JP2011248614A - System and method for evaluating utility loss amount of production line - Google Patents

Abstract

PROBLEM TO BE SOLVED: To derive a time series pattern of demand amount of utility needed for production line of factory and reveal waste of utility amount by comparing the derived pattern with performance data.SOLUTION: In a utility loss amount evaluation system 101 of production line, using a production line model where utility amount created by a user 103 through a production line model creation part 105 is granted, a simulation execution part 108 executes simulation of the production line. A utility demand pattern generation part 109 generates a time series pattern of utility demand needed for the whole production line based on utility demand amount of the whole production line acquired from the performance of the simulation. A comparison result generation part 110 generates comparison result between the time series pattern of utility demand and actual utility usage acquired from each type of a utility amount measurement sensor 107 of the production line of factory.

Description

  The present invention relates to a system and method for evaluating a utility loss amount of a production line in a factory by applying it to measurement and evaluation of a utility (steam or the like) used in a production line in the factory.

  In various industrial plants such as steel, petrochemicals, foods, and pharmaceuticals, various wastes that occur during product production are “visualized” in order to use them as judgment materials for studying ways to increase the efficiency of product production. As a technique for that purpose, a method for realizing an energy loss and a method for realizing a process loss are known.

  For example, Patent Document 1 discloses an energy information analysis means for obtaining information according to an energy intensity for each process including a setup between processes for a plurality of processes by product type in order to reduce energy consumption, Energy from the process information storage means for storing the type of process information, the information obtained by the energy information analysis means, and the information stored in the process information storage means according to the processing and schedule conditions according to the product type A scheduling system for generating a schedule including demand forecast information is disclosed. The energy information analysis means provided in this system obtains process setup information consisting of energy consumption generated during setup, setup time, dead time until process stabilization, and loss from the measured equipment energy consumption and process information. (Patent Document 1). Patent Document 2 discloses a technique for evaluating the loss by managing and comparing energy intensity used in a factory. In this method, the energy consumption data of the facility system that receives the energy supply, the energy consumption data of the production system, and the energy manufacturing data of the driving system are acquired, and the energy intensity in real time is calculated. The time series pattern of the error from the target value is visualized by comparing the value with the basic unit target value data input in advance (Patent Document 2). Patent Document 3 discloses a method for realizing a loss in a process. In this method, information on processes such as a rent, a reference time required for actual work, and a standard time obtained by adding a predetermined margin time to the reference time is stored in advance, and further, performance information generated in the process is collected. By using these pieces of information, the total production loss is calculated by converting the loss man-hours due to production into monetary amounts. By displaying this in real time, when a process loss occurs, the response is promoted (Patent Document 3).

JP 2005-92827 A JP 2007-264704 A JP 2002-91544 A

  Since the oil shock in the 1970s, energy conservation in the industry (hereinafter abbreviated as “energy saving”) has been widely performed. As a result, energy consumption and CO2 emissions have remained almost flat since the 1990s. is doing. However, the 25% reduction target for CO2 newly set by Japan is a very advanced target, and various factories are required to save more energy than has been done so far. Under these circumstances, in order to achieve further energy saving in factories where energy-saving measures have already been taken, first of all, it is clarified where the waste of various utilities (utilities) such as used steam, hot water, cold water, and air is located. Technology to show improvement points to factory managers is becoming important.

  However, in the technique described in Patent Document 1, the energy demand prediction information is obtained based on the measured facility energy consumption (that is, the actual data of facility energy consumption including waste generated in the actual production line). Since it is generated, waste generated in the actual production line is also added to the generated energy demand prediction information. In the technique described in Patent Document 2, the loss is shown by comparing the target value of the energy intensity and the current value, but nothing is shown about the calculation method of the target value. In the technique described in Patent Document 3, the man-hour loss in the process can be shown, but the man-hour is an amount related to personnel and time, and the loss of utility cannot be manifested.

  In view of the above points, the present invention derives a time-series pattern of utility demand required by a production line of a factory, and clarifies the waste of utility by comparing with actual data in an actual production line. The purpose is to be able to.

  In the present invention, the simulation execution unit executes the simulation of the production line using the production line model to which the usage amount created by the user through the production line model creation unit is given. The utility demand pattern generation unit generates a time series pattern of utility demands required by the entire production line based on the utility demand amount of the entire production line obtained during the simulation.

  According to the present invention, the time series pattern of the utility demand required by the production line of the factory is derived, so that the waste of utility is revealed by comparison with the actual usage data in the actual production line. Can be realized.

