JP2018185653A - Production management device, production management system, and production management method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To easily determine whether the cause of a deterioration in an operation rate in production management results from an increase in a cycle time or a stopping of a manufacturing line.SOLUTION: A production management device 10 for managing a production state of a manufacturing line is provided. The production management device 10 includes: a detection signal acquisition part 11 for acquiring a detection signal that is outputted each time a product is supplied from the manufacturing line; an actual cycle time determination part 11, P1 for calculating a statistical value of cycle times by using the acquired detection signal, and determining an actual cycle time being a practical cycle time by using the calculated statistical value; and a production management information generation part 11, P2 for generating production management information by using the actual cycle time.SELECTED DRAWING: Figure 2

Description

  The present disclosure relates to a production management apparatus, a production management system, and a production management method for managing production status in a production line.

  When managing production lines, production management technology is known that uses a movable rate, which is a ratio of the number of actual productions to the number of production plans, as an index that indicates the degree to which the machine equipment can be moved normally when it is desired to move it (for example, Patent Document 1). By using the movable rate, it is possible to verify the problem of the production line and the degree of maintenance.

JP-A-10-29140

  However, in the conventional production management technology, when the availability is low, it is impossible to determine whether the total stop time of the production line is a cause or an increase in cycle time is a cause. As a result, in order to investigate and solve the cause when the movable rate is low, detailed production management information other than the movable rate has to be examined.

  The present disclosure has been made to solve the above-described problem, and an object of the present disclosure is to easily determine whether the cause of the decrease in the operation rate in production management is an increase in cycle time or a stop of the production line. And

  In order to solve the above problems, the present disclosure adopts the following various aspects.

  A 1st aspect provides the production management apparatus for managing the production condition of a manufacturing line. The production management apparatus according to the first aspect obtains a statistical value of a cycle time using a detection signal acquisition unit that acquires a detection signal that is output every time a product is delivered from the production line, and the acquired detection signal. An actual cycle time determination unit that determines an actual cycle time that is an actual cycle time using the calculated statistical value, and a production management information generation unit that generates production management information using the actual cycle time. .

  According to the production management device according to the first aspect, the statistical value of the cycle time is obtained using the detection signal output every time the product is fed out from the production line, and the actual cycle time is obtained using the obtained statistical value. Since a certain actual cycle time is determined and production management information is generated using the actual cycle time, it is easy to determine whether the cause of the decrease in availability in production management is an increase in cycle time or a production line stoppage. Can be determined.

  In the production management device according to the first aspect, the actual cycle time determination unit obtains the mode value of the cycle time as the statistical value, and determines the cycle time corresponding to the mode value as the actual cycle time. good. In this case, the actual cycle time can be determined without being affected by disturbance such as a stop of the production line or while reducing the influence.

  In the production management device according to the first aspect, the actual cycle time determination unit uses, as the statistical value, an average value of total values of cycle times of a predetermined ratio from the shortest cycle time as the actual cycle time. You may decide. In this case, the actual cycle time can be determined without being affected by disturbance such as a stop of the production line or while reducing the influence.

  In the production management device according to the first aspect, the production management information generating unit uses, as the production management information, a target production quantity calculated using the actual cycle time and an actual production quantity actually produced. Information on the mobility calculated in this way may be generated. In this case, the mobility based on the actual cycle time can be known.

  In the production management apparatus according to the first aspect, the production management information generation unit may generate display information for displaying the actual cycle time and a preset cycle time as the production management information. In this case, the actual cycle time is compared with the set cycle time, and it is possible to easily determine whether the cause of the decrease in the movable rate is the increase in the cycle time or the stop of the production line.

  The production management apparatus according to the first aspect may further include a display unit for displaying the production management information. In this case, the production management information can be confirmed in the production management apparatus.

  The production management device according to the first aspect further includes a detection unit that outputs the detection signal every time a product is fed out from the production line, and the detection signal acquisition unit acquires the detection signal from the detection unit. May be. In this case, the detection signal can be acquired by the production management device.

  The second aspect provides a production management system for managing the production status of the production line. A production management system according to a second aspect includes the production management apparatus according to the first aspect, and a terminal device that receives and displays the production management information output from the production management apparatus. In this case, in the terminal device, it is possible to easily determine whether the cause of the decrease in the operation rate in production management is an increase in cycle time or a stop of the production line.

