JP2003067033A - Continuous processing stage display system - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a system which enables a person who works for a factory to instantaneously grasp information regarding specially important items to be managed in the continuous processing stage management of the factory. SOLUTION: The continuous processing stage display system comprises a detecting means, a 1st controller, a 2nd controller (not always necessary), a control means, and a display device and can display a table in specific format on the display, and the table in the specific format has in longitudinal or lateral fields the items of (1) the delay time of a specific item behind target time, (2) the stop time or facility stop time of each stage, and (3) the actual process number and target process number of an article to be processed in each specific time section.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a continuous processing step display system, and more particularly to a factory which collects particularly important items in a continuous processing step due to factory work flow in a tabular form and displays them on a predetermined display. A person who works at, for example, a daytime worker or a shift worker who shifts directly to the work, delays from the target time for a specific process, downtime for each process or equipment downtime, a predetermined time division The present invention relates to a system capable of grasping at a glance important items in time management such as the actual number of objects to be processed and the target number of objects to be processed for each item.

[0002]

2. Description of the Related Art A production management display system, for example, installed on a production line in a factory, production management information such as production target of the day, current performance, stop time, etc., and information on presence / absence of abnormality in each process of the production line The production management display system that displays and on one display is very useful as production management means in a factory that manufactures automobiles and machines. In the production management display system, various information is acquired,
Controlled, managed, displayed, or stored. Many proposals have been made in the past regarding a display device and a display method for production management information. For example, Japanese Patent Laid-Open No. 6-208690 discloses a “production management display system” and Japanese Patent Laid-Open No. 6-227.
No. 49 discloses "Andon information display device".
No. 274208 discloses "Production line display method",
Each is disclosed.

[0003] The production control information is diverse and includes daily information in each process of the production site. Conventionally, as a production management display system used in a factory, for example, various detection means for acquiring information on each process of each equipment (specifically, for example, various sensors, time measurement means (clock etc.) ) Or manually inputting necessary information by a human (for example, personal computer terminal, etc.), and a first control device for managing information from the various detecting means [hereinafter, referred to as slave PLC in this specification.
(Also referred to as (Programmable Logic Controller)], a second control device (hereinafter, also referred to as a master PLC in the present specification) that integrally manages the slave PLC, a control unit connected to the master PLC, and various kinds of acquired information. Mention may be made of a system consisting of a display for displaying.

[0004]

Generally, in a factory,
In addition to the production site where the product is produced, for example, the processing site where the product is processed (for example, including deformation and painting), the inspection site where the obtained product is inspected, or the disposal where the used product is discarded There are various processing sites, such as sites, according to the application. Since these processing sites are usually distributed over multiple facilities in the factory, the information obtained from each facility is
For example, it is displayed on a suitable display, for example, a display of a personal computer or a dedicated display board type display as a flowchart for displaying the processing steps of each facility. The flow chart and the information related thereto basically show the detailed situation of each processing step (or the apparatus used in each processing step) individually. It is not possible to easily grasp the transition of the situation in.

If only the processing steps of each facility in the factory are managed, the above-mentioned management method, for example, the management by the flow chart showing the individual processing steps, may be used. It is inconvenient to instantly grasp the minimum necessary information for grasping the change over time in the situation. For example, in the conventional management method, it is not possible to easily exchange and confirm important information between daytime workers (day workers) regarding the change over time in the processing situation of the entire factory, or, for example, Even in the case of a factory operating under a shift work system, important processing control items for each shift,
It is not possible to easily confirm the change over time such as the goal to be achieved and the degree of achievement of the goal with respect to the item.

Therefore, in the past, for example, taking the case of shifts of each shift (shift) in a factory operating under a shift work system as an example, two shifts to be changed are integrated into one display. It is not possible to simply and quickly take over the work at the time of the change by looking at the important information displayed on the screen. For example, verbal or documents between the persons in charge (for example, takeover notes and notebook memos) Or, for example, the necessary information is individually displayed on the display, and the work is handed over while watching these.

