JP2007042058A - Model-switching set up time calculating system, model-switching set up time calculation method, model-switching set up time calculation program and recording medium with storing model-switching set up time calculating program stored - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a model-switching set up time calculating system, model-switching set up time calculating method, model switching set up time calculating program and recording medium for calculating set up time for switching and starting time for switching, and when there is variation in production plan and production progress. <P>SOLUTION: The model-switching set up time calculating system comprises a input part 2 used for inputting the production plan, a production performance collecting part 1 for collecting the production performances, a predictive finish time of current model confirming part 7 for calculating the predictive finish time of the current model, a predictive-switching time calculating part 3 for calculating the scheduled switching time, a start time for switching calculating part 6 for calculating the latest starting time of the switching operations as a whole, a fore and aft switching model comparing part 4 for deciding necessary parts for switching, a switching time calculating part 5 for creating a list of operation times necessary for switching, a display 20 for starting time for switching for displaying the information, and a control part 10 for controlling the information. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention is intended to efficiently carry out a changeover process of model switching that occurs when a plurality of models are produced in a production line in which electrical products are produced through a plurality of elemental operations in a production process of a factory or the like. The model switching setup time calculation management system, the model switching setup time calculation management method, the model switching setup time calculation management program, and the recording medium storing the model switching setup time calculation management program.

  In general, there are many cases in which a plurality of models are produced in one production line or apparatus, and when changing the production model, a setup change work for switching parts and jigs required for each model occurs. This setup change work is not a work that creates added value like processing and assembly, so how to reduce the loss time for this work and improve throughput, or reduce the number of people performing the setup change from the past. It has become a challenge. In view of this, there has been proposed a technology that can solve such problems and reduce labor costs per unit (for example, see Patent Document 1).

The technology disclosed in Patent Document 1 is efficient in removing, moving, and newly installing components by comparing component layout data between the current board and the next board during the setup change operation of the component supply unit in the component mounting apparatus. Guidance is provided to show good setup change procedures.
Japanese Patent Laid-Open No. 10-224081

  However, in the method described in Patent Document 1, although efficient change means can be specifically presented for the setup change in model switching, supply is not provided because the time for actually starting the switching preparation is not presented. There was a problem that it was not possible to carry out management in consideration of a shortage due to delay or an increase in in-process inventory due to premature preparation. In addition, in the method described in Patent Document 1, the number of personnel necessary for switching and the time for completing model switching are not predicted. In some cases, there are problems that the number of personnel required for switching cannot be grasped, and that the time when model switching is completed, that is, the production start time of the next production model cannot be grasped. If there is a delay in production progress on the production line or there is a sudden plan change, it will be difficult to carry out efficient setup change work unless the time and content for starting preparations can be changed at any time. .

  The present invention was devised to solve such problems.The purpose of the present invention is to calculate the setup change work time and to set up the setup change start time in order to efficiently perform the model change setup change work. In addition to being able to calculate, if there is a change in the production plan or production progress, the setup change time can be flexibly handled by recalculating it to the appropriate time in the shortest time. Model change setup time calculation system, model change setup time calculation that can easily grasp the number of personnel required for switchover and the production start time of the next production model when there is a delay in production progress on the line or a sudden plan change A method, a model switching setup time calculation program, and a recording medium storing the model switching setup time calculation program are provided.

  In order to solve the above problems, the model switching setup time calculation system according to the present invention includes a production result collection unit 1, an input unit 2, a predicted switching time calculation unit 3, a pre-switching model comparison unit 4, as shown in FIG. Setup change time calculation unit 5, setup start time calculation unit 6, current model prediction completion time check unit 7, production progress check unit 8, production plan table 11, standard tact time table 12, used parts check table 13, standard setup change The work time table 14, the management unit 10, and the setup installation time display unit 20 are the minimum constituent requirements.

  More specifically, the input unit 2 is used when inputting a model name and a planned number of production planned for the day as a production plan. The production result collection unit 1 collects the production results by counting the production results of the current production model. The current model prediction completion time confirmation unit 7 is counted by the current production model date / time plan (the number of production plans for the current production model) and the production result collection unit 1 stored in the production plan table 11 described later. The planned remaining number is calculated from the difference from the actual production number of the current production model, and the prediction of the current model is completed based on the product of the planned remaining number and the actual tact time indicating the current actual production pace and the current time. The time is calculated. The prediction switching time calculation unit 3 produces the product of the production plan number of the current production model extracted from the production plan table 11 described later and the standard tact time of the current production model extracted from the standard tact time table 12 described later. The scheduled switching time is calculated from the sum of the start time. The production progress confirmation unit 8 compares the scheduled switching time calculated by the predicted switching time calculation unit 3 with the current model prediction completion time calculated by the current model prediction completion time confirmation unit 7 to determine whether there is a progress delay. Check. The setup start time calculation unit 6 determines the latest start of the entire setup change work from the difference between the scheduled change time calculated by the predicted change time calculation unit 3 and the required setup change work time of all the parts that need the setup change. The time is calculated. The pre-switching model comparison unit 4 compares the part code of the part currently used with the part code of the part used after switching, and sets a switching flag for parts with different part codes before and after switching. is there. The setup change time calculation unit 5 refers to a standard setup change work time table 14 to be described later and extracts a setup change work time with respect to the parts for which the switch flag is set, and creates a necessary setup change work time list. . The setup start time display unit 20 displays setup setup start time and the like. The management unit 10 manages the production plan table 11, the standard tact time table 12, the used parts confirmation table 13, and the standard setup change work time table 14, and generates generated information, input information, and acquired information. To store.

  The predicted switching time calculation unit 3 calculates the scheduled switching time corresponding to the production plan. As a result, when there is a change in the production plan, it is possible to respond flexibly by recalculating the setup change time to the appropriate time in the shortest time.

  In addition, the setup start time display unit 20 displays the standard work time and the required start time of the setup change work corresponding to the production plan for the setup change work that occurs at the time of model switching. From the necessary setup change work time list created by the setup change time calculation unit 5, the scheduled switching time, the latest setup start time of each part for which the switching flag is set, and the latest setup start time of the entire setup change work A calculation result list is displayed. As a result, the calculation result can be easily confirmed.

  In addition, the setup start time calculation unit 6 re-examines the switching start time when there is a delay in progress in actual production results. As a result, when there is a change in the production progress, the setup change time can be flexibly handled by recalculating the setup change time to an appropriate time.

  The model switching setup time calculation method of the present invention includes an input step for inputting a production plan, a production result collection step for automatically collecting production results, a current model prediction completion time confirmation step, and a predicted switching time calculation step. A setup take time calculation step, a setup change time calculation step, a model comparison step before and after switching, a setup take time display step, a management step for storing generated information, input information, and acquired information It consists of

  The predicted switching time calculating step is a step of calculating a scheduled switching time corresponding to the production plan. As a result, when there is a change in the production plan, it is possible to respond flexibly by recalculating the setup change time to the appropriate time in the shortest time.

  The setup start time display step is a step of displaying the standard work time and the required start time of the setup change work corresponding to the production plan for the setup change work that occurs at the time of model change. Calculation consisting of the required setup change work time list created in the change time calculation step, the scheduled change time, the latest change start time of each part for which the change flag is set, and the latest start time of the entire setup change work This is a step of displaying a result list. As a result, the calculation result can be easily confirmed.

  Further, the setup start time calculation step is a step of reconsidering the switching start time when there is a delay in progress due to actual production results. As a result, when there is a change in the production progress, the setup change time can be flexibly handled by recalculating the setup change time to an appropriate time.

  The model switching setup time calculation program of the present invention includes an input step for inputting a production plan, a production result collecting step for automatically collecting production results, a current model prediction completion time confirmation step, and a predicted switching time calculation step. A setup take time calculation step, a setup change time calculation step, a model comparison step before and after switching, a setup take time display step, a management step for storing generated information, input information, and acquired information Is realized.

  The predicted switching time calculating step is a step of calculating a scheduled switching time corresponding to the production plan. As a result, when there is a change in the production plan, it is possible to respond flexibly by recalculating the setup change time to the appropriate time in the shortest time.

  The setup start time display step is a step of displaying the standard work time and the required start time of the setup change work corresponding to the production plan for the setup change work that occurs at the time of model change. Calculation consisting of the required setup change work time list created in the change time calculation step, the scheduled change time, the latest change start time of each part for which the change flag is set, and the latest start time of the entire setup change work This is a step of displaying a result list. As a result, the calculation result can be easily confirmed.

  Further, the setup start time calculation step is a step of reconsidering the switching start time when there is a delay in progress due to actual production results. As a result, when there is a change in the production progress, the setup change time can be flexibly handled by recalculating the setup change time to an appropriate time.