  A 3rd aspect provides the production management method for managing the production condition of a manufacturing line. The production management method according to the third aspect obtains a detection signal output each time a product is fed out from the production line, obtains a statistical value of cycle time using the obtained detection signal, and obtains the obtained statistics. Determining an actual cycle time which is an actual cycle time using the value, and generating production management information using the actual cycle time.

  According to the production management method according to the third aspect, the same advantages as those of the production management apparatus according to the first aspect can be obtained. In addition to this, the production management method according to the third aspect can be realized as a production management program and also as a computer-readable medium on which the production management program is recorded.

The schematic block diagram which shows a production management system provided with the production management apparatus which concerns on 1st Embodiment, and a manufacturing line. The block diagram which shows the internal function structure of the production management apparatus which concerns on 1st Embodiment. The block diagram which shows the example of arrangement | positioning of the operation state acquisition apparatus in 1st Embodiment. The flowchart which shows the production management process routine performed by the production management apparatus which concerns on 1st Embodiment. Explanatory drawing which shows an example of continuous distribution of the recorded cycle time. Explanatory drawing which shows the movable rate corresponding to setting cycle time, and the movable rate corresponding to real cycle time. Explanatory drawing which shows an example of the display screen of the production management information displayed on a display apparatus. Explanatory drawing which shows the exemplary waveform of the received detection signal used in a 1st modification.

First embodiment:
Hereinafter, a production management system and a production management method according to the present disclosure will be described based on embodiments with reference to the drawings. FIG. 1 is a schematic configuration diagram illustrating a production management system and a production line including a production management apparatus according to the first embodiment. The production management system and the production line shown in FIG. 1 are commonly used in other embodiments.

  The production management system 100 includes a production management device 10 and operating state acquisition devices 20a to 20c. The production management device 10 manages the production status of the first production line L1 and the second production line L2 in cooperation with the operation state acquisition devices 20a to 20c. Note that the number of production lines L may be one, or three or more.

  Each production line L1 and L2 is provided with a transport mechanism 30 for transporting workpieces, that is, processed parts and workpieces, for example, a belt conveyor, and a transporter that moves on a track. Various production facilities 31 to 33 are arranged in the transport mechanism 30. Each of the production facilities 31 to 33 is, for example, a metal processing machine, a welding machine, a resin molding machine, a coating machine, a hot forging machine, a finished product collection machine, and a machined part supply machine. Each of the production facilities 31 to 33 includes a production process for a product to be processed in the production facility, a programmable logic controller (PLC) for executing the processing, and various sensors connected to the PLC. For example, it is incorporated in a photoelectric sensor for detecting the arrival or passage of a machined part incorporated in a production facility or a transport mechanism, a dimension sensor for measuring the dimension of a machined part, or a cutting metal processing machine for cutting a machined part. Built into a counter that counts the number of times a cutting tool is used to process a machined part, an area sensor that counts the number of discharged finished products built into the finished product collection machine, or a hand mechanism that transports finished products. A counter that counts the number of opening and closing operations and a cycle measuring instrument that measures the opening operation interval are provided. Each of these sensors is a sensor that is conventionally arranged and connected to the PLC when the production line and the production equipment are installed and arranged in order to operate the production line and the production equipment.

  In the example of FIG. 1, a first production facility 31 is arranged on the first production line L1. A second production facility 32 and a third production facility 33 are arranged in the second production line L2.

  In the vicinity of the production facility or the production facility, retrofitted first to third operation state acquisition devices 20a to 20c are mounted or arranged. In this specification, the retrofit is a device that is incorporated from the time of installation of the production facility in order to operate the production facility, or is not mounted in advance, and that controls the operation of each of the production facilities 31 to 33. It means that it is not connected to a certain PLC and is mounted and arranged regardless of the operation and control of the production facility. In the example of FIG. 1, the first, second, and third operation state acquisition devices 20a, 20b, and 20c are respectively attached to the first, second, and third production facilities 31, 32, and 33. .

  The production management apparatus 10 and the first to third operation state acquisition apparatuses 20a to 20c that are attached later can wirelessly transmit and receive data to each other as shown in FIG. The production management device 10 wirelessly transmits the generated production status information in response to requests from the terminal devices PD1 and PD2.

