled in that process is proportional to the time required for that process. In production by multiple workers, when the worker in the first process finishes work on a certain product, he or she hands that product over to the next process. At the same time that the worker in the next process begins work on that product, the worker in the first process begins work on the next product. In this way, since multiple workers work in parallel, the longest work time of each process is the time required to manufacture one product. This determines the production volume per unit time, and also the production volume per production month 1203b.

As an example, the process plan information 1204 is information that associates a product number 1204a, a process ID 1204b, a part ID 1204c, and a worker ID 1204d.

Product 1204a is information corresponding to product number 1201a in product information 1201. Process ID 1204b is information corresponding to process ID 1202c in process plan information 1202. Part ID 1204c is information corresponding to part ID 1201b in product information 1201. Worker ID 1204d is an identifier that uniquely identifies each of multiple workers in the factory.

The example in Figure 5 shows a process plan for manufacturing a product with product number 1204a "PR001" using three processes with process IDs 1204b "1," "2," and "3." In the following, it is assumed that the same worker is assigned to the same process. For example, a worker with worker ID 1204d "1" is assigned to the process with process ID 1204b "1."

Figure 6 is a schematic diagram showing an example of production performance information 1205. Production performance information 1205 is information showing past production performance.

As an example, production performance information 1205 is information that associates each of the following: product number 1205a, process ID 1205b, part ID 1205c, worker ID 1205d, work start date and time 1205e, work end date and time 1205f, and work result 1205g.

Of these, product number 1205a and part ID 1205c are information corresponding to product number 1201a and part ID 1201b, respectively, in product information 1201. Furthermore, process ID 1205b is information corresponding to process ID 1202c in process plan information 1202. Worker ID 1205d is information corresponding to worker ID 1204d in process plan information 1204.

Furthermore, the work start date and time 1205e and the work end date and time 1205f are the dates and times when work on the part indicated by the part ID 1204 started and ended, respectively. The work result 1205g is information indicating whether the work was successful or unsuccessful. In this example, success is represented by "1" and failure is represented by "0".

Figure 7 is a schematic diagram showing an example of worker-specific workability evaluation information 1206. Worker-specific workability evaluation information 1206 is information that indicates the workability evaluation value for each worker.

For example, the worker-specific workability evaluation information 1206 is information that associates a worker ID 1206a, a target period 1206b, a product number 1206c, a candidate ID 1206d, a process ID 1206e, a part ID 1206f, and a worker-specific workability evaluation value 1206g.

Worker ID 1206a is information corresponding to worker ID 1204d in process plan information 1204. Target period 1206b is the period during which worker-specific workability evaluation value 1206g was evaluated. Product number 1206c and part ID 1206f are information corresponding to product number 1201a and part ID 1201b in product information 1201, respectively. Process ID 1206e is information corresponding to process ID 1202c in process plan information 1202. Candidate ID 1206d is information corresponding to candidate ID 1202b in process plan information 1202. Worker-specific workability evaluation value is a value defined in the same way as workability evaluation value 1202g in process plan information 1202, and is a value indicating the work efficiency of each worker's work.

For example, consider the first row of the worker-specific workability evaluation information 1206. The first row contains information about work performed by a worker whose worker ID 1206a is "1" between 8:00 and 10:00 on 2022/02/01. This work involves handling a product whose product number 1206c is "PR001" in a process whose process ID 1206e is "1" in a process plan whose candidate ID 1206d is "1" and a part whose part ID 1206f is "1." In this example, the worker-specific workability evaluation value 1206g for this work is "1.0."

Figure 8 shows an example of worker-specific mind assessment information 1207. Worker-specific mind assessment information 1207 is information that shows, for each worker, a mind assessment value that indicates the state of consciousness during work.

As an example, the worker-specific mindset evaluation information 1207 is information that associates each of the following: worker ID 1207a, target period 1207b, product number 1207c, candidate ID 1207d, process ID 1207e, part ID 1207f, mindset evaluation value 1207g, failure rate 1207h, work time variation 1207i, familiarization time 1207j, and work interval time 1207k.

Worker ID 1207a, target period 1207b, product number 1207c, candidate ID 1207d, process ID 1207e, and part ID 1207f correspond to worker ID 1206a, target period 1206b, product number 1206c, candidate ID 1206d, process ID 1206e, and part ID 1206f in worker-specific workability evaluation information 1206, respectively.

Failure rate 1207h is the failure rate of work performed by a certain worker during target period 1207b. As an example, failure rate 1207h is defined as the proportion of work for which work result 1205g is "0" to the total number of work for which work result 1205g is "1" and "0" during target period 1207b.

