JP2014035574A - Production management device, production management method, and production management program - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a production management device, a production management method, and a production management program that prevent a defective from being produced.SOLUTION: A control part 10 of a production management device 1 acquires information associated with an item number of works W to be fed to a machining processing device 2 and a planned production number of the item number (S105), and counts a production number as the number of the works W to be fed to the machining processing device 2 (S111). Further, the control part determines which of a work W and a dummy work "d" indicative of change in the item number of the work W is fed to the machining processing device 2 (S101, S108), and determines abnormality of absence of the dummy work "d" (S112) when the production number of the item number is equal to or larger than the planned production number and the work W is determined (S101: NO, S108: YES, and S110: NO). Consequently, the abnormality of absence of the dummy work "d" is properly determined so as to prevent a defective from being produced.

Description

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

  Conventionally, various techniques have been proposed for efficient production. For example, Patent Document 1 discloses a production plan creation device that prevents out-of-stock and excessive inventory by selecting a production method according to the amount of shipment and determining the production priority of each product number.

JP-A-4-361367

Patent Document 1 discloses a production plan creation device that prevents out of stock and excessive inventory, but does not mention quantity management of products actually produced on a production line.
By the way, when a high-temperature facility such as a furnace is included in the production line, there are cases where an ID or the like that can manage the product number cannot be used. When performing different processing for each product number when an ID that can manage the product number cannot be used, for example, it is recognized that the product number is switched by inserting a dummy workpiece different from a normal workpiece at the beginning of each product number, and processing conditions May change. However, when a dummy workpiece is missing due to some abnormality, it is not possible to recognize that the product number has been switched, and the processing under the processing conditions of the previous product number is continued, and there is a possibility that a defective product is generated.
The present invention has been made in view of the above-described problems, and an object thereof is to provide a production management device, a production management method, and a production management program that prevent the occurrence of defective products.

The production management apparatus of the present invention manages a processing apparatus that performs different processing for each product number on a workpiece conveyed to a production line, and includes an information acquisition unit, a determination unit, a count unit, and an abnormality determination Means.
The information acquisition means acquires information regarding the product number of the workpiece to be input into the processing apparatus and the planned production number of the product number. The discriminating unit discriminates whether the conveyed product conveyed to the machining process is a workpiece or a dummy workpiece for indicating that the product number of the workpiece is changed. The counting means counts the number of productions that is the number of workpieces conveyed to the machining process. The abnormality determination means determines that there is a dummy workpiece missing abnormality when the number of productions in the product number is equal to or greater than the planned production number and the conveyed product is determined as a workpiece by the determination means.

  In the present invention, the quantity transported to the processing apparatus is managed, and even if the number of productions reaches the planned production number, the transported object to be subsequently transported is not a dummy work but a work. Determined as missing. Thereby, it is possible to appropriately determine whether the dummy workpiece is missing. The “dummy workpiece missing abnormality” here is not limited to an insertion error in which a dummy workpiece is not inserted, but also includes a recognition failure that cannot be recognized as a dummy workpiece. Also, if it is determined that the dummy workpiece is missing, for example, if the workpiece is stopped and the processing by the processing device is stopped, the subsequent workpiece with a different product number is processed under the processing conditions of the previous product number. It is possible to prevent the occurrence of defective products due to the continued operation.

Moreover, it is good also as a production management method provided with the information acquisition step similar to the above, a discrimination | determination step, a count step, and an abnormality determination step. Furthermore, a production management program for causing a computer to function as information acquisition means, determination means, count means, and abnormality determination means similar to those described above may be used.
Even such a production management method and a production management program have the same effects as the production management apparatus.

It is a schematic diagram which shows the structure of the production management apparatus by one Embodiment of this invention. It is a flowchart explaining the management process by one Embodiment of this invention. It is a flowchart explaining the transmission process by one Embodiment of this invention. It is explanatory drawing explaining the case where a dummy workpiece | work is missing.