  FIG. 2 is a block diagram showing an internal functional configuration of the production management apparatus according to the first embodiment. The production management device 10 is a device that controls the operations of the production facilities 31 to 33, that is, a device different from the PLC. Even if the production management device 10 is not used, the production facilities 31 to 33 are controlled by the PLC. Is done. The production management device 10 includes a central processing unit (CPU) 11, a storage device 12, a transmission / reception unit 13, a display device 14, and an input device 15 that are connected to each other via a bus 16 so as to communicate with each other. Yes. The CPU 11, the storage device 12, and the transmission / reception unit 13 can communicate with each other bidirectionally. The storage device 12 is, for example, a RAM, a ROM, a hard disk drive (HDD), or a solid state drive (SSD). The HDD (or SSD, ROM) obtains a statistical value of the cycle time of the detection signal, and determines an actual cycle time that is an actual cycle time from the statistical value, and an actual cycle time determination program P1 and an actual cycle time A production management information generation program P2 for generating various types of production management information using is stored. These programs are read from the HDD, expanded on the RAM, and executed by the CPU 11. The CPU 11 that executes the actual cycle time determination program P1 functions as a detection signal acquisition unit and an actual cycle time determination unit, and the CPU 11 that executes the production management information generation program P2 functions as a production management information generation unit.

  The transmission / reception unit 13 is provided in each production facility on the production lines L1 to L2 via wireless communication, or is disposed in the vicinity of each production facility in the first to third operating states. Detection signals related to the operating state are received from the acquisition devices 20a to 20c. The detection signal received by the transmission / reception unit 13 is acquired by the CPU 11 functioning as a detection signal acquisition unit. The transmission / reception unit 13 transmits various execution instructions to the first to third operating state acquisition devices 20a to 20c. The transmission / reception unit 13 further transmits the production status information as an output to the terminal devices PD1 and PD2 which are external devices, or receives input requesting execution of various processes from the terminal devices PD1 and PD2. When the transmission / reception unit 13 is an input / output I / F having a wireless communication function, the transmission / reception unit 13 is connected to the first via a wireless repeater (access point) (not shown) installed in the factory. The radio wave from the third operating state acquisition devices 20a to 20c may be received, or the transmission / reception unit 13 itself can receive the radio wave from the first to third operating state acquisition devices 20a to 20c. It may be arranged in any place. In addition, the transmission / reception unit 13 may be wired to the wireless repeater. In any case, it is only necessary to acquire information related to the operating state without making a wired connection to each of the operating state acquisition devices 20a to 20c. By doing in this way, the production management system 100 according to the present embodiment can be achieved with only a relatively simple change of mounting or arranging the first to third operating state acquisition devices 20a to 20c for each production facility. Can be installed in existing factories. The wireless communication can be realized by, for example, a wireless connection through a wireless local network (LAN) compliant with the IEEE 802.11 standard.

  The display device 14 is used to display processing contents when operating the production management system 100, or is a display unit for displaying production management information, that is, a display. The display device 14 may be provided separately from the production management device 10. The input device 15 is a device used for inputting to the production management system 100, and is, for example, a keyboard or a mouse, and further a pressure-sensitive touch panel provided on the screen of the display device 14. Also good.

  FIG. 3 is a block diagram illustrating an arrangement example of the operating state acquisition apparatus according to the first embodiment. In addition, in FIG. 3, although the 1st operation state acquisition apparatus 20a is demonstrated exemplarily, the other 2nd, 3rd operation state acquisition apparatuses 20b and 20c also have the same structure. The first operating state acquisition device 20a is in the vicinity of the first production facility 31, more specifically, the end of the transport mechanism 30 where the first production facility 31 is arranged, that is, the finished product of the line. It is arranged at a position where WP is discharged. The processed product WP may be a finally completed product or an intermediate product. The first operating state acquisition device 20a includes a detection unit 21a as a first detection unit that is connected by a signal line and is provided separately from a main body in which a controller 21b including a transmission / reception unit is stored. The detection unit 21a is disposed at the upper end of the support unit that supports the transport mechanism 30, and the main body is disposed on an intermediate side surface of the support unit. For example, a photoelectric optical sensor can be used as the detection unit 21a. According to the photoelectric optical sensor, the passage of the processed product WP conveyed by the conveyance mechanism 30 can be detected by blocking light. The detection signal output at the time of interruption is a 1 or 0 pulse signal. The photoelectric sensor includes a light source that outputs light such as visible light, infrared light, and ultraviolet light, and a light receiving unit that receives light from the light source. By disposing the first operating state acquisition device 20a in the vicinity of the first production facility 31, it is possible to detect the presence or absence of conveyance (discharge) of the processed product WP as the operational state of the first production facility 31. . Specifically, by arranging the first operating state acquisition device 20a that is retrofitted, a detection signal as information indicating an operating cycle that is one of the operating states of the first production facility 31 is acquired, and production management is performed. The device 10 can be provided.