Work time variance 1207i is the standard deviation of the work time for each task performed during the target period 1207b. Mastery time 1207j is the time required to consider a task performed during the target period 1207b as having been mastered. Work interval time 1207k is the average value of the interval time for each task during the target period 1207b.

The mind evaluation value 1207g is a value that indicates the worker's state of mind when working with the part with part ID 1207f during the target period 1207b, and the higher the value, the better the worker's state of mind. A good state of mind is one that is effective in improving product productivity, such as not feeling stressed and concentrating on the work.

When the worker's state of consciousness is not good, any of the failure rate 1207h, work time variance 1207i, familiarization time 1207j, and work interval time 1207k is likely to be greater than when the worker's state of consciousness is good. Therefore, in this embodiment, the reciprocal of the square root of the sum of the squares of the failure rate 1207h, work time variance 1207i, familiarization time 1207j, and work interval time 1207k is set as the mind evaluation value 1207f. Each of the failure rate 1207h, work time variance 1207i, familiarization time 1207j, and work interval time 1207k is an example of an indicator that indicates the worker's work performance.

Figure 9 is a schematic diagram showing an example of workability evaluation value information 1208. Workability evaluation value information 1208 is information used when creating process plan information 1202 (see Figure 3), and is information that associates workability evaluation elements 1208a with workability evaluation values 1208b. Workability evaluation elements 1208a and workability evaluation values 1208b are information that correspond to workability evaluation elements 1202f and workability evaluation values 1202g, respectively, of process plan information 1202 (see Figure 3).

Next, we will explain the process planning method related to this embodiment.

Figure 10 is a diagram showing an example of a flowchart of a process planning method according to this embodiment. Each of the following processes is started, for example, when the process planning device 1000 receives a process start instruction from an operator via the input unit 1300.

When processing begins, the process plan calculation unit 1101 acquires product information 1201 and workability evaluation value information 1208 from the memory unit 1200 (S010).

Next, the process plan calculation unit 1101 generates process plan information 1202 based on the product information 1201 and workability evaluation value information 1208 (S020).

When producing a product made up of multiple parts, there may be multiple process plans with different work orders. Such process plans can be derived using publicly known techniques. A representative technique is to calculate the work order using adjacency relationships that can be obtained from the three-dimensional shapes of parts, as described in Japanese Patent No. 4859590. Furthermore, the work content 1202d and workability evaluation elements 1202f in the process plan information 1202 can be calculated using the method described in Japanese Patent Application Laid-Open No. 2011-248622. This method uses the actual process information and product information of previous products to reuse the actual process information based on the similarity between the parts of the previous product and the new product.

The process plan information 1202 generated in this manner includes multiple process plans identified by candidate ID 1202b.

At this stage, the process plan calculation unit 1101 leaves the workability evaluation value 1202g in the process plan information 1202 blank.

Next, the workability evaluation value calculation unit 1102 calculates the workability evaluation value 1202g of the process plan information 1202 based on the workability evaluation value information 1208 (S030). As an example, the workability evaluation value calculation unit 1102 identifies the workability evaluation value 1202g corresponding to the workability evaluation element 1202f of the process plan information 1202 from the workability evaluation value information 1208. Then, the workability evaluation value calculation unit 1102 stores the identified workability evaluation value 1202g in the process plan information 1202.

Next, the planning unit 1103 acquires the production plan information 1203 from the memory unit 1200 and generates the process plan information 1204 based on the production plan information 1203 and the process plan information 1202 (S040).

As an example, the planning unit 1103 identifies, for each product, a process plan among the multiple process plans indicated in the process plan information 1202 that results in a production volume of the product per production month 1203b in the production plan information 1203 equal to or greater than the quantity 1203c, and generates process plan information 1204 related to that process plan. If multiple such process plans exist, the planning unit 1103 can identify the process plan that maximizes the manufacturing throughput or minimizes the manufacturing lead time when manufacturing the product by solving an integer programming problem. The production volume for each process plan can be calculated based on the process plan information 1202. For example, in each process plan, the total value obtained by adding up the workability evaluation values 1202g for a certain process for all part IDs 1202e used in that process is proportional to the time required for that process. Therefore, the maximum value of this total value for each process is proportional to the time required to manufacture the product. Since the number of products manufactured per unit time can be determined from that time, the production volume per production month 1203b can also be calculated.