It is a block diagram which shows the whole structure in the 1st Embodiment of this invention. It is a figure which shows the outline of the whole production line to which this invention is applied. It is a figure which shows the time and the amount of vapor | steams used for the raw material and intermediate product passing each process of a production line. It is a figure which shows the upper limit number of each work-in-process places of a production line. It is a schematic diagram which shows the relationship between a production line and the utility system power building of a factory. It is a figure which shows the basic element which comprises a Petri net. It is a figure which shows the example of the simulation of a production line. It is a figure which shows the example of a screen of a utility loss amount evaluation tool. It is a figure which shows the example of a screen of a utility loss amount evaluation tool. It is a figure which shows the model using the Petri net of a production line. It is a flowchart which shows the process of a simulation execution part. It is a figure which shows the state of the production line model in simulation time 120 minutes. It is a figure which shows the time-sequential pattern of the demand amount of the utility until 120 minutes of simulation time. It is a figure which shows the time-sequential pattern of the demand amount of the utility until 300 minutes of simulation time. It is a figure which shows the comparison result produced | generated by the comparison result production | generation part. It is a block diagram which shows the whole structure in the 2nd Embodiment of this invention. It is a figure which shows the example of a screen of a utility loss amount evaluation tool. It is a flowchart which shows the process of the simulation execution part in the 2nd Embodiment of this invention. It is a flowchart which shows the process of the simulation execution part in the 2nd Embodiment of this invention. It is a block diagram which shows the whole structure of the plant operation control system to which this invention is applied in the 3rd Embodiment of this invention. It is a block diagram which shows the whole structure in the 3rd Embodiment of this invention.

Hereinafter, embodiments for carrying out the present invention will be described with reference to the drawings.
[First Embodiment]
FIG. 1 is a block diagram showing an overall configuration of a service loss evaluation system 101 for a production line according to the first embodiment of the present invention. The utility loss amount evaluation system 101 includes a production line model creation unit 105, a storage device 106, a simulation execution unit 108, a utility demand pattern generation unit 109, a comparison result generation unit 110, and interfaces 111 to 116. Consists of

  The interface 111 is an interface for the user 103 to input the production line information 102 through a terminal device (input / output terminal including a display, a mouse, and a keyboard) 104. The production line model creation unit 105 performs processing for creating a production line model using a Petri net in accordance with the production line information 102 input through the interface 111.

  The storage device 106 is a storage device for storing the production line model created by the production line model creation unit 105 through the interface 112.

  The interface 115 is an interface for allowing the user 103 to execute a simulation through the terminal device 104. The simulation execution unit 108 performs processing related to simulation execution in accordance with an instruction from the user 103. The interface 113 is an interface for acquiring the production line model from the storage device 106 when the simulation execution unit 108 uses the production line model stored in the storage device 106.

  The utility demand pattern generation unit 109 acquires the utility demand for the entire production line at each simulation time obtained during the simulation performed by the simulation execution unit 108, and generates a time series pattern of utility demand. Process.

  The interface 114 is an interface for acquiring information on the actual usage amount of the utility from various usage amount measurement sensors 107 provided in the production line of the factory. The comparison result generation unit 110 compares the time series pattern of the utility demand generated by the utility demand pattern generation unit 109 with the actual usage amount of the utility acquired from the various usage amount measurement sensors 107. Then, processing for generating the comparison result is performed. The interface 116 is an interface for displaying the comparison result generated by the comparison result generation unit 110 on the screen of the terminal device 104.

  FIG. 2 is a schematic diagram of the entire production line of a factory to which the utility loss amount evaluation system 101 shown in FIG. 1 is applied. In this factory, it is assumed that products are produced in the following four steps.

(Process 1)
The raw material A stored in the raw material warehouse 201 is placed on the production line 202, steam is supplied through the steam supply device 203, and the intermediate product A is generated. The generated intermediate product A is transported to the work-in-process area 204.

(Process 2)
The raw material B stored in the raw material warehouse 205 is placed on the production line 206, and the intermediate product C created in step 3 is integrated by the fusion device 207 to generate the intermediate product B. The generated intermediate product B is transported to the work-in-process storage 208.

(Process 3)
The raw material C stored in the raw material warehouse 209 is placed on the production line 210 and steam is supplied through the steam supply device 211 to generate an intermediate product C. The generated intermediate product C is transported to the work-in-process area 212.

(Process 4)
The intermediate product A placed in the work in process place 204 is placed on the production line 213, and the intermediate product B created in the step 2 is integrated by the fusion device 214. Then, steam is supplied to the integrated device through the steam supply device 215 to complete the product. The completed product is conveyed to the product warehouse 216.