The present invention is intended to solve the above-mentioned problems of the prior art, and its purpose is to identify particularly important items that should be intensively managed in continuous process management by a factory line work. Important items in time management, such as delay time from the target time of a specific process, stop time for each process or equipment stop time, processing for each predetermined time segment, by displaying in tabular form on a predetermined display It is an object of the present invention to provide a system in which a person who is involved in the processing management of a factory can instantly grasp the actual processing number and the processing target number of articles to be processed by looking at the display on the display.

[0008]

That is, the continuous processing step display system according to the first aspect of the present invention is (a) arranged at a predetermined position of each processing step in a factory that continuously processes an article to be processed. And (b) a first control device equipped with a first storage device that stores process management information in each processing step and capable of controlling each of the above information;
Equipped with a second storage device that stores each of the information from the first control device, and access the first control device, to obtain each of the information from the first control device, or the A second control device capable of controlling each information, and (d) accessing the second control device, acquiring the respective information from the second control device, or controlling the respective information, Control means capable of creating a table in a predetermined format in which specific information about each processing step is created from each of the information, and (e)
A continuous processing step display system comprising a display capable of displaying a table of the predetermined format, wherein the table of the predetermined format has the following items in either a vertical column or a horizontal column: (1) , Delay time from the target time (2) stop time or equipment stop time for each process (3) for articles to be processed for each predetermined time segment,
It is characterized in that the actual processing number and the processing target number are described (hereinafter referred to as i). In addition, the continuous processing step display system of the second invention,
(F) A detection means provided at a predetermined position of each processing step in the factory that continuously processes the article to be processed,
(G) A first control device equipped with a first storage device that stores process control information in each processing step and capable of controlling each of the above information; and (h) access to the first control device. A control means capable of obtaining each of the information from the first control device or controlling each of the information, and creating a table in a predetermined format in which specific information regarding each processing step is described from each of the information; (I) A continuous processing step display system comprising a display capable of displaying the table of the predetermined format, wherein the table of the predetermined format has the following items in either the vertical column or the horizontal column: (1) Delay time from target time of specific process (2) Stop time or equipment down time for each process (3) For articles to be processed for each predetermined time segment,
The following processing step display system of the present invention is particularly preferable, in which the actual processing number and the processing target number are described (hereinafter referred to as ii). (iii) In addition to the above items (1) to (3) in any of the vertical or horizontal columns of the table of the predetermined format, the following items: (4) Direct shifts during daytime or shift work (5) Identification The time when the specific process was stopped because it was filled with the products to be processed due to the stop of the process after the process of (6) The product to be processed was not carried in due to the stop of the process before the specific process. By this, the time when the specific process is stopped (7) The processing time required for one article to be processed, (8) The actual inventory number and the maximum inventory number in the inventory management of each process (9) Direct processing The continuous processing step display system of i in which at least one of the actual processing number and the processing target number is described for the article to be processed. (iv) The means for controlling each of the information or the means for creating a table of a predetermined format from each of the information is a table in which a command for each of the information or a command for creating the table is entered i or ii Continuous processing process display system. (v) A continuous processing step display system of i in which the first control device, the second control device, and the control means are connected via a network. (vi) A continuous processing step display system according to ii, wherein the first control device and the control means are connected via a network. The term “treatment” in the present invention means production (eg assembly, mixing, casting, etc.), processing (eg deformation, forging, painting, polishing, grinding, etc.), inspection (eg surface inspection, internal inspection, non-inspection). Destructive inspection, etc.), disposal (eg, destruction, combustion), etc. are used to mean various operations that can be performed in a factory.

[0009]

BEST MODE FOR CARRYING OUT THE INVENTION The detection means may be any means capable of detecting various information or inputting the detection result to a predetermined device, for example, various sensors, time measuring means (eg, clock, timer, etc.). Means means for manually inputting necessary information by a human (for example, personal computer terminal, input device using buttons, switches, keys, etc.), and these may be used alone or in combination. The detection means obtains information necessary for managing each continuous processing step in a factory where the articles to be processed are continuously processed and information necessary for determining the presence or absence of abnormality in each step. It is provided at a predetermined position to obtain, for example, a predetermined position of each process of each equipment. The type, number, size, shape, etc. of the detection means are
Select as appropriate according to the information to be acquired. Since the information obtained from each detection means is not equivalent, each information may be weighted and evaluated. Specifically, for example, when a sensor is used as the detection means and a plurality of sensors are provided in each process of each facility, a value is attached to the information obtained from each sensor according to the degree of importance, or The information obtained from each sensor may be ranked according to an appropriate scale.