Hereinafter, a production management device, a production management method, and a production management program according to the present invention will be described with reference to the drawings.
(One embodiment)
As shown in FIG. 1, the production management apparatus 1 according to an embodiment of the present invention manages a processing apparatus 2 that performs different processing for each product number on a workpiece W conveyed to a production line 30.
The production management device 1 includes a control unit 10 and a recognition unit 11. The control unit 10 is configured by a normal sequencer or the like. The recognition unit 11 includes a sensor or the like, detects the shape or the like of a conveyed product conveyed to the production line 30, and transmits the detected information to the control unit 10. The production management device 1 is configured to be able to exchange information with the pre-process management device 20 that manages other processing steps performed in the front stage of the processing device 2 in the production line 30.
The processing device 2 is controlled by the production management device 1 and performs processing on the workpiece W conveyed to the production line 30 under different processing conditions for each product number.

  The pre-process management device 20 has a fluid product number history table 21. In the fluid product number history table 21, the product number and the planned production quantity are associated with each other and stored in the order in which they are conveyed to the production line 30. When there is an information transmission request from the production management device 1, the pre-process management device 20 transmits information regarding the product number at the top of the fluid product number history table 21 and the planned production number of the product number to the production management device 1. The information regarding the product number and the planned production quantity that have been transmitted to the production management apparatus 1 is deleted from the fluid product number history table 21 and other information is added up.

  The production line 30 of the present embodiment includes high-temperature equipment such as a furnace in the previous stage of the processing apparatus 2 managed by the production management apparatus 1. Therefore, an ID or the like that can manage the product number cannot be given to the work W conveyed to the production line 30. Therefore, in the present embodiment, a dummy work d for indicating that the product number changes at the head of each product number of the work W is made to flow. Specifically, the dummy work d1 is made to flow at the head of the work WA having the product number A, the dummy work d2 is made to flow at the head of the work WB having the product number B, and the dummy work d3 is made to flow to the head of the work WC having the product number C. And so on.

  The dummy workpiece d is configured so that it can be identified as not a workpiece W by a sensor or the like constituting the recognition unit 11 by changing the shape of the workpiece W or processing a pallet for conveying the workpiece W. The Since the dummy workpiece d flows at the head of each product number of the workpiece W, the production management apparatus 1 can recognize that the product number of the workpiece W has been switched by identifying the workpiece W and the dummy workpiece d. . Further, the dummy workpiece d is given a number based on the shape or the like, and the production management apparatus 1 can recognize the number based on the recognized shape or the like of the dummy workpiece d.

  By the way, normally, as shown in FIG. 1, a dummy work d is made to flow at the head of each product number. However, as shown in FIG. 4A, the production management apparatus 1 may not be able to recognize the dummy workpiece dn that should have been at the head of the product number due to, for example, a loading error or a recognition failure of the dummy workpiece dn by the transport loader. . In such a case, as shown in FIG. 4 (b), if there is no information on the planned production quantity, the processing apparatus 2 processes the previous product number until the next dummy workpiece d (n + 1) is recognized. Processing under conditions will continue. In the example shown in FIG. 4, since the dummy workpiece d2 to be input at the head of the product number B is missing, it should be processed under the condition of the product number B until the next dummy workpiece d3 is recognized. Since the workpiece WB is processed under the condition of the product number A, a large number of defective products are generated. In addition, the work time until the return becomes longer.

Therefore, in this embodiment, the generation of defective products is prevented by adding the planned production quantity information to the product number information.
Here, the management process executed by the control unit 10 of the production management apparatus 1 will be described based on the flowchart shown in FIG. This process is executed when the recognition unit 11 recognizes a conveyed product conveyed to the processing apparatus 2.

  In the first step S101 (hereinafter, “step” is omitted and is simply indicated by the symbol “S”), it is determined whether or not the conveyed product recognized by the recognition unit 11 is a dummy workpiece d. When it is determined that the workpiece is not the dummy workpiece d (S101: NO), the process proceeds to S108. When it is determined that the workpiece is a dummy workpiece d (S101: YES), the process proceeds to S102.

