WORK ANALYSIS DEVICE, WORK ANALYSIS METHOD AND COMPUTER-READABLE MEDIUM
20220215327 · 2022-07-07
Inventors
Cpc classification
G06V40/103
PHYSICS
Y02P90/02
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
G06Q10/063114
PHYSICS
Y02P90/30
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
G05B19/418
PHYSICS
G06V20/52
PHYSICS
International classification
G06Q10/06
PHYSICS
G06V20/52
PHYSICS
Abstract
A work analysis device configured to analyze a work step that includes a plurality of processes, the work analysis device including: a reception unit configured to receive a captured image of a work area; a detector unit configured to parse the captured image and detecting the position and orientation of a worker working in the work area; a determination unit configured to determine the process being performed by the worker on the basis of the position and orientation of the worker; and a generation unit configured to measure a work time for each of the processes and generating a time chart representing the processes in the work step performed by the worker.
Claims
1. A work analysis device configured to analyze a work step that includes a plurality of processes, the work analysis device comprising: a reception unit configured to receive a captured image of a work area; a detector unit configured to parse the captured image and detecting the position and orientation of a worker working in the work area; a determination unit configured to determine the process being performed by the worker on the basis of the position and orientation of the worker; and a generation unit configured to measure a work time for each of the processes and generating a time chart representing the processes in the work step carried out by the worker.
2. The work analysis device according to claim 1, further comprising: an imaging unit configured to capture the captured image and transmit the captured image to the reception unit.
3. The work analysis device according to claim 1, further comprising: a layout analysis unit configured to compare a process included in the time chart and a benchmark process that is a process included in a work step that is a benchmark, and analyze whether or not an improvement is needed with regard to the layout of parts on a workstation in accordance with the benchmark process.
4. The work analysis device according to claim 3, wherein the layout analysis unit identifies that an improvement is needed with regard to the layout of parts when the sequence of the processes included in the time chart is different from the sequence of the benchmark processes.
5. The work analysis device according to claim 3, wherein the layout analysis unit assigns a score to the transition between the processes included in the time chart, and identifies that an improvement is needed with regard to the layout of parts when the total of the scores with respect to the transition between the processes is greater than or equal to a predetermined threshold.
6. The work analysis device according to claim 1, further comprising: a process analysis unit configured to identify that the worker missed work in a process included in the time chart when the work time of the worker for said process is shorter by a predetermined percentage or more than a standard time predefined for said process.
7. A work analysis method for analyzing a work step that includes a plurality of processes, the work analysis method comprising: a reception step for receiving a captured image of a work area; a detection step for parsing the captured image and detecting the position and orientation of a worker working in the work area; a determination step for determining the process being performed by the worker on the basis of the position and orientation of the worker; and a generation step for measuring a work time for each of the processes being performed and generating a time chart representing the processes in the work step carried out by the worker.
8. A non-transitory computer-readable medium storing a program for executing on a computer each of the steps in the work analysis method according to claim 7.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0020]
[0021]
[0022]
[0023]
[0024]
[0025]
[0026]
[0027]
[0028]
[0029]
[0030]
DETAILED DESCRIPTION
[0031] Example Application
[0032] An example application of a work analysis device according to the present invention is described with reference to
[0033] The work analysis device 1 receives a captured image from a camera 2. The work analysis device 1 detects a person from the captured image and detects the position and orientation of the person. The work analysis device 1 can determine the work details of a worker, that is, the workstation at which the worker is performing a work step among the plurality of workstations in a cell on the basis of the position and orientation of the person.
[0034] The work analysis device 1 can generate a time chart representing the flow of work step processes by the worker by measuring the work time [of the worker] at each of the workstations. The work analysis device 1 analyzes whether the workstations are arranged appropriately, or whether the work step processes and the like by the worker are appropriate by comparing the time chart generated with a benchmark time chart prepared in advance. The result of the analysis by the work analysis device 1 is presented to the user. The user can use the analysis result from the work analysis device 1 to change the layout of the workstations, exchange the parts placed at a workstation, revise the benchmark time chart, or the like.
[0035] The camera 2 may be installed to overlook a work area, or may be installed at a workstation enclosure oriented toward the travel area of the worker. A plurality of cameras 2 may be installed at each workstation, for example. The camera 2 simply needs to capture a range in which the position and body orientation of the worker in the work area can be recognized; a wide-angle camera or a fish-eye lens camera may be used for the camera 2, for example.