FIG. 3 is a diagram showing the time required for the raw material / intermediate product to pass through each step 1 to 4 shown in FIG. 2 and the amount of steam used in each step 1 to 4.
The value of this transit time and the amount of steam used includes values estimated from data obtained during factory operations, and the minimum required values of raw materials and intermediate products obtained during product research and development. . In this embodiment, the latter value is entered.

FIG. 4 is a diagram showing the maximum number of intermediate products that can be stored in the in-process product storage area 204 of the intermediate product A, the in-process product storage area 208 of the intermediate product B, and the in-process product storage area 212 of the intermediate product C shown in FIG.
In FIG. 4, the work-in-process yard 204 for the intermediate product A is represented as work-in-process yard A, the work-in-process yard 208 for intermediate product B is represented as the work-in-process yard B, and the work-in-process yard 212 for the intermediate product C is represented as the work-in-process yard. C. It is assumed that the work-in-process places A to C cannot store a work-in-progress larger than the limit number shown in FIG. For this reason, if this number of intermediate products already exists in the work in process yard, or if it is estimated that the number of intermediate products in the work in process yard exceeds this number, the intermediate to the work in process yard Product production lines and processes will stop.

FIG. 5 is a schematic diagram showing the relationship between the utility system power building (power facility) of the factory having the production lines 202, 206, 210 and 213 shown in FIG. 2 and the production line.
The utility system power building 501 supplies all the various utilities such as steam used in the production lines 202, 206, 210 and 213. The various utilities supplied from the utility grid power building 501 are supplied by the various utility measurement sensors 107 shown in FIG. 1 before being distributed to the various devices in the production lines 202, 206, 210 and 213. The total amount is measured. In addition, from the production lines 202, 206, 210 and 213, various utility returns (for example, water in the case of steam) are supplied to the utility system power building 501.

  Next, a production line simulation method implemented by the utility loss evaluation system 101 shown in FIG. 1 will be described. As a simulation method, discrete event simulation is used, and in this embodiment, a Petri net is used as one means. Petri nets are simulation methods for representing discrete event systems, and are also used as production line simulations.

  FIG. 6 is a diagram showing basic components of the Petri net. The Petri net includes a place 601, a token 602, an arc 603, and a transition 604.

FIG. 7 is a diagram showing an example of a production line simulation using this Petri net.
A place, arc and transition are connected to express a production line. The place represents the process itself or a part of the process, and the token represents the raw material / intermediate product in the middle of the process. Since a time can be given to a place using a method called a timed Petri net, the movement of a token along the time can be expressed. Thereby, movement of a raw material and an intermediate product can be shown.

  A transition can move a token to the next place only when there are tokens in all of the places connected by the arc. In addition, the number of tokens is one at the destination. In the example of FIG. 7, the token cannot be transferred to the place 703 through the transition 704 unless there is a token in both the place 701 and the place 702. This indicates that when two or more raw materials / intermediate products are required for production, if either one is missing, an intermediate product / product combining them cannot be produced. In addition, a place can be used as a raw material warehouse / work in process storage place by allowing a plurality of tokens to be placed thereon.

  The production line simulation itself using the Petri net as shown in FIG. 7 is a method that has been used to see the efficiency of the product flow in the production line. However, in the present invention, for the purpose of predicting a change in the required amount of utility, the usage amount can be set in a place as described below. Then, while the token exists, it is considered that the utility amount set for the place is used.

  Next, a method for evaluating the service demand amount of the production line by the service loss evaluation system 101 shown in FIG. 1 will be described. In the utility loss evaluation system 101 shown in FIG. 1, the user 103 inputs the production line information 102 through the terminal device 104, and the production line model creation unit 105 uses the production line information 102 to perform production using the Petri net. Create a line model.

  FIG. 8 is a diagram illustrating a screen configuration example of the utility loss amount evaluation tool displayed on the terminal device 104 in order to input the production line information 102 and create a production line model. On the screen of the utility loss evaluation tool 801, areas 802 to 805 are provided.

  In the area 802, a general place that represents each part / whole or entire process of the production line, a place that represents a warehouse or a work-in-process place, an arc and a transition are displayed. These can be operated by a mouse operation (drag). A place, arc, or transition can be selected and placed in the region 803. By connecting these places, arcs, and transitions in this area 803, a model of a production line using a Petri net can be constructed.

  When the mouse pointer 806 is placed on the general place placed in the area 803 and clicked, the transit time and various usage amounts as shown in FIG. 3 can be set in the areas 804 and 805. . In the area 804, the time until the token passes through the place can be set. In the area 805, the type of utility (for example, steam) to be used in the place can be selected, the amount of the utility can be input, and the unit of the amount can be selected and set. In the area 805 shown in FIG. 8, there is only one utility type that can be selected. However, an initial setting screen (not shown) is used so that a plurality of utility types (for example, steam and electricity) can be selected in the area 805. It is also possible to set.