  In S102, it is determined whether or not the count value of the counter that counts the number of productions coincides with the planned production number of the product number X transported before the dummy workpiece d. Note that when the workpiece W is not input before the dummy workpiece d, that is, when the dummy workpiece d is at the head, the planned production number is regarded as zero. When it is determined that the count value matches the planned production quantity (S102: YES), the process proceeds to S104. When it is determined that the count value does not match the planned production number (S102: NO), that is, when the count value is smaller than the planned production number, the process proceeds to S103.

In S103, it is determined that the missing part number X that has been transported before the dummy workpiece d is abnormal, and the process proceeds to S104. The information indicating that the product number X is missing or the count value that is the actual number of products processed by the processing device 2 can be notified to other management devices.
Even if the production number of the product number X is less than the planned production number, if the dummy workpiece d is recognized, the machining condition can be changed to the condition of the next product number Y and the production can be continued. In the embodiment, the process proceeds to S104. Of course, when it is determined in S103 that the product number X is missing, the process may proceed to, for example, S113 to abnormally stop the machining process in the machining apparatus 2.

In subsequent S <b> 104, an information request regarding the next product number Y is transmitted to the previous process management apparatus 20.
Here, the transmission process executed by the pre-process management apparatus 20 will be described with reference to FIG. The transmission process shown in FIG. 3 is executed at a predetermined interval.
In S201, it is determined whether an information request from the production management apparatus 1 has been received. If it is determined that an information request has not been received (S201: NO), this process ends. When it is determined that the information request has been received (S201: YES), the process proceeds to S202.
In S202, the information regarding the product number at the top of the fluid product number history table 21 and the planned production number of the product number is transmitted to the production management apparatus 1, and this process is terminated.

Returning to FIG. 2, in step S <b> 105 after the request for information on the next product number is transmitted to the previous process management device 20, the product number information and information related to the planned production number of the product number are acquired from the previous process management device 20.
In S106, the processing conditions of the processing apparatus 2 are changed based on the product number information acquired in S105.
In S107, the count value of the counter that counts the number of production is reset.

  When it is determined that the conveyed product recognized by the recognition unit 11 is not the dummy workpiece d (S101: NO), it is determined whether or not the conveyed product recognized by the recognition unit 11 is the workpiece W in S108. To do. When it is determined that the workpiece is a workpiece W (S108: YES), the process proceeds to S110. When it is determined that the conveyed product recognized by the recognition unit 11 is not the workpiece W (S108: NO), the process proceeds to S109.

In S109, since it is determined that the conveyed product recognized by the recognition unit 11 is neither the dummy workpiece d nor the workpiece W, it is determined that there is an abnormality in a device such as a sensor, and the process proceeds to S113.
When it is determined that the conveyed product recognized by the recognition unit 11 is the workpiece W (S108: YES), whether or not the count value of the counter that counts the production number is less than the planned production number of the product number is determined. Determine whether. When it is determined that the count value is equal to or greater than the planned production quantity (S110: NO), the process proceeds to S112. When it is determined that the count value is less than the planned production quantity (S110: YES), the process proceeds to S111.
In S111, the count value of the counter that counts the number of productions is incremented, and this process ends.

When it is determined that the count value is equal to or greater than the planned production number (S110: NO), it is determined that the dummy workpiece d is missing. Here, the “abnormality of missing dummy workpiece d” is not limited to a loading error in which the dummy workpiece d is not loaded from the transfer loader, but also includes a recognition failure in which the recognition unit 11 cannot recognize the dummy workpiece d. .
In S113, the conveyance of the workpiece W is abnormally stopped, and the machining process in the machining apparatus 2 is stopped.

