JP2012043310A - Method, program and apparatus for managing production facility - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method, program and apparatus for managing a production facility capable of improving productivity of a production line.SOLUTION: A method of managing a production facility acquires the number of processed cases for each production facility, detects a disorder that occurs in the production facility and, in the event of the disorder in a plurality of the production facilities, calculates the sum of average recovery time and remaining work time obtained from the number of scheduled production and the number of the processed cases as production completion time for each of the production facilities in which the disorder occurs, and reports the production facility for which the production completion time is the longest.

Description

  The present invention relates to a production facility management method, a production facility management program, and a production facility management apparatus.

  When a failure such as a failure occurs in any production facility in a production line equipped with one or more production facilities, it is desired to restore it early. In Patent Document 1, a production facility that prioritizes restoration is guided with emphasis on either load leveling or delivery time. In patent document 2, the production facility which gives priority to improvement is led according to the unit availability.

JP-A-3-251351 JP 2008-112209 A

  However, the techniques of Patent Documents 1 and 2 do not necessarily avoid a decrease in productivity of the production line.

  The present invention has been made in view of the above problems, and an object thereof is to provide a production facility management method, a production facility management program, and a production facility management apparatus that can improve the productivity of a production line.

  In order to solve the above-mentioned problem, the production facility management method disclosed in the specification acquires the number of processed cases of each production facility, detects a failure occurring in the production facility, and the failure occurs in a plurality of the production facilities. For each of the production facilities in which a failure has occurred, the sum of the average recovery time, the scheduled production number and the remaining work time obtained from the number of processed cases is calculated as the production completion time, and the production completion time is the longest. Notification of production equipment.

  In order to solve the above problems, a production facility management program disclosed in the specification includes a step of acquiring, in a computer, a processed number of each production facility, a step of detecting a failure occurring in the production facility, and the failure Calculating a sum of an average recovery time, a scheduled production number, and a remaining work time obtained from the number of processed cases as a production completion time for each of the production facilities in which a failure has occurred, when occurring at a plurality of the production facilities; And notifying the production facility having the longest production completion time.

  In order to solve the above problems, the production facility management apparatus disclosed in the specification includes a storage unit that stores an average recovery time and a planned production number of each production facility, and a reception unit that receives the number of processed items of each production facility. A detection unit that detects a failure that occurs in each of the production facilities; and when the failure occurs in a plurality of the production facilities, for each of the production facilities in which the failure has occurred, an average recovery time, the number of productions, and the A calculation unit that calculates the sum of the remaining work time obtained from the number of processed cases as a production completion time, and a notification unit that notifies the production facility with the longest production completion time.

  According to the production facility management device, the production facility management method, and the production facility management program disclosed in the specification, the productivity of the production line can be improved.

1 is a block diagram for explaining an overall configuration of a production system including a production facility management device according to Embodiment 1. FIG. It is an apparatus block diagram of a production facility management apparatus. It is a table showing equipment MCT stored according to kind. It is a table showing the average recovery time stored according to event. It is a figure for demonstrating the equipment input remainder at a predetermined timing. It is a table showing the calculation process of remaining MCT according to equipment. It is a table showing the calculation result of remaining MCT according to equipment. It is the figure which represented the calculation result of FIG. 7 with the bar graph. It is a figure for demonstrating an example of the flowchart performed when calculating remaining MCT. It is a figure for demonstrating an example of the flowchart performed when determining a recovery priority. It is a figure for demonstrating the other example of a production line.

  Hereinafter, embodiments will be described with reference to the drawings.

  FIG. 1 is a block diagram for explaining an overall configuration of a production system 100 including a production facility management apparatus 10 according to the first embodiment. With reference to FIG. 1, the production system 100 includes a production facility management apparatus 10, a plurality of production facilities 20, a plurality of input / output units 30, and a plurality of terminals 40. In the present embodiment, as a plurality of production facilities 20, production facilities 20a to 20e are provided. In addition, input / output units 30a to 30e are provided as the plurality of input / output units 30, and are provided corresponding to the production facilities 20a to 20e, respectively. Moreover, the terminals 40a-40e are provided as the some terminal 40, and are provided corresponding to each of the production facilities 20a-20e. For example, the terminal 40a is connected to the production facility 20a via the input / output unit 30a.

  The production facilities 20a to 20e are devices that produce products such as electric devices and machines. The products produced by the production facilities 20a to 20e are not particularly limited. In the present embodiment, one production line is configured by the production facilities 20a to 20e. Therefore, the production in the production system 100 is completed when the article undergoes production processing in order in the production facilities 20a to 20e. There may be a plurality of varieties subjected to production processing in the production facilities 20a to 20e. In the present embodiment, the production facilities 20a to 20e perform production processing on the varieties A and B.