  The detection unit 21a is a variety of sensors that are attached to the first production facility 31 or arranged in the vicinity of the first production facility 31 as a retrofit, and performs processing and processing on a processed part by the production facility. Unlike existing sensors connected to a programmable logic controller (PLC). The detection unit 21a may be provided integrally with the first operating state acquisition device 20a. The detection unit 21a is a detection unit that can count the processing, the operation related to the processing, the operation start, the execution or completion timing, and the number of times of the processing target product in the production facility. The detection unit 21a may be a detection unit that includes only a detection element and outputs an analog signal. Alternatively, in addition to the detection element, a signal output from the detection element may be converted into a digital signal. A detection unit including a circuit for outputting may be used. The controller 21b includes a central processing unit (CPU) and a storage device (not shown). The controller 21b transmits the detection signal received from the detection unit 21a via the transmission / reception unit wirelessly to the production management apparatus 10 according to an arbitrary communication protocol, or from the production management apparatus 10 Receive execution instructions. When the signal input from the detection unit 21a is an analog signal, the controller 21b is high (1) in the active high logic when the signal value is equal to or greater than a predetermined value, less than a specified value, or in an arbitrary range. In the active low logic, the detection signal is transmitted to the production management apparatus 10 through the transmission / reception unit after being converted into a digital signal taking Low (1). Therefore, in the present embodiment, only the detection unit 21a can function as the detection unit, and the detection unit can be realized by the detection unit 21a and the controller 21b. The controller 21b may store the detection signal received from the detection unit 21a in a storage device and transmit the detection signal to the production management device 10 in accordance with the execution command received from the production management device 10.

  As a sensor used as the detection unit 21a, other optical sensors, sound sensors, thermal sensors, current sensors, distance sensors, atmospheric pressure sensors, acceleration sensors, rotational speed sensors, humidity sensors, and pressure sensors are used in addition to photoelectric sensors. Can be. Each sensor is a sensor for detecting the operating state of the production facility, and how it is used will be described below. In the present embodiment, the operating state means operations and operations related to processing and processing on the processing target product in the production line and the production facility. For example, the operation, operation start, execution, stop, completion Such a state may be included. Hereinafter, the third production facility 33 will be described as an example of the production facility.

  The optical sensor including the illuminance sensor is used to detect the number of times that the indicator lamp is turned on or off when the third production facility 33 is provided with an indicator lamp that is repeatedly turned on and off every processing cycle. Used for. The machining cycle of the third production facility 33 can be acquired as an operating state by a detection signal corresponding to the number of times the indicator lamp is turned on or off. In addition, when a color sensor is used as the light sensor, the lighting color of the indicator lamp having a plurality of colors can be determined, so that the operation cycle of the production facility corresponding to the lighting color can be acquired. The sound sensor is used for detecting operation sound such as motor sound, air discharge sound and door opening / closing sound in the third production facility 33, and sound accompanying processing such as cutting sound and hammering sound. When the sound volume detected by the sound sensor exceeds the specified sound volume, the detection signal is output from the operating state acquisition device 20c, whereby the operation or processing cycle can be acquired as the operating state.

  The thermal sensor is used to detect discharge of a high-temperature processed part from the third production facility 33. Specifically, an infrared sensor capable of detecting the temperature of a processed part, or a thermostat capable of detecting that the temperature of the processed part is equal to or higher than a specified temperature, lower than a specified temperature, or in an arbitrary temperature range may be used. When an infrared sensor is used, a detection signal is output when the detection temperature is equal to or higher than a specified temperature, and when a thermostat is used, an operation signal is used as the detection signal, so that the third production is performed. The machining cycle of the facility 33 can be acquired as an operating state.

