JP2005025449A

JP2005025449A - Production management method for molding machine and production management system therefor

Info

Publication number: JP2005025449A
Application number: JP2003189522A
Authority: JP
Inventors: Katsuyuki Uno; 勝之羽野; Tatsuo Morimura; 達男守村
Original assignee: Sumitomo Heavy Industries Ltd
Current assignee: Sumitomo Heavy Industries Ltd
Priority date: 2003-07-01
Filing date: 2003-07-01
Publication date: 2005-01-27

Abstract

<P>PROBLEM TO BE SOLVED: To provide a production management method which introduces information from peripheral utilities, such as a molded product pick up machine, a molded product inspecting machine and so on, to execute production management in a multiple-set management system managing a plurality of molding machines. <P>SOLUTION: The production management method is provided with injection molding machines (1-1 to 1-n) equipped with the molded product pick up machines (2-1 to 2-n), the molded product inspecting machine 4 and a management device 5, and manages the number of molded products to be produced by each injection molding machine by means of the management device, and then produces the planned total production number of the molded products. The molded product inspecting machine, which determines whether the products picked up by each molded product pick up machine are defective and disposes of the defective products, outputs the result of the inspection indicating at least either the number of normal products or the number of defective products. The management device corrects the planned total production number based on the planned total production number, the number of shots from the beginning of the production to the present in each injection molding machine, the number of the products picked up from the beginning of the production to the present sent from each molded product pick up machine; and the result of the inspection. Then, the management device allocates the values thus corrected to each injection molding machine and makes each injection molding machine produce the allocated number of the products. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