  In addition, the production facilities 20a to 20e output the number of articles for which production processing has been completed for each product as signals related to the number of processed items at a predetermined timing. For example, the production facilities 20a to 20e may output a signal related to the number of processed items each time the production process for one article is completed. The production facilities 20a to 20e may output a signal related to the number of processed items each time a production process for a predetermined number of articles is completed. In addition, the production facilities 20a to 20e may output a signal regarding the number of processed cases for each predetermined period. If the processed number of each production facility and the planned production number of the production system 100 are obtained, the “equipment remaining balance” in each production facility can be calculated.

  Here, “equipment surplus” is the sum of “line surplus” and “all work in progress before the production facility”. “Line input remaining” is the total number of articles that have been input to the production line and have not been subjected to production processing in any of the production facilities. Therefore, it is possible to derive the “remaining line input” from the planned number of production and the number of processed products in each production facility. In addition, “all work in progress before the production facility” means that the production process has been completed at one of the production facilities before the production facility, but the production process has not yet been completed at the production facility. There is no total number of goods. Therefore, the “all work in progress before the production facility” can be derived from the number of processed items in each production facility. From the above, the “equipment remaining balance” can be derived from the planned production number and the number of processed items of each production facility.

  As an example, a case will be described in which the facility input remaining in the production facility 20a is “30” and the facility input remaining in the production facility 20b is “32” for the type A. In this case, the total number of articles that have been input to the production line and have not been subjected to production processing in the production facility 20a is “30”. In addition, the total number of articles that have not been input to the production facility 20b and have been subjected to production processing in the production facility 20a is “2”.

  Further, the production facilities 20a to 20e output an alarm signal when a failure such as a failure occurs in the production facilities 20a to 20e. The production facilities 20a to 20e that output the alarm signal stop the production process. In the present embodiment, the production facilities 20a to 20e output different error numbers as signals according to events.

  The input / output units 30a to 30e are interfaces for outputting signals from the production facilities 20a to 20e and inputting signals to the production facilities 20a to 20e. The terminals 40a to 40e acquire signals from the production facilities 20a to 20e and input signals to the production facilities 20a to 20e via the input / output units 30a to 30e. The terminals 40a to 40e are connected to the production facility management apparatus 10 via a LAN (Local Area Network). The production facilities 20a to 20e acquire signals from the production facility management apparatus 10 and input signals to the production facility management apparatus 10 via the LAN. For example, the terminals 40 a to 40 e output to the production facility management apparatus 10 a signal regarding the number of processed cases output by the production facilities 20 a to 20 e and a signal regarding an error number.

  The production facility management apparatus 10 includes a reception unit 11, a detection unit 12, an MCT calculation unit 13, a priority order calculation unit 14, a planned production number storage unit 15, a product-specific facility MCT storage unit 16, an average recovery time storage unit 17, and a facility-specific A remaining MCT storage unit 18 and a display unit 19 are included.

  FIG. 2 is a device configuration diagram of the production facility management apparatus 10. Referring to FIG. 2, the production facility management apparatus 10 includes a CPU (Central Processing Unit) 101, a LAN interface 102, a RAM (Random Access Memory) 103, an HDD (Hard Disk Drive) 104, a display unit 19, and the like. Each device is connected by a bus. As an example, the production facility management apparatus 10 is realized by the CPU 101 executing the production facility management program stored in the HDD 104. As an example, the RAM 103 functions as the planned production quantity storage unit 15 and the facility-specific remaining MCT storage unit 18. Also, the HDD 104 functions as the product-specific equipment MCT storage unit 16 and the average recovery time storage unit 17.

  The planned production number storage unit 15 stores the planned production number for each product type. The planned number of production is the total number of products produced by the production system 100. The scheduled production number stored in the planned production number storage unit 15 is rewritten as needed by the user.

  The type-specific equipment MCT storage unit 16 stores the equipment MCT for each type. Here, MCT is a machine cycle time, and is a remaining work time required for production processing. The facility MCT is an MCT for one article in each production facility. Specifically, the equipment MCT for the product type A being “0.2h” means that the work time required to perform the production process for one product of the product type A in the target production equipment is 0.2 hours. It means that there is. FIG. 3 is a table showing the equipment MCT stored for each product type. In the table of FIG. 3, the MCT of each production facility is stored for product type A and product type B.

  The average recovery time storage unit 17 stores the average recovery time of the facility in which the failure has occurred, for each facility and for each failure event. The average recovery time is an estimated value of the average time required for recovery of production equipment. Therefore, the average recovery time may deviate from a value obtained by averaging the actual recovery times when the same production facility and the same event occur. The average recovery time can be determined in advance based on the actual time required for the recovery. FIG. 4 is a table showing the average recovery time stored for each event. In the table of FIG. 4, for each event, the average recovery time of each production facility is stored, and an error number is also stored.