  Further, as shown in FIG. 7, the model switching setup time calculation system of the present invention includes a production result collection unit 31, an input unit 32, a current model prediction completion time confirmation unit 33, and a prediction switching time calculation unit 34. , The pre- and post-switching model comparison unit 35, the internal setup time calculation unit 36, the setup change necessary personnel calculation unit 37, the switch completion time calculation unit 38, the plan achievement prediction unit 39, the setup change required personnel display unit 51, and A display unit 50 including a plan achievement prediction display unit 52, a production plan table 41, a standard tact time table 42, a used parts table 43, a used equipment jig / tool table 44, a work guidance table 45 and a standard setup change work time table. The management part 40 which manages 46 is comprised.

  More specifically, the input unit 32 is used when inputting a model name and a planned number of machines planned for production on the day as a production plan. The prediction switching time calculation unit 34 calculates the product of the production plan number of the current production model extracted from the production plan table 41 and the standard tact time of the current production model extracted from the standard tact time table 42, and the production start time. The scheduled switching time is calculated from the sum. The model comparison unit 35 before and after switching compares the component code of the currently used component with the component code of the component used after switching, and sets a switching flag for components with different component codes before and after switching. Compare the type of equipment and jigs currently used with the type of equipment and jigs used after switching, and set the switching flag for equipment and jigs that are different before and after switching, and switch models. And a procedure for extracting instructional content given to the user from time to time. The internal setup time calculation unit 36 refers to the standard setup change work time table 46 to determine the setup change work time with respect to the parts having the switch flag, the equipment and jigs having the switch flag, and the extracted instruction content. Extracting and creating a necessary setup change work time list. The necessary setup change manpower calculation unit 37 refers to the required setup change work time list to calculate the total required setup change work time, and all setup changes are completed at the preset internal setup target time. This is to calculate the number of personnel required to do this. The production result collection unit 31 counts the number of production results of the current production model. The current model prediction completion time confirmation unit 33 calculates the planned remaining number from the difference between the daily plan of the current production model stored in the production plan table 41 (the production planned number of the current production model) and the actual production number. The current model prediction completion time is calculated from the sum of the product of the planned remaining number and the actual tact time indicating the current actual production pace and the current time. The switching completion time calculation unit 38 calculates a necessary setup change time when the setup change work is performed based on the number of personnel calculated by the setup change required personnel calculation unit, and calculates the required setup change time and the current model prediction. The model switching completion time is calculated based on the current model predicted completion time calculated by the completion time confirmation unit. The plan achievement prediction unit 39 compares the planned switching time calculated by the predicted switching time calculation unit 34 with the model switching completion time calculated by the switching completion time calculation unit 38 to confirm whether there is a production progress delay. Is.

  The predicted switching time calculation unit 34 calculates the scheduled switching time corresponding to the production plan. As a result, when there is a change in the production plan, the setup change time can be recalculated to an appropriate time.

  The plan achievement prediction unit 39 compares the planned switching time calculated by the predicted switching time calculation unit 34 with the model switching completion time calculated by the switching completion time calculation unit 38, and delays in the production progress. In addition to determining whether or not there is a delay in progress at the obtained model change completion time, a recovery measure is examined. As a result, when there is a change in production progress, an appropriate model switching completion time can be recalculated by reviewing the number of personnel required for switching.

  Further, the setup change necessary personnel display unit 51 displays the number of personnel calculated by the setup change required personnel calculation unit 37, and the plan achievement prediction display unit 52 is produced by the plan achievement prediction unit 39. When it is determined that there is a progress delay, a recovery plan is displayed, and when the plan achievement prediction unit 39 determines that there is no production progress delay, the model switching completion calculated by the switching completion time calculation unit 38 is completed. Information on the latest production plan corresponding to the production progress delay in the production line and the plan change such as time is displayed. As a result, the user can easily grasp the number of personnel required for switching and the production start time of the next production model.

  As shown in FIG. 8, the model switching setup time calculation method of the present invention includes a production plan setting step S600 in which a production plan table is created based on data input by a user, the number of production plans, and a standard tact time table. Switching scheduled time setting step S601 for calculating the scheduled switching time from the product of the standard tact time of the current production model extracted from the above and the production start time, internal setup required time calculating step S602, and setup change required It consists of personnel calculation step S603 and model switching completion time prediction step S606, and more preferably, the number of personnel arranged in the production line or device is the number of personnel calculated in setup change required personnel calculation step S603. Step S604 for determining whether or not the number is smaller, and adding personnel when it is determined that the number is smaller Step S605 is compared with the planned switching time calculated in the scheduled switching time setting step S601 and the model switching completion time calculated in the model switching completion time prediction step S606 to confirm whether there is a production progress delay. This includes a production progress presence / absence confirmation step S607 and a step S608 for reconsidering the model switching completion time when there is a production progress delay.

  The internal setup required time calculation step 602 compares the part code of the part currently used with the part code of the part used after switching, and extracts parts with different part codes before and after switching. Comparing the types of equipment and jigs currently used with the types of equipment and jigs used after switching, and extracting the types of equipment and jigs that are different before and after switching The procedure for extracting the guidance content given to the user at the time of model switching is implemented, and the standard stage for the equipment and jigs with different parts codes and types and the instruction content before and after the switching. A setup change work time is extracted with reference to the change work time table, and a necessary setup change work time list is created.

  In addition, the setup change required manpower calculating step S603 refers to the required setup change work time list to calculate the total time of the required setup change work time, and all the setup change work is set to the preset internal setup target. It calculates the number of people required to finish on time.

  The model switching completion time prediction step S606 calculates the planned remaining number from the difference between the daily plan of the current production model stored in the production plan table and the actual production number of the current production model. The current model prediction completion time is calculated from the product of the number of units and the actual tact time indicating the current actual production pace, and the current time, and further calculated according to the number of personnel calculated by the above-mentioned replacement-required personnel calculation unit. Calculate the required setup change time when the replacement work is performed, and calculate the model change completion time based on the calculated required setup change time and the current model prediction completion time calculated by the current model prediction completion time confirmation unit To do.

  Further, the scheduled switching time setting step S601 is a step of calculating the scheduled switching time corresponding to the production plan. As a result, when there is a change in the production plan, the setup change time can be recalculated to an appropriate time.

  The production progress presence / absence confirmation step S607 is to determine whether or not there is a delay in progress at the obtained model change completion time. As a result, when there is a change in production progress, an appropriate model switching completion time can be recalculated by reviewing the number of personnel required for switching.

  Further, a step change necessary personnel display step for displaying the number of personnel calculated in the step change necessary personnel calculation step S603 may be further provided. As a result, the required number of personnel can be easily confirmed.

  The model switching setup time calculation program of the present invention includes a production plan setting step S600, a scheduled switching time setting step S601, an internal setup required time calculation step S602, a setup change required personnel calculation step S603, and a model switching completion time. The prediction step S606 is executed by a computer. Preferably, the number of personnel calculated in the necessary number of steps necessary to calculate the change in the number of steps arranged in the change necessary number display step and in the production line or the apparatus is calculated in step S603. Step S604 for determining whether there is less, Step S605 for adding personnel when it is determined that there is less, Step S607 for confirming whether production has progressed, and reconsidering the model change completion time when there is a delay in production progress Step S608 is further executed by the computer.

  Further, the scheduled switching time setting step S601 is a step of calculating the scheduled switching time corresponding to the production plan. As a result, when there is a change in the production plan, the setup change time can be recalculated to an appropriate time.

  The production progress presence / absence confirmation step S607 is to determine whether or not there is a delay in progress at the obtained model change completion time. As a result, when there is a change in production progress, an appropriate model switching completion time can be recalculated by reviewing the number of personnel required for switching.

  The recording medium of the present invention stores the above-described model switching setup time calculation program.

  According to the model switching setup time calculation system, the model switching setup time calculation method, the model switching setup time calculation program, and the recording medium storing the model switching setup time calculation program of the present invention, the model switching setup time change work In order to carry out the process efficiently, it is possible to calculate the setup change work time and the setup change start time, and when there is a change in the production plan and production progress, set the setup change time to the shortest time. It is possible to respond flexibly by recalculating the time. In addition, when there is a delay in production progress on the production line or when there is a sudden plan change, there are various effects that the number of personnel required for switching and the production start time of the next production model can be easily grasped.

  Hereinafter, a model switching setup time calculation system, a model switching setup time calculation method, a model switching setup time calculation program, and a recording medium storing this model switching setup time calculation program according to the present invention will be described with reference to the drawings. The description will be given with reference.

<Embodiment 1>
FIG. 1 is an explanatory diagram showing Embodiment 1 of the configuration of the model switching setup time calculation system of the present invention.