In the present embodiment, when the dummy workpiece d is not recognized due to a missing dummy workpiece d or the like and the workpiece W is conveyed even though the count value has reached the planned production number, the conveyance of the workpiece W is stopped abnormally. Then, the processing in the processing apparatus 2 is stopped. That is. In this embodiment, when there is a missing abnormality of the dummy workpiece d, the processing by the processing apparatus 2 is stopped before a defective product is made. Thereby, even if there is a missing abnormality of the dummy workpiece d, it is possible to prevent the occurrence of defective products due to the workpiece W being processed under the processing conditions of different product numbers.
If it is confirmed after the abnormal stop that the dummy workpiece d is simply missing or poorly recognized, for example, the processing from S104 is executed, and the processing condition in the processing apparatus 2 is changed to the processing condition of the next product number. Since it can be restarted quickly, the return time can be minimized.

  As described in detail above, the production management device 1 manages the processing device 2 that performs different processing for each product number on the workpiece W conveyed to the production line 30. Processing is executed. That is, the information regarding the product number of the workpiece W conveyed to the processing apparatus 2 and the scheduled number of production of the product number is acquired (S105 in FIG. 2). Further, it is determined whether the object to be fed into the processing apparatus 2 is a workpiece W or a dummy workpiece d for indicating that the product number of the workpiece W changes (S101, S108), and is conveyed to the processing apparatus 2. The production number which is the number of workpieces W to be counted is counted (S111). If it is determined that the production number in the product number is equal to or greater than the planned production number and the conveyed product is the workpiece W (S101: NO, S108: YES, S110: NO), the dummy workpiece d is missing. (S112).

  In the present embodiment, when the quantity conveyed to the processing apparatus 2 is managed and the number of productions reaches the planned production quantity, the conveyance object to be subsequently conveyed is not the dummy workpiece d but the workpiece W. Then, it is determined that the dummy workpiece d is missing. Thereby, it is possible to appropriately determine whether the dummy workpiece d is missing.

  Moreover, in this embodiment, when it determines with it being a missing defect of the dummy workpiece | work d (S112), the conveyance of the workpiece | work W is stopped and the processing process in the processing apparatus 2 is stopped (S113). Thereby, it is possible to prevent the occurrence of defective products by continuing the processing under the processing conditions of the previous product number for subsequent workpieces W having different product numbers.

Further, if the production number in the product number is less than the planned production number and is determined to be a dummy workpiece (S101: YES, S102: NO), it is determined that the workpiece W is missing (S103). Thereby, it is possible to appropriately determine whether the workpiece W is missing.
Furthermore, in this embodiment, when it is determined that the workpiece is missing (S103), the workpiece W is continuously conveyed and the machining process in the machining apparatus 2 is continued. Even when there is an abnormality in the missing workpiece W, the processing apparatus 2 is not stopped, so that the working time is not extended.

  In this embodiment, the control unit 10 constitutes “information acquisition unit”, “discrimination unit”, “counting unit”, “abnormality determination unit”, “abnormality stop unit”, and “work piece missing determination unit”. . Further, S104 in FIG. 2 corresponds to processing as a function of “information acquisition means”, S101 and S108 correspond to processing as a function of “discrimination means”, and S111 corresponds to processing as a function of “counting means”. S112 corresponds to processing as a function of “abnormality determination means”, S113 corresponds to processing as a function of “abnormality stop means”, and S103 corresponds to processing as a function of “workpiece loss determination means”. Equivalent to.

(Other embodiments)
The production management apparatus of the above embodiment is a sequencer. However, in the other embodiments, any apparatus may be used as long as the apparatus can execute each process of the above embodiment. Moreover, it is good also as a program for performing each process with software, and you may comprise so that a part of process may be performed with hardware.

  Moreover, in the said embodiment, although the production management apparatus and the processing apparatus were comprised by the separate apparatus, in other embodiment, you may be comprised by one apparatus. In another embodiment, the recognition unit may be configured by an apparatus separate from the production management apparatus.