【０００１】
【発明の属する技術分野】
本発明は成形機の生産管理方法及び生産管理システムに関し、特に複数台の成形機の生産管理を１台の管理装置で一括して行うのに適した生産管理方法及び生産管理システムに関する。
【０００２】
【従来の技術】
図４〜図９を参照して、複数台の成形機の管理方法の一例として、本出願人により提案（特願２００１−１９３２３４号）されている射出成形機の稼働状況表示方法について説明する。上記提案による稼働状況表示方法は、図４に示すような射出成形機の複数台管理システムに適用されている。図４において、同じ場所に複数台の射出成形機１０−１〜１０−ｎが設置され、これらはディスプレイ装置付きの管理装置２０で一括管理されている。つまり、管理装置２０は、射出成形機１０−１〜１０−ｎにおけるそれぞれの制御装置に接続されており、射出成形機１０−１〜１０−ｎのそれぞれに設置された各種センサからの様々な情報を各制御装置経由で受信し、受信した情報を内蔵の管理プログラムに基づいて射出成形機別に処理すると共に、処理した結果を内蔵のメモリに保存及び管理画面としてディスプレイ装置に表示する。情報の種別によっては受信した生情報がそのままメモリに保存される。
【０００３】
次に、上記の管理装置２０において各射出成形機の稼働状況を表すためにディスプレイ装置にて表示される管理画面には複数種類あり、そのうちの４つの例について説明する。
【０００４】
図５は、複数台の射出成形機の運転状況をリアルタイムに表示する運転状況画面である。この運転状況画面では、複数台の射出成形機の稼働状況が、画面分割形式にてすべての号機（ここでは１号機〜３０号機）についてリアルタイムで一括して１画面に表示される。例えば、９号機について拡大して示した図６をも参照して説明すると、左上に号機の番号、右上に成形条件変更カウンタの計数値Ｃ１（ここでは１７）、右横に２４時間稼働状況グラフ、下側にはショット数（５２９）とサイクル時間（１４．９ｓｅｃ）とが表示されている。ここで、成形条件変更カウンタというのは、生産を開始してから現在までに何回成形条件が変更されたかを計数するカウンタのカウント結果である。このカウンタは管理装置２０に備えられる。各射出成形機における制御装置には成形条件の変更を検出する手段が設けられ、管理装置２０では各制御装置からの検出結果を受けてそれぞれをカウントし、各号機別にカウント結果をディスプレイ装置に表示させる。管理装置２０では、この表示値を必要に応じてリセット可能である。
【０００５】
また、２４時間稼働状況グラフというのは、現時点から過去２４時間における射出成形機の稼働状況を色分けにして１本の第１の棒グラフＢ１で表示するものである。稼働状況は、稼働、通常の停止（スタンバイ中）、異常発生による停止、電源切りの４種類で規定され、２４時間前から現時点までの時間経過に対応させて前記４種類の状況が色分け区分表示される。ここでは、稼働が青色、通常の停止が黄色、異常発生による停止が赤色、電源切りが灰色で示され、図６では便宜上、青色は右下がりの細いハッチング、黄色は縦のハッチング、赤は右さがりの太いハッチング、灰色は左下がりの太いハッチングで示している。また、第１の棒グラフＢ１の最下端が２４時間前、最上端が現時点をそれぞれ示し、例えば、過去２４時間前から１２時間前までは通常の停止、過去１２時間前から現時点までは稼働中であれば、第１の棒グラフＢ１は下半分が黄色、上半分が青で表示されることになる。
【０００６】
上記提案では更に、各号機の分割画面内に射出成形機の外観がアイコン画像として表示され、しかもその背景は、現在の稼働状況を示すために、前記稼働、前記通常の停止、前記異常発生による停止、前記電源切りの４種類について第１の棒グラフＢ１における色分けと同じ対応色関係で表示されるようにしている。つまり、上記の例示と同じとすると、背景色は青となる。
【０００７】
このような運転状況画面を見ることで、オペレータあるいは管理者はどの号機が過去２４時間においてどのような稼働状況であったのかを一目瞭然で知ることができる。なお、２４時間という数値は、通常は固定値であるが、可変としても良い。
【０００８】
ところで、管理装置２０では、ディスプレイ装置における上記の運転状況画面における各号機の分割画面における特定箇所をクリックすることで該当する号機のみの稼働状況を詳細に示す総括グラフ画面を表示可能にしている。
【０００９】
図７は、総括グラフ画面の例であり、この総括グラフ画面では号機別（ここでは１０号機）に、２４時間分の品質データの変化状況、異常発生の有無、設定変更の有無が時刻を横軸にして１画面にて表示される。図７において、最上段のグラフはショット数の累積値の変化を示す折れ線グラフであり、縦に入っている複数の線、例えば線Ｌ１は１８時近辺で成形の中断（異常発生）があったことを示す。Ｌ２の『状態』というのは、前に述べた稼働状況の表示と同じであり、稼働、通常の停止（スタンバイ中）、異常発生による停止、電源切りの４種類で規定され、２４時間分の状態が時刻に対応させて色分け表示される。Ｌ３の『条件名』というのは、成形条件の変更、つまり成形品毎の条件名が変更されると色を変更し、変更された時刻を示すグラフである。言い換えれば、これは成形品が変わると変更されるものであり、色別表示されるが、色そのものに意味があるわけではなく、色が変わった時刻に意味がある。一方、Ｌ４の『項目』というのは、成形条件内の条件項目が変更されると色を変え変更されたことを時刻とともに表示するグラフである。例えば、射出の条件や型開の条件等が変更された場合に色が変更されるものであり、これも色そのものというより、色が変わった時刻に意味がある。このため、『条件名』、『項目』の色は、『状態』とは異なり、４色以上が用意される。
【００１０】
また、Ｌ５の１段目のグラフは図７下側の表示項目選択欄に示されている表示項目の『充填時間』の時間経過を示し、２段目は同様に『最小クッション位置』の時間経過を示す。３段目のグラフは『保圧完了位置』を示し、４段目、５段目はそれぞれ、『Ｖ／Ｐ切換位置』、『充填前位置』の時間経過を示す。
【００１１】
上記提案では更に、総括グラフ画面の右横に更に、過去２４時間における当該号機の稼働状況を、０〜１００％の稼働率で第２の棒グラフＢ２により、第１の棒グラフＢ１と同様の色別に、２４時間を示す数値と共に表示するようにしている。図７では、過去２４時間の稼働率が２８％であることを示し、図７下側の表示項目選択欄に示されている『時間表示』の箇所に稼働率計算のベースになっている２４という数字が表示されている。なお、ここでの『時間表示』の欄の数字は任意に変更することができる。つまり、表示項目選択欄に示されている『日時』、『時間表示』は任意に設定することができ、ここでは２０００年９月４日１０時から２４時間という数値が設定されていることにより、図７最上部に示されているように、２０００年９月４日１０時から２０００年９月５日１０時までの２４時間分が表示される。仮に、『時間表示』に１２という数字を入力すれば、１２時間をベースとした過去１２時間分の稼働率が第２の棒グラフＢ２で表示される。この場合、図７の１段目〜８段目のグラフあるいは項目も過去１２時間分について示されることになる。このような第２の棒グラフＢ２によれば、任意な時間の任意な時刻からの稼働率を表示できる。
【００１２】
図８は、設定履歴画面の例であり、この設定履歴画面では号機別（ここでは１０号機）に、設定変更の履歴が、変更した項目、変更前及び変更後の設定値、変更日時と共に１画面にて表示される。
【００１３】
図９は、異常履歴画面の例であり、この異常履歴画面では号機別（ここでは１０号機）に、異常発生の履歴が、異常の項目、発生日時、解除日時と共に１画面にて表示される。
【００１４】
前に述べたように、図７の総括グラフ画面は図５の運転状況画面にリンクしており、図５の運転状況画面における各号機の特定箇所（アイコン）をクリックすることで表示されるようになっている。また、図８の設定履歴画面、図９の異常履歴画面はそれぞれ図７の総括グラフ画面にリンクしており、図７の総括グラフ画面の特定箇所（アイコン）をクリックすることで任意の画面が直接表示されるようになっている。
【００１５】
【発明が解決しようとする課題】
ところで、射出成形機には、成形品取出し機が備えられる。成形品取出し機では取り出した成形品の数を射出成形機の制御装置に通知するが、チャックミスと呼ばれる取出し不良の場合がある。この場合、成形品取出し機は取出し不良があったことを制御装置に通知する。成形品取出し機ではまた、制御装置において成形不良の判別を行った際に送られてくる指令により成形品を廃棄する。制御装置では、生産開始から現在までのショット数に取出し不良の数、成形不良により廃棄された数を反映させて生産数を実生産数として把握している。
【００１６】
射出成形機にはまた、成形品検査機が備えられる。成形品検査機は、成形品取出し機で取り出された成形品に対して良品、不良品の判別を行うものであり、不良品は廃棄すると共に、良品数、不良品数の少なくとも一方を示す検査結果を制御装置に通知する。この場合、制御装置は、生産開始から現在までのショット数に上記の取出し不良の数と成形不良による廃棄数と検査結果とを反映させて生産数を実生産数として把握することになる。
【００１７】
射出成形機において、正確な実生産数の管理は大変重要である。しかし、射出成形機を複数台管理するこれまでの複数台管理システムでは、各成形品取出し機や成形品検査機などの周辺設備からの情報（成形不良による廃棄、チャックミス、不良品数）を総合的に把握して生産管理することは行っていない。
【００１８】
その結果、成形品取出し機での成形不良による廃棄及びチャックミスや、成形品検査機での不良品数が多かった場合に、実際に必要な生産数を下回ってしまったり、あらかじめ成形不良及びチャックミスや不良品発生数を見込んで多めに生産した場合の仕掛品を増やしてしまうという問題が生じることになる。
【００１９】
そこで、本発明の課題は、成形品取出し機や成形品検査機などの周辺設備からの情報をも取り入れて生産管理を行うことのできる生産管理方法を提供することにある。
【００２０】
本発明の他の課題は、複数台の成形機を管理する複数台管理システムにおいて、各成形品取出し機や成形品検査機などの周辺設備からの情報をも取り入れて生産管理を行うことのできる複数台管理システム用の生産管理方法及び生産管理システムを提供することにある。
【００２１】
【課題を解決するための手段】
本発明によれば、周辺設備として成形品取出し機、成形品検査機の少なくとも一方を備えた少なくとも１台の成形機の生産数を管理装置により管理し、あらかじめ知られている予定生産数だけ成形を行うようにする生産管理方法であって、前記管理装置は、生産開始から現在までのショット数と生産開始から現在までの成形品取出し数とに基づいて前記予定生産数の補正を行って、補正数分だけ増産を行わせることを特徴とする成形機の生産管理方法が提供される。
【００２２】
また、前記成形品取出し機、成形品検査機の両方を備える場合、前記成形品検査機は、前記成形品取出し機で取り出された成形品に対して良品、不良品の判別を行うと共に不良品を廃棄するものであって良品数、不良品数の少なくとも一方を示す検査結果を出力し、前記管理装置は、生産開始から現在までのショット数と前記成形品取出し機から送られてくる、生産開始から現在までの成形品取出し数と、前記検査結果とに基づいて前記予定生産数の補正を行って、補正数分だけ増産を行わせるようにしても良い。
【００２３】
本生産管理方法の別の形態においては、前記管理装置が複数台の前記成形機からの前記成形品取出し数を共有し、あらかじめ知られている複数台の成形機による予定総生産数と、各成形機における生産開始から現在までのショット数と、各成形機における前記成形品取出し数とに基づいて前記予定総生産数の補正を行うと共に、補正された値を前記複数台の成形機に割り振って各成形機に割り振られた分の増産を行わせることができる。
【００２４】
この別の形態においても、前記管理装置は前記複数台の成形機の各制御装置に接続されたパーソナルコンピュータで実現されて良いし、前記複数台の成形機の複数の制御装置のうちの１つで実現されても良い。
【００２５】
この別の形態においては、前記成形品取出し機、成形品検査機の両方を備える場合、前記成形品検査機は、前記複数台の成形機における各成形品取出し機で取り出された成形品に対して良品、不良品の判別を行うと共に不良品を廃棄するものであって良品数、不良品数の少なくとも一方を示す検査結果を出力し、前記管理装置は、前記予定総生産数と、各成形機における生産開始から現在までのショット数と、前記成形品取出し機から送られてくる、生産開始から現在までの成形品取出し数と、前記検査結果とに基づいて前記予定総生産数の補正を行うと共に、補正された値を前記複数台の成形機に割り振って各成形機に割り振られた分の増産を行わせる。
【００２６】
この別の形態においてはまた、前記成形品取出し機、成形品検査機の両方を備える場合、前記成形品検査機は、前記複数台の成形機毎に設置されて前記複数台の各成形機における各成形品取出し機で取り出された成形品に対して良品、不良品の判別を行うと共に不良品を廃棄するものであって良品数、不良品数の少なくとも一方を示す検査結果を出力し、前記管理装置は、前記予定総生産数と、各成形機における生産開始から現在までのショット数と、前記成形品取出し機から送られてくる、生産開始から現在までの成形品取出し数と、複数の前記成形品検査機からの検査結果とに基づいて前記予定総生産数の補正を行うと共に、補正された値を前記複数台の成形機に割り振って各成形機に割り振られた分の増産を行わせる。
【００２７】
本発明によればまた、複数台の成形機の生産数を管理装置により管理し、あらかじめ知られている予定生産数だけ成形を行うようにする成形機の生産管理方法であって、前記複数台の成形機は、生産開始から現在までのショット数と、各前記成形機の良品判別機能から送られてくる、生産開始から現在までの良品数、不良品数の少なくとも一方を示す検査結果を出力し、前記管理装置は前記検査結果と前記生産数とに基づいて前記予定生産数の補正を行なって、補正数分だけ増産を行なわせることを特徴とする成形機の生産管理方法が提供される。
【００２８】
本発明によれば更に、周辺設備として成形品取出し機、成形品検査機の少なくとも一方を備えた少なくとも１台の成形機の生産数を管理する管理装置を備え、あらかじめ知られている予定生産数だけ成形を行うようにする成形機の生産管理システムであって、前記管理装置は、生産開始から現在までのショット数と生産開始から現在までの成形品取出し数とに基づいて前記予定生産数の補正を行って、補正数分だけ増産を行わせることを特徴とする成形機の生産管理システムが提供される。
【００２９】
本発明によれば更に、複数台の成形機の生産数を管理する管理装置を備え、あらかじめ知られている予定生産数だけ成形を行うようにする成形機の生産管理システムであって、前記複数台の成形機は、生産開始から現在までのショット数と、各前記成形機の良品判別機能から送られてくる、生産開始から現在までの良品数、不良品数の少なくとも一方を示す検査結果を出力し、前記管理装置は前記検査結果と前記生産数とに基づいて前記予定生産数の補正を行なって、補正数分だけ増産を行なわせることを特徴とする成形機の生産管理システムが提供される。
【００３０】
なお、上記生産管理方法、生産管理システムのいずれにおいても、前記管理装置は前記成形機の制御装置に接続されたパーソナルコンピュータで実現されて良いし、前記成形機の制御装置で実現されても良い。
【００３１】
【発明の実施の形態】
図１を参照して、本発明による生産管理方法及び生産管理システムの好ましい実施の形態について説明する。ここでは、図７で説明した提案と同様に、射出成形機の複数台管理システムに適用する場合について説明する。図１において、同じ場所に複数台の射出成形機１−１〜１−ｎが設置され、これらはディスプレイ装置付きの管理装置５で一括管理されている。つまり、管理装置５は、射出成形機１−１〜１−ｎにおけるそれぞれの制御装置３−１〜３−ｎに接続されており、射出成形機１−１〜１−ｎのそれぞれに設置された各種センサからの様々な情報を各制御装置経由で受信し、受信した情報を内蔵の管理プログラムに基づいて射出成形機別に処理すると共に、処理した結果を内蔵のメモリに保存及び管理画面としてディスプレイ装置に表示する。情報の種別によっては受信した生情報がそのままメモリに保存される。特に、本形態による管理装置５は、以下で説明する機能に加えて図５〜図９を参照して説明したような管理機能をも有するものとする。また、本形態では、説明を容易にするために、射出成形機１−１〜１−ｎはすべておなじ成形品を成形するものとし、管理装置５には射出成形機１−１〜１−ｎで生産されるべき成形品の総数が予定総生産数としてあらかじめ設定入力されているものとする。これにより、管理装置５は、射出成形機１−１〜１−ｎにそれぞれ、予定生産数を割り当てる。各射出成形機は割り当てられた予定生産数分を生産する。
【００３２】
射出成形機１−１〜１−ｎにはそれぞれ、成形品取出し機２−１〜２−ｎが備えられている。各成形品取出し機は、成形品の取出し数を管理装置５に通知し、チャックミスがあった場合にはその旨を通知する。これにより、管理装置５では、成形品の取出し数、つまり実生産数、チャックミスにより搬送ライン６に送ることのできなかった成形品の数を射出成形機別に把握することができる。成形品取出し機ではまた、制御装置においてあるショットの成形に成形不良があったことを判別すると、そのショットの成形品を廃棄すべく、成形品取出し機に廃棄の指令を出す。この場合、成形品取出し機は、成形品と搬送ラインに送らずに廃棄する。この廃棄された数も管理装置５において射出成形機別に把握されている。勿論、管理装置５は、各制御装置から送られてくるショット数情報により、生産開始から現時点までのショット数をも射出成形機別に把握している。なお、成形品取出し機からの情報は、対応する射出成形機の制御装置にも送られる。
【００３３】
各成形品取出し機で取り出された成形品は、搬送ライン６により成形品検査機４に送られる。ここでは、成形品検査機４は、すべての射出成形機１−１〜１−ｎからの成形品の検査を行うものとする。成形品検査機４は、成形品に対して良品、不良品の判別を行うものであり、不良品は廃棄すると共に、良品数、不良品数の少なくとも一方を示す検査結果を管理装置５に通知する。
【００３４】
図２、図３は、管理装置５が、各成形品取出し機、成形品検査機からの上記のような情報を管理プログラムに基づいて処理することにより、付属のディスプレイ装置により表示する生産数表示画面の例を示している。これらの生産数表示画面は射出成形機別に表示されるものである。つまり、これらの生産数表示画面は前に述べた総括グラフ画面のように、図５の運転状況画面にリンクしており、図５の運転状況画面における各号機の特定箇所（アイコン）をクリックすることで表示されるようになっている。
【００３５】
図２の生産数表示画面では、表示している号機番号（ここでは１６号機）、運転状態（ここでは稼働中）、割り当てられた予定生産数（ここでは１５００個）、現在までの生産数（ここでは２００個）、予定残数（ここでは１５００−２００＝１３００個）、達成率（ここでは１３％）、生産完了予定時間（ここでは、１時間２分）等が表示される。なお、生産完了予定時間は、予定残数と１ショット当たりのサイクル時間とで算出することができる。
【００３６】
図３の取出機生産モニタ画面は、図２の生産数表示画面における『取出機情報』のアイコンをクリックすることで表示される画面であり、号機別に表示される。従って、本画面も１６号機の画面となるが、ここでは本画面に示された数値は図２に示された数値と必ずしも対応していない。本画面では、成形サイクル（１ショット当たりのサイクル時間で、ここでは１０．５ｓｅｃ）、１ショット生産数（１ショットで生産される成形品の数で、ここでは１５個）、取出数（現在までの取出し回数で、ここでは１２０回）、総生産数（ここでは１８００個）、排出数（成形不良の判別により廃棄された数で、ここでは２０個）、チャックミス（ここでは３個）、不良率（ここでは１％）、初期排出回数（ここでは１０回）、サンプリング間隔（ここでは２０ショット毎）等が表示される。
【００３７】
