CN103984326A - Production management system and method - Google Patents
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Abstract
The invention relates to the field of production management informationization and discloses a production management system. The production management system comprises a fault feedback control device, an input/output control device, an information control device, a display device and a remote control device. The operating state of a production line is analyzed by analyzing fault information fed back by the fault feedback control device so as to achieve production management. Meanwhile, the relationship between the yield and the fault rate is analyzed by collecting related information of each working procedure in a production line, and therefore the production process can be optimized. The invention further discloses a production management method. The production management system and method have the advantages that the functions of data collection, analysis, management and display are integrated, the functions of data backup, synchronized network monitoring, on-site production state monitoring and the like are also achieved, and the production management system and method are high in adaptability and have high application value.
Description
Technical Field
The present invention relates to the field of production management informatization, and in particular, to a production management system and a production management method.
Background
In a production line of a conventional factory, a number of processing steps increases with an update of a product to be produced, information related to the production steps increases, and a manager is often unsuited to a lot of information and does not know where to perform management. Another problem caused by the increasing number of production processes is that faults occur frequently in the production line, and due to the large number of processes, coordination between the processes is a very difficult task.
In the prior art, a linear analysis method is often adopted to analyze a plurality of factors influencing the production process one by one, or more important factors are selected for analysis, and various sudden factors on the production line cannot be covered. In addition, in the operation process of the production line, various uncertain factors are more, and accurate analysis data cannot be obtained by a data analysis method for analyzing and managing the operation condition of the production line by collecting fixed data. On the basis that accurate analysis data cannot be obtained, a manager can only adopt a traditional management means to manage, and the management method is difficult to consider the whole production line, so that the production efficiency cannot be improved, and the effective control of the product cost is hindered.
In view of the above, there is a need to develop a novel production management system and method that can comprehensively analyze various data on the production line, dynamically adapt to various sudden failures on the production line, and monitor various states on the production line, thereby achieving efficient management.
Disclosure of Invention
Aiming at the defect that the management efficiency is low and the maintenance reaction speed cannot be recorded in the prior art, the invention provides a novel production management system and a novel production management method, which are used for monitoring the operation condition of each procedure of a production line and counting data, thereby achieving the purposes of promoting production and improving efficiency.
In order to achieve the purpose, the invention can adopt the following technical scheme:
the production management system comprises a fault return control device, an input/output control device, an information control device, a display device and a remote control device; wherein,
the fault return control device is used for collecting fault information sent out on a production line, and the fault return control device enables each production process to correspond to production line operators, raw materials, parts, intermediate assembly parts and tools one by one, wherein the production processes respectively comprise one or more operators and quantitative raw materials, parts, intermediate assembly parts and tools;
the input and output control device is used for sending the fault information collected by the fault return control device to the information control device;
the information control device is used for receiving fault information, recording and counting the fault information of each process according to the corresponding relation between the production process recorded by the process schedule and production line operators, raw materials, parts, intermediate assemblies and tools, calculating the actual OEE value of each process according to the fault information of each process obtained through counting, comparing the actual OEE value of each process with a plan OEE value, a yellow face limit value and a red face limit value which are input in advance, and returning to a green face state when the error between the actual OEE value and the plan OEE value is smaller than the yellow face limit value, wherein the green face state indicates that the production line is in a normal working state;
the display device is used for displaying the working state of the production line returned by the information control device;
the remote control device is used for calling production data stored in the information control device from the information control device at a remote end and displaying the production data on a remote client, wherein the production data comprises fault information and an actual OEE value, and the remote client comprises a computer device connected with the information control device through an Ethernet.
In the embodiment of the invention, the fault return control device comprises an equipment wire stop trigger and an equipment wire stop help trigger, wherein the equipment wire stop trigger is used for triggering fault information when the production line stops in a whole line; the equipment non-stop help trigger is used for triggering equipment non-stop faults, wherein the equipment non-stop faults comprise affairs which are generated without stopping a production line, occupy operator time and are unrelated to the operation of the production line.
