JPH0665457B2 - Production control method in a production line consisting of a plurality of work steps and production control device used therefor - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION [Field of Industrial Application] The present invention is used for a production control method in a production line in which a large number of workers make a product through a series of work steps in a sewing factory, and the like. Production control device.

[Conventional technology]

For example, in a sewing factory, products are manufactured through many intermediate processes by the work shared by many workers, from the cutting process of cloth to the final process such as buttoning. As described above, since the work in process at each stage sequentially goes through the hands of many workers, each work process is organically related to each other to form a series of sewing processes. Even if the processing speed is reduced in only one work process, it has a great influence on the operation rate and productivity as a whole, and causes the reduction. However, depending on the work process, there are those that can be easily performed and those that require complicated sewing technology.As the process becomes more than one, the work speed and quality of the work depend on the skill of the worker. Each worker has strengths and weaknesses depending on the type of work, and the work speed and the like also depend on the health condition of each worker at that time. Therefore, it is an ideal and a goal in a production system to allocate an optimum worker to each work process at each time so as to make the whole work flow fast and constant.

By the way, as a conventional production system, a synchro system, a bundle system, a tact system and the like are widely known and are also used in a sewing factory. this house,
The synchro system is a production system in which a work-in-process product that has finished each work process is flowed from worker to worker one by one, and products are accumulated only in the last worker's place. Further, the bundle system is a production system in which a work-in-process product is bundled into a certain number of sheets to form one bundle (one lot), and the one work-in-process product is used as a flow unit for processing while moving between workers. . Therefore, in this system, each worker stores the work-in-process finished each work process in his or her place, and when a certain number of the work-in-process is accumulated, the work-in-process is set to 1 Send it to the next worker as a lot. The final tact system predetermines an appropriate quantity of work in progress as one lot, and each worker stores the work in progress that has been assigned the work process in his / her place and gives a signal of the tact. This is a production system in which the work in progress is sent to the next worker all at once in batches to proceed with the work.

[Problems to be solved by the invention]

It can be said that the above-mentioned synchronizing system is the best production system as long as the workers are optimally assigned to each work process and all the work processes are ideally advanced. However, it is extremely difficult for managers and site supervisors to properly allocate workers to each work process, and if there is a problem with the allocation, the operating rate and productivity will drop all at once. In addition, even if appropriate allocation is made, it will be greatly affected if a worker assigned to a complicated work process is absent, and again, the physical and mental condition of the worker at that time and the work equipment It is rare for all work processes to proceed in a state close to ideal due to various factors such as the quality of the condition, and once it deviates from the ideal state,
The synchro system has the greatest influence on its characteristics.

Also, in the bundle system, each worker has a certain amount or more of work-in-progress even if a part of the work process is disturbed, so the influence on the whole work is suppressed as much as possible. However, the bundle system cannot be said to be a production system that is suitable for the recent trend toward small-lot production of a large number of products, because the amount of work in process for each process increases if the operator is overwhelmed by the available space. The production period also takes a long time.

The tact system has the same, if less, drawbacks as the sync system described above. further,
In any of the production systems, there is a problem that it is difficult for the manager to grasp the situation of the site, and after some problem occurs, he is forced to deal with it later and later.
Although some systems have been announced to solve such problems, they use computers and other large-scale equipment and cannot be immediately adopted due to the installation location and facility cost. It is a thing.

The present invention has been made in view of the above circumstances, does not have the above-mentioned drawbacks in the above-mentioned production systems, and allows an administrator to easily grasp the situation at the site,
As a result, it is possible to take action in advance before a definite trouble state is reached, and a production management method that can be carried out relatively inexpensively and at a relatively low space for installing necessary equipment, and It is a technical subject to provide a production control device to be used.

[Means for solving problems]

According to the present invention, as a technical means for achieving the above object, a production control method in a production line including a plurality of work steps and a production control apparatus used for the method are configured as follows.

That is, the production management method according to the present invention (hereinafter, referred to as "time bundle system") divides all workers into a plurality of groups each including a plurality of workers, and divides a series of work processes into each of the groups. In addition, the work process is subdivided within each group, and the work process is subdivided and assigned to each worker who constitutes the group, and the work time of one day is divided into a plurality of unit work time The target quantity of work-in-process to be processed is set appropriately in each group, and in each group, the work-in-process is sequentially flowed from worker to worker, and the final process assigned to that group is performed. The work-in-process finished is stored in the place of the last worker of the group, and a signal is given each time the unit work time has elapsed. If there is a work in process of the target quantity at the location of the last worker of the group at the time of the signal, the work in process of the target quantity is delivered as one lot to the next group, and If the target quantity of work in process does not exist, the work in progress is not delivered to the next group and that fact is displayed, and the target quantity of work in progress is delivered to the next group by a signal after the unit work time has elapsed. The main idea is to record whether or not each group has a unit work time.