  The receiving unit 11 receives the number of processed items from each of the production facilities 20a to 20e at a predetermined timing. The MCT calculation unit 13 acquires the number of processed products for each of the production facilities 20 a to 20 e from the reception unit 11 and extracts the planned production number from the production number storage unit 15. The MCT calculation unit 13 calculates “equipment remaining” from the planned production number and the processed number of production facilities 20a to 20e. FIG. 5 is a diagram for explaining the remaining equipment input at a predetermined timing. Line A in FIG. 5 is a name of a line configured by the production facilities 20a to 20e.

  Next, the MCT calculation unit 13 calculates a facility-specific remaining MCT based on the facility input remaining. The remaining MCT is the time required to perform production processing on all the items remaining in the facility for each production facility, and is the remaining work time. The MCT calculation unit 13 calculates the facility-specific remaining MCT based on the facility input remaining received from the production facilities 20a to 20e and the facility MCT stored in the product-specific facility MCT storage unit 16. The remaining MCT is obtained by calculating and adding the product of “equipment remaining” and “equipment MCT” for each product type.

  FIG. 6 is a table showing the calculation process of the remaining MCT for each facility. As an example, in the equipment 3 (production equipment 20c), the equipment input remaining for the product type A is “34”, the equipment MCT is “0.2”, the equipment input remaining for the product type B is “54”, and The facility MCT is “0.4”. Therefore, the remaining MCT in the production facility 20c is 34 × 0.2 + 54 × 0.4 = 28.4h. In addition, in equipment 5 (production equipment 20e), the equipment input remaining for product type B is “38”, the equipment MCT is “0.2”, the equipment input remaining for product type B is “58”, and the equipment The MCT is “0.4”. Therefore, the remaining MCT in the production facility 20e is 38 × 0.2 + 58 × 0.4 = 30.8h. These calculation results are temporarily stored in the facility-specific remaining MCT storage unit 18. FIG. 7 is a table showing the calculation result of the remaining MCT for each facility. In FIG. 7, an example of the calculation result of the line B not shown in FIG. 1 is also shown.

  The detection part 12 receives the signal regarding the error number which each production equipment 20a-20e outputs. Thereby, the detection part 12 can detect the failure which generate | occur | produces in each production equipment 20a-20e according to event. The detection unit 12 transmits the detection result to the priority order calculation unit 14.

  Based on the detection result of the detection unit 12, the priority order calculation unit 14 determines whether or not a plurality of production facilities have failed during the same period. Here, when there are failures in a plurality of production facilities within the same period, there are failures in a plurality of production facilities within a predetermined period and a plurality of production facilities that have not yet been restored remain. Refers to the case. The priority level calculation unit 14 calculates the priority level for restoration of the production facility when a failure occurs in a plurality of production facilities during the same period.

  A specific example will be described. FIG. 8 is a bar graph showing the calculation results for the line A described in FIG. Referring to FIG. 8, it can be determined which production facility has the longest remaining MCT. The priority order calculation unit 14 further adds the average recovery time to the remaining MCT. A value obtained by adding the average recovery time to the remaining MCT means time (production completion time) required for completion of production processing including recovery work time in the target production facility.

  For example, it is assumed that the error number E001 is output from the facility 3 (production facility 20c) and the error number E002 is output from the facility 5 (production facility 20e). In this case, for the production facility 20c, the remaining MCT is “28.4h” and the average recovery time is “3.0h”, so the production completion time in the production facility 20c is 31.4h. Further, for the production facility 20e, the remaining MCT is “30.8h” and the average recovery time is “0.1h”, so the production completion time in the production facility 20e is 30.9h.

  By preferentially restoring the production facility with the longer production completion time, after the restoration, it takes a long time for a plurality of production facilities that have failed to operate redundantly. Therefore, the line operation rate can be improved. Therefore, the productivity of the line can be improved.

  The priority calculation unit 14 calculates at least a production facility having the longest production completion time for a production facility in which a failure has occurred during the same period. Preferably, the priority ranking calculation unit 14 calculates the ranking of the production equipment in the order of the longest production completion time for the production equipment in which a failure has occurred during the same period. The priority order calculation unit 14 gives the calculated result to the display unit 19. The display unit 19 displays the result given from the priority order calculation unit 14. Thereby, the user can determine which recovery of the production equipment is prioritized.

  FIG. 9 is a diagram for explaining an example of a flowchart executed when the remaining MCT is calculated. Referring to FIG. 9, the MCT calculation unit 13 monitors the input event (step S1). Next, the MCT calculation unit 13 determines whether an event has occurred (step S2). If it is determined “No” in step S2, step S1 is executed again. The event is, for example, when any of the production facilities 20a to 20e outputs a signal regarding the number of processed cases. Therefore, the MCT calculation unit 13 can determine whether an event has occurred based on the signal acquired from the reception unit 11.