  As shown in FIG. 1, the model switching setup time calculation system according to the first embodiment includes a production result collection unit 1, an input unit 2, a predicted switching time calculation unit, a model comparison unit before and after switching, and a setup switching time calculation. Unit 5, setup installation time calculation unit 6, current model prediction completion time confirmation unit 7, production progress confirmation unit 8, production plan table 11, standard tact time table 12, used component confirmation table 13, standard setup change work time table 14 The management unit 10 that manages the production plan table 11, the standard tact time table 12, the used part confirmation table 13, and the standard setup change work time table 14, and the setup installation time display unit 20 are the minimum constituent requirements. is there.

  The production result collection unit 1 acquires information indicating when and how many minutes the model has passed a certain point in the production line, that is, the point at which the production of the model is completed with the work performed at that point. Hardware for storing this information in the production plan table 11 of the management unit 10. The production result collection unit 1 is, for example, a reader that reads a barcode attached to a model, a passage sensor, or the like, and the embodiment thereof is not limited.

  The input unit 2 is hardware for storing the input production plan in the production plan table 11. For example, the input unit 2 inputs information such as a keyboard and a reader that reads a barcode in which the model name and the number of units are registered. Anything that can be done.

  The prediction switching time calculation unit 3, the pre-switching model comparison unit 4, the setup change time calculation unit 5, the setup start time calculation unit 6, and the current model prediction completion time confirmation unit 7 are given information, Any device that can calculate data based on information stored in the management unit 10 may be used.

  The production progress confirmation unit 8 compares the scheduled switching time calculated by the predicted switching time calculation unit 3 with the current model prediction completion time calculated by the current model prediction completion time confirmation unit 7 to determine whether there is a progress delay. Check. Specifically, it is determined whether there is a progress delay of 30 minutes or more.

  The management unit 10 uses the production plan table 11, the standard tact time table 12, the used component confirmation table 13 and the standard setup change work time table 14 as the minimum configuration requirements, and can store given information. Anything is fine.

  Next, a first embodiment of the model switching setup time calculation method of the present invention implemented using the above-described model switching setup time calculation system will be described with reference to FIG.

  FIG. 2 is a flowchart showing the first embodiment of the model switching setup time calculation method of the present invention.

  First, using the input unit 2, the model name and the planned number of production planned for the day are input, and the production plan composed of the model name and the planned number is shown in the production plan table (example in Table 1). (Step S100).

この表１に示すように、生産計画テーブル１１は、例えば、生産が計画されている機種の機種名と、機種毎の計画台数とからなる。ここでは、この計画台数に関する情報として、４月分の計画台数と、一日毎の計画台数を示す日次計画とが含まれている。具体例を示すと、例えば機種名が「ＴＴ３００ＭＭ」の機種の４月分の計画台数は「４０００」であり、日次計画は、４月１日（４／１）が「１０００」、４月２日（４／２）が「１０００」、４月３日（４／３）が「１０００」、４月４日（４／４）が「１０００」となっている。

As shown in Table 1, the production plan table 11 includes, for example, model names of models for which production is planned and planned numbers for each model. Here, the information on the planned number includes the planned number for April and a daily plan indicating the planned number for each day. As a specific example, for example, the model number for the model whose model name is “TT300MM” for April is “4000”, and the daily plan is “1000” for April 1 (4/1). 2nd (4/2) is “1000”, 3rd April (4/3) is “1000”, 4th April (4/4) is “1000”.

  Next, the scheduled switching time setting (step S101) is performed. Details will be described with reference to the scheduled switching time setting flow of FIG.

  FIG. 3 is a flowchart showing an example of a scheduled switching time setting flow in the model switching setup time calculation method shown in FIG.

  In the scheduled switching time setting flow, first, the production plan table 11 is referred to, and the model name and date / time plan (planned number) of models scheduled for production on the day are extracted using the date of the day as a key (step S200). ). For example, if it is April 1, the model name “TT300MM”, the date / time plan “1000”, the model name “TT400ML”, and the date / time plan “1000” are extracted.

  Next, the standard tact time is extracted with reference to a standard tact time table (one example is omitted in Table 2) 12 using the model name of the model currently being produced as a key (step S201).

この表２に示すように、標準タクトタイムテーブル１２は、例えば、機種名と、この機種名の機種を１台生産する際にかかる時間を示すタクトタイム（秒／台）とからなる。具体例を挙げると、例えば機種名「ＴＴ３００ＭＭ」をキーとした場合、抽出される標準タクトタイムは「１５．０（秒／台）」である。

As shown in Table 2, the standard tact time table 12 includes, for example, a model name and a tact time (second / unit) indicating a time required for producing one model of this model name. For example, when the model name “TT300MM” is used as a key, the extracted standard tact time is “15.0 (seconds / unit)”.

  The predicted switching time calculation unit 3 calculates the scheduled switching time using the data extracted above (step S202). The calculation is performed according to the following formula 1.

Scheduled switching time = Production start time + Standard tact time x Production planned number (Formula 1)
With the calculation of the scheduled switching time, the scheduled switching time setting (step S101) is completed.

  Next, following step S101 described above, the necessary time for setting change is calculated (step S102). Details will be described with reference to the flow for calculating required setting time in FIG.

  FIG. 4 is a flowchart showing an example of a setup change required time calculation flow in the model switching setup time calculation method shown in FIG.

  In the setup change required time calculation flow, first, with respect to a list of parts used in the current production model, a used parts table (a part of the example is omitted in Table 3) 13 is referenced using the model name as a key. (Step S300).

この表３に示すように、使用部品テーブル１３は、例えば、各機種を生産する際に使用される部品の部品コードと必要数とからなる。ここでは、機種名「ＴＴ３００ＭＭ」、「ＴＴ４００ＭＸ」・・・「ＴＴ５００ＭＸ」の機種に関する情報が格納されており、各機種は部品名「部品Ａ」〜「部品Ｑ」の部品を使用して生産されている。具体例を挙げると、機種名「ＴＴ３００ＭＭ」の機種については、部品名「部品Ａ」の部品は部品コード「ＡＢＣ００１」の部品であり、必要数は「１」個である。

As shown in Table 3, the used component table 13 includes, for example, a component code and a required number of components used when each model is produced. Here, information on models with model names “TT300MM”, “TT400MX”... “TT500MX” is stored, and each model is produced using parts with parts names “part A” to “part Q”. ing. As a specific example, for the model with the model name “TT300MM”, the part with the part name “part A” is the part with the part code “ABC001”, and the required number is “1”.

  Then, for the list of parts used when producing the model that is planned to be produced next, the used parts table 13 is collated using the model name as a key (step S301).

  Next, the result of collation in step S300 and step S301 is extracted by the pre-switching model comparison unit 4 (step S302), and switching is performed for components having different component codes before and after switching. A switching flag is set as a necessary part (step S303).

  The necessary parts before and after the switching and the switching flag are stored in the switching necessary parts list. An example of the part list required for switching is shown in Table 4 with a part omitted.

この表４に示すように、切替必要部品リストは、例えば、切替前の機種の機種名と、この機種を生産する際に使用される部品の部品コードおよび必要数と、切替後の機種の機種名と、この機種を生産する際に使用される部品の部品コードおよび必要数と、表中「○」を用いて示された切替フラグとからなる。具体例を挙げると、切替前の機種の機種名は「ＴＴ３００ＭＭ」であり、この機種を生産する際に必要とされる部品は「部品Ａ」〜「部品Ｑ」まである。一方、切替後の機種の機種名は「ＴＴ４００ＭＸ」であり、この機種を生産する際に必要とされる部品「部品Ａ」〜「部品Ｑ」までのうち、「部品Ｂ」、「部品Ｃ」、「部品Ｅ」および「部品Ｐ」については、使用される部品の部品コードまたは必要数が機種名「ＴＴ３００ＭＭ」の機種を生産する際に使用されている部品の部品コードまたは必要数と異なっているため、切替フラグがたっている（即ち、「○」が示されている）。

As shown in Table 4, the list of necessary parts for switching includes, for example, the model name of the model before switching, the part code and required number of parts used when producing this model, and the model of the model after switching. It consists of a name, a part code and a necessary number of parts used when producing this model, and a switching flag indicated by “◯” in the table. As a specific example, the model name of the model before switching is “TT300MM”, and the parts required for producing this model are “part A” to “part Q”. On the other hand, the model name of the model after switching is “TT400MX”, and “part B”, “part C” among the parts “part A” to “part Q” required for producing this model , "Part E" and "Part P" are different from the part code or required number of parts used when producing the model of the model name "TT300MM". Therefore, the switching flag is set (that is, “◯” is shown).

  Next, the setup change time calculation unit 5 is used to refer to a standard setup change work time table (a part of the example is omitted in Table 5) 14 with the part name in the above-described required part list as a key. Then, the setup change work time is extracted, and a necessary setup change work time list (one example is omitted from Table 6) is created (step S305).