The first control device (slave PLC) may be any device that can control the information from the sensor. The second control device (master PLC) may be any device that can acquire the above-mentioned information from the slave PLC or control the above-mentioned information. Therefore, the system including the slave PLC and the master PLC may be, for example, a process management system (for example, a system in which the various sensors described above, a plurality of computers and databases are combined) provided in each factory. The process management system may be various types of systems. For example, in a factory that uses an existing process management system, a usable part of the process management system (for example, various control computers and processes). The acquired information) can be used as is. It is also possible to construct a continuous processing step display system of the present invention that does not use the second control device, in which case the control means directly accesses the first control device. It is advisable to use the most suitable system according to the case.

As the control means in the present invention, for example, a control computer connected to the master PLC or the slave PLC, for example, a control personal computer can be used. The control computer may be, for example, a system including a plurality of computers connected by a network, if necessary.

The display for displaying the factory layout and various other useful information in addition to the factory layout is, for example, a conventional monitor in a factory monitor or a personal computer, such as a CRT or a liquid crystal display, alone or in combination. Can be used. As the display, it is possible to use another type of display such as an electronic display board.

Each item provided in either the vertical column or the horizontal column of the table of the predetermined format used in the system of the present invention will be described below. (1) Delay time from the target time of a specific process When the processing time in a specific process is longer than the target processing time (time preset for the processing in a specific process) When a delay occurs from the target processing time, the delay time (the time of the delayed portion) is displayed in an appropriate unit (for example, minutes or seconds). (2) Stop time or equipment stop time for each process If each process is stopped for various reasons (for example, including the reasons (5) and (6) below), the stop time is , It's not a serious thing to stop each process,
For example, when a part of the equipment of each process (for example, one fan in a process where there are multiple fans) is stopped, the equipment stop time is set in an appropriate unit (for example, minutes or seconds). indicate. Of the equipment of each process, stopping the important equipment causes the entire process to be stopped (the stop time in this case is included in the stop time for each process described above),
For example, as described above, stopping one of the plurality of fans does not stop the entire process (the stop time in this case is included in the equipment stop time for each process). However, even if one of the plurality of fans is stopped, this fan should be repaired immediately. Therefore, it is described as equipment stop time, managed by this system, and repaired at an appropriate time. (3) Regarding the articles to be processed for each predetermined time segment,
The actual number of treatments and the target number of treatments The working hours on a regular day or each shift are managed by a timetable divided into a plurality of sections at appropriate time intervals. The time interval corresponding to each of the above-mentioned sections is the work efficiency (for example, the work efficiency is different between 2:00 am and 2:00 pm) and other matters (for example, work efficiency at each hour in the working hours of the daytime or each shift), for example, It may be appropriately selected in consideration of the time for meal). Therefore,
Normally, the time interval is different for each section, but it may be the same for all sections.