  When it determines with "Yes" in step S2, the MCT calculation part 13 produces the equipment input remainder by the procedure mentioned above (step S3). Next, the MCT calculation unit 13 extracts the facility-specific equipment MCT from the product-specific facility MCT storage unit 16 (step S4). Next, the MCT calculation unit 13 calculates the remaining MCT for each line and for each facility according to the above-described procedure (step S5). Next, the facility-specific remaining MCT storage unit 18 stores the remaining MCT calculated in step S5 (step S6). Thereafter, the process is executed again from step S1.

  FIG. 10 is a diagram for explaining an example of a flowchart executed when the restoration priority is determined. With reference to FIG. 10, the priority calculation part 14 monitors the operation condition of each production facility (step S11). Next, the priority order calculation unit 14 determines whether or not a failure has occurred in a plurality of production facilities during the same period based on the detection result of the detection unit 12 (step S12). If it is determined “No” in step S12, step S11 is executed again.

  When it determines with "Yes" in step S12, the priority calculation part 14 extracts the remaining MCT memorize | stored in the remaining MCT memory | storage part 18 classified by equipment (step S13). Next, the priority calculation unit 14 extracts the average recovery time for each facility and event from the average recovery time storage unit 17 (step S14). Next, the priority order calculation unit 14 calculates the restoration priority order by the above-described procedure (step S15). Next, the priority order calculation unit 14 gives the calculated priority order to the display unit 19. Thereby, the display part 19 displays a priority (step S16). Thereafter, step S11 is executed again.

  According to the present embodiment, since the remaining MCT in each production facility is calculated, the remaining work time required for the production process in each production facility can be obtained. Further, by adding the average recovery time to the remaining MCT, the production completion time when the recovery is necessary is calculated. When a failure occurs in a plurality of production facilities, the production facility with the longest production completion time is displayed, so that the restoration person can determine which production facility to prioritize. From the above, the productivity of the production line can be improved.

  In addition, although the said Example demonstrated the case where a failure generate | occur | produced in several production equipment in the same production line like Fig.11 (a), it is not restricted to it. For example, the above embodiment can be applied to a production system having a plurality of production lines. Referring to FIG. 11B, it is assumed that a plurality of production lines, line A and line B, are provided. Even if a failure occurs in one of the production facilities on line A and a failure occurs on any production facility on line B within the same period, the one with the longer production completion time mentioned above will be restored with priority. As a result, the productivity of the production line can be improved.

  Although the embodiments of the present invention have been described in detail above, the present invention is not limited to such specific embodiments, and various modifications and changes can be made within the scope of the gist of the present invention described in the claims. It can be changed.

DESCRIPTION OF SYMBOLS 10 Production equipment management apparatus 11 Receiving part 12 Detection part 13 MCT calculation part 14 Priority order calculation part 15 Production planned number storage part 16 Equipment MCT storage part according to kind 17 Average recovery time storage part 18 Remaining MCT storage part according to equipment 19 Display part 20 Production equipment 30 Input / output unit 40 Terminal 100 Production system

Claims (5)

Obtain the number of processed items for each production facility,
Detecting faults occurring in the production facility,
When the failure occurs in a plurality of the production facilities, for each of the production facilities where the failure has occurred, the sum of the average recovery time, the planned number of productions and the remaining work time obtained from the number of processed cases is calculated as the production completion time And
A production facility management method comprising notifying the production facility having the longest production completion time.   The production facility management method according to claim 1, wherein the average recovery time is determined according to a type of a failure that occurs in the production facility.   3. The production facility management method according to claim 1, wherein priorities are notified in descending order of the production completion time for the plurality of production facilities in which a failure has occurred. On the computer,
Obtaining the number of processed items for each production facility;
Detecting a failure occurring in the production facility;
When the failure occurs in a plurality of the production facilities, for each of the production facilities where the failure has occurred, the sum of the average recovery time, the planned number of productions and the remaining work time obtained from the number of processed cases is calculated as the production completion time And steps to
And a step of notifying the production facility having the longest production completion time. A storage unit for storing the average recovery time and the planned number of production of each production facility;
A receiving unit for receiving the number of processed items of each production facility;
A detection unit for detecting a failure occurring in each of the production facilities;
When the failure occurs in a plurality of the production facilities, for each of the production facilities where the failure has occurred, the sum of the average recovery time and the remaining work time obtained from the planned number of productions and the number of processed cases is used as the production completion time. A calculation unit for calculating,
A production facility management apparatus comprising: a notification unit that notifies the production facility having the longest production completion time.

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