In the embodiment of the present invention, one input/output control device is connected to a plurality of fail-back control devices in a one-to-many manner.
In this embodiment of the present invention, the input/output control device is further configured to store process identifiers, where the number of the process identifiers is equal to the number of the fault return control devices connected to the input/output control device, and each process identifier corresponds to one fault return control device; when the input/output control device transmits the failure information collected by the failure return control device to the information control device, the input/output control device simultaneously transmits a process identifier corresponding to the failure return control device to the information control device; the input/output control device receives the failure information and the process identifier, and rearranges the correspondence between the production process described in the process schedule and the production line operator, the material, the component, the intermediate assembly, and the tool.
In the embodiment of the invention, the input and output control device also returns a yellow face state and a red face state, and returns the yellow face state when the error between the actual OEE value and the planned OEE value is greater than the yellow face limit value and less than the red face limit value; and returning to the red face state when the error between the actual OEE value and the planned OEE value is larger than the red face limit value.
In the embodiment of the present invention, the input/output control device is further configured to record a planned OEE value, an actual OEE value, stop times of each process, required operators, and each process required by a current product, a stop time of a production line, a working state of the production line, and a history of failure information, calculate the actual OEE value, compare the planned OEE value, the stop times of each process, required operators, and each process required by the current product, the stop time of the production line, and statistical correlation strengths between the working state of the production line and the history of failure information, obtain a process having the largest influence on the actual OEE value according to the statistical correlation strengths, and analyze an influence of a process failure on an error between the actual OEE value and the planned OEE value, and a variation cause of the error.
In the embodiment of the invention, the system further comprises a database device, wherein the database device is connected with the information control device through the Ethernet, and is used for storing the process schedule of each product produced by the production line.
In the embodiment of the present invention, the failure information includes standby shutdown information, process shutdown information, model change shutdown information, maintenance shutdown information, and quality shutdown information; when the production line waits for the raw materials, the parts or the intermediate assembly parts to be matched, the fault return control device sends out the information of the machine halt of the to-be-prepared materials; when the production line is stopped, the fault return control device sends out process crash information; when the model of the produced product is changed on the production line, the fault return control device sends out the information of the model changing and the crash; when the production line or production equipment in the production line is maintained, the fault return control device sends out maintenance crash information; when the operator finds that the product quality is in problem, the fault return control device sends out quality crash information.
In the embodiment of the present invention, the system further includes an interaction control device, and the interaction control device is configured to adjust the operation parameters of the information control device in real time, and may export the data calculated by the information control device in time.
The production management method is obtained by applying the production management system.
The invention has the following remarkable technical effects:
the system can effectively monitor each process on the whole production line, has wide monitoring range and good adaptability, can effectively monitor and manage various types of production lines, and is particularly suitable for the production lines with multiple processes and complex processes.
Furthermore, the process with strong relevance is found out by collecting fault information and analyzing the correlation degree among the fault information, the process elements and the yield, so that the hot spot process on the production line can be obtained, and a more accurate guide is provided for the optimization and integration of the subsequent processes.
Drawings
Fig. 1 is a schematic diagram of a production management system.
Fig. 2 is a schematic structural diagram of the failure return control apparatus.
Fig. 3 is a flow chart diagram of a production management method.
Fig. 4 is a diagram of failure-time information given by the information control apparatus.
Detailed Description
The present invention will be described in further detail with reference to examples.