  A current sensor including a current checker operates an actuator provided in the third production facility 33, or an operation of a processing machine that requires electric power for processing such as a welding machine, that is, processing in the third production facility 33. Used to detect actions related to the discharge of completed parts. Specifically, a detection signal indicating that the current value during operation of the actuator and the processing machine is greater than or equal to the specified current value, less than the specified current value, or in an arbitrary current value range is produced from the third operating state acquisition device 20c. It is transmitted to the management apparatus 10 and the processing cycle of the third production facility 33 can be acquired as the operating state. In addition to this, by using a sensor capable of measuring and detecting a high voltage such as a lightning sensor, a high voltage (high energy) instantaneously generated in an arc welding machine or an induction hardening machine is detected. The processing cycle of the third production facility 33 can be acquired as an operating state.

  The distance sensor detects the distance from a target such as a jig, a cutting tool, a robot hand, or a machined part provided in the third production facility 33, or through a processing operation or a machining operation of the third production facility 33, or It is used to detect the discharge of the processed part by the movement of the processed part itself. Specifically, a detection signal indicating that the distance to the object is greater than or equal to the specified distance, less than the specified distance, or in an arbitrary distance range is transmitted from the third operating state acquisition device 20c to the production management device 10. The machining cycle of the third production facility 33 can be acquired as the operating state. As the distance sensor, for example, a sensor that emits infrared light, laser light, ultrasonic waves, sound waves, etc., and measures the distance to the object based on the time until the reflected wave reflected by the object returns. Is used.

  The atmospheric pressure sensor and the water level sensor are respectively used in the cutting, cleaning, quenching, and tempering processes using the liquid such as water and oil, and the cutting and cleaning processes. Is used to detect the discharge of the processed parts through the processing operation of the third production facility 33 by detecting the change in the level of the liquid used in the process. Specifically, a detection signal indicating that the pressure or water level (liquid level) is greater than or equal to a specified value, less than the specified value, or in an arbitrary range is transmitted from the third operating state acquisition device 20c to the production management device 10. Thus, the machining cycle of the third production facility 33 can be acquired as an operating state.

  The acceleration sensor, the proximity switch, and the Doppler sensor are disposed at the front ends of the doors and cylinders provided in the third production facility 33, and are used to detect discharge of the processed parts through opening / closing of the doors and reciprocation of the cylinders.

  The rotation speed sensor detects the rotation speed of a jig, a cutting tool, a rotary table, a processed part, etc. provided in the third production facility 33, or through the processing operation of the third production facility 33, or the processed component itself. Is used to detect the discharge of the processed part. Specifically, a detection signal indicating that the detected rotational speed is greater than or equal to a specified value, less than the specified value, or in an arbitrary range is transmitted from the third operating state acquisition device 20c to the production management device 10, The machining cycle of the third production facility 33 can be acquired as an operating state.

  The pressure sensor and the pressure sensor are arranged on the door, operation panel, or part where pressure is applied such as pressing or pinching provided in the third production facility 33, and the door opening / closing, operation panel operation, pressing or pinching is performed. Used to detect the discharge of the workpiece through detection.

  The gyro sensor detects the tilt and speed of the jig, cutting tool, robot hand, processed part, etc. provided in the third production facility 33, through the processing operation of the third production facility 33, or the processed component itself. Is used to detect the discharge of the processed part. Specifically, a detection signal indicating that the detected inclination or speed is equal to or greater than a specified value, less than the specified value, or in an arbitrary range is transmitted from the third operating state acquisition device 20c to the production management device 10. The machining cycle of the third production facility 33 can be acquired as the operating state. The tilt sensor detects the tilt of the jig, the cutting tool, the robot hand, the machining part, etc. included in the third production facility 33 and the tilt of the processing apparatus table or the seesaw type conveyance unit, thereby providing Used to detect the discharge of the processed part through the processing operation. Specifically, a detection signal indicating that the detected inclination is equal to or greater than a specified value, less than a specified value, or in an arbitrary range is transmitted from the third operating state acquisition device 20c to the production management device 10, and The processing cycle of the third production facility 33 can be acquired as an operating state.