なお、図３において、排出数というのは以下のようにして得られる。前述したように、射出成形機では制御装置が各種センサからの信号に基づいて成形良、不良の判別をショット毎に行っており、不良の判別結果を得た場合には成形品取出し機にそのショットの成形品を搬送ライン６に送らず廃棄する旨の信号を送る。この場合、成形品取出し機は成形品を廃棄する。廃棄された成形品の数が排出数である。また、不良率は、（排出数＋チャックミス数）／総生産数で算出される。初期排出回数というのは、成形作業を開始してからあるショット分についてはすべて廃棄し、成形が安定してから生産開始に入る。この廃棄されるショット数が初期排出回数であり、これは『初期排出回数』の左側に表示されている『初期成形品排出』の項目を『ＯＮ』とし、『初期排出回数』に数値『１０』を設定することで実行される。なお、本形態では、生産開始からを対象としているので、初期排出回数は本生産管理の対象外である。『初期排出回数』の右側には実際に排出された回数が『１０』と表示されている。また、『サンプリング間隔』は、その左側の『サンプル動作』の項目を『ＯＮ』とし、『サンプリング間隔』に数値『２０』を設定することで実行される。『サンプリング間隔』の右側にはサンプリングされた数を示す『サンプル数』が『２０』として表示されている。
【００３８】
図２、図３の画面は、ディスプレイ装置の１画面内に分割表示されても良い。
【００３９】
次に、管理装置５による生産管理動作について説明する。前述したように、管理装置５は、各射出成形機１−１〜１−ｎの制御装置３−１〜３−ｎ及び成形品取出し機２−１〜２−ｎからの情報により射出成形機別に生産数を管理すると共に、成形品検査機４からの情報をも使用して総生産数を管理している。勿論、生産数というのは、射出成形機において生産開始から現在のショットまでの総ショット数により成形された成形品数から排出数、チャックミス数を減算した値である。排出数とチャックミス数との和は、成形品取出し機により取り出されなかった成形品の数である。従って、実生産数は、生産開始から現在のショットまでの総ショット数と、生産開始から現在までの成形品取出し数とにより算出することができる。一方、実総生産数というのは、すべての射出成形機１−１〜１−ｎの現時点での実生産数の合計値から成形品検査機４において不良品として廃棄された数を減算した値である。
【００４０】
管理装置５は、各成形品取出し機において取り出されなかった成形品数と、成形品検査機において廃棄された成形品数との和を算出し、あらかじめ設定されている予定総生産数を補正、つまり上記和を予定総生産数に加算する。管理装置５はまた、上記和を増産数とし、この増産数を射出成形機１−１〜１−ｎに割り振る。割振り方法は、射出成形機１−１〜１−ｎに均等に割り振るようにしても良いが、以下の方法が好ましい。
【００４１】
つまり、射出成形機１−１〜１−ｎは前に述べた不良率がすべて同じであるとは限らない。不良率の小さい射出成形機は、不良率の大きい射出成形機よりも早めに予定生産数を達成できる。このことから、管理装置５は、上記増産数を、不良率の小さい射出成形機には多めに割振り、不良率の大きい射出成形機には少なめに割り振るようにする。これにより、各射出成形機の生産完了時刻を揃えることができ、効率の良い生産を行うことができる。なお、不良率に代えて、他の要素、例えば稼動率を割振りの要因に用いても良い。
【００４２】
図１の実施の形態は、本発明を複数台管理システムに適用した最も好ましい形態であり、本発明はこの形態に限定されるものでは無い。
【００４３】
例えば、本発明は複数台管理システムでなく、単一の射出成形機にも適用可能である。つまり、管理装置５は、複数台の射出成形機ではなく１台の射出成形機の管理装置としても動作可能である。この場合、図１で言えば、射出成形機が１台のみの構成となる。そして、管理装置５は、１台の射出成形機の制御装置、これに備えられた成形品取出し機、成形品の搬送ラインに設置された１台の成形品検査機からの情報に基づいて１台の射出成形機の生産管理を行う。つまり、管理装置５は、生産開始から現在までのショット数と成形品取出し機から送られてくる、生産開始から現在までの成形品取出し数と、成形品検査機の検査結果とに基づいてあらかじめ射出成形機に設定されている予定生産数の補正を行い、補正数分、すなわち成形品取出し機で排出されてしまった成形品数、及び成形品検査機で廃棄されてしまった成形品数分だけ増産を行わせるようにする。なお、この場合、管理装置５のディスプレイ装置では、図５のような運転状況画面は表示しない。
【００４４】
また、成形品検査機が、オンライン形式でなく、オフライン形式で射出成形機とはまったく別の場所に設置されているような場合には、管理装置は成形品取出し機からの情報のみを用いて上記のような生産管理を行うようにしても良い。これは、
管理される射出成形機が１台のみの場合、複数台の場合のいずれにおいても同じである。
【００４５】
更に、管理装置５は、通常、パーソナルコンピュータで実現されるが、射出成形機の制御装置において実現されても良い。これは、射出成形機の制御装置は、一般的なパーソナルコンピュータと同程度の情報処理機能を有し、射出成形機の制御盤にはディスプレイも備えられるのが普通であるからである。これも、管理される射出成形機が１台のみの場合、複数台の場合のいずれにおいても同じである。しかし、複数台の場合はいずれか１台をメイン制御装置とし、このメイン制御装置において他の射出成形機の制御装置及び成形品取出し機からの情報、成形品検査機からの情報を収集するようにするのが好ましい。いずれにしても、制御装置には、管理装置５において使用される管理プログラムと同じプログラムがメモリに格納される。
【００４６】
更に別の例をあげると、図１において、成形品検査機が成形品検査機４のみならず、射出成形機毎に成形品取出し機の後段に設置される場合がある。つまり、射出成形機毎に設置される成形品検査機ではある検査項目について検査を行い、成形品検査機４では別の検査項目について検査を行う。このような場合であっても、射出成形機毎の成形品検査機から出力される良品数が射出成形機毎の実生産数となり、成形品検査機４から出力される良品数が総生産数となるだけであり、生産管理動作は上記の説明と基本的に変わりは無い。また、図１において、成形品検査機４が無く、射出成形機毎に成形品取出し機の後段に成形品検査機が設置される場合もある。この場合であっても、射出成形機毎の成形品検査機から出力される良品数が射出成形機毎の実生産数となり、これらの和が総生産数となるだけであり、生産管理動作は上記の説明と基本的に変わりは無い。
【００４７】
更に、上記の形態は、説明を簡単にするために、複数台の射出成形機１−１〜１−ｎのすべてが同じ成形品を成形する場合について説明したが、複数台の射出成形機１−１〜１−ｎがそれぞれ別の成形品を成形する場合でも生産管理動作は基本的に同じである。つまり、複数台の射出成形機１−１〜１−ｎがそれぞれ別の成形品を成形する場合には、前に述べた１台の射出成形機の生産管理を複数台分について時分割的に行うものと考えれば良い。また、複数台の射出成形機１−１〜１−ｎのうち何台かは別の成形品を生産し、残りの射出成形機は同じ成形品を生産する場合でも、上記何台かについては１台の射出成形機の生産管理を時分割的に行い、残りの射出成形機については複数台管理システムと同じ生産管理を時分割的に行うようにすれば良い。
【００４８】
更に、成形品取出し機等の周辺設備を備えず、複数台の成形機のみを管理する場合にも、本発明を適用することができる。この場合、良品、不良品の判別は、各ショット毎に各々の成形機にて検出される「Ｖ／Ｐ切換位置」、「最小クッション位置」などの検出値に基づいた良品判別機能を用いて行われる。複数台の成形機に備えられた良品判別機能によって、良品、不良品を判別し、判別された良品、不良品の少なくとも一方を示す検査結果と、生産開始から現在までのショット数との結果を比較し、比較結果に基づいて予定生産数の補正を行ない、生産効率の良い成形機の予定生産数の増産などを行なう。この場合でも、複数台の成形機は、各制御装置経由に接続されたパーソナルコンピュータで実現されても良いし、複数台の成形機の複数の制御装置のうちの１つで実現されても良い。
【００４９】
更に言えば、本発明は、実施の形態のような射出成形機に限らず、他の成形機、例えば押出し成形機のようなものにも適用され得る。
【００５０】
【発明の効果】
本発明によれば、１台の成形機管理システム、複数台管理システムのいずれにおいても正確な実生産数、総生産数をリアルタイムで把握できることにより、あらかじめ不良率を見込んで生産されていた仕掛品を低減できる。
【００５１】
特に、複数台管理システムの場合、各射出成形機と周辺設備からの情報を一元管理することにより、各射出成形機での生産計画（後工程での生産数や不良率を計算に入れた生産予定数）などを短時間で作成できる。
【図面の簡単な説明】
【図１】本発明による生産管理方法を射出成形機の複数台管理システムに適用する場合の構成を示した図である。
【図２】図１の管理装置に備えられたディスプレイ装置により表示される生産数表示画面の例を示した図である。
【図３】図１の管理装置に備えられたディスプレイ装置により表示される取出機生産モニタ画面の例を示した図である。
【図４】本出願人により提案され、本発明も適用され得る射出成形機の多数台管理システムの構成を概略的に示した図である。
【図５】図４に示された管理装置のディスプレイ装置で表示される管理画面の一例として運転状況画面の例を示した図である。
【図６】図５に示された分割画面の一つを拡大して示した図である。
【図７】図４に示された管理装置のディスプレイ装置で表示される管理画面の他の例として総括グラフ画面の例を示した図である。
【図８】図４に示された管理装置のディスプレイ装置で表示される管理画面の他の例として設定履歴画面の例を示した図である。
【図９】図４に示された管理装置のディスプレイ装置で表示される管理画面の他の例として異常履歴画面の例を示した図である。
【符号の説明】
１−１〜１−ｎ、１０−１〜１０−ｎ射出成形機
２−１〜２−ｎ成形品取出し機
３−１〜３−ｎ制御装置
４成形品検査機
５、２０管理装置[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a production management method and a production management system for a molding machine, and more particularly to a production management method and a production management system suitable for performing production management of a plurality of molding machines collectively with a single management apparatus.
[0002]
[Prior art]
With reference to FIGS. 4 to 9, an operation status display method for an injection molding machine proposed by the present applicant (Japanese Patent Application No. 2001-193234) will be described as an example of a method for managing a plurality of molding machines. The operation status display method according to the above proposal is applied to a management system for a plurality of injection molding machines as shown in FIG. In FIG. 4, a plurality of injection molding machines 10-1 to 10-n are installed at the same place, and these are collectively managed by a management device 20 with a display device. That is, the management device 20 is connected to each control device in the injection molding machines 10-1 to 10-n, and various kinds of sensors from various sensors installed in the injection molding machines 10-1 to 10-n. Information is received via each control device, and the received information is processed for each injection molding machine based on a built-in management program, and the processed result is stored in a built-in memory and displayed on a display device as a management screen. Depending on the type of information, the received raw information is stored in the memory as it is.
[0003]
Next, there are a plurality of types of management screens displayed on the display device in order to represent the operating status of each injection molding machine in the management device 20, and four examples of them will be described.
[0004]
FIG. 5 is an operation status screen that displays the operation status of a plurality of injection molding machines in real time. On this operation status screen, the operating status of a plurality of injection molding machines is displayed on a single screen in real time for all the units (here, No. 1 to No. 30) in a screen division format. For example, referring to FIG. 6 showing the enlarged view of the No. 9 machine, the No. machine number is shown in the upper left, the count value C1 of the molding condition change counter in the upper right (here, 17), and the 24-hour operation status graph on the right. On the lower side, the number of shots (529) and the cycle time (14.9 sec) are displayed. Here, the molding condition change counter is a count result of a counter that counts how many times molding conditions have been changed from the start of production to the present. This counter is provided in the management apparatus 20. The control device in each injection molding machine is provided with means for detecting a change in molding conditions, and the management device 20 receives the detection results from each control device and counts them, and displays the count results for each machine on the display device. Let In the management device 20, this display value can be reset as necessary.
[0005]
The 24-hour operation status graph is a single first bar graph B1 in which the operation status of the injection molding machine in the past 24 hours from the current time is color-coded. The operation status is defined by four types: operation, normal stop (during standby), stop due to abnormality, and power-off, and the four types of status are displayed in different colors according to the passage of time from 24 hours ago to the present time. Is done. Here, operation is shown in blue, normal stop is yellow, stop due to abnormality is red, and power off is shown in gray. In FIG. 6, for convenience, blue is thin hatching with a downward slope, yellow is vertical hatching, and red is right The hatching is thick, and the gray color is shown with a thick, downward-sloping hatch. In addition, the lowermost end of the first bar graph B1 indicates 24 hours ago, and the uppermost end indicates the current time point, for example, normal stop from the past 24 hours to 12 hours ago, and active from the past 12 hours to the current time. If there is, the first bar graph B1 is displayed with the lower half in yellow and the upper half in blue.
[0006]
In the above proposal, the appearance of the injection molding machine is further displayed as an icon image in the divided screen of each unit, and the background is due to the operation, the normal stop, and the occurrence of an abnormality to indicate the current operation status. The four types of stop and power off are displayed in the same color relationship as the color classification in the first bar graph B1. That is, if it is the same as the above example, the background color is blue.