FIG. 9 is a diagram showing a state in which the mouse pointer 901 is clicked on the place for warehouse / work-in-place storage arranged in the area 803 of the utility loss evaluation tool 801 shown in FIG.
In this state, an area 902 for inputting and setting the initial state token number and the token upper limit number is displayed instead of the areas 804 and 805 shown in FIG. The initial number of tokens means the number of raw materials / intermediate products already existing in the warehouse / work in process storage area. On the other hand, the upper limit number of tokens indicates the limit of the number of raw materials / intermediate products that can be placed in the warehouse / work-in-place storage area as shown in FIG. When the setting button 903 is pressed to set these numbers, if the initial number of tokens exceeds the maximum number of tokens, a warning message is displayed so that the number can be re-entered.

FIG. 10 shows an example in which the production line model creation unit 105 creates the Petri net model of the production line shown in FIG. 2 based on the input operation with the utility loss evaluation tool 801 shown in FIGS. FIG.
In this Petri net model, each process is represented as one place. Place 1001 represents process 1, place 1002 represents process 2, place 1003 represents process 3, and place 1004 represents process 4. The place 1005 is the raw material warehouse 201, the place 1006 is the intermediate product A in-process storage area 204, the place 1007 is the raw material storage area 205, the place 1008 is the intermediate product B in-process storage area 208, and the place 1009 is the raw material storage area 209. The place 1010 represents the work-in-process storage area 212 for the intermediate product C, and the place 1011 represents the product warehouse 216.

  Although not shown in FIG. 10, for the places 1001 to 1004, the passing time and usage amount of each process as shown in FIG. 3 are set by the operations in the areas 804 and 805 in FIG. For the places 1006, 1008, and 1010, the upper limit number as shown in FIG. 4 is set by operating the area 902 in FIG.

  The Petri net model shown in FIG. 10 is an example, and may be different for each user who performs modeling. For example, with respect to the process 1, a conveying section until the raw material is placed on the production line 202, a section from when the raw material is placed on the line 202 until reaching the steam supply apparatus 203, a section where the steam supply apparatus 203 receives the steam supply, and a line 202 thereafter. There are various methods such as five places such as a section until exit and a transport section to the work-in-process storage area 204. In the following description, it is assumed that the production line model creation unit 105 has created the Petri net model shown in FIG. The created Petri net model can be reused by storing it in the storage device 106 through the interface 112 shown in FIG.

  Next, in the utility loss evaluation system 101 shown in FIG. 1, the process of the simulation execution unit 108 when the user 103 instructs the execution of the simulation based on the Petri net model shown in FIG. 10 through the terminal device 104. Will be described.

FIG. 11 is a flowchart showing the processing of the simulation execution unit 108 when a simulation execution is instructed.
First, the simulation execution unit 108 substitutes 0 for the simulation time t (step S1). Subsequently, the simulation execution unit 108 calculates the total amount of usage set in the area 805 in FIG. 8 for the place where the token exists, and uses the calculation result as the usage demand pattern generation unit 109 in FIG. (Step S2).

  Subsequently, the simulation execution unit 108 compares the number of existing tokens with the upper limit number of tokens set in the area 902 of FIG. 9 for each warehouse / work-in-place storage place. At this time, if the values of the numbers match, the token movement from each warehouse / work-in-place storage place that supplies tokens to the production line leading to the place is locked, that is, cannot be moved. On the other hand, if the values do not match, it is determined whether the token movement from each warehouse / work place storage place that supplies tokens to the production line leading to that place is locked. The lock is released (step S3).

  Subsequently, the simulation execution unit 108 next passes the token from each warehouse / work-in-place storage place where the lock is not applied and the general place where “token existence time = time set in the area 804 of FIG. 8”. To the place (step S4). Subsequently, the simulation execution unit 108 determines whether or not the simulation time t has reached a preset simulation end time (for example, input when the user instructs the simulation execution) (step S5). If the simulation end time has not been reached, the simulation execution unit 108 advances the simulation time t by one unit time (for example, 1 minute) (step S6), returns to step S2, and continues the simulation. When the simulation end time is reached in step S5, the simulation execution unit 108 ends the process.