この表５に示すように、標準段取替え作業時間テーブル１４は、例えば、部品の部品名と、この部品名別に示された、作業の内容を示す段取替え作業、この作業にかかる時間を示す段取替え作業時間（分）、および１つの部品の段取替えにかかる時間を示す合計（分）とからなる。具体例を挙げると、部品名は「部品Ａ」〜「部品Ｑ」まであり、例えば部品名「部品Ａ」の部品については、段取替え作業が「ライン供給」および「空箱処理」の２つあり、「ライン供給」の段取替え作業時間は「２．０」分であり、「空箱処理」の段取替え作業時間は「１．０」分であり、従って、「部品Ａ」の段取替えにかかる時間の合計は「３．０」分である。

As shown in Table 5, the standard setup change work time table 14 includes, for example, the part name of the part, the setup change work indicating the contents of the work indicated by the part name, and the stage indicating the time required for this work. It consists of a replacement work time (minutes) and a total (minutes) indicating the time required for the replacement of one part. For example, the part names are “part A” to “part Q”. For example, for the part with the part name “part A”, there are two part change operations, “line supply” and “empty box processing”. Yes, the setup change work time of “line supply” is “2.0” minutes, the setup change work time of “empty box processing” is “1.0” minutes, and therefore the setup change of “part A”. The total time taken for is “3.0” minutes.

この表６に示すように、必要段取替え作業時間リストは、例えば、切替前の機種の機種名と、この機種を生産する際に使用される部品の部品コードおよび必要数と、切替後の機種の機種名と、この機種を生産する際に使用される部品の部品コードおよび必要数と、部品毎に示された、切替フラグおよび段取替え作業時間とからなる。

As shown in Table 6, the necessary setup change work time list includes, for example, the model name of the model before switching, the part code and necessary number of parts used when producing this model, and the model after switching. Model name, part code and necessary number of parts used when producing this model, and switching flag and setup change work time shown for each part.

  As a specific example, the model name of the model before switching is “TT300MM”, and the component codes of “part A” to “part Q” used when producing this model are “ABC001” and “BCD002”. ... "HGF221", the required number of each part is "1", and the model name of the model after switching is "TT400MX", and "part A" used when producing this model The part code of “part Q” is “ABC001”, “BCD002”... “HGF221”, and the required number of “part A” is “1”, “part B” is “2”. “Part Q” is “1”, the switching flag is “Part B”, “Part C”, “Part E”, and “Part P”, and the setup change work time is “2” for “Part B”. .0 ”,“ Part C ”is“ 3.0 ”, and“ Part E ”is“ 1 ”. 5 "is a minute," Parts P "is" 4.0 "minute.

  Completion of the required setup change time calculation (step S102) is completed with the creation of the required setup change work time list.

  Next, the latest take-up start time calculation (step S103) is performed using the set-up start time calculation unit 6, and details will be described with reference to the latest take-up start time calculation flow in FIG. .

  FIG. 5 is a flowchart showing an example of the latest setup start time calculation flow in the model switching setup time calculation method shown in FIG.

  First, the scheduled switching time calculated in the scheduled switching time setting (step S101) is referred to (step S400).

  Next, the required setup change work time list (Table 6) calculated in the setup change required time calculation (step S102) is referred to (step S401). Furthermore, from this required setup change work time list, the setup change work time for one part (for example, the part displayed in the bottom column) among the parts that have the switching flag is set as the setup change work time of the corresponding part. Are extracted (step S402).

  Then, using Formula 2 below, the start time of the setup change work of the one part (hereinafter also simply referred to as “work start time”) is determined from the scheduled switching time and the setup change work time of the corresponding part. The work start time is set as the latest changeover start time of the one component (step S403).

Work start time = scheduled switching time-changeover work time for the relevant part (Formula 2)
Next, it is determined from the necessary setup change work time list whether or not there is a part that has a switching flag and whose work start time has not been calculated (step S404).

  If the switching flag is set and there is no part whose work start time has not been calculated (when the determination result in step S404 is NO), the process proceeds to step S407.

  In addition, when the switching flag is set and there is a part for which the work start time is not calculated (when the determination result in step S404 is YES), one of the parts for which the work start time has not been calculated ( For example, the component displayed in the lowermost column) is selected, and the setup change work time related to this one component is extracted as the setup change work time of the corresponding component (step S405). Then, using the following formula 3, the work start time is obtained from the work start time obtained immediately before (referred to as “previous work start time” in formula 3) and the setup change work time of the corresponding part, and this work start time. Is set as the latest start time of the part changeover (step S406).

Work start time = previous work start time-setup time for the corresponding part (Formula 3)
Further, after the setting, the process returns to step S404 again, and until the setup change latest start time is set for all the parts for which the switching flag is set (until the determination result in step S404 becomes NO), step S404 to step S404. S406 is repeated.

  When all the setup change latest start time settings are completed (if the determination result in step S404 is NO), the setup change latest start time set immediately before is set as the latest setup start time of the entire setup change work ( Step S407).

  Then, the required setup change work time list, the scheduled switching time, the latest setup start time of each part and the latest start time of the entire setup change work are combined together in the setup setup time list (see Table 7). As an example is partially omitted), the latest setting time calculation (step S103) is completed by displaying it on the setting time display unit 20 (step S408).

この表７に示すように、この算出結果リストにおいて、例えば、段取替え最遅着手時刻は、必要段取替え作業時間リストの段取替え作業時間を示す欄の右側に部品毎に表示されており、切替予定時刻および段取替え作業全体の最遅着手時刻は、段取替え最遅着手時刻の下側にそれぞれ表示されている。

As shown in Table 7, in this calculation result list, for example, the latest setup change start time is displayed for each part on the right side of the column showing the setup change work time in the required setup change work time list. The scheduled time and the latest start time of the entire setup change work are respectively displayed below the latest setup change latest time.

  As a specific example, the switching flags are “part B”, “part C”, “part E”, and “part P”, and the latest start time of setup change is “part B” is “14:08”. Yes, “Part C” is “14:10”, “Part E” is “14:14”, “Part P” is “14:56”, and the scheduled switching time is “15:00”. The latest start time of the entire setup change work is “14:08”.

  Next, the current model prediction completion time confirmation (step S104) is performed using the current model prediction completion time confirmation unit 7, and details will be described with reference to the current model prediction completion time confirmation flow of FIG.

  FIG. 6 is a flowchart showing an example of a current model predicted completion time confirmation flow in the model switching setup time calculation method shown in FIG.

  First, the production plan number of the current production model stored in the production plan table 11 is collated (step S500).

  Next, the production results collection unit 1 collates the production results of the current production model being counted (step S501). Then, based on the information obtained in step S500 and step S501, the current planned remaining number is calculated using the following mathematical formula 4 (step S502).

Planned remaining quantity = Planned quantity-Actual production quantity (Formula 4)
Next, in order to calculate the current production speed, the time taken for production from the current production record number to the pace confirmation set number collected by the production record collection unit 1 (hereinafter also simply referred to as “production time”). ) Are tabulated (step S503). Note that the pace confirmation set number used here is an arbitrary number set in advance, and it is desirable to set in consideration for calculating a realistic production pace depending on the production model and product type.

  Further, using the production time obtained in step S503, the actual tact time is calculated by the following formula (5) (step S504).

Actual tact time = production time / pace confirmation set number (Formula 5)
Based on the information obtained in steps S502 and S504, the current model prediction completion time is calculated using the following formula 6 (step S505).

Current model prediction completion time = current time + actual tact time × plan remaining number (Formula 6)
With the calculation of the current model prediction completion time, the current model prediction completion time confirmation (step S104) is completed.

  Next, the production progress confirmation unit 8 is used to compare the scheduled switching time calculated in step S101 with the current model prediction completion time calculated in step S104, and there is a progress delay of 30 minutes or more. Whether or not (step S105).

  If there is no progress delay of 30 minutes or more (when the determination result in step S105 is NO), all the procedures according to the model switching setup time calculation method of the first embodiment are completed.

  On the other hand, when a progress delay of 30 minutes or more is found (when the determination result in step S105 is YES), the scheduled switching time is corrected (step S106), and the process proceeds to step S103. The procedure for correcting the scheduled switching time in step S106 is the same as that in step S101 except that the actual tact time is used instead of the standard tact time, and thus detailed description thereof is omitted.

  Further, the standard of 30 minutes is set in advance, but can be arbitrarily changed.

<Embodiment 2>
FIG. 7 is an explanatory diagram showing Embodiment 2 of the configuration of the model switching setup time calculation system of the present invention.

