System and method for optimizing manufacturing workforce

• US 8,140,369 B2
• Filed: 08/21/2008
• Issued: 03/20/2012
• Est. Priority Date: 08/21/2008
• Status: Active Grant

• Current Assignee: Toyota Motor Engineering & Manufacturing North America Incorporated (Toyota Motor Corporation)
• Original Assignee: Toyota Motor Engineering & Manufacturing North America Incorporated (Toyota Motor Corporation)
• Inventors: Paul, Robin, Hicks, Thomas, Ryder, Dan, Evers, Gregory, Weber-Hicks, Angela Colleen
• Primary Examiner(s): Meinecke Diaz, Susanna M
• Application Number:
  US12/195,466
• Publication Number:
  US 20100049574A1
• Time in Patent Office: 1,307 Days
• Field of Search: 705/7.14
• US Class Current: 705/7.14
• CPC Class Codes: G06Q 10/06 Resources, workflows, human or project management; Enterprise or organisation planning; Enterprise or organisation modelling
• CPC Class Codes: G06Q 10/063112 Skill-based matching of a person or a group to a task
• CPC Class Codes: G06Q 10/06315 Needs-based resource requirements planning or analysis
• CPC Class Codes: G06Q 50/04 Manufacturing
• CPC Class Codes: Y02P 90/30 Computing systems specially adapted for manufacturing

Abstract

A method and system for optimizing the manufacturing workforce and reducing workforce boredom in an assembly plant is provided. A master database contains all the plant workers along with all of the assembly tasks required to be performed at the assembly plant for a predetermined period, a repetitive threshold value for each worker, and a burden value for each assembly task. Each worker is assigned to a particular assembly task based upon the attributes of the worker and the assembly task requirements. A first schedule is generated by matching assembly tasks to a worker. The first schedule is then used to generate a second schedule such that workers do not exceed a repetitive value threshold or a burden value threshold. Thus the method and system generates schedules such that workers are given a variety of assembly tasks and therefore are not bored by performing the same task repetitively.

Claims

1. A system for facilitating the optimization of manufacturing workforce and reducing workforce boredom in an assembly plant having multiple assembling tasks and workers comprising:

a first database storing all of the workers assigned to work in the assembly plant, all of the assembly tasks required to be performed at the assembly plant over a predetermined period of time, the first database further storing a plurality of repetitive task factors,

a processor operable to calculate each of the repetitive task factors based upon a degree of inattentiveness a particular task induces on a particular worker;

the processor further operable to calculate the degree of inattentiveness using a work history of the particular worker, and a degree of attentiveness required for a particular task;

the each of the plurality of repetitive task factors assigned to a respective one of the assembly tasks;

a repetitive value threshold for each worker, the processor calculating a repetitive threshold value for each worker, the repetitive threshold value based upon a degree of intellectual stimulation needed by a respective worker to remain attentive;

a processor in communication with the first database, the processor operable to generate a first schedule, the first schedule including each worker, each worker assigned more than one assembly task, the processor further operable to process the first schedule and total a value of repetitive task factors associated with every assembly tasked assigned to each worker so as to determine the total value of repetitive task factors for each of the workers, the processor further operable to compare the total value of repetitive task factors of each of the workers to determine if the total value of repetitive task factors exceeds the repetitive value threshold of a respective worker, the processor further operable to generate a second schedule, the second schedule reassigning assembly tasks to a worker in instances where the total value of repetitive task factors of a worker exceeds the worker'"'"'s repetitive value threshold.

2. The system as set forth in claim 1, wherein the first database includes training skills and physical abilities of each worker.

3. The system as set forth in claim 2, wherein the first database includes training skills and physical abilities best suited to accomplish each assembly task.

4. The system as set forth in claim 3, wherein the processor is further operable to process the first database to assign each task a worker by matching training skills and physical abilities of a particular worker to the training skills and physical abilities best suited to accomplish a particular assembly task.

5. The system as set forth in claim 1, further including a burden value for each of said tasks, each of the burden value is calculated based upon physical motions the task requires a worker to perform.

6. The system as set forth in claim 5, further including a burden value threshold.

7. The system as set forth in claim 6, wherein the processor is further operable to process the first database so as to generate a second schedule assigning a worker to each of said tasks, wherein a worker exceeds neither the repetitive value threshold assigned to said worker, nor the burden value threshold.

8. The system as set forth in claim 4 or 7, further including the step of generating an alert if a second schedule contains an instance where a worker is scheduled a same assembly task in the first schedule, or if the second schedule contains an instance where a total burden value of a worker from the first schedule and the second schedule exceed a predetermined total of burden values.

9. The system as set forth in claim 1, wherein a greedy algorithm is used to process the first database with the second database to assign each task a worker thereby generating a first schedule, and then further processes the first database so as to generate a second schedule assigning a worker to each of said tasks, wherein no worker exceeds the repetitive value threshold assigned to said worker.

10. The system as set forth in claim 1, wherein a tree-based algorithm is used to process the first database to assign each task a worker thereby generating a first schedule, and then further process the first database so as to generate a second schedule assigning a worker to each of said tasks, wherein no worker exceeds the repetitive value threshold assigned to said worker.