In any of the vertical columns or the horizontal columns of the table of a predetermined format used in the system of the present invention, the above items (1) to
In addition to (3), other suitable items may be provided. Hereinafter, examples of items that are preferably provided will be described. (4) When the products are processed in the factory (or the specific processing steps of the factory) in the working system of only regular daytime workers (day workers) in the daytime or shift work, the processing steps are performed by the daytime workers. Is maintained and managed, a message to that effect, such as "every day"
Describe as "day shift." In addition, when a product is processed in a factory (or a specific processing step of the factory) in a shift work system, for example, a four shift and three shift work system, three shifts of four shifts (one shift of the other shift) Since the treatment process is maintained and managed during the holidays, the name of the person who is currently working is stated at the prescribed location in the above table. The described format may be a format that allows each train to be clearly distinguished. In particular,
For example, 1st shift, 2nd shift, 3rd shift, 1st shift, 2nd shift, 3rd shift,
Described as A straight, B straight, C straight, Shift 1, Shift 2, Shift 3. (5) The time when the specific process is stopped due to being filled with articles to be processed due to the stop of the post-process of the specific process. The time when the specific process is temporarily stopped is displayed because the product to be processed cannot be newly loaded into the specific process because it is filled with the desired process. (6) The time during which the specific process was stopped because the article to be processed was not delivered due to the stop of the previous process of the specific process. Since the goods to be processed are not carried in and the supply of the goods to be processed is interrupted, the time at which the specific process is temporarily stopped is displayed. (7) Processing time required for each article to be processed Accurately grasping the processing time required for each article to be processed is important for improving work efficiency. (8) Actual inventory number and maximum inventory number in inventory management of each process Since the maximum inventory number of each process is fixed, confirm the actual inventory number and the maximum inventory number to confirm the processing that is accumulated in each process. It is possible to grasp the situation of the goods that should be used. (9) Actual number of treatments and target number of treatments for articles to be processed in a predetermined straight line The actual number of treatments and the target number of treatments for articles to be directly processed in a predetermined straight line are important as a measure of the processing situation in each straight line.

As the table of the predetermined format, it is usually convenient to use a rectangular table consisting of vertical columns and horizontal columns. However, depending on the continuous processing steps to be controlled and the display, other shapes can be used. Can be used alone or in combination with the rectangular table. When using a rectangular table, in the vertical and horizontal columns, enter the name of each item in Japanese within a rectangular frame, or use the system of the present invention in a foreign country. In other cases, other suitable languages other than Japanese,
For example, write in English, French, German, etc.
If necessary, the names of each item may be written together in two or more languages.

It is preferable that the slave PLC, the master PLC and the control means in the first aspect of the present invention or the slave PLC and the control means in the second aspect of the present invention are connected via a network. The network may be, for example, a network that is uniquely constructed by connecting the respective facilities, or may be an existing network such as the Internet as all or part of the network. Slave PLC and master P in the first invention
LC and control means, or slave P in the second invention
A large computer may be used as the LC and the control means. For example, when handling information that can be managed by a relatively small computer, a personal computer is used in terms of cost, installation area, and ease of handling. It is convenient to use.

Various programs for effectively operating the slave PLC, the master PLC, and the control means, for example, a process control program and a program for constructing or creating the evaluation standard (for example, a main program and some subprograms) Program consisting of) may be independently incorporated in the slave PLC, the master PLC and the control means, or the slave PLC,
It may be incorporated in another computer that can be used by the master PLC and the control means. When it is necessary to use several programs in combination, even if the programs distributed in a plurality of places are mutually utilized by allowing each device or control means to access each other through a network, for example. Good.

[0018]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The basic concept of the continuous processing step display system of the present invention will be described below with reference to the drawings. FIG. 1 is a diagram for explaining the basic configuration of an example of the present continuous processing step display system. Various sensors for monitoring or controlling each process are arranged in each facility (only facility A and facility C are shown in FIG. 1) in the factory. The information obtained from each sensor is transmitted to the slave PLC. Specifically, for example, the information acquired from the sensor of the equipment A is transmitted to the slave PLC 1, and the information acquired from the sensor of the equipment C is transmitted to the slave PLC 3. Slave P
The LC1 to the slave PLC 4 are centrally managed by the master PLC. In this example, the master PLC is accessible from the control PC, and various information including information on the continuous processing steps (continuous processing step table) to be displayed as a table in a specific format can be obtained.

The display of the control PC or other dedicated display system (for example, an electronic display board) is
It is possible to display the continuous processing step table or various other necessary information in addition thereto. An example of the continuous processing step table [FIG. 1 (a)] displayed on the display is shown in the rectangular portion indicated by the up arrow from the control PC in FIG. In addition, in FIG.
An enlarged view of the continuous treatment process table of FIG. 1 (a) is shown.