  As shown in FIG. 7, the model switching setup time calculation system according to the second embodiment includes a production result collection unit 31, an input unit 32, a current model prediction completion time confirmation unit 33, and a prediction switching time calculation unit 34. A pre-switching model comparison unit 35, an internal setup time calculation unit 36, a setup change required personnel calculation unit 37, a switch completion time calculation unit 38, a plan achievement prediction unit 39, a management unit 40, and a production plan. The table 41, the standard tact time table 42, the used parts table 43, the used equipment jig / tool table 44, the work guidance table 45, the standard setup change work time table 46, and the display unit 50 are the minimum constituent requirements. It is what.

  The production result collection unit 31 acquires information indicating when and how many minutes the model has passed a certain point in the production line, that is, a point where the production of the model is completed with the work performed at that point. This is hardware for storing this information in the production plan table 41. The production result collection unit 31 is, for example, a reader that reads a barcode attached to a model, a passage sensor, or the like, and the embodiment thereof does not matter.

  The input unit 32 is hardware for storing the input production plan in the production plan table 41. For example, the input unit 32 inputs information such as a keyboard and a reader that reads a barcode in which the model name and the number of units are registered. Anything that can be done.

  Current model prediction completion time confirmation unit 33, prediction switching time calculation unit 34, pre-switching model comparison unit 35, internal setup time calculation unit 36, setup change required personnel calculation unit 37, switching completion time calculation unit 38, and plan achievement prediction unit 39 is only required to be able to calculate data based on given information or information managed by the management unit 40. For example, a predetermined CPU 39 (central processing unit) may be used. This is realized by executing the program.

  Further, the plan achievement prediction unit 39 compares the planned switching time calculated by the predicted switching time calculation unit 34 with the model switching completion time calculated by the switching completion time calculation unit 38 to switch the model switching completion time. It is determined whether or not there is a progress delay by determining whether or not it is later than the scheduled time by a preset time (for example, 30 minutes) or more.

  The management unit 40 manages information in the production plan table 41, the standard tact time table 42, the used parts table 43, the used equipment jig / tool table 44, the work guidance table 45 and the standard setup change work time table 46. Any information can be used as long as it can store given information or read data in each table as required.

  The display unit 50 includes a setup change necessary personnel display unit 51 and a plan achievement prediction display unit 52, and is, for example, an LCD (Liquid Crystal Display) liquid crystal display device or a CRT (Cathode Ray Tube).

  Next, a second embodiment of the model switching setup time calculation method of the present invention implemented using the above-described model switching setup time calculation system will be described with reference to FIG.

  FIG. 8 is a flowchart showing the second embodiment of the model switching setup time calculation method of the present invention.

  First, the input unit 32 is used to input the model name and the planned number that are planned for production, and the production plan composed of the model name and the planned number is stored in the production plan table 41 (step S600). ).

  An example of the production plan table 41 is the same as Table 1 shown in the second embodiment, and a description thereof is omitted here.

  Next, the predicted switching time calculation unit 34 performs the scheduled switching time setting (step S601). Details of the scheduled switching time setting will be described with reference to the scheduled switching time setting flow in FIG.

  FIG. 9 is a flowchart showing an example of a scheduled switching time setting flow in the model switching setup time calculation method shown in FIG.

  In the scheduled switching time setting flow, first, the production plan table 41 is referred to, and using the date of the day as a key, the model name and daily plan (planned number) of the model planned for production on the day are extracted. The production number of the current production model is collated (step S700). For example, on April 1, the model name “TT300MM”, the daily plan “1000”, the model name “TT400ML”, and the daily plan “1000” are extracted from the production plan table 41, and the current production model is the model. If the model name is “TT300MM”, the daily plan “1000” is collated using the model name “TT300MM” as a key.

  Next, the standard tact time table 42 is extracted with reference to the standard tact time table 42 using the model name of the model currently being produced as a key (step S701).

  An example of the standard tact time table 42 is the same as that in Table 2 of the first embodiment, and a detailed description thereof is omitted here.

  Next, the scheduled switching time is calculated using the daily plan collated in step S700 and the standard tact time extracted in step S701 (step S702). The calculation is performed according to the following formula 7.

Scheduled switching time = production start time + standard tact time x daily plan (Formula 7)
The scheduled switching time setting (step S601) is completed with the calculation of the scheduled switching time.

  Next, following the above-described step S601, the pre-switching model comparison unit 35 and the internal setup time calculation unit 36 perform the internal setup required time calculation (step S602). The details are shown in FIG. This will be described with reference to the necessary time calculation flow.

  FIG. 10 is a flowchart showing an example of an internal setup required time calculation flow in the model switching setup time calculation method shown in FIG.

  In the internal setup required time calculation flow, first, a list of parts used in the current production model is referred to the used parts table 43 using the model name as a key (step S800).

  An example of the used component table 43 is the same as Table 3 in the first embodiment, and thus detailed description thereof is omitted here.

  Then, for the list of parts used when producing the model that is planned to be produced next, the used parts table 43 is collated using the model name as a key (step S801).

  Next, by comparing the information obtained as a result of the collation in step S800 and step S801, information on parts having different component codes and necessary numbers before and after switching is used as a switching required part. By setting a switching flag, different parts are extracted (step S802), and a switching required parts list is created from the information obtained as a result of collation in steps S800 and S801 and the switching flag (step S803).

  An example of the switching required component list is the same as that in Table 4 of the first embodiment, and thus detailed description thereof is omitted here.

  Next, with respect to the list of equipment and jigs used in the current production model, the used equipment jig / tool table 44 is referred to using the model name as a key (step S804).

  An example of the used equipment jig tool table 44 is shown in Table 8 with a part thereof omitted.

この表８に示すように、使用設備治工具テーブル４４は、例えば、各機種を生産する際に使用される設備または治工具の種類と必要数とからなる。ここでは、機種名「ＴＴ３００ＭＭ」、「ＴＴ４００ＭＸ」・・・「ＴＴ５００ＭＸ」の機種に関する情報が格納されており、各機種は設備名または治工具名「パレット」〜「トルクレンチ」の設備および治工具を使用して生産されている。具体例を挙げると、機種名「ＴＴ３００ＭＭ」の機種については、設備名「パレット」の設備として種類「パレットＡ」の設備が使用されており、必要数は「１」個であり、設備名「製品受け台」の設備として種類「受け台Ａ」の設備が使用されており、必要数は「１」個であり、治工具名「エアドライバー」の治工具として種類「ビットＡ」の治工具が使用されており、必要数は「１」個であり、治工具名「トルクレンチ」として種類「トルク○○」の治工具が使用されており、必要数は「１」個である。

As shown in Table 8, the used equipment jig / tool table 44 includes, for example, types of equipment or jigs used when producing each model and the required number. Here, information on the model names “TT300MM”, “TT400MX”... “TT500MX” is stored, and each model is a facility name or tool name “pallet” to “torque wrench” facility and tool. Has been produced using. As a specific example, for the model with the model name “TT300MM”, the equipment of the type “pallet A” is used as the equipment with the equipment name “pallet”, the required number is “1”, and the equipment name “ The equipment of the type “cradle A” is used as the equipment of the “product cradle”, the required number is “1”, and the tool of the type “bit A” as the jig of the tool name “air driver” Is used, the required number is “1”, the tool of the type “torque XX” is used as the tool name “torque wrench”, and the required number is “1”.

  Then, with respect to the list of equipment and jigs used when producing the model that is planned to be produced next, the used equipment jig / tool table 44 is referred to using the model name as a key (step S805). .

  Next, by comparing the information obtained as a result of collation in Steps S804 and S805, the information on the types of equipment and jigs used and the number of necessary tools and jigs before and after switching is different. Then, by setting a switching flag as a switching-necessary equipment tool, the equipment and jigs that need to be changed are extracted (step S806), and the information and switching flag obtained as a result of collation in steps S804 and S805, The switch-required equipment jig / tool list is created (step S807).

  An example of the list of necessary jigs for switching is shown in Table 9 with a part omitted.