FIG. 12 is a diagram showing a state when the simulation time is 120 minutes for the Petri net model shown in FIG.
The numbers below each token indicate the simulation time since the token reached that place. 10 minutes have passed since the product arrived at step 1 represented by place 1001, 10 minutes have passed since the product arrived at step 4 represented by place 1004, and the product arrived at step 2 represented by place 1002. It shows that 15 minutes have passed. Further, there are two work-in-progress items in the work-in-process area of the intermediate product C represented by the place 1010, and the production is not performed in the process 3 because there is the upper limit number shown in FIG. 4 (no token exists). ). The required amount of steam in the state of FIG. 12 can be confirmed from the amount of steam used in steps 1 to 4 shown in FIG. 3, and it can be seen that 15 kg is required in both steps 1 and 4.

  In the utility loss amount evaluation system 101 shown in FIG. 1, the utility demand pattern generation unit 109 calculates the total usage amount transmitted in step S <b> 2 while the simulation execution unit 108 executes the process of FIG. 11. Based on the results, a time series pattern of utility demand is generated.

  FIG. 13 is a diagram showing a time series pattern of utility demand generated by the utility demand pattern generation unit 109 until the simulation time reaches 120 minutes. The necessary usage amount 1301 when the simulation time is 120 minutes is 15 kg as described with reference to FIG.

FIG. 14 is a diagram showing a time series pattern of utility demands generated by the utility demand pattern generation unit 109 until the simulation time reaches 300 minutes.
The time series pattern of utility demand shown in FIG. 13 and FIG. 14 is the result of adding the minimum required amount of steam used in each step 1 to 4 shown in FIG. This is a time series pattern of the usage amount that should be supplied at the minimum in the entire production line. Therefore, when production is performed under the same conditions as in the simulation, it is possible to evaluate the loss in utility amount by comparing the amount actually used in the production line.

  Here, the production line model shown in FIG. 10 is an example of what can be created as a model. However, for example, with respect to the process 1, there are three places: a section from the placement on the line 202 to the arrival at the steam supply device 203, a section for receiving the steam supply by the steam supply apparatus 203, and a section until the exit from the line 202 thereafter. When subdivided and modeled, the required amount of service can be given in a finer form with respect to the simulation time width, so that the loss evaluation of the service amount is given in more detail.

  In the utility loss evaluation system 101 shown in FIG. 1, the comparison result generation unit 110 first displays the time series pattern of the utility demand as shown in FIGS. 13 and 14 generated by the utility demand pattern generation unit 109. get. Subsequently, the comparison result generation unit 110 acquires information on the actual usage amount of the utility from the various usage amount measurement sensors 107 on the production line of the factory through the interface 114. Then, the comparison result generation unit 110 generates a comparison result between the time series pattern of the utility demand and the actual usage amount of the utility, and transmits the comparison result to the terminal device 104 through the interface 116.

FIG. 15 is a diagram illustrating an example of a comparison result generated by the comparison result generation unit 110 and displayed on the screen of the terminal device 104.
The actual usage amount 1502 of the utility demand is superimposed on the utility demand time series pattern 1501 generated by the utility demand pattern generation unit 109. As can be seen from the figure, the period 1503 from when the simulation time reaches about 150 minutes until it reaches about 195 minutes supplies a lot of utility even though the amount of utility actually required is small. It can be seen that the energy has been saved. In this way, it is possible for a plant manager, a person in charge at the site, or the like who is assumed as a user to use it as a judgment material for energy saving.

[Second Embodiment]
In the first embodiment described above, the simulation is performed on the assumption that each step is completed as shown in FIG. However, the factory production line may stop due to equipment failure, and it may not work as expected. In addition, problems may be discovered in product quality and intermediate products and products may be removed. In such a case, when the simulation result and the actual usage amount of the utility are compared, the usage amount is compared between the different production states.

  Therefore, as a second embodiment, an operation method of the utility loss amount evaluation system 101 in such a case will be described. In this operation method, when the production line is stopped or the intermediate product or product is removed during the actual production, the production status is the same by performing only the simulation that takes those situations into account. It makes it possible to compare the amount of service in the state.

  FIG. 16 is a block diagram showing the overall configuration of the production line utility loss amount evaluation system in the second embodiment, and the same reference numerals are given to the same parts as in FIG. The difference from the utility loss evaluation system shown in FIG. 1 is that line stop / discard information 1601 is added to information input by the user 103.

  After the actual production, the user 103 obtains the line stop / discard information 1601 such as the production line stop and the work-in-progress or product discard, and inputs the line stop / discard information 1601 through the terminal device 104. Thereby, the production line model creation unit 105 creates a production line model to which the line stop / discard information 1601 is added.

FIG. 17 is a diagram illustrating a screen configuration example of the utility loss amount evaluation tool displayed on the terminal device 104.
This screen is basically the same as the utility loss evaluation tool screen shown in FIG. 8, except that an area 1701 is displayed on the right side of the screen when the mouse pointer is placed on the place and clicked. Is different. In this area 1701, with respect to the place where the mouse pointer is placed, the time when the delay occurred on the production line (time and hour) and the delay time (how long and how long) It is possible to input and set information on the time when the work-in-progress and the product are removed.