Referring to FIG. FIG. 2 is a diagram showing an example of a continuous treatment process table of an automobile coating factory, shift 2
This is a table for managing the important items of the continuous processing steps in (Shift 2, Double shift). Further, all items in the continuous processing step table in FIG. 2 are written in English. 2 will be described in more detail. The following items are described in the vertical column of the table of FIG. 2 (left column in the figure; except shift 2, which is a common item in the vertical and horizontal columns): (a1) Pretreatment and electrodeposition process (PTM & ED Line) (b1) Metal inspection process (Metal Insp.) (C1) Sealer process (Sealer Line) (d1) Primer coating process (e1) Primer inspection process (Primer Insp.) (F1) ) Preparation process (Preparation Line) (g1) Top coat A process (Top Coat A Line) (h1) Top coat B process (Top Coat B Line) (i1) Top coat inspection process (Top Coat Insp.) (J1) Final inspection Process (Final Insp.) (K1) Wax process (Wax Line) In addition to the above-mentioned items, important items for managing the continuous treatment process of the coating factory may be added at appropriate times.

The following items are described in the horizontal columns of the table of FIG. 2 (upper column in the figure; except for shift 2, which is a common item in the vertical and horizontal columns): (a2) Delayed stop ( Delay Stop), unit: minute (b2) Equipment stop (Equip.Stop), unit: minute (c2) Body Full (d2) Body Short (e2) Takt (f2) ) Inventory (g2) Total (h2) Time division (14:30 ~ 15:00, 15:00 ~ 15:30, etc.)

In the table of FIG. 2, the items (a2) to (d2) are 0 for each of the steps (a1) to (k1). Also, the tact of (e2) is 1.30, and in this example, 1.3
It is painted in 0 minutes. Inventory of (f2)
In this example, the section of is divided into upper and lower parts by a broken line,
The maximum number of stocks in the lower section, the actual number of stocks in the upper section,
It can be seen that the actual number of stocks and the maximum number of stocks are different in each process described in (a1) to (k1). The total section of (g2) is also divided into upper and lower parts by broken lines, and the target processing number is shown in the lower section and the actual processing number is shown in the upper section. In each of the steps (a1) to (k1), the processing target number (287 in this example) is the same, but the actual number of processing is 218 to
It can be seen that the number of processes is different from 303 units, and the actual number of processes and the target number of processes are different in each process. The time segment of (h2) is divided into different time intervals depending on the time zone. For example, in this example, 30 minutes interval such as 14:30 to 15:00 and 18:00 to 1
There are three time intervals, one hour interval such as 9:00 and 45 minutes interval such as 19:15 to 20:00. It can be seen that the actual number of processes and the target number of processes for each time segment are very different. Note that the time segment of (h2) may be provided with a spare segment such as the two segments on the right side.

Returning to the explanation of FIG. In addition to the continuous treatment process chart of FIG. 1 (a), FIG.
The factory layout as shown in (b) and other information may be displayed. 1 (a) and 1 (b) are displayed on, for example, a large-sized light emitting display plate,
Anyone, including the members of each shift, can confirm the status of the continuous processing process (understand the status of important items) and whether there is any abnormality in the continuous processing process from the information shown in Fig. 1 (a) and Fig. 1 (b). Can be grasped immediately.

FIG. 3 shows an example of a continuous processing step table displayed on the display of a personal computer by the continuous processing step display system. In this example, in addition to the continuous processing process chart of FIG. 1 (a) and the factory layout of FIG. 1 (b), a flowchart of a specific process (upper left of FIG. 3)
And a timetable associated with the flowchart (see FIG.
Left middle).

FIG. 4 shows an example of a time table for each shift (shift) in a table of a predetermined format displayed by the present continuous processing step display system. For example, when the display of a personal computer is used as the display means, such a timetable is provided at the lower part of the page displaying the table of the predetermined format, and after viewing the table, refer to it if necessary. Good to do. From Figure 4, for example, the start time of each shift is 6:00 for one shift (Shift 1), 14:00 for two shifts (Shift 2), and 22:00 for three shifts (Shift 3). Yes, and Takt is 1.2 for Direct Shift (Shift 1).
It is 0, two shifts (Shift 2) is 1.30, and three shifts (Shift 3) is 1.40.