Example 1
A production management system, as shown in fig. 1 and 2, including a failure return control device (101), an input/output control device (102), an information control device (103), a display device (104), and a remote control device (105); wherein,
the fault return control device (101) is used for collecting fault information sent out on a production line, and the fault return control device (101) enables each production process to correspond to production line operators, raw materials, parts, intermediate assemblies and tools required by each process one by one. In order to realize the one-to-one correspondence relationship, first, the information should be counted and a process schedule should be prepared according to the number of operators required in each process, the time required for each operator to complete each process, and the materials, parts, intermediate assemblies or necessary tools required for each process, next, a distribution failure return control device (101) is arranged according to the process sequence listed in the process schedule, for example, unique individual identification information is collected from each of the raw material, the part, the intermediate assembly, or the final product, the individual identification information is correlated with each other to have a relationship of inheritance to be managed by collation of a comparable correlation, therefore, the assembly production line can be assembled by adopting the universal production management device, and the universal type of the whole production management system is improved. Usually, the fault return control device (101) is located at an operation station of an operator, and is connected with production line equipment through electrical connection, or can be used for the operator of each process to master operation, as an optional simplified scheme, the fault return control device (101) can comprise an equipment wire stop trigger (1011) and an equipment wire stop help trigger (1012), wherein the equipment wire stop trigger (1011) is used for triggering a wire stop fault under the condition that the production line is stopped completely, and pressing a button of the equipment wire stop trigger (1011) means that the whole production line has a major fault which must be stopped; the equipment offline help trigger (1012) is used for triggering equipment offline faults, the equipment offline faults comprise affairs which are generated without stopping the production line, occupy operator time and are irrelevant to the operation of the production line, normally, operators do not always work on the production line, in order to process some sudden time or some situations which can not accurately control the time, such as change of production process, maintenance of non-important parts, replacement of product models, supplement of raw materials or other materials and situations caused by product quality problems, the equipment offline help trigger (1012) needs to be triggered, but after a button of the equipment offline help trigger (1012) is pressed, the time for the operators to stop working on the production line and process other affairs is recorded by the information control device (103), the line stopping fault and the line stopping fault are collectively called fault information, and when the fault is eliminated, the fault return control device (101) sends out reset information for resetting; in addition, the reset information can also be directly sent to the information control device (103) through the interaction control device (107), and the reset mode is usually adopted for the line stop fault. The manufacturing processes include one or more operators and quantities of materials, parts, intermediate assemblies, and tools, respectively. The type of the production line fault is divided into the equipment non-stop line fault and the equipment non-stop line fault, the information control device (103) can obtain the actually required time of each process by counting the time of the equipment non-stop line fault, and the counted time of the equipment non-stop line fault can be used as the production history information of the production line to be processed, so that an index capable of better reflecting the running state of the production line is obtained, the index replaces the existing problem that the measurement is difficult due to the physical quantity of the running state of a certain process of the production line or the production line, and meanwhile, the index is simplified.
The input/output control device (102) is configured to send the fault information collected by the fault return control device (101) to the information control device (103), in this embodiment, the input/output control device (102) may be a data receiving/sending device with a switching function, and the device sends the collected fault information or other data to the information control device (103) through the switch (108), and specifically, the input/output control device (102) may select an I/O module with an ethernet or serial port connection function.
The information control device (103) is used for receiving fault information, recording and counting the fault information of each process according to the corresponding relation between the production process and production line operators, raw materials, parts, intermediate assemblies and tools recorded in the process schedule, calculating the actual OEE value of each process according to the counted fault information of each process, wherein the OEE is short for all Equipment efficiency, the actual OEE value of each process is compared with a plan OEE value, a yellow face limit value and a red limit value which are input in advance, when the error between the actual OEE value and the plan OEE value is smaller than the yellow face limit value, a green face state is returned, and the green face state indicates that the production line is in a normal working state.
In this embodiment, the information control device (103) is used for monitoring and displaying the production rate of the workshop assembly line, the condition of the assembly line and the process state, has data integration capability, can compare data from different sources, obtains the strength correlation among the data, and represents the strength correlation by a chart. The information control device (103) can be conveniently connected with any PLC, driver, instrument, bar code and the like, and has the functions of displaying production information, logging, remote programming and the like.