Further, in the production control device according to the present invention, each worker is arranged in a plurality of groups each made up of a plurality of people, and a series of work processes is divided according to the number of the groups, and further within each group. A work table for subdividing each work assigned to each worker, an informing means for notifying the worker of each preset unit work time, and a final work of each group. A work-in-progress of a target quantity preset in the unit work time and preset as the quantity of work-in-process to be processed within the unit work time is divided into one lot, and the signal of the unit time elapses by the informing means. At the time of occurrence, there is a fractionation means for delivering the work in process of the target quantity in the place of the last worker of the group to the next group as one lot, and the distribution means for each group A plurality of display means for displaying whether or not the target quantity of work-in-process has been delivered to the next group by the notification of the progress of the unit work by the notification means, and each display means for each group. The gist is that it is provided with a recording means for recording the obtained result for each unit work time.

[Work]

According to this time bundle system, all workers are assigned to a plurality of groups, a predetermined work process is assigned to each group, and the worker is assigned to each work process for each group. Appropriate allocation is possible, and even if there is a worker's absence, etc., allocation only within that group is necessary, and if a part of the work process is disturbed, it will be dealt with quickly within the group Further, the workers can help each other, and the influence on the entire work can be suppressed as much as possible. In addition, between each group, as the unit work time elapses, the work-in-progress of the preset quantity as the target quantity is set as one lot, and the work-in-process for one lot or two lots is batched at the same time. Since it is sent to the next group, the amount of work in process can be relatively small and the production period can be relatively short. And
If the target quantity of work-in-process is not in the place of the final worker of each group at the time of the signal that the unit work time has passed, it is displayed for each group, so each worker can see the display. You can work while grasping the current situation. In addition, whether or not the target quantity of work-in-process could be delivered to the next group when the unit work time has elapsed is sequentially recorded for each unit work time for each group. You can grasp the situation of the whole line by seeing
When there is a problem with some work process, it is possible to detect it promptly and take appropriate measures at that time, and it is important to grasp the precursor before a definite trouble occurs. It is also possible to avoid reaching.

Further, according to the production management device of the present invention, the time bundle system can be preferably implemented.

〔Example〕

Hereinafter, preferred embodiments of the present invention will be described with reference to the drawings.

Taking brassiere sewing work as an example, the series of sewing processes include cup backing darts sewing, same-side back and side sewing, cup-lace side-by-side sewing, cup-lace press-fitting, and so on.
…, Cup attachment, presser foot stitching, wire wrapping stitching, wire pushing in, …………………, strap tab attachment,
It consists of many work processes such as press-fitting, strap attachment, and metal fitting attachment. Therefore, before starting the work, for example, 15 workers are divided into 3 groups of 5 groups each of A group, B group and C group, and a series of work steps is divided into 3 groups. Assign to each group. Further, in each group, the person in charge of the group allocates a work process to each constituent worker. At this time, the optimal allocation is performed by having a highly skilled worker take charge of work processes that require complicated sewing technology, or by having one worker share the two processes for work processes that can be performed easily. Although it is necessary to do it, each group consists of a relatively small number of workers, such as 5 people, so the group manager must fully understand the skill and physical condition of each worker. It is relatively easy to properly allocate each worker, and it is relatively easy to correct the allocation even if a worker is absent. On the other hand, the daily work time, for example, 7.5 hours, is divided into 15 and a unit time (delivery time) of 30 minutes is determined, and the target number of work-in-progress products to be processed per unit time is 100, for example. To set. The target number of sheets or the unit work time may be changeable depending on the time zone and the work situation, and is not necessarily fixed. Then, the person in charge of the group informs all the constituent workers of the group of the target number of sheets per unit working time.