If the workability evaluation value for each worker is known in advance, the work time for each task can be determined based on that workability evaluation value, and the manufacturing throughput and manufacturing lead time can be calculated based on that work time. The worker ID 1204d in the process plan information 1204 is the worker ID corresponding to the workability evaluation value used to calculate the manufacturing throughput or manufacturing lead time. Even if the workability evaluation value for each worker is not known in advance, the manufacturing throughput and manufacturing lead time can be calculated using the workability evaluation value 1202g in the process plan information 1202. In this case, the planning unit 1103 simply assigns the worker ID in the process plan information 1204 as appropriate.

Note that while we have imposed a constraint that production volume must be equal to or greater than the planned production volume, it is also possible to impose a constraint that each worker's daily working hours must not exceed the daily working hours set for each worker.

Also, as mentioned above, it is assumed here that one process is handled by one worker. In this case, in the process plan information 1204, the same process ID 1204b corresponds to the same worker ID 1204d.

Next, the process planning device 1000 instructs the production line to carry out production based on the process planning information 1204 generated in step S040 via the communication unit 1500, network N, and external device 2000, and acquires from the memory unit 1200 the production performance information 1205 accumulated as each worker on the production line carries out production (S050).

Next, the workability evaluation unit 1104 performs a process to generate workability evaluation information by worker 1206 based on the workability evaluation value of the process plan that formed the process plan information 1204 and the production performance information 1205 (S060). Details of this process will be described later.

Next, the mindset evaluation unit 1105 performs a process to generate mindset evaluation information for each worker 1207 based on the worker performance evaluation information 1206 and the production performance information 1205 (S070). Details of this process will be described later.

Next, the planning unit 1103 determines whether the mind evaluation value meets the criteria (S080).

As an example, the planning unit 1103 calculates the total of the mind evaluation values 1207f for all parts handled by a certain worker in a certain process as the consciousness state evaluation value indicating the consciousness state of that worker in that process. Then, if the total of the consciousness state evaluation values for all workers is equal to or greater than a predetermined threshold, the planning unit 1103 determines that the mind evaluation value meets the criteria.

Alternatively, the planning unit 1103 may determine that the mind evaluation value meets the criteria if there is no worker whose consciousness state evaluation value is below a predetermined threshold.

Furthermore, if there is no worker whose current consciousness state evaluation value is lower than the consciousness state evaluation value calculated the previous time (the previous day or the previous shift), the planning unit 1103 may determine that the mind evaluation value meets the criteria.

Here, if it is determined that the mind evaluation value meets the criteria (YES), the process returns to step S050.

On the other hand, if it is determined that the mind evaluation value does not meet the criteria (NO), proceed to step S090. In this case, it is considered that the worker's state of consciousness is deteriorating due to a mismatch between the worker's aptitude and the work, or changes over time such as the worker's fatigue or boredom.

Therefore, in step S090, the planning unit 1103 modifies the process plan information 1204 to plan the allocation of workers whose mind evaluation values are expected to meet the criteria of step S080.

As an example, the planning unit 1103 generates multiple change proposals in which the worker ID 1204d assigned to the part ID 1204c in the current process plan information 1204 is changed in various ways. In the example of Figure 5, the worker ID 1204d "1" has already been assigned to the part ID 1204c "1", but the planning unit 1103 also assigns worker IDs 1204d "2", "3", ... to the part ID 1204c "1". The same applies to part IDs 1204c other than "1".

Furthermore, the planning unit 1103 calculates an awareness state evaluation value for each worker for each of the multiple change proposals. For example, in a certain change proposal, a worker whose worker ID 1204d is "1" is assigned to parts whose component IDs 1204c are "5," "6," "7," and "8." In this case, the planning unit 1103 identifies the mind evaluation values 1207g corresponding to the component IDs 1204c of "5," "6," "7," and "8" from the mind evaluation values 1207g corresponding to the worker ID 1204d of "1" in the worker-specific mind evaluation information 1207. The planning unit 1103 then calculates the awareness state evaluation value of the worker whose worker ID 1204d is "1" by summing the identified mind evaluation values 1207g.

If a change plan includes a part that a certain worker has never handled, the mind evaluation value 1207g corresponding to that worker and part does not exist in the worker-specific mind evaluation information 1207. In this case, the planning unit 1103 can calculate the mind evaluation value 1207g corresponding to that worker and part by using the approximation formula 1401 in Figure 14, which will be described later.

The planning unit 1103 then generates, as changed process plan information 1204, the process plan information corresponding to the change plan that, among the multiple change plans, results in a production volume per production month 1203b that is equal to or greater than the quantity 1203c in the production plan information 1203 and that results in the largest total value of the consciousness state evaluation values for all workers. The production volume for each change plan can be calculated based on the worker performance evaluation information 1206. For example, in each change plan, the total value obtained by adding up the worker performance evaluation values 1206g for a certain worker for all part IDs 1204c handled by that worker is proportional to the time required for the process assigned to that worker. Therefore, the maximum value of this total value for each process is proportional to the time required to manufacture the product. Since the number of products manufactured per unit time can be determined from that time, the production volume per production month 1203b can also be calculated.