この表９に示すように、切替必要設備治工具リストは、例えば、切替前の機種の機種名と、この機種を生産する際に使用される設備や治工具の種類および必要数と、切替後の機種の機種名と、この機種を生産する際に使用される設備や治工具の種類および必要数と、表中「○」を用いて示された切替フラグとからなる。具体例を挙げると、切替前の機種の機種名は「ＴＴ３００ＭＭ」であり、この機種を生産する際に必要とされる設備および治工具の設備名または治工具名は「パレット」、「製品受け台」、「エアドライバー」〜「トルクレンチ」まである。一方、切替後の機種の機種名は「ＴＴ４００ＭＸ」であり、この機種を生産する際に必要とされる設備名または治工具名「パレット」、「製品受け台」、「エアドライバー」〜「トルクレンチ」までのうち、「製品受け台」および「エアドライバー」については、使用される設備および治工具の種類が機種名「ＴＴ３００ＭＭ」の機種を生産する際に使用されている設備および治工具の種類と異なっているため、切替フラグがたっている（即ち、「○」が示されている）。

As shown in Table 9, for example, the list of necessary equipment jigs for switching includes, for example, the model name of the model before switching, the types and necessary numbers of equipment and jigs used when producing this model, and after switching. The model name of the model, the type and necessary number of equipment and jigs used when producing the model, and a switching flag indicated by “◯” in the table. As a specific example, the model name of the model before switching is “TT300MM”, and the equipment name or tool name of the equipment and jigs required when producing this model is “pallet”, “product receiving”. There are "base", "air driver"-"torque wrench". On the other hand, the model name of the model after switching is “TT400MX”, and the equipment name or tool name required for production of this model is “pallet”, “product cradle”, “air driver” to “toru” Among the “Lux Wrench”, “Product cradle” and “Air driver” are the type of equipment and jigs used when producing models with the model name “TT300MM”. Since it is different from the type, a switching flag is set (that is, “◯” is shown).

Next, with respect to the guidance item regarding the next production model, the work guidance table 45 is referred to using the model name of the next production model as a key (step S808).
An example of this work guidance table table 45 is shown in FIG.

この表１０に示すように、作業指導表テーブル４５は、例えば、切替後の機種名と、切替後に実施される作業の作業名と、各作業に関する指導内容とからなる。ここでは、切替後に機種名「ＴＴ４００ＭＸ」および機種名「ＴＴ５００ＭＸ」の機種が生産される場合に必要とされる指導内容が一例として示されているが、実際には、この生産ラインや装置において扱いうる全ての機種に関する指導内容が、作業指導表テーブル４５に格納されている。具体例を挙げると、切替後に機種名「ＴＴ４００ＭＸ」の機種が生産される場合には、作業名「作業Ａ」〜「作業Ｚ」までの作業が実施され、例えば作業名「作業Ａ」の作業に関する指導内容として「品質注意ポイント指導」がある。切替後に機種名「ＴＴ５００ＭＸ」の機種が生産される場合には、作業名「作業Ａ」〜「作業Ｚ」までの作業が実施され、例えば作業名「作業Ａ」の作業に関する指導内容として「組付治具に確実にセットして作業を実施し、位置ズレなどがないように注意すること」がある。

As shown in Table 10, the work guidance table 45 includes, for example, the model name after switching, the work name of work performed after switching, and the guidance content regarding each work. Here, the instruction content required when the model name “TT400MX” and the model name “TT500MX” are produced after switching is shown as an example. The instruction content regarding all possible models is stored in the work instruction table table 45. As a specific example, when a model with the model name “TT400MX” is produced after switching, the work from the work names “work A” to “work Z” is performed. For example, the work with the work name “work A” is performed. There is “Guidance on Quality Caution Points” as the content of the guidance. When a model with the model name “TT500MX” is produced after switching, the work from the work name “work A” to “work Z” is performed. Be sure to set it on the attached jig and perform the work, and make sure there is no misalignment. "

  Next, instruction items necessary for producing the next production model are extracted (step S809), and a necessary instruction content list is created using the extracted instruction items (step S810).

  An example of the necessary instruction content list is shown in Table 11 with a part omitted.

この表１１に示すように、必要指導内容リストは、例えば、切替後の機種名と、切替後に実施される作業の作業名と、各作業に関する指導内容とからなる。具体例を挙げると、切替後に機種名「ＴＴ４００ＭＸ」の機種が生産される場合には、作業名「作業Ａ」〜「作業Ｚ」までの作業が実施され、例えば作業名「作業Ａ」の作業に関する指導内容として「品質注意ポイント指導」がある。

As shown in Table 11, the necessary instruction content list includes, for example, a model name after switching, a work name of work performed after switching, and a guidance content regarding each work. As a specific example, when a model with the model name “TT400MX” is produced after switching, the work from the work names “work A” to “work Z” is performed. For example, the work with the work name “work A” is performed. There is “Guidance on Quality Caution Points” as the content of the guidance.

  Next, the standard setup change work time table 46 is referred to using the part name in the above-mentioned necessary part list for switching, the equipment name or tool name in the necessary tool list for switching, and the work name in the required instruction content list as keys. Then, the corresponding internal setup work time is extracted (step S811).

  An example of the standard setup change work time table 46 is shown in FIG.

この表１２に示すように、標準段取替え作業時間テーブル４６は、例えば、項目と、各項目に関する１つまたは複数の内容と、この内容にかかる作業時間、即ち内段取作業時間（分）と、項目毎の内段取作業時間の合計（分）とからなる。具体例を挙げると、項目は、部品に関しては「部品Ａ」〜「部品Ｑ」まであり、設備および治工具に関しては「パレット」〜「トルクレンチ」まであり、指導項目に関しては「作業Ａ」〜「作業Ｚ」まであり、内容は、例えば、項目「部品Ａ」に関しては「ライン供給」と「空箱処理」とであり、項目「パレット」に関しては「入替」であり、項目「作業Ａ」に関しては「品質注意ポイント指導」であり、内段取作業時間は、例えば、項目「部品Ａ」の内容「ライン供給」が「２．０」分であり、「パレット」が「１０」分であり、「作業Ａ」が「２．０」分であり、合計は、例えば、項目「部品Ａ」が「３．０」分であり、項目「パレット」が「１０」分であり、項目「作業Ａ」が「２．０」分である。

As shown in Table 12, the standard setup change work time table 46 includes, for example, items, one or a plurality of contents related to each item, and work times related to the contents, that is, internal setup work time (minutes). And the total (minutes) of the internal setup work time for each item. Specific examples include “part A” to “part Q” for parts, “pallet” to “torque wrench” for equipment and jigs, and “operation A” for instruction items. There are up to “operation Z”, and the contents are, for example, “line supply” and “empty box processing” for the item “part A”, “replacement” for the item “pallet”, and the item “operation A”. For “Quality Caution Point Guidance”, for example, the content of the item “Part A” “Line Supply” is “2.0” minutes and “Pallet” is “10” minutes. Yes, "Work A" is for "2.0", and the total is, for example, the item "Part A" is for "3.0", the item "Palette" is for "10", and the item " “Work A” is “2.0” minutes.

  Next, a necessary setup change work time list is created from the information in which the switch flag is set among the information on the necessary instruction content list and the required switch tool list and the internal setup work time extracted in step S811 (step S812). ).

  An example of the necessary setup change work time list is shown in Table 13 with a part omitted.

この表１３に示すように、必要段取替え作業時間リストは、例えば、切替前の機種の機種名と、この機種を生産する際に使用される部品、設備および治工具の名称を示す項目と、各項目の内容および必要数と、切替後の機種の機種名と、この機種を生産する際に使用される部品、設備および治工具の名称を示す項目と、各項目の内容および必要数と、切替後の機種を生産する際に必要な指導項目を示す項目と、各項目の内容と、全ての項目の内段取作業時間（分）と、全ての項目の内段取作業時間の合計（分）とからなる。具体例を挙げると、切替前の機種の機種名は「ＴＴ３００ＭＭ」であり、切替後の機種の機種名は「ＴＴ４００ＭＸ」であり、項目は「部品Ｂ」、「部品Ｃ」、「部品Ｅ」・・・「製品受け台」、「エアドライバー」・・・「作業Ａ」、「作業Ｂ」・・・「作業Ｚ」であり、例えば項目「部品Ｂ」の内容および必要数は、切替前の機種に関しては「ＢＣＤ００２」および「１」個であり、切替後の機種に関しては「ＢＣＤ００２」および「２」個であり、例えば項目「作業Ａ」の内容は「品質注意ポイント指導」であり、例えば項目「部品Ｂ」の内段取作業時間は「２．０」分であり、全ての項目の内段取作業時間の合計は「４５．０」分である。

As shown in Table 13, the necessary setup change work time list includes, for example, model names of models before switching, items indicating names of parts, facilities, and jigs and tools used when producing the models, Contents and required number of each item, model name of the model after switching, items indicating names of parts, equipment and jigs used when producing this model, contents and required number of each item, Items indicating the guidance items required when producing the model after switching, the contents of each item, the internal setup work time (minutes) of all items, and the total of the internal setup work time of all items ( Min). For example, the model name of the model before switching is “TT300MM”, the model name of the model after switching is “TT400MX”, and the items are “part B”, “part C”, and “part E”. ... "Product cradle", "Air driver" ... "Work A", "Work B" ... "Work Z", for example, the content and required number of items "Part B" are before switching There are “BCD002” and “1” for the models of “BCD002”, and “BCD002” and “2” for the models after switching, for example, the content of the item “Work A” is “Quality Caution Point Guidance”, For example, the internal setup work time of the item “part B” is “2.0” minutes, and the total of the internal setup work time of all items is “45.0” minutes.