[0026]

EFFECT OF THE INVENTION By using the continuous processing step display system of the present invention, it is possible to manage continuous processing by the flow work of a factory.
By gathering particularly important items that should be focused on in a tabular format and displaying them on a predetermined display, important items in time management, specifically, the delay time from the target time of a specific process, each process Stop time or equipment stop time, the actual number of treatments and the target number of treatments for the goods to be treated for each predetermined time segment, such as those who are engaged in the treatment management of the factory, for example, those who normally work (daytime workers) and each shift The members of the above can instantly grasp the information by looking at the display on the display. Therefore, it becomes easy to manage the time of the continuous processing steps in a specific factory, and it is possible to immediately take measures against the delay or stop of each step, so that the processing efficiency in a specific factory can be improved and, for example, a plurality of factories can be processed. Also in the manufacturing and processing of the product related to the above, it is possible to minimize the influence of the delay of the manufacturing and processing in a specific factory and improve the overall processing efficiency.

As the various information used in the continuous processing step display system of the present invention, the information in each step of the existing processing line is used as it is, or a part of it is extracted, or if necessary, processed and used. Therefore, it is possible to more effectively utilize the information on each process of the existing processing line.

[Brief description of drawings]

FIG. 1 is a diagram for explaining the basic configuration of an example of a continuous processing step display system of the present invention.

FIG. 2 is a diagram showing an example of a continuous processing step table displayed using the present continuous processing step display system.

FIG. 3 is a diagram showing an example of a continuous processing step table displayed on a display of a personal computer by the continuous processing step display system.

FIG. 4 is a diagram showing an example of a time table for each shift (shift) in a table of a predetermined format displayed by the present continuous processing step display system.

Claims (6)

[Claims] 1. (a) A detection means provided at a predetermined position of each processing step in a factory that continuously processes articles to be processed, and (b) process management information in each processing step is stored. A first control device equipped with a first storage device and capable of controlling each of the above information; and (c) a second storage device storing each of the information from the first control device. And a second control device capable of accessing the first control device, acquiring the respective information from the first control device, or controlling the respective information, and (d) the second control device. To obtain each of the information from the second control device, or to control each of the information, it is possible to create a table in a predetermined format that describes specific information about each processing step from each of the information. Control means, and (e) a device capable of displaying the table of the predetermined format. A continuous processing step display system including a play, wherein the table of the predetermined format has the following items in either the vertical column or the horizontal column: (1) Delay time of a specific step from a target time (2 ) Stop time or equipment stop time for each process (3) Regarding the articles to be processed for each predetermined time segment,
A processing step display system characterized in that the actual processing number and the processing target number are described. 2. (f) A detection means provided at a predetermined position of each processing step in a factory for continuously flowing articles to be processed, and (g) step management information for each processing step is stored. A first control device equipped with a first storage device and capable of controlling each of the above information; and (h) accessing the first control device to obtain each of the information from the first control device. Or control means capable of controlling each of the above information and creating a table of a predetermined format in which specific information regarding each processing step is described from each of the information, and (i) displaying the table of the predetermined format. A continuous processing step display system comprising a display, wherein the table of the predetermined format has the following items in either a vertical column or a horizontal column: (1) Delay time from a target time of a specific step (2 ) Downtime or equipment downtime for each process (3) Per During classification, an article to be treated,
A processing step display system characterized in that the actual processing number and the processing target number are described. 3. In addition to the above items (1) to (3) in any of the vertical or horizontal columns of the table of the predetermined format, the following items are: (4) Direct shifts during daytime or shift work (5 ) The time when the specified process was stopped because it was filled with the products to be processed due to the stop of the post-process of the specific process (6) The product to be processed was carried in as the process before the specific process was stopped. The time when the specific process was stopped due to the absence of the process (7) The processing time required for one item to be processed (8) The actual number of stocks and the maximum number of stocks in the inventory management of each process (9) The processing step display system according to claim 1 or 2, wherein at least one of the actual number of objects to be processed and the target number of objects to be processed is described. 4. The means for controlling the information or the means for creating a table of a predetermined format from the information is a table in which a command for the information or a command for creating the table is entered. The processing step display system according to claim 1 or 2. 5. The processing step display system according to claim 1, wherein the first control device, the second control device, and the control means are connected via a network. 6. The processing step display system according to claim 2, wherein the first control device and the control means are connected via a network.