By changing the process plan information 1204 in this way, the aforementioned total value becomes equal to or exceeds the threshold value, increasing the likelihood that the mind evaluation value will be determined to meet the criteria in step S080.

Furthermore, even with the changed process plan information 1204, the production volume per production month 1203b will be equal to or greater than the quantity 1203c in the production plan information 1203, so the production plan can be adhered to.

Note that here the total value of the consciousness state assessment scores of all workers is used as the objective function, but the total value of the differences in consciousness state assessment scores from the previous time for all workers may be used as the objective function, and a process plan that maximizes this objective function may be identified. Also, the average value of the increase in consciousness state assessment scores from the previous time for all workers may be used as the objective function, and a process plan that maximizes this objective function may be identified.

Next, the planning unit 1103 determines whether production of the product has ended (S100). If it is determined that production has not ended (NO), the process returns to step S050.

As a result, the planning unit 1103 repeatedly makes the judgment in step S080 while the worker is working based on the process plan information 1204, and each time the judgment is negative, it changes the process plan information 1204 in step S090 and replans the work allocation. By repeatedly making the judgment in step S080 in this way, it is possible to capture changes in the worker's state of mind while manufacturing a product, and by further changing the process plan information 1204, it is possible to maintain the worker's state of mind in a good state.

On the other hand, if it is determined in step S100 that production has ended (YES), processing ends. Note that even if the determination in step S080 is never negative even once after repeated execution, processing ends when production has ended.

Next, we will explain the process of generating the worker-specific workability evaluation information 1206 in step S060.

Figure 11 shows an example of a flowchart for the process of generating worker-specific workability evaluation information 1206.

First, the workability evaluation unit 1104 obtains the workability evaluation value 1202g from the process plan information 1202 (S061).

Next, the workability evaluation unit 1104 obtains the work start date and time 1205e and work end date and time 1205f for each worker for each part from the production performance information 1205 (S062).

Next, the workability evaluation unit 1104 calculates the difference between the work end date and time 1205f and the work start date and time 1205e for each part and each worker, and calculates this as the actual work time (S063).

Next, the workability evaluation unit 1104 calculates the workability evaluation value 1206g for each worker and for each part based on the workability evaluation value 1202g and the actual work time (S064).

As an example, the workability evaluation unit 1104 totals the workability evaluation values 1202g of the process plan that formed the basis of the process plan information 1204 for all parts handled by a certain worker. Furthermore, the workability evaluation unit 1104 totals the actual work times for all parts handled by a certain worker. The workability evaluation unit 1104 calculates the worker-specific workability evaluation value 1206g for a certain worker for each part based on the ratio between the total workability evaluation values 1202g obtained in this way and the total actual work times. For example, the workability evaluation unit 1104 calculates the worker-specific workability evaluation value 1206g for that part by multiplying the ratio between the total workability evaluation values 1202g and the total actual work times by the actual work time for that part.

The worker-specific workability evaluation value 1206g for a part with no actual work time is calculated based on the actual work time for a part similar to that part. Whether parts are similar to each other can be determined arbitrarily from information that represents the characteristics of the parts, such as the work content, part shape, and part mass. Similarly, the worker-specific workability evaluation value 1206g may also be calculated based on the similarity of the parts for other process plan candidates in the process plan information 1202 that were not adopted in the process planning information 1204. By using the similarity of the parts in this way, the worker-specific workability evaluation value 1206g can be calculated for parts with no actual work time or for process plan candidates that were not adopted.

Next, the workability evaluation unit 1104 determines whether the process of calculating the workability evaluation values 1206g for each worker has been completed for all workers (S065). If it is determined that the process has not been completed for all workers (NO), the process returns to step S064. On the other hand, if it is determined that the process has been completed for all workers (YES), the process ends.

Next, we will explain the process of generating worker-specific mindset evaluation information 1207 in S070 of Figure 10.

Figure 12 shows an example of a flowchart for the process of generating worker-specific mindset assessment information 1207.

First, the mind evaluation unit 1105 obtains the worker-specific workability evaluation value 1206g from the worker-specific workability evaluation information 1206 (S071).

Next, the mindset evaluation unit 1105 acquires the work start date/time 1205e, work end date/time 1205f, and work result 1205g for each part by each worker from the production performance information 1205 (S072). Note that the following assumes that the target period 1207b of the worker mindset evaluation information 1207 includes the work start date/time 1205e and work end date/time 1205f in the production performance information 1205.