In the above-described embodiment, the pre-process management apparatus is an apparatus that manages the previous processing of the production management apparatus. However, in other embodiments, the pre-process management apparatus is an apparatus that controls the entire production line, for example. Etc. Anything may be used. Moreover, as long as the production management apparatus can acquire information on the product number and the planned production quantity of the product number, any configuration may be used. For example, the pre-process management device may be omitted, and the information regarding the product number and the planned production number of the product number may be directly input to the production management device.
As mentioned above, this invention is not limited to the said embodiment at all, In the range which does not deviate from the meaning of invention, it can implement with a various form.

DESCRIPTION OF SYMBOLS 1 ... Production management apparatus 2 ... Processing apparatus 10 ... Control part (Information acquisition means, discrimination | determination means, count means, abnormality determination means, abnormal stop means, workpiece missing determination means)
DESCRIPTION OF SYMBOLS 11 ... Recognition part 20 ... Pre-process management apparatus 21 ... Fluid part number history table 30 ... Production line W ... Work d ... Dummy work

Claims (6)

A production management device (1) for managing a processing device (2) that performs different processing for each product number on a workpiece (W) conveyed to a production line (30),
Information acquisition means (S105) for acquiring information related to the product number of the workpiece conveyed to the processing apparatus and the planned production number of the product number;
Discrimination means (S101, S108) for discriminating whether the conveyed product conveyed to the processing apparatus is the workpiece or a dummy workpiece (d) for indicating that the product number of the workpiece changes;
Counting means (S111) for counting the number of productions that is the number of the workpieces conveyed to the processing apparatus;
When the production number in the product number is equal to or greater than the planned production number, and the discrimination means determines that the conveyed product is the workpiece, an abnormality determination unit (S112) that determines that the dummy workpiece is missing. )When,
A production management device comprising:   When it is determined by the abnormality determining means that the dummy workpiece is missing, an abnormality stopping means (S113) is further provided for stopping the workpiece conveyance and stopping the machining process in the machining apparatus. The production management device according to claim 1.   Work missing determination means for determining that the workpiece is missing when the production number in the product number is less than the planned production number and the conveyed product is the dummy work by the determination means ( The production management apparatus according to claim 1, further comprising S103).   The production management according to claim 3, wherein when the workpiece missing determination unit determines that the workpiece missing is abnormal, conveyance of the workpiece is continued and machining processing in the machining apparatus is continued. apparatus. A production management method for managing a processing device (2) for performing different processing for each product number on a workpiece (W) conveyed to a production line (30),
An information acquisition step (S105) for acquiring information related to the product number of the workpiece conveyed to the processing apparatus and the planned production number of the product number;
A discriminating step (S101, S108) for discriminating whether the conveyed product conveyed to the processing apparatus is the workpiece or a dummy workpiece (d) for indicating that the product number of the workpiece changes;
A counting step (S111) for counting the number of productions that is the number of the workpieces conveyed to the processing apparatus;
When the production number in the product number is equal to or greater than the planned production number, and the determination step determines that the conveyed product is the workpiece, an abnormality determination step (S112) for determining that the dummy workpiece is missing. )When,
A production management method comprising: A production management program for managing a processing device (2) for performing different processing for each product number on a workpiece (W) conveyed to a production line (30),
Information acquisition means (S105) for acquiring information relating to the product number of the workpiece conveyed to the processing apparatus and the planned production number of the product number;
A discriminating means (S101, S108) for discriminating whether the conveyed product conveyed to the processing apparatus is the workpiece or a dummy workpiece (d) for indicating that the product number of the workpiece changes;
Counting means (S111) for counting the number of productions that are the number of the workpieces conveyed to the processing apparatus;
And an abnormality determination unit that determines that the dummy workpiece is missing when the number of productions in the product number is equal to or greater than the planned number of productions and the determination unit determines that the conveyed product is the workpiece. (S112),
Production management program characterized by causing a computer to function as

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