In addition to displaying the operating state of the production line, the information control device (103) has the following functions:
when the fault information is given, the correlation or interaction between the quality history of the product and the production line can be known. The information control device (103) needs to establish the following trend graph. The above trend graph is generally established using a variable X, generally expressed as the abscissa, and a variable Y, generally expressed as the ordinate. In the trend graph, a variable X represents a temporal element including the total operating time of the entire production line and the production dead time caused by the non-stop line fault; the variable Y represents a yield factor, which is generally expressed by the number of products to be produced or by a quantization process for each process, and a quantized index is used as a yield. After the trend graph is established, a correlation model can be established between the yield and the fault, and more importantly, the complex structural relationship between the multi-process multivariable based on the production history information can be simplified by using the correlation between the yield and the fault, so that the function of simplifying the model is achieved. Using the trend graph, an automated analysis of the model can also be performed and the root cause of the yield change can be found from the yield variation factors listed above. It should be noted that the trend graph may be represented as a graph, and may represent the data association between the temporal element and the productivity element.
Further, with respect to the correlation between the production and the failure reflected in the above-described trend graph, the information control device (103) further seeks the correlation between the production and the failure by a combination of the period of the production stagnation and all types of non-stop failures, for example, by a route coefficient of a co-dispersed configuration analysis based on a statistical analysis method or a partial correlation coefficient of a graph modeling.
After establishing the trend graph and obtaining the correlation between the yield and the fault, in order to further analyze the influence of factors such as raw materials on the yield and the quality of the finally obtained product, 2 or more than 2 elements in the target are locked by taking a product with a complicated process which changes every day as a target, wherein the index is related to the general characteristics of each process, for example, 2 or more than 2 processes with the largest difference between the actual OEE value and the planned OEE value in the target, and the general characteristics of the processes are locked as the target elements. By locking the target elements, it is possible to find a root process in the production line that has an influence on the quality variation of the product in a production process that requires machining or assembly using a raw material, a part, or an intermediate assembly. As shown in FIG. 4, FIG. 4 discloses a process sequence table obtained by performing the above analysis process on the crash information, in which the process Line19-A located at the top of FIG. 4 indicates that Line19-A is the root process having the greatest influence on the variation in product quality throughout the production Line.
The display device (104) is used for displaying the working state of the production line returned by the information control device (103).
The remote control device (105) is used for calling the production data stored in the information control device (103) from the information control device (103) at a remote end and displaying the production data at a remote client, wherein the production data comprises fault information and an actual OEE value, and the remote client comprises a computer device connected with the information control device (103) through an Ethernet. The remote control device (105) may be a mobile phone terminal (1051), a notebook (1052) or a PC (1053).
One input/output control device (102) is connected to a plurality of fail-back control devices (101) in a one-to-many manner.
The input and output control device (102) is also used for storing process identifiers, the number of the process identifiers is equal to the number of the fault return control devices (101) connected with the input and output control device (102), and each process identifier corresponds to one fault return control device (101); when the input/output control device (102) transmits the failure information collected by the failure return control device (101) to the information control device (103), the input/output control device simultaneously transmits a process identifier corresponding to the failure return control device (101) to the information control device (103); the input/output control device (102) receives the failure information and the process identifier, and then rearranges the correspondence between the production process described in the process schedule and the production line operator, the raw material, the component, the intermediate assembly, and the tool.
The input and output control device (102) also returns a yellow face state and a red face state, and returns the yellow face state when the error between the actual OEE value and the planned OEE value is greater than the yellow face limit value and less than the red face limit value; and returning to the red face state when the error between the actual OEE value and the planned OEE value is larger than the red face limit value.
The input and output control device (102) is also used for recording a planned OEE value, an actual OEE value, each process required by the current product, required operators, stop time of each process, stop time of the production line, working state of the production line and historical records of fault information, calculating the actual OEE value, comparing the planned OEE value, each process required by the current product, required operators and stop time of each process, the stop time of the production line and statistical correlation strength between the working state of the production line and the historical records of the fault information, obtaining the process with the largest influence on the actual OEE value according to the statistical correlation strength, and analyzing the influence of process faults on errors between the actual OEE value and the planned OEE value and the change reasons of the errors.
The production management system also comprises a database device (106), the database device (106) is connected with the information control device (103) through the Ethernet, and the database device (106) is used for storing a process schedule of each product produced by the production line.