Next, the mind evaluation unit 1105 calculates the difference between the work start date and time 1205e and the work end date and time 1205f for each row of the production performance information 1205 as the actual work time, and calculates the work time variation and familiarization time based on this actual work time (S073).

Furthermore, the mind evaluation unit 1105 calculates the difference between the work end date/time 1205f and the work start date/time 1205e of two consecutive rows of the production performance information 1205 as the work interval time. The mind evaluation unit 1105 also calculates the failure rate 1207h based on the work results 1205g of the production performance information 1205. For example, the mind evaluation unit 1105 calculates the failure rate 1207h as the percentage of "0"s in the work results 1205g corresponding to the same product number 1205a, the same process ID 1205b, and the same worker ID 1205d during the target period 1207b.

The work time variance, familiarization time, and work interval time are calculated as follows:

Figure 13(a) is a schematic diagram showing an example of the work status of a worker identified by the mind evaluation unit 1105 based on the production performance information 1205. The horizontal axis of Figure 13(a) indicates the work date and time, and the vertical axis indicates whether or not the worker is currently working. Also, here, the example shows a worker with worker ID "1."

In addition, in Figure 13(a), work start date and time 1301a corresponds to work start date and time 1205e in a certain row of production performance information 1205, and work end date and time 1301b corresponds to work end date and time 1205f in the same row. Furthermore, work start date and time 1301d is the date and time when the next task started after the task was completed at work end date and time 1205f.

The worker is considered to have been in a working state during the period from the work start date and time 1301a to the work end date and time 1301b. Therefore, the mind evaluation unit 1105 calculates the difference between the work start date and time 1301a and the work end date and time 1301b as the actual work time 1301c.

In addition, the period from the work end date and time 1301b to the work start date and time 1301d is considered to be a period in which the person was not working. Therefore, the mind evaluation unit 1105 calculates this period as the actual work interval time 1301e.

Figure 13(b) is a schematic diagram showing an example of a graph showing the distribution of calculated actual work times 1301c for each part. As shown in Figure 13(b), even when the same worker works on the same part, there is variation in the actual work times 1301c. As an example, the mind evaluation unit 1105 calculates the standard deviation of the actual work times 1301c for each part and worker as the work time variation 1207i.

Figure 13(c) is a schematic diagram showing an example of the time progression of the calculated actual work time 1301c. As shown in Figure 13(c), the actual work time for the same part by the same worker tends to become shorter with each additional work compared to the first time the work was started. This is because the worker becomes more proficient at the work as the number of times the work is performed increases. Furthermore, if the worker is good at a task, the actual work time will decrease more quickly as the number of times the work is performed increases compared to tasks that the worker is not good at. In this way, the strengths and weaknesses of the worker are reflected in the rate at which the actual work time decreases. Therefore, the mind evaluation unit 1105 calculates the time from the first actual work time or the maximum actual work time to the work date and time when the actual work time reaches a predetermined rate of decrease as the proficient time 1207j.

Figure 13(d) is a schematic diagram showing an example of a graph showing the distribution of calculated actual task interval times 1301e for each part. As shown in Figure 13(d), even when the same worker is working on the same part, the actual task interval time 1301e varies depending on the worker's state of mind. Therefore, the mind evaluation unit 1105 calculates the average actual task interval time 1301e for each part and worker as the task interval time 1207k. Furthermore, if a worker is good at working with a certain part, that worker will perform the work one after another, and therefore the actual task interval time 1301e corresponding to that part will be shorter than for tasks that the worker is not good at.

In this way, the mind evaluation unit 1105 can calculate the work time variation 1207i, familiarization time 1207j, and work interval time 1207k based on the production performance information 1205.

In addition, the mind evaluation unit 1105 calculates the work time variation 1207i, familiarization time 1207j, work interval time 1207k, and failure rate 1207h for parts that a certain worker has not handled before as follows:

Figure 14 is a schematic diagram showing an example of a method for calculating the work time variation 1207i for parts that a worker has not handled before.

The horizontal axis of Fig. 14 is the worker-specific workability evaluation value _E1i of the worker with worker ID "1". Note that the subscript "i" indicates the part ID that the worker with worker ID "1" has handled. The vertical axis of Fig. 14 is the work time variation of the worker with worker ID "1".