[0036] The work analysis device 1 may be configured with the camera 2 (imaging unit) into a single unit. A portion of the processing in the work analysis device 1, such as the process for detecting a person, or the like in a captured image, may also be executed by the camera 2. Moreover, the analysis result from the work analysis device 1 may be transmitted to an external device for presentation to a user.
[0037] The above-described work analysis device 1 parses a captured image of a work area and detects the position and orientation of a worker. The work analysis device 1 can more accurately understand at which workstation a worker is performing a work step, that is, the process for which a worker is performing work, by detecting the orientation of the worker. The work analysis device 1 can also generate a time chart more accurately for representing the flow of processes in a work step by the worker. Consequently, the work analysis device 1 can more accurately identify whether the workstations are arranged appropriately, whether the flow of processes by the worker is appropriate, or the like.
Embodiments
Device Configuration
[0038] An example of the hardware configuration for the work analysis device 1 according to an embodiment is described with reference to
[0039] The work analysis device 1 may be a generic computer such as a personal computer, a server computer, a tablet terminal, or a smartphone, or may be an embedded computer such as an onboard computer. However, the functions of a single device or all the devices may be implemented via dedicated hardware devices such as an ASIC or FPGA. or
[0040] The work analysis device 1 can be connected to the camera 2 via wire (USB cable or LAN cable, etc.) or wireless (WiFi, etc.), and receives image data that is captured by the camera 2. The camera 2 is an imaging device having an optical system that contains a lens and an imaging element (an image sensor such as a CCD, CMOS, etc.).
[0041] Next, an example with regard to the functional configuration of the work analysis device 1 is described.
[0042] The reception unit 10 includes a function of receiving a captured image from the camera 2. The reception unit 10 transfers the captured image received to the detector unit 11. The reception unit 10 may store the captured image received in the auxiliary storage device 103.
[0043] The detector unit 11 includes a function to parse the captured image from the camera 2 to detect a person who is the worker. The detector unit 11 includes a person detector unit 11A, position detector unit 11B, and an orientation detector unit 11C. The person detector unit 11A uses an algorithm for detecting a person, to detect a person from the captured image. The position detector unit 11B detects the position of the person detected; and the position of the person may be taken as the coordinate at the center of a rectangle surrounding the person that was detected. The orientation detector unit 11C detects which workstation the person detected is facing. The orientation detector unit 11C may detect the orientation of the worker, for example, via an AI that uses captured images of persons as the training data, or on the basis of the positional relationship between the head and an arm.
[0044] The process management table 12 stores information pertaining to each process. The position information for a workstation may be stored in the process management table 12 in association with, for example, a process corresponding to aforesaid workstation. The position information for a workstation may be computed in advance in accordance with the installation position of the camera 2, and can be stored in the process management table 12. The process management table 12 also stores information pertaining to a work step that is a benchmark. Information on the benchmark processes included in a work step that is a benchmark and a standard work time (standard time) for performing the work for each benchmark process may be stored in the process management table 12.
[0045] The determination unit 13 includes a function to determine the process for which a worker is performing work. The determination unit 13 references the process management table 12 and identifies the workstation that the worker is facing on the basis of the position and orientation of the person (worker) detected by the detector unit 11, and determines which process of the work step is being performed by the worker.
[0046] The time chart generation unit 14 includes a function to generate a time chart. The time chart generation unit 14 measures the work time within a processes being performed by the worker on the basis of a determination result from the determination unit 13. The work time can be computed from, for instance, the number of frames and the frame rate of a captured image in which a worker remains at a workstation corresponding to aforesaid process. The time chart generation unit 14 generates a time chart on the basis of the work times within each process.
[0047] The layout analysis unit 15 includes a function to analyze whether or not the layout of parts on a workstation is appropriate. The layout analysis unit 15 can compare the (flow of) processes included in the time chart generated with the (flow of) benchmark processes to analyze whether or not the layout of part is appropriate.
[0048] The process analysis unit 16 includes a function to analyze whether or not a process in the processes included in the time chart (the processes performed by the worker) has missed work. The processes included in the time chart generated by the time chart generation unit 14 can be compared with the benchmark processes included in a work step that is a benchmark to verify whether there is missed work in the time chart.
[0049] The output unit 17 includes a function to present the time chart generated by the time chart generation unit 14 and the analysis result from the layout analysis unit 15 and the process analysis unit 16 on a display or the like. The output unit 17 may transmit the time chart generated and the analysis result to an external device so that the external device may display the time chart generated and the analysis result.
[0050] Processing for Analyzing a Work Step
[0051] The overall flow of process that analyzes a work step is described according to
[0052] The reception unit 10 receives a captured image from the camera 2 in step S20. The reception unit 10 transfers the captured image received to the detector unit 11.