  FIG. 17 shows an example of a screen for a general place. However, when the mouse pointer is clicked on a place representing a warehouse or a work in progress place, information on the time when the work in progress or product is removed is input. The area for setting is displayed in the same manner.

  In the area 1701 shown in FIG. 17, there is no column for inputting the number of work-in-process items or products removed (the number is automatically set as one). However, in consideration of the case where a plurality of work-in-progress items and products are removed, it is also possible to make an initial setting so that the number of work-in-process items and products removed can be entered and set in area 1701 on an initial setting screen (not shown) It has become.

18 and 19 are flowcharts showing processing of the simulation execution unit 108 when the user 103 instructs the execution of simulation through the terminal device 104 in the utility loss evaluation system 101 shown in FIG.
When the user 103 instructs execution of the simulation, the user 103 inputs the same time as the time when the actual production (production where the production line is stopped or the intermediate product or product is removed) is started as the simulation start time. Shall be kept.

  As shown in FIG. 18, the simulation execution unit 108 first acquires information on the simulation start time input when the simulation execution is instructed (step S <b> 21). Subsequently, the simulation execution unit 108 sets the (simulation time at which a delay has occurred) in each place, the time at which the delay set for each place in the area 1701 in FIG. 17 occurs, and the simulation start time acquired in step S21. (Step S22). For example, if the simulation start time (that is, the actual production start time) is 13:00 and the time at which the delay has occurred is 14:00, (simulation time at which the delay has occurred) is obtained as 60 minutes in step S22. .

  Subsequently, the simulation execution unit 108 sets the (simulation time for removing the product / intermediate product) in each place, the removal time set for each place in the area 1701 in FIG. 17, and the simulation start time acquired in step S21. (Step S23). For example, if the simulation start time is 13:00 and the removal time is 14:30, (simulation time for removing the product / intermediate product) is obtained as 90 minutes in step S23. Then, the simulation execution unit 108 ends the process of FIG. 18 and proceeds to the process of FIG.

  In the process of FIG. 19, the simulation execution unit 108 first substitutes 0 for the simulation time t (step S31). Subsequently, the simulation execution unit 108 repeats the same processing as steps S2 to S4 shown in FIG. 11 (step S32).

  Subsequently, the simulation execution unit 108 compares the current simulation time t with each place (simulation time when a delay occurs) obtained in step S22 of FIG. Then, the place where the two times coincide with each other is set in a delay state (step S33).

  Subsequently, the simulation execution unit 108 compares the delay time t ′ with the delay time set in the area 1701 in FIG. 17 in each place in the delay state. Then, the delay state of the place where the two times coincide with each other is eliminated, and the delay time t ′ of the place is set to 0 (step S34).

  Subsequently, the simulation execution unit 108 compares the current simulation time t with each place (simulation time when the product / intermediate product is removed) obtained in step S23 of FIG. Then, the tokens existing in the place where the two times coincide with each other are removed by the number set in the area 1701 in FIG. 17 (step S35).

  Subsequently, the simulation execution unit 108 determines whether or not the simulation time t has reached a preset simulation end time (step S36). If the simulation end time has not been reached, the simulation execution unit 108 advances the delay time t ′ of each place in the delay state by one unit time (step S37), and advances the simulation time t by one unit time. Advance (step S38), return to step S32, and continue the simulation. If the simulation end time is reached in step S36, the simulation execution unit 108 ends the process.

  In the utility loss amount evaluation system shown in FIG. 16, the functions of the utility demand pattern generation unit 109 and the comparison result generation unit 110 are the same as those in the utility loss amount evaluation system 101 shown in FIG. is there. When the comparison result generation unit 110 performs the comparison, the comparison result generation unit 110 acquires the data of the actual usage amount recorded at the time of actual production recorded in the various usage amount measurement sensors 107. When there is no function, the usage amount data measured by various usage amount measurement sensors 107 during actual production is stored in the storage device 106, and the usage amount data is acquired from the storage device 106. It is good.

  In the service loss evaluation system shown in FIG. 16, the user 103 inputs the line stop / discard information 1601 to link the production line information with the created Petri net production line model. It is also possible to automatically input the line stop / discard information 1601 from various systems that record information on the production line.