[0007]
By looking at such an operation status screen, the operator or administrator can know at a glance which unit has been in what operating status in the past 24 hours. The numerical value of 24 hours is usually a fixed value, but may be variable.
[0008]
By the way, in the management apparatus 20, the general graph screen which shows the operation | movement condition of only the applicable number machine in detail can be displayed by clicking the specific location in the division | segmentation screen of each number machine in said driving | running condition screen in a display apparatus.
[0009]
FIG. 7 is an example of a summary graph screen. In this summary graph screen, the change status of quality data for 24 hours, presence / absence of abnormality, and presence / absence of setting change by time for each unit (here, No. 10). It is displayed on one screen as an axis. In FIG. 7, the uppermost graph is a line graph showing changes in the cumulative value of the number of shots, and a plurality of vertically entered lines, for example, the line L1, has a molding interruption (occurrence of anomaly) around 18:00. It shows that. The “state” of L2 is the same as the display of the operation status described above, and is defined by four types: operation, normal stop (during standby), stop due to abnormality occurrence, and power off, and 24 hours worth The status is displayed in different colors according to the time. The “condition name” of L3 is a graph showing the change time when the molding condition is changed, that is, when the condition name for each molded product is changed, the color is changed. In other words, this is changed when the molded product changes, and is displayed by color, but the color itself is not meaningful, but is meaningful at the time when the color changes. On the other hand, the “item” in L4 is a graph that displays the change in color with time when the condition item in the molding condition is changed. For example, the color is changed when an injection condition, a mold opening condition, or the like is changed, and this is also more meaningful at the time when the color changes rather than the color itself. For this reason, four or more colors are prepared for “condition name” and “item”, unlike “status”.
[0010]
Further, the first graph of L5 shows the elapsed time of the “filling time” of the display item shown in the display item selection column on the lower side of FIG. 7, and the second row similarly shows the time of “minimum cushion position”. Show progress. The third graph shows the “holding pressure completion position”, and the fourth and fifth graphs show the elapsed time of “V / P switching position” and “pre-filling position”, respectively.
[0011]
In the above proposal, further on the right side of the summary graph screen, the operation status of the unit in the past 24 hours is displayed in the same color as the first bar graph B1 by the second bar graph B2 at an operation rate of 0 to 100%. Are displayed together with a numerical value indicating 24 hours. FIG. 7 shows that the operating rate for the past 24 hours is 28%, and the operating rate calculation is based on “time display” in the display item selection field on the lower side of FIG. The number is displayed. The numbers in the “time display” column here can be arbitrarily changed. In other words, the “date and time” and “time display” shown in the display item selection field can be arbitrarily set, and here, a numerical value of 24 hours from 10:00 on September 4, 2000 is set. As shown in the uppermost part of FIG. 7, 24 hours from 10:00 on September 4, 2000 to 10:00 on September 5, 2000 are displayed. If the number “12” is entered in “time display”, the operation rate for the past 12 hours based on 12 hours is displayed in the second bar graph B2. In this case, the graphs or items in the first to eighth stages in FIG. 7 are also shown for the past 12 hours. According to such 2nd bar graph B2, the operation rate from arbitrary time of arbitrary time can be displayed.
[0012]
FIG. 8 shows an example of a setting history screen. In this setting history screen, the history of setting change is 1 for each unit (here, No. 10), along with changed items, pre-change and post-change set values, and change date and time. Displayed on the screen.
[0013]
FIG. 9 shows an example of an abnormality history screen. In this abnormality history screen, an abnormality occurrence history is displayed on one screen for each unit (here, No. 10) together with the item of the abnormality, the occurrence date and time, and the release date and time. .
[0014]
As described above, the summary graph screen of FIG. 7 is linked to the operation status screen of FIG. 5 and is displayed by clicking a specific location (icon) of each unit on the operation status screen of FIG. It has become. Further, the setting history screen of FIG. 8 and the abnormality history screen of FIG. 9 are linked to the general graph screen of FIG. 7, respectively, and an arbitrary screen can be displayed by clicking a specific location (icon) on the general graph screen of FIG. It is displayed directly.
[0015]
[Problems to be solved by the invention]
Incidentally, the injection molding machine is equipped with a molded product take-out machine. The molded product take-out machine notifies the control unit of the injection molding machine of the number of molded products taken out, but there is a case where a take-out failure called a chuck error occurs. In this case, the molded product take-out machine notifies the control device that there is a take-out failure. The molded product take-out machine also discards the molded product according to a command sent when the control device determines molding failure. The control device grasps the number of production as the actual production number by reflecting the number of take-out defects and the number discarded due to molding defects in the number of shots from the start of production to the present.
[0016]
The injection molding machine is also provided with a molded product inspection machine. The molded product inspection machine discriminates non-defective products and defective products from the molded products taken out by the molded product take-out machine. The defective products are discarded and the inspection result indicates at least one of the number of good products and defective products. To the control device. In this case, the control device grasps the production number as the actual production number by reflecting the number of defective take-outs, the number of discards due to molding defects, and the inspection result in the number of shots from the start of production to the present.
[0017]
In an injection molding machine, accurate management of the actual production number is very important. However, the conventional multi-unit management system that manages multiple injection molding machines comprehensively collects information from peripheral equipment such as molded product take-out machines and molded product inspection machines (disposal due to molding defects, chuck mistakes, number of defective products). We do not grasp and manage production.
[0018]
As a result, if there are many scraps and chuck mistakes due to molding defects in the molded product take-out machine, or if there are many defective products in the molded product inspection machine, the actual number of production may be reduced, or molding defects and chuck errors may occur in advance. As a result, there is a problem of increasing the number of work-in-progress when a large number of products are produced in anticipation of the number of defective products.
[0019]
Accordingly, an object of the present invention is to provide a production management method capable of performing production management by incorporating information from peripheral equipment such as a molded product take-out machine and a molded product inspection machine.
[0020]
Another object of the present invention is that a multi-unit management system that manages a plurality of molding machines can perform production management by incorporating information from peripheral equipment such as each molded product take-out machine and molded product inspection machine. It is an object of the present invention to provide a production management method and a production management system for a multi-unit management system.
[0021]
[Means for Solving the Problems]
According to the present invention, the number of production of at least one molding machine provided with at least one of a molded product take-out machine and a molded product inspection machine as peripheral equipment is managed by the management device, and molding is performed for a known number of productions known in advance. The management device performs the correction of the planned production number based on the number of shots from the start of production to the present and the number of molded articles taken from the start of production to the present, A production management method for a molding machine, characterized in that production is increased by the number of corrections.