[0053] The detector unit 11 (person detector unit 11A) detects a person from the captured image fed thereto from the reception unit 10 and detects the position and orientation of the person detected. Any kind of algorithm may be used for the person detection. A classifier that combines image features, such as HoG or Haar-like image features with boosting may be used, or a deep-learning based (e.g., R-CNN, Fast R-CNN, YOLO, SSD, etc.) person recognition classifier may be used.
[0054] The detector unit 11 (position detector unit 11B) may also detect the position of the person detected in the captured image. The position of the person may be specified as the coordinate at the center of a rectangle surrounding the person that was detected. In addition, the work area may be segmented into a grid and the position of the person may be specified by noting in which the area the person exists.
[0055] The detector unit 11 (orientation detector unit 11C) may also detect the orientation of the person (worker) detected. Here, a method for detecting the orientation of the worker is described with reference to
[0056]
[0057] As illustrated in
θ=αθ.sub.face+βθ.sub.body(0≤θ≤2π,α+β=1) (Formula 1)
where, for example α=β=½, the orientation of the person may be the mean of the orientation of the face θ.sub.face and the orientation of the body θ.sub.body. Additionally, taking α=⅔, β=⅓, the orientation of the person may be specified (detected) with a priority given to the orientation of the face θ.sub.face.
[0058] Moreover, the orientation detector unit 11C may detect the orientation of the person on the basis of the mutual positional relationship of the head, an arm, and a hand. For instance, the orientation detector unit 11C may take the orientation of a line segment bisecting the line segments extending from the center of the head to the left and right hands respectively as the orientation of the person.
[0059]
[0060] As illustrated in
θ=αθ.sub.face+βθ.sub.body(−π/2≤θ≤π/2,α+β=1) (Formula 2)
α and β may be established as appropriate in accordance with the priority of the orientation of the face θ.sub.face or the orientation of the body θ.sub.body, similar to the case in
[0061] Moreover, the orientation detector unit 11C may detect the orientation of the person on the basis of the mutual positional relationship of the head, body, an arm, and a hand. The orientation detector unit 11C may estimate the orientation of the person on the basis of the angle of an arm relative to the body, for instance.
[0062] In step S22 in
[0063]
[0064] The determination unit 13 acquires the position information for the travel areas a to c from the process management table 12 and determines in which travel area the worker is present on the basis of the position information of the worker detected in step S21. The determination unit 13 also acquires the position information of the workstations A to G from the process management table 12 and can determine at which workstation work is being performed on the basis of information on the position and orientation of the worker detected in step S21. That is, the determination unit 13 can determine the process for which a worker is performing work. The determination unit 13 can also determine the time for a worker to transition from a process the worker is currently performing to the next process.
[0065] The determination unit 13 can count the number of frames of the captured image until the worker moves to the next step to thereby compute the work time for each process. The determination unit 13 may store the work time calculated for each process in the auxiliary storage device 103.
[0066] The detector unit 11 (person detector unit 11A) determines whether or not the worker has completed the work step in step S23. The person detector unit 11A can determine that the worker has completed work step, for instance, when the person detector unit 11A does not detect a person in the captured image fed thereto from the reception unit 10. The person detector unit 11A may also determine that the worker has completed the work step when the worker changes orientation from the workstation G where the last process is performed to the workstation A where the first process is performed. The processing continues to step S24 when the series of work steps by the worker is completed (YES, at step S23). The processing returns to step S20 when the worker has not completed the work step (NO, at step S23). The processing from step S20 through step S22 is repeated for each frame of captured image fed in from the reception unit 10 between returning to step S20 and until the work steps are complete.
[0067] The time chart generation unit 14 generates a time chart in step S24 representing the flow of processes performed by the worker. The time chart generated may be presented on a display or the like, which is the output device 105. Here, an example of the time chart generation unit 14 generating a time chart is described using
[0068]
[0069] The time Worker X requires for either of the processes C, D is two minutes. The standard time for either of the processes C, D is three minutes. The Worker X performs the processes C, D in a time that is shorter than the standard time; the spaces corresponding the processes C, D for the Worker X are enclosed in dotted lines to highlight the space. In contrast, the Worker Y requires five minutes and six minutes for the processes A, D respectively. The standard time for either the processes A, D are two minutes and three minutes respectively. The Worker Y performs the processes A, D in a time that is longer than the standard time; the spaces corresponding the processes A, D for the Worker Y are enclosed in double lines to highlight the space.