[Third Embodiment]
In the utility loss amount evaluation system 101 shown in FIG. 1, the utility demand pattern creation unit 109 can create a time series pattern of utility demand. Therefore, as in the example of the steam in FIG. 3, for the utility used in each process and part, if a value considering the loss to the production line is set instead of the minimum required utility amount, FIG. It is possible to obtain a time series pattern of the minimum necessary amount of utility to be supplied to the production lines 202, 206, 210 and 213 from the utility system power building 501 shown in FIG. Therefore, the utility loss amount evaluation system 101 shown in FIG. 1 can be applied to an operation control system of an industrial plant.

FIG. 20 is a block diagram showing the overall configuration of an operation control system for an industrial plant.
The plant operation control system 1901 includes an interface 1903, an interface 1905, a utility demand calculation module 1906, an interface 1909, an interface 1910, a utility demand correction module 1911, an optimum operation control module 1912, and an interface. 1913, a storage device 1914, and an interface 1915.

  The interface 1903 is an interface for acquiring a production plan having time information as production facility information from the scheduler of the management resource planning (ERP) system 1902. An interface 1905 is an interface for reading a manufacturing prescription from the manufacturing execution system (MES) and the distributed control system (DCS) 1904.

  The utility demand amount calculation module 1906 estimates various necessary usage amounts such as hot water, cold water, air, electrical machinery, and steam to be given to the production facility as a utility demand pattern having time information from the production plan and manufacturing prescription. This is an arithmetic module with the logic of

  The interface 1909 is an interface for acquiring the state quantities of the production facility 1907 and the utility facility 1908. An interface 1910 is an interface for acquiring a state quantity of an environmental condition such as an outside air temperature.

  The utility demand correction module 1911 includes logic for correcting the utility demand pattern obtained from the utility demand calculation module 1906 using the production equipment 1907, the utility equipment 1908, and the state quantities of the environmental conditions. This is an arithmetic module.

  The optimum operation control module 1912 includes means for performing optimum calculation for distributing loads to a plurality of utility facilities using the utility demand pattern corrected by the utility demand correction module 1911, and various utility facilities. This is an arithmetic module having means for determining the operation plan for the utility equipment using the time taken to output the required utility amount and the result of the optimum calculation.

  The interface 1913 is an interface for issuing an operation command to the utility equipment 1908 so as to perform an operation according to the operation plan determined by the optimum operation control module 1912. The storage device 1914 is a storage device that holds data required by the utility demand calculation module 1906, the utility demand correction module 1911, and the optimum operation control module 1912. The interface 1915 is an interface for acquiring data from the storage device 1914.

  With such a configuration, the plant operation control system 1901 is a system for estimating energy consumption by estimating a time series pattern of the minimum usage amount necessary for the production facility.

21 is a block diagram in which the utility loss amount evaluation system 101 shown in FIG. 1 is incorporated into the utility demand amount calculation module 1906 of the plant operation control system 1901 shown in FIG.
As shown in FIG. 21, the utility loss amount evaluation system 101 is incorporated in the utility demand amount calculation module 1906, and the number of necessary raw materials is input based on the production plan. Furthermore, the first embodiment As described above, information on various production lines can be input, and the time series pattern of utility demand generated by the utility demand pattern generation unit 109 in the utility loss assessment system 101 is used as the utility loss assessment system 101. Output from the plant, the plant operation control system 1901 can be applied to the production line.

  The present invention is not limited to the above-described embodiments, and various other application examples and modifications can of course be taken without departing from the gist of the present invention described in the claims.