[0022]
In addition, when both the molded product take-out machine and the molded product tester are provided, the molded product tester discriminates the non-defective product and the defective product from the molded product taken out by the molded product take-out machine. Output the inspection result indicating at least one of the number of non-defective products and the number of defective products, and the management device sends the number of shots from the start of production to the present time and is sent from the molded product take-out machine. The planned production number may be corrected based on the number of molded products taken from the present to the present and the inspection result, and production may be increased by the corrected number.
[0023]
In another form of the production management method, the management device shares the number of molded products taken out from a plurality of the molding machines, and the planned total production number by a plurality of molding machines known in advance, The planned total production number is corrected based on the number of shots from the start of production in the molding machine to the present and the number of molded products taken out in each molding machine, and the corrected value is allocated to the plurality of molding machines. As a result, it is possible to increase production by the amount allocated to each molding machine.
[0024]
Also in this other embodiment, the management device may be realized by a personal computer connected to each control device of the plurality of molding machines, or one of the control devices of the plurality of molding machines. It may be realized with.
[0025]
In this another form, when both the molded product take-out machine and the molded product inspecting machine are provided, the molded product inspecting machine applies to the molded product taken out by each molded product take-out machine in the plurality of molding machines. The non-defective product and the defective product are discriminated and the defective product is discarded, and an inspection result indicating at least one of the number of non-defective products and the number of defective products is output. The planned total number of productions is corrected based on the number of shots from the start of production to the present, the number of molded products taken from the production start to the present sent from the molded product takeout machine, and the inspection result. At the same time, the corrected value is allocated to the plurality of molding machines to increase production by the amount allocated to each molding machine.
[0026]
In this other embodiment, when both the molded product take-out machine and the molded product inspection machine are provided, the molded product inspection machine is installed in each of the plurality of molding machines, and in each of the plurality of molding machines. The non-defective product and defective product are discriminated from the molded product taken out by each molded product take-out machine and the defective product is discarded. The inspection result indicating at least one of the number of good products and the number of defective products is output and managed. The apparatus includes the planned total number of production, the number of shots from the start of production in each molding machine to the present, the number of molded articles taken from the start of production to the present sent from the molded product take-out machine, and a plurality of the aforementioned The planned total production number is corrected based on the inspection result from the molded product inspection machine, and the corrected value is allocated to the plurality of molding machines to increase the production amount allocated to each molding machine. .
[0027]
According to the present invention, there is also provided a production control method for a molding machine in which the number of productions of a plurality of molding machines is managed by a management device, and molding is performed for a predetermined number of productions known in advance. This molding machine outputs the number of shots from the start of production to the present, and the inspection result indicating at least one of the number of non-defective products from the start of production to the present, sent from the non-defective product discrimination function of each molding machine. The management apparatus corrects the scheduled production number based on the inspection result and the production number, and provides a production management method for a molding machine characterized in that the production is increased by the correction number.
[0028]
According to the present invention, it is further provided with a management device for managing the production number of at least one molding machine provided with at least one of a molded product take-out machine and a molded product inspection machine as peripheral equipment, and a known production number known in advance. A production management system for a molding machine that performs only molding, and the management device is configured to calculate the planned production number based on the number of shots from the start of production to the present and the number of molded products taken from the start of production to the present A production management system for a molding machine is provided, which performs correction and increases production by the number of corrections.
[0029]
According to the present invention, there is further provided a molding machine production management system comprising a management device for managing the number of productions of a plurality of molding machines, wherein the molding is performed for a predetermined number of productions known in advance. Each molding machine outputs the number of shots from the start of production to the present and the inspection results indicating at least one of the number of non-defective products from the start of production to the present sent from the non-defective product discrimination function of each molding machine. Then, the management device corrects the scheduled production number based on the inspection result and the production number, and provides a production management system for a molding machine characterized in that the production is increased by the correction number. .
[0030]
In both the production management method and the production management system, the management device may be realized by a personal computer connected to the control device of the molding machine, or may be realized by the control device of the molding machine. .
[0031]
DETAILED DESCRIPTION OF THE INVENTION
A preferred embodiment of a production management method and a production management system according to the present invention will be described with reference to FIG. Here, as in the proposal described with reference to FIG. 7, a case where the present invention is applied to a multiple-unit management system for injection molding machines will be described. In FIG. 1, a plurality of injection molding machines 1-1 to 1-n are installed in the same place, and these are collectively managed by a management device 5 with a display device. That is, the management device 5 is connected to each of the control devices 3-1 to 3-n in the injection molding machines 1-1 to 1-n, and is installed in each of the injection molding machines 1-1 to 1-n. Receive various information from various sensors via each control device, process the received information for each injection molding machine based on the built-in management program, save the processed result in the built-in memory and display it as a management screen Display on the device. Depending on the type of information, the received raw information is stored in the memory as it is. In particular, the management apparatus 5 according to the present embodiment has a management function as described with reference to FIGS. 5 to 9 in addition to the functions described below. Further, in this embodiment, in order to facilitate the description, all of the injection molding machines 1-1 to 1-n mold the same molded product, and the management apparatus 5 includes the injection molding machines 1-1 to 1-n. It is assumed that the total number of molded products to be produced in (1) is set and inputted in advance as the planned total production number. Thereby, the management apparatus 5 allocates the scheduled production number to each of the injection molding machines 1-1 to 1-n. Each injection molding machine will produce the number of scheduled productions allocated.
[0032]