As shown in FIG. 14 , there is a correlation between the work time variance and the worker-specific workability evaluation value. Therefore, the mind evaluation unit 1105 calculates an approximate expression 1401 that approximates the relationship between the work time variance D1 _i and the worker-specific workability evaluation value E1 _i . The mind evaluation unit 1105 then obtains the workability evaluation value 1202 g of a part that the worker with worker ID "1" has never handled from the process plan information 1202, and calculates the work time variance by substituting the workability evaluation value 1202 g into the approximate expression 1401. The work time variance calculated in this manner serves as an estimate of the work time variance 1207 i corresponding to a part that the worker has never handled. In this way, even for a part that the worker has never handled, the mind evaluation unit 1105 can estimate the work time variance 1207 i for that part by using the approximate expression 1410.

In a similar manner, the mind evaluation unit 1105 can estimate indicators such as the familiarization time 1207j, task interval time 1207k, and failure rate 1207h for parts that the worker has not handled before based on the approximate formula 1401.

Referring again to Figure 12. Next, the mind evaluation unit 1105 calculates a mind evaluation value 1207f for each worker and each part based on the work time variance 1207i, familiarization time 1207j, work interval time 1207k, and failure rate 1207h (0S74). For example, as described above, the mind evaluation unit 1105 calculates the reciprocal of the square root of the sum of the squares of the work time variance 1207i, familiarization time 1207j, work interval time 1207k, and failure rate 1207h as the mind evaluation value 1207f.

Next, the mind evaluation unit 1105 determines whether the mind evaluation values 1207f have been calculated for all parts handled by all workers (S075).

If it is determined that processing has not been completed for all workers (NO), processing returns to S074. On the other hand, if it is determined that processing has been completed for all workers (YES), processing of this flow ends.

This completes the basic processing of the process planning method according to this embodiment.

Figure 15 is a schematic diagram showing an example of the screen 1501 displayed on the display unit 1400 by the planning unit 1103 based on the process plan information 1204 regenerated in step S090.

As shown in FIG. 15, screen 1501 has a selection field 1501a, a current process plan information display field 1501b, a changed process plan information display field 1501c, a production performance period display field 1501d, a performance work time display field 1501e, a performance awareness state evaluation value display field 1501f, an estimated work time display field 1501g, and an estimated awareness state evaluation value display field 1501h.

The selection field 1501a is a field where the user selects a product number. The current process plan information display field 1501b is a field that displays information corresponding to the product number in the selection field 1501a in the process plan information 1204 (see Figure 5) used on the current production line. In this example, the process ID 1204b, part ID 1204c, and worker ID 1204d are displayed in the current process plan information display field 1501b.

The changed process plan information display field 1501c is a field that displays information corresponding to the product number in the selection field 1501a in the process plan information 1204 changed in step S090. As an example, the process ID 1204b, part ID 1204c, and worker ID 1204d are displayed in the changed process plan information display field 1501c.

The production performance period display field 1501d is a field that displays the target period 1207b used to calculate the mind evaluation value 1207f and the process plan information 1204.

The actual work time display field 1501e is a field that displays a bar graph showing the actual work time 1301c (see Figure 13) for each worker ID. Here, the total actual work time 1301c for each part handled by each worker is shown as a bar graph. For example, the bar graph for worker ID "1" has four areas, each corresponding to the actual work time for part IDs "1," "2," "3," and "4."

The estimated work time display column 1501g is a column that displays, in a bar graph, the estimated work time for each worker ID when manufacturing a product according to the information displayed in the changed process plan information display column 1501c. The estimated work time for a given worker is the sum of all worker-specific workability evaluation values 1206g for the parts that the worker handles in a given process, multiplied by a proportionality constant. For example, according to the changed process plan information display column 1501c, a worker with worker ID "1" handles parts with part IDs "2," "5," "6," and "7" in the process with process ID "1." In this case, the estimated work time for worker ID "1" is the sum of worker-specific workability evaluation values 1206g for the process ID "1" and part IDs "2," "5," "6," and "7" multiplied by a proportionality constant. The bar graph for worker ID "1" has four regions, and the height of each region is proportional to the workability evaluation value for each of the part IDs "2," "5," "6," and "7" above.

The actual work time display field 1501e and the estimated work time display field 1501g each display a target time. The target time is the upper limit of the work time required to produce a number of products equal to or greater than the planned production volume. If the bar graphs of all workers do not exceed this target time, the planned production volume of products can be manufactured.

The actual consciousness state evaluation value display field 1501f is a field that displays a bar graph showing the actual consciousness state evaluation value for each worker ID. As mentioned above, the consciousness state evaluation value for a given worker is the total sum of the mind evaluation values 1207f for all parts handled by that worker. Here, the consciousness state evaluation value for each worker is shown as a bar graph. For example, the bar graph for worker ID "1" has four areas, each of which corresponds to the mind evaluation value 1207f for part IDs "1," "2," "3," and "4."