  DESCRIPTION OF SYMBOLS 101 ... Usage loss amount evaluation system, 102 ... Production line information, 103 ... User, 104 ... Terminal device, 105 ... Production line model preparation part, 106 ... Memory | storage device, 107 ... Various usage measurement sensors, 108 ... Simulation execution 109: Utility demand pattern generation unit, 110 ... Comparison result generation unit, 111-116 ... Interface, 201 ... Raw material warehouse for raw material A, 202 ... Production line for process 1, 203 ... Steam supply device, 204 ... Work in progress Place A, 205 ... Raw material warehouse for raw material B, 206 ... Production line for step 2 207 ... Fusion device for raw material B and intermediate product C, 208 ... Work in process place B, 209 ... Raw material warehouse for raw material C, 210 ... Step 3 Production line 211, steam supply device 212, work place storage C 213, production line 214, 214, fusion of intermediate product A and intermediate product C , 215... Steam supply device, 216... Product warehouse, 501. Transition, 801... Example of screen configuration of utility loss amount evaluation tool, 802 to 805... One area of utility loss amount evaluation tool screen, 806... Mouse pointer, 901. 1 area, 903... Setting button, 1001... Place representing step 1, 1002... Place representing step 2, 1003... Place representing step 3, 1004. Place, 1006: Place representing work-in-process yard A204, 1007: Raw material of raw material B A place representing the storage 205, 1008 a place representing the work-in-process storage place B208, 1009 a place representing the raw material warehouse 209 of the raw material C, 1010 a place representing the work-in-process storage place C210, S1 to S6 a process flow of the simulation execution unit 108 , 1301... At time t = 120 minutes of the utility demand time series pattern obtained by the utility loss amount evaluation system 101, 1501... The utility demand time series pattern obtained by the utility loss amount evaluation system 101, 1502. Actual steam consumption measured by the sensor 503, 1601 ... Disposal information such as line stop / intermediate product, etc., 1701 ... One area of the utility loss evaluation tool screen, S21 to S23 ... Simulation execution unit 108 simulates delay occurrence time Flow chart to be obtained as time, S31 to S38 ... Process of the simulation execution unit 108 , 1901... Plant operation control system, 1902... Management resource planning (ERP) system, 1903... Interface for acquiring production plan with time information from scheduler of management resource planning (ERP) system 102, 1904 ... Manufacturing execution system, distributed control system (MES, DCS), 1905 ... Interface for reading manufacturing prescription from manufacturing execution system (MES) or distributed control system (DCS) 104, 1906 ... Utility demand calculation module, 1907 ... Production equipment , 1908 ... utility equipment, 1909 ... interface for obtaining state quantities of production equipment and utility equipment, 1910 ... interface for obtaining state quantities of environmental conditions such as outside air temperature, 1911 ... utility demand correction module, 1912 ... Optimal operation control module, 1913 ... Start up to utility equipment Interface issues an instruction of stopping, 1914 ... storage device, an interface for acquiring data of the time constant from 1915 ... storage device

Claims (8)

The amount of service required when the raw material or intermediate product passes through the factory production line, the time required for the raw material or intermediate product to pass through part or all of the production line, Create a production line model based on the fact that the conditions under which the next production starts when raw materials or intermediate products move from multiple production lines to a smaller number of production lines are entered as production line information. Production line model creation department,
Based on the production line model, a simulation execution unit that executes a simulation of the production line;
A utility demand pattern for generating a time series pattern of utility demands required by the entire production line based on the overall utility demand of the production line obtained during the simulation performed by the simulation execution unit. A production line utility loss evaluation system characterized by comprising a generation unit. The said production line model preparation part produces the production line model using a Petri net, The utilization loss amount evaluation system of the production line of Claim 1 characterized by the above-mentioned. The production line model creation unit
Information indicating that a place representing a passage part of the production line through which raw materials or intermediate products pass and a place representing a warehouse or work in progress storage place for storing raw materials or intermediate products are selected as Petri net places;
Information indicating that the usage amount necessary for the place is set for the place representing the passing part;
The production line model according to claim 2, wherein a production line model including the selected place and having a usage amount set for the place representing the passing portion is created based on the input of. Line usage loss evaluation system. The simulation execution unit obtains the usage amount set in the place at a place where a token exists at a predetermined time interval at the time of executing the simulation, and calculates the total of the obtained usage amount, 4. The utility loss evaluation system for a production line according to claim 3, wherein the calculation result is transmitted to the utility demand pattern generation unit. The production line model creation unit has a token for a place representing the warehouse or work-in-process place based on the input of the maximum number of tokens that can exist for the place representing the warehouse or work-in-process place. 5. The service line loss evaluation system for a production line according to claim 4, wherein an upper limit number is set. Further, a comparison result generation unit that compares the time series pattern of the utility demand generated by the utility demand pattern generation unit with the utility amount actually used in the production line and generates the comparison result The utility loss amount evaluation system for a production line according to claim 5. The production line model creation unit creates a production line model to which the information on the line stop or product disposal is added based on the input of the information about the line stop or product disposal actually generated in the production line,
The said simulation execution part changes the state in each time of simulation using the information of the said line stop or product disposal, The utilization loss amount evaluation system of the production line of Claim 6 characterized by the above-mentioned. In the production line utility loss evaluation method in the system having the production line model creation unit, the simulation execution unit, and the utility demand pattern generation unit,
The amount of service required when the raw material or intermediate product passes through the factory production line, the time required for the raw material or intermediate product to pass through part or all of the production line, When the raw material or intermediate product moves from a plurality of production lines to a smaller number of production lines, the conditions for starting the next production are input as production line information, and the production line model creation unit Creating a production line model,
Based on the production line model, the simulation execution unit executes a simulation of the production line;
Based on the total utility demand of the production line obtained during the simulation, the utility demand pattern generation unit generates a time series pattern of utility demand required by the entire production line. And a step of evaluating the utility loss amount of the production line.

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