The injection molding machines 1-1 to 1-n are provided with molded product take-out machines 2-1 to 2-n, respectively. Each molded product take-out machine notifies the management device 5 of the number of molded products taken out, and if there is a chuck error, notifies that fact. Thereby, the management device 5 can grasp the number of molded products taken out, that is, the number of actual productions, the number of molded products that could not be sent to the transfer line 6 due to a chuck error, for each injection molding machine. In addition, when the control unit determines that there is a molding defect in a shot, the molded product take-out machine issues a discard command to the molded product take-out machine in order to discard the shot molded product. In this case, the molded product take-out machine is discarded without being sent to the molded product and the conveying line. The number discarded is also ascertained by the management apparatus 5 for each injection molding machine. Of course, the management device 5 also knows the number of shots from the start of production to the present time for each injection molding machine based on the number-of-shots information sent from each control device. Information from the molded product take-out machine is also sent to the control device of the corresponding injection molding machine.
[0033]
The molded product taken out by each molded product take-out machine is sent to the molded product inspecting machine 4 through the conveyance line 6. Here, the molded product inspection machine 4 shall inspect the molded products from all the injection molding machines 1-1 to 1-n. The molded product inspection machine 4 discriminates a good product and a defective product from the molded product, discards the defective product, and notifies the management device 5 of an inspection result indicating at least one of the number of good products and the number of defective products. .
[0034]
2 and 3 show the production number display that the management device 5 displays on the attached display device by processing the above information from each molded product take-out machine and molded product inspection machine based on the management program. An example of the screen is shown. These production number display screens are displayed for each injection molding machine. That is, these production number display screens are linked to the operation status screen of FIG. 5 like the above-described general graph screen, and a specific location (icon) of each unit on the operation status screen of FIG. 5 is clicked. Is displayed.
[0035]
In the production number display screen of FIG. 2, the displayed unit number (here, No. 16), the operating state (in operation here), the assigned production number (here, 1500 pieces), the production number up to the present ( Here, 200 are displayed, a planned remaining number (here 1500-200 = 1300), an achievement rate (here 13%), a scheduled production completion time (here 1 hour 2 minutes), and the like. Note that the estimated production completion time can be calculated from the planned remaining number and the cycle time per shot.
[0036]
The unloader production monitor screen of FIG. 3 is a screen that is displayed by clicking the “Unloader information” icon on the production number display screen of FIG. Therefore, this screen also becomes the screen of the No. 16 machine, but here, the numerical values shown on this screen do not necessarily correspond to the numerical values shown in FIG. In this screen, molding cycle (cycle time per shot, here 10.5 sec), 1-shot production number (number of molded products produced in 1 shot, here 15), take-out number (to date) , In this case 120 times), total production number (here 1800), number of discharges (number discarded due to molding failure, here 20), chuck mistake (here 3), The defect rate (here, 1%), the initial discharge number (here, 10 times), the sampling interval (here, every 20 shots), and the like are displayed.
[0037]
In FIG. 3, the number of discharges is obtained as follows. As described above, in the injection molding machine, the control device determines whether molding is good or defective on a shot basis based on signals from various sensors. A signal to discard the shot molded product without sending it to the conveying line 6 is sent. In this case, the molded product take-out machine discards the molded product. The number of moldings discarded is the number of emissions. Further, the defect rate is calculated by (number of discharges + number of chuck mistakes) / total number of production. With regard to the initial number of discharges, all shots after the molding operation is started are discarded, and production starts after the molding is stabilized. The number of shots to be discarded is the initial number of discharges, which is set to “ON” for the item “initial part discharge” displayed on the left side of the “initial number of discharges”, and the numerical value “10” It is executed by setting. In this embodiment, since the start of production is targeted, the initial number of discharges is not subject to the production management. The number of times of actual discharge is displayed as “10” on the right side of “initial number of discharges”. The “sampling interval” is executed by setting the “sample operation” item on the left side to “ON” and setting the numerical value “20” to the “sampling interval”. On the right side of “sampling interval”, “number of samples” indicating the number of samples is displayed as “20”.
[0038]
The screens of FIGS. 2 and 3 may be divided and displayed within one screen of the display device.
[0039]
Next, the production management operation by the management device 5 will be described. As described above, the management device 5 uses the information from the control devices 3-1 to 3-n and the molded product take-out devices 2-1 to 2-n of the injection molding machines 1-1 to 1-n, and the injection molding machines. The number of production is managed separately, and the total number of production is managed using information from the molded product inspection machine 4. Of course, the production number is a value obtained by subtracting the number of discharges and the number of chuck mistakes from the number of molded products formed by the total number of shots from the start of production to the current shot in the injection molding machine. The sum of the number of discharges and the number of chuck mistakes is the number of molded products that have not been taken out by the molded product take-out machine. Therefore, the actual production number can be calculated from the total number of shots from the start of production to the current shot and the number of molded products taken from the start of production to the present. On the other hand, the actual total production number is a value obtained by subtracting the number discarded as defective products in the molded product inspection machine 4 from the total value of the current actual production numbers of all the injection molding machines 1-1 to 1-n. It is.
[0040]
The management device 5 calculates the sum of the number of molded products that have not been taken out by each molded product take-out machine and the number of molded products that have been discarded by the molded product inspection machine, and corrects the preset planned total production number, that is, Add the sum to the planned total production. The management device 5 also sets the above sum as the increased production number, and allocates this increased production number to the injection molding machines 1-1 to 1-n. The allocation method may be equally allocated to the injection molding machines 1-1 to 1-n, but the following method is preferable.
[0041]
That is to say, the injection molding machines 1-1 to 1-n do not always have the same defective rate described above. An injection molding machine with a small defect rate can achieve the planned production number earlier than an injection molding machine with a large defect rate. For this reason, the management apparatus 5 allocates the increased number of production to the injection molding machine having a small defect rate, and allocates the production increase to a small amount to the injection molding machine having a large defect rate. Thereby, the production completion time of each injection molding machine can be made uniform, and efficient production can be performed. Instead of the defective rate, other factors such as an operating rate may be used as an allocation factor.
[0042]
The embodiment of FIG. 1 is the most preferable form in which the present invention is applied to a plurality of management system, and the present invention is not limited to this form.
[0043]