The fault information comprises standby machine halt information, process machine halt information, model change machine halt information, maintenance machine halt information and quality machine halt information; when the production line waits for the raw material, the part or the intermediate assembly part to be matched, the fault return control device (101) sends out the information of the machine halt of the raw material; when the production line is stopped, the fault return control device (101) sends out process crash information; when the model of the produced product is changed on the production line, the fault return control device (101) sends out the information of the model changing crash; when a production line or production equipment in the production line is maintained, the fault return control device (101) sends out maintenance crash information; when the operator finds a product quality problem, the failure return control device (101) sends out quality crash information.
The production management system also comprises an interactive control device (107), wherein the interactive control device (107) is used for adjusting the operation parameters of the information control device (103) in real time and can export the data calculated by the information control device (103) in time.
The production management method, as shown in fig. 3, using the production management system described above, includes the following specific steps:
failure return control step (201): the fault information sent out on the production line is collected, and the fault return control device (101) enables each production process to correspond to production line operators, raw materials, parts, intermediate assemblies and tools one by one, wherein the production processes respectively comprise one or more operators and quantitative raw materials, parts, intermediate assemblies and tools.
Input/output control step (202): failure information collected by the failure return control device (101) is transmitted to the information control device (103).
Information control step (203): receiving fault information, recording and counting the fault information of each process according to the corresponding relation between the production process recorded by the process schedule and production line operators, raw materials, parts, intermediate assemblies and tools, calculating the actual OEE value of each process according to the fault information of each process obtained through counting, comparing the actual OEE value of each process with a plan OEE value, a yellow face limit value and a red face limit value which are input in advance, and returning to a green face state when the error between the actual OEE value and the plan OEE value is smaller than the yellow face limit value, wherein the green face state indicates that the production line is in a normal working state.
A display step (204): the operation state of the production line returned by the information control device (103) is displayed.
Remote control step (205): and calling the production data stored in the information control device (103) from the information control device (103) at a remote end, and displaying the production data on a remote client, wherein the production data comprises fault information and an actual OEE value, and the remote client comprises a computer device connected with the information control device (103) through Ethernet.
Database storage step (206): the data base device (106) is connected with the information control device (103) through Ethernet and is used for storing the procedure schedule of each product produced by the production line.
Interaction control step (207): the operation parameters of the information control device (103) are adjusted in real time, and the data calculated by the information control device (103) can be exported in time.
In summary, the above-mentioned embodiments are only preferred embodiments of the present invention, and all equivalent changes and modifications made in the claims of the present invention should be covered by the claims of the present invention.
Claims (10)
1. A production management system is characterized by comprising a failure return control device (101), an input/output control device (102), an information control device (103), a display device (104), and a remote control device (105); the fault return control device (101) is used for collecting fault information sent out on a production line, and the fault return control device (101) enables each production process to correspond to production line operators, equipment, parts, intermediate assemblies and tools one by one, wherein the production processes respectively comprise one or more operators and quantitative raw materials, parts, intermediate assemblies and tools;
an input/output control device (102) for transmitting failure information collected by the failure return control device (101) to an information control device (103);
the information control device (103) is used for receiving the fault information, recording and counting the fault information of each process according to the corresponding relation between the production process recorded by the process schedule and production line operators, raw materials, parts, intermediate assemblies and tools, calculating the actual OEE value of each process according to the counted fault information of each process, comparing the actual OEE value of each process with a plan OEE value, a yellow face limit value and a red face limit value which are input in advance, and returning to a green face state when the error between the actual OEE value and the plan OEE value is smaller than the yellow face limit value, wherein the green face state indicates that the production line is in a normal working state;
the display device (104) is used for displaying the working state of the production line returned by the information control device (103); the remote control device (105) is used for calling the production data stored in the information control device (103) from the information control device (103) at a remote end and displaying the production data at a remote client, wherein the production data comprises fault information and an actual OEE value, and the remote client comprises a computer device connected with the information control device (103) through an Ethernet.