The estimated consciousness state evaluation value display field 1501h is a field that displays, in a bar graph, the consciousness state evaluation value estimated for each worker ID when manufacturing a product according to the information in the changed process plan information display field 1501c. Here, the consciousness state evaluation value for each worker ID calculated in step S090 is displayed in the estimated consciousness state evaluation value display field 1501h.

In this example, as shown in the current process plan information display field 1501b and the changed process plan information display field 1501c, the part IDs assigned to the worker with worker ID "1" have been changed from "1," "2," "3," and "4" to "2," "5," "6," and "7." In the estimated consciousness state evaluation value display field 1501h, the four areas in the bar graph for worker ID "1" correspond to the mind evaluation values 1207f for the changed part IDs "2," "5," "6," and "7."

By displaying this screen 1501 on the display unit 1400, the user can visually understand how the work time or consciousness state evaluation value changes in response to changes in the process plan information 1204.

In this embodiment described above, the mind evaluation unit 1105 generates worker-specific mind evaluation information 1207, including a mind evaluation value 1207g, based on indicators such as work time variance (step S070). If it is determined in step S080 that the mind evaluation value does not satisfy the criteria, the planning unit 1103 changes the process plan information 1204 to plan a task allocation in which the mind evaluation value is expected to satisfy the criteria (step S090).

The mind evaluation value is a value that indicates whether a worker is in an effective state of mind for improving product productivity, such as not feeling stressed or concentrating on their work. By planning work assignments so that the mind evaluation value meets the standard, it is possible to create an environment where workers can concentrate on their work and reduce stress. As a result, it is possible to maintain a good state of mind for workers on the production line and maintain product production efficiency.

<Hardware configuration>
FIG. 16 is a diagram illustrating an example of a hardware configuration of a process planning apparatus 1000 according to this embodiment.

As shown in FIG. 16, the process planning device 1000 has a processor 1001, memory 1002, storage device 1003, communication device 1004, display device 1005, input device 1006, and reading device 1007. These components are interconnected by a bus 1009.

The storage device 1003 is a non-volatile storage device such as an HDD (Hard Disk Drive) or SSD (Solid State Drive), and stores the process planning program related to this embodiment.

The process planning program may be recorded on a computer-readable recording medium 1008, and the processor 1001 may be configured to read the process planning program from the recording medium 1008.

Examples of the recording medium 1008 include physically portable recording media such as CD-ROMs (Compact Disc - Read Only Memory), DVDs (Digital Versatile Discs), and USB (Universal Serial Bus) memory. Semiconductor memory such as flash memory and hard disk drives may also be used as the recording medium 1008.

The process planning program may also be stored in a device connected to a public line, the Internet, a LAN (Local Area Network), etc. In this case, the processor 1001 simply reads and executes the process planning program.

Memory 1002 is hardware that temporarily stores data, such as DRAM (Dynamic Random Access Memory), on which the process planning program is deployed.

The processor 1001 is a CPU (Central Processing Unit) or GPU (Graphical Processing Unit) that controls each part of the process planning device 1000. The processor 1001 works in cooperation with the memory 1002 to execute the process planning program, thereby realizing the processing unit 1100 in Figure 1.

The storage unit 1200 in Figure 1 is realized by the storage device 1003 and memory 1002. The communication device 1004 is hardware such as a NIC (Network Interface Card) for connecting the process planning device 1000 to the network N. The communication device 1004 realizes the communication unit 1500 in Figure 1.

The display device 1005 is hardware such as a liquid crystal display or organic EL display for implementing the display unit 1400 in Figure 1. The input device 1006 is hardware such as a keyboard or mouse for implementing the input unit 1300 in Figure 1.

The reading device 1007 is hardware such as a CD drive for reading data recorded on the recording medium 1008.

The effects described in this specification are merely examples and are not intended to be limiting; other effects may also be present.

The present invention is not limited to the above-described embodiments and includes various modifications. For example, the above-described embodiments have been described in detail to clearly explain the present invention, and the present invention is not necessarily limited to those including all of the components described. Furthermore, it is possible to replace part of the configuration of one embodiment with the configuration of another embodiment, and it is also possible to add the configuration of another embodiment to the configuration of one embodiment. Furthermore, it is possible to add, delete, or replace part of the configuration of each embodiment with other configurations.