For example, the present invention can be applied to a single injection molding machine instead of a multiple-unit management system. That is, the management device 5 can operate as a management device for one injection molding machine instead of a plurality of injection molding machines. In this case, if it says in FIG. 1, it will be the structure of only one injection molding machine. The management device 5 is based on information from a control device for one injection molding machine, a molded product take-out machine provided in the control device, and one molded product inspection machine installed in a molded product conveyance line. Production control of injection molding machines. In other words, the management device 5 preliminarily determines the number of shots from the start of production to the present, the number of molded products taken from the start of production to the present, and the inspection result of the molded product inspection machine. Correct the planned production number set in the injection molding machine, and increase the production by the number of corrections, that is, the number of molded products discharged by the molded product take-out machine and the number of molded products discarded by the molded product inspection machine. To do. In this case, the operation status screen as shown in FIG. 5 is not displayed on the display device of the management device 5.
[0044]
In addition, when the molded product inspection machine is installed in a completely different place from the injection molding machine in the offline format instead of the online format, the management device uses only the information from the molded product take-out machine. Production management as described above may be performed. this is,
When only one injection molding machine is managed, the same is true in the case of a plurality of injection molding machines.
[0045]
Furthermore, although the management apparatus 5 is normally implement | achieved by the personal computer, you may implement | achieve in the control apparatus of an injection molding machine. This is because the control device of the injection molding machine has an information processing function similar to that of a general personal computer, and the control panel of the injection molding machine is usually provided with a display. This is the same in both cases where only one injection molding machine is managed and plural injection machines are managed. However, in the case of a plurality of units, one of them is used as a main control unit, and in this main control unit, information from other injection molding machine control units and molded product take-out machines and information from molded product inspection machines are collected. Is preferable. In any case, the same program as the management program used in the management device 5 is stored in the control device in the memory.
[0046]
As another example, in FIG. 1, the molded product inspection machine may be installed not only in the molded product inspection machine 4 but also in the subsequent stage of the molded product take-out machine for each injection molding machine. In other words, a molded product inspection machine installed for each injection molding machine inspects a certain inspection item, and the molded product inspection machine 4 inspects another inspection item. Even in such a case, the number of non-defective products output from the molding product inspection machine for each injection molding machine becomes the actual production number for each injection molding machine, and the number of non-defective products output from the molding product inspection machine 4 is the total production number. The production management operation is basically the same as described above. In FIG. 1, there is a case where there is no molded product inspection machine 4 and a molded product inspection machine is installed after the molded product take-out machine for each injection molding machine. Even in this case, the number of non-defective products output from the molding product inspection machine for each injection molding machine is the actual production number for each injection molding machine, and the sum of these is the total production number. There is basically no difference from the above explanation.
[0047]
Further, in the above embodiment, the case where all of the plurality of injection molding machines 1-1 to 1-n form the same molded product has been described in order to simplify the description. However, the plurality of injection molding machines 1 The production management operations are basically the same even when -1 to 1-n form different molded products. That is, when a plurality of injection molding machines 1-1 to 1-n mold different molded products, the production management of one injection molding machine described above is performed in a time-sharing manner for a plurality of units. Think of it as something to do. Moreover, even if some of the plurality of injection molding machines 1-1 to 1-n produce different molded products and the remaining injection molding machines produce the same molded product, Production management of one injection molding machine may be performed in a time-sharing manner, and the remaining injection molding machines may be managed in a time-sharing manner in the same way as the multi-machine management system.
[0048]
Furthermore, the present invention can also be applied to the case where only a plurality of molding machines are managed without providing peripheral equipment such as a molded product take-out machine. In this case, a non-defective product or a defective product is discriminated using a non-defective product discrimination function based on detected values such as “V / P switching position” and “minimum cushion position” detected by each molding machine for each shot. Done. Non-defective products and defective products are identified by the non-defective product identification function provided in multiple molding machines, and the results of the inspection results indicating at least one of the determined good products and defective products and the number of shots from the start of production to the present are displayed. Comparing and correcting the planned production quantity based on the comparison result, the production volume of the molding machine with high production efficiency is increased. Even in this case, the plurality of molding machines may be realized by a personal computer connected via each control device, or may be realized by one of a plurality of control devices of the plurality of molding machines. .
[0049]
Furthermore, the present invention can be applied not only to the injection molding machine as in the embodiment but also to other molding machines such as an extrusion molding machine.
[0050]
【The invention's effect】
According to the present invention, it is possible to grasp an accurate actual production number and a total production number in real time in any one of the molding machine management system and the multiple machine management system, so that the work-in-progress produced in advance with a defect rate expected. Can be reduced.
[0051]
In particular, in the case of a multi-unit management system, by centrally managing information from each injection molding machine and peripheral equipment, the production plan for each injection molding machine (production that includes the number of production and defective rate in the subsequent process) (Scheduled number) etc. can be created in a short time.
[Brief description of the drawings]
FIG. 1 is a diagram showing a configuration when a production management method according to the present invention is applied to a multiple-unit management system for injection molding machines.
2 is a diagram showing an example of a production number display screen displayed by a display device provided in the management apparatus of FIG. 1;
FIG. 3 is a diagram showing an example of an unloader production monitor screen displayed by a display device provided in the management apparatus of FIG. 1;
FIG. 4 is a diagram schematically showing the configuration of a multi-unit management system for injection molding machines proposed by the present applicant and to which the present invention can also be applied.
FIG. 5 is a diagram showing an example of an operation status screen as an example of a management screen displayed on the display device of the management device shown in FIG. 4;
6 is an enlarged view of one of the divided screens shown in FIG.
7 is a diagram showing an example of a general graph screen as another example of the management screen displayed on the display device of the management device shown in FIG. 4; FIG.
FIG. 8 is a diagram showing an example of a setting history screen as another example of the management screen displayed on the display device of the management device shown in FIG. 4;
FIG. 9 is a diagram showing an example of an abnormality history screen as another example of the management screen displayed on the display device of the management device shown in FIG. 4;
[Explanation of symbols]
1-1 to 1-n, 10-1 to 10-n injection molding machine
2-1 to 2-n Mold take-out machine
3-1 to 3-n control device
4 Molded product inspection machine
5, 20 Management device