[0070] The time chart T70 makes it possible to highlight the spaces corresponding to cases where the work time for a process by a worker is shorter or longer than the standard time. Hereby, a user can spot a delay, or the like, in the work of each worker. Note that highlighting is not limited to enclosing a space with a dotted line or a double line; emphasis may be added by changing the background color of the space to be highlighted.
[0071]
[0072] The layout analysis unit 15 analyzes whether or not the layout of parts placed on the workstation is appropriate on the basis of the time chart for the workers in step S25 of
[0073] A method of analysis by the layout analysis unit 15 and the process analysis unit 16 is described using
[0074]
[0075] In the time chart T90 illustrated in
[0076]
[0077] Scores are computed with regard to the three patterns below. [0078] Pattern 1: A.fwdarw.B.fwdarw.C.fwdarw.D.fwdarw.E Score=4 [0079] Pattern 2: A.fwdarw.B.fwdarw.C.fwdarw.B.fwdarw.C.fwdarw.D.fwdarw.E Score=6 [0080] Pattern 3: A.fwdarw.B.fwdarw.D.fwdarw.B.fwdarw.C.fwdarw.D.fwdarw.E Score=8
If the score for each pattern is calculated on the basis of the points depicted in
[0081] The layout analysis unit 15 identifies whether improvement is needed with regard to the layout of parts in a case where the score thusly calculated for the actual processes is greater than or equal to a predetermined threshold. For example, when the predetermined threshold is taken as seven points, the layout analysis unit 15 determines that the actual processes in pattern 1 and pattern 2 are normal, and determines that actual processes in pattern 3 require improvement.
[0082] The predetermined threshold is not limited to the above example of the scores from adding points with respect to the transition between processes depicted in
[0083]
[0084] In the example in
[0085] In step S26 of
Effects of the Embodiment
[0086] In the above embodiment the work analysis device 1 can more accurately capture the workstation at which a worker is working, that is, which process a worker is performing on the basis of the position and orientation of the worker.
[0087] The work analysis device 1 generates a time chart via a time chart generation unit 14. The layout analysis unit 15 can analyze whether or not an improvement is needed with regard to the layout of parts by comparing the processes in a time chart with benchmark processes in a work step that is a benchmark. The layout analysis unit 15 may also assign a score to the flow of processes indicated in the time chart on the basis of the scores established for the transition between processes. The layout analysis unit 15 is capable of flexibly analyzing whether or not an improvement is needed by assigning a score to the transitions between the processes included in a time chart.
[0088] The process analysis unit 16 can more accurately analyze whether or not there is missed work on the basis of the worker's work time for the processes included in the time chart.
[0089] Additional Considerations
[0090] The above-described embodiment is merely for providing illustration of an example configuration of the present invention. The present invention is not limited to the specific form above described and may be modified in various ways within the scope of the technical ideas therein. For instance, the scoring of points and predetermined threshold illustrated in
[0091] Additionally, the table illustrated in
[0092] Supplemental Note 1
[0093] (1) A work analysis device (1) configured to analyze a work step that includes a plurality of processes, the work analysis device including:
[0094] a reception unit (10) for receiving a captured image of a work area;
[0095] a detector unit (11) for parsing the captured image and detecting the position and orientation of a worker working in the work area;
[0096] a determination unit (13) for determining the process being performed by the worker on the basis of the position and orientation of the worker; and
[0097] a generation unit (14) for measuring a work time for each of the processes and generating a time chart representing the processes in the work step carried out by the worker.
[0098] (2) A work analysis method for analyzing a work step that includes a plurality of processes, the work analysis method including:
[0099] a reception step (S20) for receiving a captured image of a work area;
[0100] a detection step (S21) for parsing the captured image and detecting the position and orientation of a worker working in the work area;
[0101] a determination step (S22) for determining the process being performed by the worker on the basis of the position and orientation of the worker; and
[0102] a generation step (S23) for measuring a work time for each of the processes being performed and generating a time chart representing the processes in the work step carried out by the worker.
TABLE-US-00001 Reference Numerals 1: Work Analysis Device 101: Processor 102: Main Memory Device 103: Auxiliary Memory Device 104: Communication I/F 105: Output Device 10: Reception Unit 11: Detector Unit 11A: Person Detector Unit 11B: Position Detector Unit 11C: Orientation Detector Unit 12: Process Management Table 13: Determination Unit 14: Time Chart Generation Unit Layout Analysis Unit 16: Process Analysis Unit 17: Output Unit 2: Camera