The work is started after the conditions for the work as described above are set. FIG. 1 schematically shows the arrangement state of each worker and various instruments. In the figure, 1A, 1B and 1C are worktables on which sewing tools such as a sewing machine are installed,
Five workers are assigned to each group. In the embodiment, the production lines are arranged in parallel and two groups are provided. A bulletin board 2 and an indicator lamp 3 are installed at the position X at the location of the final worker of each group. The target number is displayed on the bulletin board 2, such as "100". The indicator lamp 3 consists of two color lamps, green and red.
Whether or not the target number of 100 sheets could be achieved for each minute delivery time is to turn on the green lamp when the group workers have achieved it and the red lamp when they have not achieved it. It is to inform by. The operation of turning on the indicator light 3 is performed by the signal box 4 as shown in FIG. 3, which is installed by the final operator of each group, who is also the counter and the deliverer of the next group. . In FIG. 3, 5 is a switch button for turning on the green lamp,
Reference numeral 6 is a red lamp lighting switch button, and 7 and 8 are display confirmation lamps. When the green or red lamp of the indicator lamp 3 is turned on, the lamp continues to be turned on until just before the next delivery time, and immediately before that, the lamp of the indicator lamp 3 is automatically turned off. FIG. 2 schematically shows a wiring state of each electric appliance used in this system. In the figure, 9 is a power supply box, and 10 is a target / actual result counter. The target / actual result counter 10 is a device for displaying the target number of products for each group for one day, and displaying the number of finished products up to that point while sequentially updating it, as shown in FIG. It has a clear board structure and is
It is placed on the delivery table 11 shown in the figure. In FIG.
12 is the target number display LED, 13 is the actual number display LED, 14
Is a target / actual number table count selector, 15 is an increase / decrease count selector, 16 is a target / actual number table counter, 17 is a reset button, 18 is a lamp blinking time setting counter, and 19 is the same display counter. . A management plate 20 is placed for each group near the delivery table 11 at the location of the worker who performs the final inspection. This management board 20 is made of a white board, and using green and red magnet boards, the status of achievement or non-achievement of the target number of sheets for each delivery time is displayed for each group. Further, the centralized management device 22 is installed on the office desk 21 of the office away from the work site. In this centralized management 22, the signals are transferred automatically and one after another according to the input operation to the signal box 4 described above regarding the achievement / non-achievement of the target number of sheets for each group and each 30 minutes of the delivery time. Is displayed, and the target number of sheets for the current day and the number of sheets increased at that point are also displayed. FIG. 5 shows an example of the board configuration of the centralized management device 22. In the figure, 23 is a display LED for each time, the upper side of the display example of each group is a row 24 of green LEDs, and the lower side is a row 25 of red LEDs. Further, 26 is a target number display LED, 27 is an actual number display LED, 28 is an OFF switch, and 29 is an electronic buzzer. A broadcasting facility 30 is provided at the work site to notify the worker of the delivery time every 30 minutes.

The production control device is not limited to the one having the above-mentioned configuration, and any device having substantially the same function may be used. For example, a production control device similar to the central control device may be used instead of the simple control plate. You may also set it up. Further, the central control device of the office may be omitted. Furthermore, the card may be turned on the spot every 30 minutes to notify each worker of the delivery time without providing broadcasting equipment.

In the workplace having the above-mentioned facilities, the work is started when each worker is placed in each predetermined place of the worktables 1A, 1B, 1C. The work is carried out in each group by sequentially flowing the work-in-process one by one to the workers while performing the sewing process at each stage, and the work-in-process completed after the final process assigned to each group. Goods are stored in the place of the last worker of the group. At this time, if there is a delay in the flow of work-in-progress in some work processes in the group, another worker in the group will support the process and make adjustments within the group, and Endeavor to prevent a decrease in utilization rate and productivity. Then, when the predetermined delivery time of 30 minutes has passed, the broadcasting facility 30 makes a chime sound. When there is a signal by this chime, the final worker of each group counts the work in progress, and if there is a target number of 100 work in progress at that place, the 100
The final worker (counter) of each group sends one batch of work-in-progress to the place of the first worker of the next group at the same time, and presses the lighting switch button 5 of the signal box 4 to display the indicator lamp 3 Turn on the green lamp. In this way, the work-in-progress is sent to the next group all at once in accordance with the signal of the delivery time, so that the amount of work-in-process can be relatively small and the production period can be relatively short. On the other hand, when the number of work-in-process at the final worker of the group is less than the target number of 100, the last worker of the group does not put the work-in-process into the next group, and the signal box 4 The red switch lamp 6 is pressed to light the indicator lamp 3 into a red lamp. The lighting of the indicator lamp 3 continues until immediately before the next delivery time elapses, so that each worker can grasp the current work status by looking at it. Along with the lighting operation of the indicator lamp 3, an operator who conducts the final inspection attaches a green or red magnet board for each group to the control plate 20 surface, and a green or red LE for the central control unit 22.
D lights up automatically. For the delivery between the groups mentioned above, the work in process is performed by using the delivery case or bundle string.
Fractionation is performed on each of 0 sheets, and each batch is performed. It is also possible to insert a card for every 100 pieces of work-in-progress so that the division of one lot can be known by the card. Furthermore, the final worker of the group can check the counter by a counter. You may make it a number.