Claims

Production that controls the production number of at least one molding machine equipped with at least one of a molded product take-out machine and a molded product inspection machine as peripheral equipment by a management device, and performs the molding for the number of productions known in advance. A management method, wherein the management device corrects the planned production number based on the number of shots from the start of production to the present and the number of molded articles taken from the start of production to the present, and increases production by the number of corrections. A production control method for a molding machine, characterized in that it is performed.

2. The production management method according to claim 1, wherein the management device is a control device of the molding machine or a personal computer connected to the control device.

3. The production management method according to claim 1, further comprising both the molded product take-out machine and the molded product tester, wherein the molded product tester is a non-defective product for the molded product taken out by the molded product take-out machine. The defective device is discriminated and the defective product is discarded, and the inspection result indicating at least one of the number of non-defective products and the number of defective products is output. The planned number of production is corrected based on the number of molded articles taken from the start of production to the present, sent from the take-out machine, and the inspection result, and production is increased by the number of corrections. Production control method for molding machines.

The production management method according to claim 1, wherein the management device shares the number of molded products taken out from a plurality of the molding machines, a planned total production number by a plurality of molding machines known in advance, The planned total production number is corrected based on the number of shots from the start of production in the molding machine to the present and the number of molded products taken out in each molding machine, and the corrected value is allocated to the plurality of molding machines. A production management method for a molding machine, characterized in that production is increased by the amount allocated to each molding machine.

5. The production management method according to claim 4, comprising both the molded product take-out machine and the molded product tester, wherein the molded product tester is a molding taken out by each of the molded product take-out machines in the plurality of molding machines. A non-defective product and a defective product are discriminated and discarded, and an inspection result indicating at least one of the number of non-defective products and the number of defective products is output. Based on the number of shots from the start of production in each molding machine to the present, the number of molded articles taken from the start of production to the present sent from the molded product take-out machine, and the inspection result, the estimated total production number A production control method for a molding machine, wherein correction is performed, and the corrected value is assigned to the plurality of molding machines to increase production for each molding machine.

5. The production management method according to claim 4, comprising both the molded product take-out machine and the molded product inspection machine, wherein the molded product inspection machine is installed in each of the plurality of molding machines. The non-defective product and defective product are discriminated from the molded product taken out by each molded product take-out machine in the machine and the defective product is discarded, and an inspection result indicating at least one of the number of good products and defective products is output. The management device includes the planned total number of production, the number of shots from the start of production in each molding machine to the present, the number of molded articles taken from the start of production to the present sent from the molding product take-out machine, and a plurality of And correcting the planned total production number based on the inspection result from the molding product inspection machine, and allocating the corrected value to the plurality of molding machines to increase the production allocated to each molding machine. It is characterized by letting you do Production control method for a molding machine.

A production management method for a molding machine in which the number of productions of a plurality of molding machines is managed by a management device, and molding is performed for a predetermined number of productions known in advance,
The plurality of molding machines have an inspection result indicating at least one of the number of shots from the start of production to the present and the number of non-defective products from the start of production to the present sent from the non-defective product discrimination function of each molding machine. And the management device corrects the scheduled production number based on the inspection result and the production number, and causes the production to be increased by the correction number.

A management device that manages the number of production of at least one molding machine provided with at least one of a molded product take-out machine and a molded product inspection machine as peripheral equipment is provided, and molding is performed for a known number of productions known in advance. A production management system for a molding machine,
The management device corrects the planned production number based on the number of shots from the start of production to the present and the number of molded articles taken from the start of production to the present, and increases production by the number of corrections. Production control system for molding machines.

A production management system for a molding machine that includes a management device for managing the number of productions of a plurality of molding machines, and performs molding for a predetermined number of productions known in advance,
The plurality of molding machines have an inspection result indicating at least one of the number of shots from the start of production to the present and the number of non-defective products from the start of production to the present sent from the non-defective product discrimination function of each molding machine. And the management device corrects the scheduled production number based on the inspection result and the production number, and increases the production by the correction number.

10. The production management system according to claim 8, wherein the management device is a control device of the molding machine or a personal computer connected to the control device.