2. The production management system according to claim 1, wherein the failure return control means (101) includes a device shutdown trigger (1011) and a device shutdown help trigger (1012), wherein the device shutdown trigger (1011) is configured to trigger failure information in the event of a production line shutdown; the equipment non-stop help trigger (1012) is used for triggering equipment non-stop faults, which include transactions that are generated without stopping the production line, require operator time, and are unrelated to operating the production line.
3. The production management system according to claim 1, wherein one input/output control device (102) is connected to a plurality of fail-back control devices (101) in a one-to-many manner.
4. The production management system according to claim 3, wherein the input/output control device (102) is further configured to store process identifiers, the number of process identifiers being equal to the number of fault return control devices (101) connected to the input/output control device (102), each process identifier corresponding to a respective fault return control device (101); when the input/output control device (102) transmits the failure information collected by the failure return control device (101) to the information control device (103), the input/output control device simultaneously transmits a process identifier corresponding to the failure return control device (101) to the information control device (103); the input/output control device (102) receives the failure information and the process identifier, and then rearranges the correspondence between the production process described in the process schedule and the production line operator, the raw material, the component, the intermediate assembly, and the tool.
5. The production management system according to claim 1, wherein the input output control means (102) further returns a yellow face state and a red face state, and returns the yellow face state when an error between the actual OEE value and the planned OEE value is greater than a yellow face limit value and less than a red face limit value; and returning to the red face state when the error between the actual OEE value and the planned OEE value is larger than the red face limit value.
6. The production management system according to claim 1, wherein the input/output control device (102) is further configured to record a planned OEE value, an actual OEE value, each process required by the current product, a required operator, a stop time of each process, a stop time of the production line, an operating state of the production line, and a history of failure information, calculate the actual OEE value according to the planned OEE value, each process required by the current product, the required operator, the stop time of each process, the stop time of the production line, and a statistical correlation strength between the operating state of the production line and the history of failure information, obtain a process having the greatest influence on the actual OEE value according to the statistical correlation strength, and analyze an influence of a process failure on an error between the actual OEE value and the planned OEE value and a cause of a variation of the error.
7. The production management system according to claim 1, further comprising a database device (106), wherein the database device (106) is connected to the information control device (103) via an ethernet, and the database device (106) is configured to store a schedule of processes for each product produced by the production line.
8. The production management system according to claim 1, wherein the failure information includes standby downtime information, process downtime information, change type downtime information, maintenance downtime information, and quality downtime information; when the production line waits for the raw material, the part or the intermediate assembly part to be matched, the fault return control device (101) sends out the information of the machine halt of the raw material; when the production line is stopped, the fault return control device (101) sends out process crash information; when the model of the produced product is changed on the production line, the fault return control device (101) sends out the information of the model changing crash; when a production line or production equipment in the production line is maintained, the fault return control device (101) sends out maintenance crash information; when the operator finds a product quality problem, the failure return control device (101) sends out quality crash information.
9. The production management system according to claim 1, further comprising an interactive control device (107), wherein the interactive control device (107) is configured to adjust the operation parameters of the information control device (103) in real time, and to export the data calculated by the information control device (103) in time.
10. A production management method characterized by applying the production management system according to any one of claims 1 to 9.
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| CN201410231796.1A CN103984326B (en) | 2014-05-28 | 2014-05-28 | Production management system and method |
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|---|---|---|---|
| CN201410231796.1A CN103984326B (en) | 2014-05-28 | 2014-05-28 | Production management system and method |
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| CN103984326A true CN103984326A (en) | 2014-08-13 |
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| CN111240286A (en) * | 2020-01-19 | 2020-06-05 | 珠海格力电器股份有限公司 | System and method for reducing misjudgment of line stop reason |
| CN111308923A (en) * | 2019-09-29 | 2020-06-19 | 深圳市纳设智能装备有限公司 | Control method and control device of CVD (chemical vapor deposition) equipment |
| CN113344477A (en) * | 2021-08-05 | 2021-09-03 | 捷尔杰（天津）设备有限公司 | Task synchronization control method and device, electronic equipment and computer storage medium |
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