  With the creation of the necessary setup change work time list (step S812), the internal setup required time calculation (step S602) is completed. Note that steps S800 to S810 described above are performed in the pre-switching model comparison unit 35, and steps S811 to S812 described above are performed in the internal setup time calculation unit 36.

  Next, the setup necessary staff calculation unit 37 is used to calculate setup necessary staff (step S603). Details will be described with reference to the setup necessary staff calculation flow in FIG.

  FIG. 11 is a flowchart showing an example of a flow for calculating the necessary personnel for setup change in the model switching setup time calculating method shown in FIG.

  First, with reference to the necessary setup change work time list created in the calculation of required internal setup time (step S602), the total of the internal setup work times of all items (hereinafter also referred to as “necessary setup change work time”). .) Is extracted (step S900).

Next, the internal setup target time is collated (step S901). The internal setup target time is a target value of setup change time in the process for achieving a given production plan, and is, for example, “within 10 minutes within setup change for all operations”. Next, the number of personnel required for the setup change (hereinafter also referred to as “necessary number of personnel”) is calculated from the total required setup change work time and the internal setup target time using the following formula 8 (step S902).
Necessary number of staff = Total required setup change work time / Internal setup target time (Formula 8)
With the calculation of the necessary number of personnel (step S902), the necessary number of personnel for changing the setup (step S103) is completed.

  Next, it is determined whether or not the number of personnel involved in the setup change and the manufacturing after the setup change is equal to or more than the necessary number calculated in step S603 (step S604).

  If the number is smaller than the necessary number of personnel (if the determination result in step S604 is YES), the display of the number of personnel and the content for instructing the addition of the number of personnel is displayed on the necessary personnel display section 51. Is displayed (step S605), the process proceeds to step S606.

  If the number is greater than or equal to the required number of personnel (if the determination result in step S604 is NO), the number of necessary personnel is displayed in the setup change necessary personnel display unit 51, and then the process proceeds to step S606.

  In step S606, the model switching completion time prediction is performed using the current model prediction completion time confirmation unit 33 and the switching completion time calculation unit 38. For details, refer to the model switching completion time prediction flow in FIG. explain.

  FIG. 12 is a flowchart illustrating an example of a model switching completion time prediction flow in the model switching setup time calculation method illustrated in FIG.

  First, with reference to the production plan table 41, using the date of the current day as a key, the model name and daily plan of the model that is planned to be produced on that day are extracted, and the number of daily plans for the current production model ( Hereinafter, it is also referred to as “planned number” (step S1000).

  Next, the production result collecting unit 31 collates the production number of the current production model being counted (hereinafter also referred to as “result number”) (step S1001). Based on the information obtained in step S1000 and step S1001, the current planned remaining number is calculated using the following formula 9 (step S502).

Planned remaining number = Planned number-Actual number (Formula 9)
Next, in order to calculate the current production speed, the time (hereinafter also referred to as “production time”) collected from the current production record number to the pace confirmation set number collected by the production record collection unit 31. ) (Step S1003). Note that the number of pace confirmation settings used here is an arbitrary number set in advance, and it is desirable to set in consideration to calculate a realistic production pace according to the production model and product type. Using the production time obtained in step S1003, the actual tact time is calculated by the following formula 10 (step S504).

Actual tact time = production time / pace confirmation setting number (Formula 10)
Next, based on the information obtained in steps S1002 and S1004, the current model prediction completion time is calculated (step S1005) using the following formula 11.

Current model prediction completion time = current time + actual tact time × plan remaining number (Formula 11)
Next, the total of the internal setup work times of all items is extracted from the required setup change work time list created in step S812 as the total required setup change work time for the next model change (step S1006).

  Next, based on the information obtained from the current model predicted completion time obtained in step S1005 and the total required setup change work time obtained in step S1006, the model change completion time is calculated using the following formula 12. Is calculated (step S1007).

Model change completion time = Current model prediction completion time + Total required setup change work time (Formula 12)
With the calculation of the model switching completion time (step S1007), the model switching completion time prediction (step S1006) is completed.

  The above-described steps S1000 to S1005 are performed by the current model prediction completion time confirmation unit 33, and the above-described steps S1006 to S1007 are performed by the switching completion time calculation unit 38.

  Next, the planned achievement prediction unit 39 is used to compare the planned switching time calculated in step S601 with the model switching completion time calculated in step S606 to determine whether there is a production progress delay. Judgment is made (step S607).

  If there is no progress delay more than the preset time (when the determination result in step S607 is NO), the model change completion time is displayed on the plan achievement prediction display unit 52, and the second embodiment. All the procedures according to the model switching setup time calculation method are completed. In addition, the plan achievement prediction display unit 52 includes, as necessary, the latest production plan, a list of necessary parts to be switched, a list of necessary tools for switching, a list of necessary jigs and tools, a necessary instruction content list, a necessary setup change work time list, and the like. Is displayed.

  On the other hand, when a progress delay of a preset time or more is found (when the determination result in step S607 is YES), after reviewing the recovery plan (step S608), the plan achievement prediction display unit 52 The recovery plan is displayed, and all procedures according to the model switching setup time calculation method of the second embodiment are completed. As an example of this recovery plan, there is support by other line or indirect department personnel to shorten the setup change time.

  As a criterion for determining whether or not there is a progress delay, a preset length of time is used, but the length of time can be arbitrarily changed.

  Furthermore, the list of necessary parts to be switched, the list of necessary jigs for switching, the list of necessary guidance contents and the list of necessary setup change work times, the production plan table 41, the standard tact time table 42, the used parts table 43, the used equipment jigs. The tool table 44, the work guidance table table 45, and the standard setup change work time table 46 are recorded in a computer data recording means or a computer readable recording medium used when realizing a model change setup time calculation system.

  The model switching setup time calculation program of each of the first and second embodiments implements the above-described model switching setup time calculation method, and the recording medium of the present embodiment stores this model switching setup time calculation. A computer-readable recording medium storing a program. Also, examples of the recording medium include a semiconductor storage element such as a mask ROM (Read Only Memory) and a flash ROM, a hard disk, a flexible disk, a MO (Magneto-Optic) disk, a CD-ROM (Compact Disc Read Only Memory), and a DVD. -ROM (Digital Versatile Disc Read Only Memory), magneto-optical disk, IC (Integrated Circuit) card, magnetic tape, etc., and other recording media that can record programs. Also good. Further, the program itself may be transmitted by communication and recorded on a recording medium.

  Furthermore, when creating a model switching setup time calculation program, a program that periodically executes steps S104 and S105, and steps S601 to S608 described above is assembled to match the current production pace. In this state, it is possible to always keep track of the latest start time of setup change.

  In addition, when the model or the number of units planned for production is changed, the latest latest start time is obtained by performing the main flow from step S100 and step S600 using the new production plan after the change. Can be obtained.

  Since it has such a configuration, the model switching setup time calculation system, the model switching setup time calculation method, the model switching setup time calculation program of the present invention, and the record storing this model switching setup time calculation program According to the medium, it is possible to efficiently carry out the process of changing the model.

  The model switching setup time calculation system, the model switching setup time calculation method, the model switching setup time calculation program, and the recording medium storing the model switching setup time calculation program of the present invention vary in the production plan and the production progress. It can be effectively used for use in certain cases.