Furthermore, the above-mentioned configurations, functions, processing units, processing means, etc. may be implemented in part or in whole in hardware, for example by designing them as integrated circuits. Furthermore, the above-mentioned configurations, functions, etc. may be implemented in software by a processor interpreting and executing a program that implements each function. Information such as the program, decision table, and files that implement each function can be stored in memory, a storage device such as an HDD or SSD, or a recording medium such as an IC (Integrated Circuit) card, SD (Secure Digital) card, or DVD (Digital Versatile Disc). Furthermore, the control lines and information lines shown are those considered necessary for explanation, and do not necessarily represent all control lines and information lines in the product. In reality, it can be assumed that almost all components are interconnected.

1000...Process planning device, 1001...Processor, 1002...Memory, 1003...Storage device, 1004...Communication device, 1005...Display device, 1006...Input device, 1007...Reading device, 1008...Recording medium, 1009...Bus, 1100...Processing unit, 1101...Process plan calculation unit, 1102...Workability evaluation value calculation unit, 1103...Planning unit, 1104...Workability evaluation unit, 1105...Mine evaluation unit, 1200...storage unit, 1201...product information, 1202...process plan information, 1203...production plan information, 1204...process plan information, 1205...production performance information, 1206...worker performance evaluation information, 1207...worker mindset evaluation information, 1208...workability evaluation value information, 1300...input unit, 1400...display unit, 1500...communication unit, 1501...screen, 2000...external device.

Claims (6)

a mind evaluation unit that calculates a mind evaluation value that indicates the state of consciousness of the worker when the worker performed the work, based on an index that indicates the performance of the work performed by the worker;
a planning unit that, when planning work allocation, if the mind evaluation value calculated when the worker is assigned to a process plan does not satisfy a criterion, changes the process plan to a process plan whose calculated mind evaluation value satisfies the criterion, and plans work allocation ;
a workability evaluation unit that evaluates a workability evaluation value indicating the work efficiency of an executed work for each part and each worker handled in the work,
The mind evaluation unit
determining an approximate expression that approximates the relationship between the index and the workability evaluation value for a certain worker ;
When the assignment includes an operation relating to a part that the worker has never handled, the workability evaluation value relating to the part that the worker has never handled is substituted into the approximation formula to estimate the index relating to the part that the worker has never handled;
the planning unit changes the process plan so that the mind evaluation value calculated based on the estimated index satisfies the criterion .
Process planning device. The process planning system according to claim 1,
The index is one or more of a failure rate of the task, a variation in task time, a learning time for the task, and a task interval time.
Process planning device. The process planning system according to claim 1 ,
the planning unit plans the allocation of the work using the process plan in which the calculated mind evaluation value satisfies the criterion under the condition that the number of products produced in the work is equal to or greater than a planned production volume;
Process planning device. The process planning system according to claim 1,
the planning unit repeatedly determines whether the mind evaluation value satisfies the criterion while the worker is performing the work based on the plan, and re-plans the allocation of the work every time it is determined that the mind evaluation value does not satisfy the criterion;
Process planning device. a mind evaluation unit that calculates a mind evaluation value that indicates the state of consciousness of the worker when the worker performed the work, based on an index that indicates the performance of the work performed by the worker;
a planning unit that, when planning work allocation, if the mind evaluation value calculated when the worker is assigned to a process plan does not satisfy a criterion, changes the process plan to a process plan whose calculated mind evaluation value satisfies the criterion, and plans work allocation;
a workability evaluation unit that evaluates a workability evaluation value indicating the work efficiency of an executed work for each part and each worker handled in the work,
The mind evaluation unit
determining an approximate expression that approximates the relationship between the index and the workability evaluation value for a certain worker;
When the assignment includes an operation relating to a part that the worker has never handled, the workability evaluation value relating to the part that the worker has never handled is substituted into the approximation formula to estimate the index relating to the part that the worker has never handled;
the planning unit changes the process plan so that the mind evaluation value calculated based on the estimated index satisfies the criterion.
Process planning system. The computer
calculating a mind evaluation value indicating the state of consciousness of the worker when the worker performed the work based on an index indicating the performance of the work performed by the worker;
When planning work allocation, if the mind evaluation value calculated when the worker is assigned to a process plan does not satisfy a criterion, changing the process plan to one in which the calculated mind evaluation value satisfies the criterion, and planning work allocation;
evaluating a workability evaluation value indicating the work efficiency of the performed work for each part and each worker handled in the work,
In the step of calculating the mind evaluation value,
An approximate expression that approximates the relationship between the index and the workability evaluation value is obtained for a certain worker;
When the assignment includes an operation relating to a part that the worker has never handled, the index relating to the part that the worker has never handled is estimated by substituting a workability evaluation value relating to the part that the worker has never handled into the approximation formula;
In the step of planning the allocation of work, the mind evaluation value calculated based on the estimated index is changed to the process plan that satisfies the criterion.
Process planning methods.