When there is a signal that the delivery time has passed, if there is only 98 pieces of work in progress at the location of the last worker in the group, for example, do not deliver the work in progress to the next group and put a red lamp on the indicator lamp 3. Although the lights are turned on, the first two work-in-process products processed in the next unit work time are insufficiently applied as described above to form one lot. Therefore, at the time of the next delivery, the green lamp is turned on in the indicator lamp 3, and thus the red lamp is not turned on twice in succession in the indicator lamp 3 in the normal working state. When the red lamp is continuously lit twice, it is limited to the case where a sewing tool such as a sewing machine is out of order. Further, when there are two lots of work in progress at the place of the final worker of the group at the time of delivery, the two lamps should be delivered to the next group together, and the indicator lamp 3, the control board 20, and the central control device. 22 Display it in an appropriate way.

The work and operation as described above are repeated for each unit work time, and as the work progresses, the status of the work is recorded and displayed one after another on the management board 20 and the centralized management device 22. Therefore, the person in charge and the manager of the group will be able to see the work situation at a glance, and if there is a problem in some work process, detect it promptly and take appropriate measures at that time. It's possible, and you'll be able to catch the warning sign and take steps to avoid it before you reach a critical problem.

〔The invention's effect〕

Since the present invention is constructed and operates as described above,
When this time bundle system is applied to a production line, the drawbacks of the conventional production system can be eliminated, and the site manager and manager can easily understand the situation at the site. If there is any problem in a part of the work process, it can be dealt with promptly. Also, since the worker can proceed with the work while knowing the status of the work he / she is involved with, if the work is likely to be delayed and the target quantity cannot be achieved in the unit work area, the next unit work time will be reached. It helps to raise the awareness of workers by trying to catch up with the delay, which in turn leads to improved productivity. Moreover, in implementing this time bundle system, it does not require so much space for the installation of necessary equipment, and does not require much equipment cost.

Further, the production management apparatus according to the present invention can preferably implement the time bundle system.

[Brief description of drawings]

FIG. 1 shows an embodiment of the present invention, FIG. 1 is a schematic diagram for explaining a production control method, a schematic diagram showing a schematic configuration of a production control device, and FIG. 2 are electrical wiring in the production control device. And FIG. 3 to FIG. 5 are front views showing various equipments used for carrying out the production control method and a board configuration of the various equipments constituting the production control apparatus. Is. 1A, 1B, 1C ... Workbench, 3 ... Indicator light, 4 ... Signal box, 10 ... Target / actual counter, 20 ... Management board, 22 ... Centralized control device, 30 ... Broadcasting equipment.

Claims (2)

[Claims] 1. All workers are divided into a plurality of groups each consisting of a plurality of persons, a series of work processes is divided and assigned to each of the groups, and the work processes are subdivided into respective groups. Allocate to each worker who makes up the group and 1
Divide the daily work time into multiple unit work times, and set the target quantity of work in process to be processed within that unit work time as appropriate, and change from worker to worker in each group. Work is carried out while flowing work-in-progress in sequence, work-in-process finished after the final process assigned to the group is stored in the place of the last worker of the group, and a signal is given each time the unit work time elapses. If there is a target quantity of work in process at the location of the last worker of the group at the time of the signal, the work in quantity of the target quantity is set as one lot and delivered to the next group, If there is no target work in progress at the operator's place, the work in progress is displayed without being delivered to the next group, and the work in progress of the target quantity is displayed by the signal after the unit work time has elapsed. To group Meta whether the each group so as Yuku sequentially recorded for each unit operation time, production management method in the production line comprising a plurality of working steps. 2. Each worker is assigned to a plurality of groups, each of which is divided into a plurality of groups, and a series of work processes is divided according to the number of the groups, and further subdivided in each group. A workbench for carrying out each work assigned to each worker, a notification means for notifying the worker of the elapse of a preset unit work time, and a station for the last worker of each group. , A group of work-in-process products having a target quantity preset as the number of work-in-process products to be processed within the unit work time is divided into one lot, and when the notification means gives a signal indicating that the unit time has elapsed, the group A fractionation means for delivering a target quantity of work-in-process at the final worker's place as one lot to the next group, and arranged for each group,
A plurality of display means for displaying whether or not the target quantity of work-in-process has been delivered to the next group by the signal of the unit work time elapsed by the notification means, and the result displayed by each display means for each group. And a recording means for recording the data for each unit work time, in a production line including a plurality of work processes.