It is explanatory drawing which shows one Embodiment of a structure of the model switching setup time calculation system of this invention. It is a flowchart which shows one Embodiment of the model switching setup time calculation method of this invention. 3 is a flowchart illustrating an example of a scheduled switching time setting process in the model switching setup time calculation method illustrated in FIG. 2. FIG. 3 is a flowchart showing an example of a setup change required time calculation process in the model switching setup time calculation method shown in FIG. 2. FIG. It is a flowchart which shows an example of the latest setup start time calculation process among the model switching setup time calculation methods shown in FIG. 3 is a flowchart illustrating an example of a current model predicted completion time confirmation process in the model switching setup time calculation method illustrated in FIG. 2. It is explanatory drawing which shows Embodiment 2 of a structure of the model switching setup time calculation system of this invention. It is a flowchart which shows Embodiment 2 of the model switching setup time calculation method of this invention. It is a flowchart which shows an example of the switching scheduled time setting process among the model switching setup time calculation methods shown in FIG. It is a flowchart which shows an example of the internal setup required time calculation process among the model switching setup time calculation methods shown in FIG. It is a flowchart which shows an example of a setup change required personnel calculation process among the model switching setup time calculation methods shown in FIG. It is a flowchart which shows an example of the model switching completion time prediction process among the model switching setup time calculation methods shown in FIG.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Production result collection part 2 Input part 3 Prediction switching time calculation part 4 Model change part before and after switching 5 Setup change time calculation part 6 Setup start time calculation part 7 Current model prediction completion time confirmation part 8 Production progress confirmation part 10 Management part 11 Production plan table 12 Standard tact time table 13 Used parts confirmation table 14 Standard setup change work time table 20 Setup installation time display part 31 Production result collection part 32 Input part 33 Current model prediction completion time confirmation part 34 Predictive switching time calculation part 35 Model comparison unit before and after switching 36 Internal setup time calculation unit 37 Required personnel calculation unit for setup change 38 Switching completion time calculation unit 39 Plan achievement prediction unit 40 Management unit 41 Production plan table 42 Standard tact time table 43 Parts used table 44 Equipment used Tool table 45 Work guidance table 46 Standard setup change time table It requires personnel display unit replacement Le 50 display unit 51 stage 52 Plan achieved prediction display unit

Claims (18)

A model switching setup time calculation system that calculates the time required for setup change work that occurs when switching models when producing multiple models in the production process,
An input unit for the user to enter production plan data;
A production performance collection department that counts the production performance of current production models,
The current model forecast completion time is calculated by calculating the planned remaining number from the difference between the date and time plan of the current production model stored in the production plan table and the actual production quantity, and calculating the current model forecast completion time based on this planned remaining quantity A time confirmation unit;
A predicted switching time calculation unit for calculating a scheduled switching time based on the production planned number of the current production model extracted from the production plan table;
Compare the part code of the part currently used with the part code of the part used after switching, and extract the parts with different part codes before and after switching,
For parts whose part codes are different before and after switching, a setup change time calculation unit that extracts a setup change work time by referring to the standard setup change work time table and calculates a required setup change work time;
Based on the estimated switching time calculated by the predicted switching time calculation unit and the necessary setup change work time of all the parts that need the setup change calculated by the setup change time calculation unit, the start time of the setup change work is determined. A model switching setup time calculation system comprising a setup setup time calculation unit for calculating.   The current model prediction completion time confirmation unit calculates the current model prediction completion time from the sum of the product of the planned remaining number and the actual tact time indicating the current actual production pace and the current time. Model switching setup time calculation system.   The predicted switching time calculation unit calculates a scheduled switching time from a sum of a product of the planned number of production and a standard tact time of a current production model extracted from a standard tact time table and a production start time. Model switching setup time calculation system described in 1.   The model switching setup time calculation system according to claim 1, further comprising a setup setup time display unit that displays a setup time of setup change work calculated by the setup setup time calculation unit. A model switching setup time calculation system that calculates the time required for setup change work that occurs when switching models when producing multiple models in the production process,
An input unit for the user to enter production plan data;
A predicted switching time calculation unit for calculating a scheduled switching time based on the production planned number of the current production model extracted from the production plan table;
Compare the part code of the part currently used with the part code of the part used after switching, extract the parts with different part codes before and after switching, and currently used equipment and tools The type of equipment and tools used after switching are compared, the procedure for extracting equipment and tools that are different before and after switching, and the guidance given to users when switching models A model comparison part before and after switching to carry out the procedure;
Refer to the standard changeover work time table for the parts and parts of different parts codes before and after switching, and the types of equipment and jigs, and the contents of the instructions. An internal setup time calculator for creating a list;
Referring to the required setup change work time list, calculate the total required setup change work time, and calculate the number of personnel required for all the setup change work to finish at the preset internal setup target time. The necessary personnel calculation section
A production performance collection department that counts the production performance of current production models,
Current model forecast that calculates the planned remaining number from the difference between the daily plan of the current production model stored in the production plan table and the actual production number, and calculates the current model forecast completion time based on this planned remaining number A completion time confirmation section;
The required setup change time is calculated when the setup change work is performed according to the number of personnel calculated by the setup change required personnel calculation section, and the calculated required setup change time and the current model predicted completion time confirmation section are calculated. A switching completion time calculation unit that calculates a model switching completion time based on the current model prediction completion time;
A plan achievement prediction unit that compares the planned switching time calculated by the predicted switching time calculation unit with the model switching completion time calculated by the switching completion time calculation unit to determine whether there is a delay in production progress; A model changeover setup time calculation system characterized by comprising:   6. The current model prediction completion time confirmation unit calculates a current model prediction completion time from the sum of the product of the planned remaining number and the actual tact time indicating the current actual production pace and the current time. Model switching setup time calculation system.   The predicted switching time calculation unit calculates a scheduled switching time from a sum of a product of the planned number of production and a standard tact time of a current production model extracted from a standard tact time table, and a production start time. Model switching setup time calculation system described in 1.   6. The model switching setup time calculation system according to claim 5, further comprising a setup change required personnel display unit for displaying the number of personnel calculated by the setup change required personnel calculation unit. A model switching setup time calculation method for calculating the time required for setup change work that occurs when switching models when producing multiple models in a production process,
A production performance collection step that counts the production performance of current production models,
The current model forecast completion time is calculated by calculating the planned remaining number from the difference between the date and time plan of the current production model stored in the production plan table and the actual production quantity, and calculating the current model forecast completion time based on this planned remaining quantity A time confirmation step;
A predicted switching time calculating step for calculating a scheduled switching time based on the production planned number of current production models extracted from the production planning table;
A model comparison step before and after switching that compares a part code of a part that is currently used with a part code of a part that is used after switching, and extracts parts that have different part codes before and after switching,
For parts with different part codes before and after switching, a setup change time calculation step for extracting the setup change work time with reference to the standard setup change work time table and calculating the required setup change work time;
Based on the estimated switching time calculated in the predicted switching time calculation step and the necessary setup change work time of all the parts that need the setup change calculated in the setup change time calculation step, the start time of the setup change work is determined. A model switching setup time calculation method comprising: a setup setup time calculation step for calculating.   10. The current model prediction completion time confirmation step calculates the current model prediction completion time from the sum of the product of the planned remaining number and the actual tact time indicating the current actual production pace and the current time. Model changeover setup time calculation method.   The predicted switching time calculating step calculates a scheduled switching time from a sum of a product of the planned production number and a standard tact time of a current production model extracted from a standard tact time table, and a production start time. Model switching setup time calculation method described in 1.   The model switching setup time calculation method according to claim 9, further comprising a setup setup time display step for displaying a setup time of setup change work calculated in the setup setup time calculation step. A model switching setup time calculation method for calculating the time required for setup change work that occurs when switching models when producing multiple models in a production process,
A production plan setting step in which a production plan table is created based on data entered by the user;
A planned switching time setting step for calculating a planned switching time based on the production planned number of the current production model extracted from the production plan table;
Compare the part code of the part currently used with the part code of the part used after switching, extract the parts with different part codes before and after switching, and currently used equipment and tools The type of equipment and tools used after switching are compared, the procedure for extracting equipment and tools that are different before and after switching, and the guidance given to users when switching models In addition, refer to the standard changeover work time table for the equipment and jigs with different parts codes and different types before and after switching, and the contents of the instructions. An internal setup required time calculation step for extracting and creating a required setup change work time list;
Referring to the required setup change work time list, calculate the total required setup change work time, and calculate the number of personnel required for all the setup change work to finish at the preset internal setup target time. The necessary steps for calculating the necessary number of setup changes,
Calculate the remaining planned number from the difference between the daily plan of the current production model stored in the production plan table and the actual production number of the current production model, and calculate the current model predicted completion time based on this remaining plan number Further, the necessary setup change time when the setup change work is performed according to the number of personnel calculated by the setup change required personnel calculation section is calculated, and the calculated required setup change time and the current model prediction completion time confirmation section are calculated. A model switching completion time prediction step for calculating a model switching completion time based on the current model prediction completion time calculated by
Plan achievement prediction step for comparing the planned switching time calculated by the scheduled switching time setting step with the model switching completion time calculated by the model switching completion time prediction step to determine whether or not there is a delay in production progress And a model changeover setup time calculation method.   14. The model switching setup time calculation method according to claim 13, wherein the current model prediction completion time is a sum of a product of the planned remaining number and an actual tact time indicating a current actual production pace and a current time.   The scheduled switching time setting step calculates the scheduled switching time from the sum of the product of the planned number of production and the standard tact time of the current production model extracted from the standard tact time table and the production start time. Model switching setup time calculation method described in 1.   The model change setup time calculation method according to claim 13, further comprising a setup change required personnel display step of displaying the number of personnel calculated in the setup change required personnel calculation step.   A model switching setup time calculation program for causing a computer to execute each step of the model switching setup time calculation method according to any one of claims 9 to 16.   A computer-readable recording medium storing the model switching setup time calculation program according to claim 17.

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