  In addition to this, it is possible to detect discharge of a processed part by detecting a human operation using a human sensor or a capacitive sensor, or to use a humidity sensor to perform cutting using a liquid such as water or oil, By detecting a change in humidity caused by the liquid used in the cleaning, quenching, and tempering steps, it is possible to detect the discharge of the processed part.

  The operation of the production management apparatus 10 will be described. FIG. 4 is a flowchart showing a production management processing routine executed by the production management apparatus according to the first embodiment. This processing routine is executed by the CPU 11 executing the actual cycle time determination program P1 and the production management information generation program P2, and the CPU 11 starts up after the production management device 10 is started until the production management device 10 is terminated. Meanwhile, the actual cycle time determination program P1 and the production management information generation program P2 are repeatedly executed.

  The production management device 10, that is, the CPU 11 acquires the detection signal from the detection unit 21a received by the transmission / reception unit 13 (step S100). The CPU 11 sequentially records the reception time of the detection signal in the storage device 12. The detection unit 21a may output a detection signal obtained by converting an analog signal such as a current output from the detection element into a digital signal by a circuit provided therein, or an analog signal such as a current output from the detection element. It may be output as a detection signal.

  The CPU 11 calculates the mode value of the cycle time (CT) using the detection signal received so far and the detection signal received this time (step S110). Specifically, the CPU 11 performs a statistical process using the cycle time calculated using the reception time of the detection signal recorded in the storage device 12, obtains the mode value of the cycle time, and calculates the actual cycle time. To decide. As is well known to those skilled in the art, the cycle time means the detection interval of the detection signal, for example, the rising or falling interval of each pulse signal, and corresponds to the manufacturing interval of each workpiece. The number of detection signals, that is, the number of pulse signals corresponds to the number of manufactured products.

  The mode value in the first embodiment is (1) a random variable that maximizes the density function when the recorded cycle time is regarded as a continuous distribution, and (2) when the recorded cycle time is regarded as a discrete distribution. A random variable that maximizes the random variable is obtained, and the obtained random variable, that is, the cycle time is calculated as the mode time. The CPU 11 determines the actual cycle time by obtaining the mode cycle time. Since the statistical processing in (1) and (2) is a well-known technique, description thereof is omitted.

  FIG. 5 is an explanatory diagram showing an example of a continuous distribution of recorded cycle times. In FIG. 5, the horizontal axis indicates the cycle time CT, and the vertical axis indicates the probability density. By applying statistical processing to the recorded cycle time, the elements shown in the example of FIG. 5 such as the cycle time D1 at the time of changeover and the cycle time D2 at the time of repair are not connected to the actual processing of the workpiece. The actual cycle time RCT can be determined without being affected by the resulting cycle time. The CPU 11 may determine, instead of the mode value, the average value of the total cycle times extracted at a predetermined ratio such as the top 5% and 10% from the shortest recorded cycle time value as the actual cycle time. good. The extraction ratio can be arbitrarily set according to the purpose.

  The CPU 11 executes the production management information generation program P2 to generate production management information (step S120). Specifically, the production plan number, that is, the target production number is calculated using the actual cycle time, and the actual operation rate is calculated in comparison with the production actual number, that is, the actual production number. FIG. 6 is an explanatory diagram showing the mobility corresponding to the set cycle time and the mobility corresponding to the actual cycle time. The set cycle time is a theoretical or preset cycle time to be realized for the production lines L1 and L2, and individual operation errors and operation deviations of the production facilities 31 to 33 are taken into consideration. Not. In FIG. 6, the horizontal axis represents the cycle time CT, the vertical axis represents the movable rate, and the broken line DL1 represents a characteristic line with the same number of workpieces S manufactured within the predetermined period T. In FIG. 6, the set cycle time is set to CT = 36 sec, and the production plan number X within the predetermined period T calculated using the set cycle time is X = T / 36, which is relative to the production plan number X. The movable rate (A / X), which is the ratio of the production record number A, is 80%. On the other hand, when the actual cycle time is CT42 sec, the production plan number Y within the predetermined period T calculated using the actual cycle time is Y = T / 42, and the production results with respect to the production plan number X The mobility (A / Y), which is the ratio of the number A, is 93.3%.

  Further, the CPU 11 creates display screen data as display information for displaying the production management information shown in FIG. 7 (step S130), displays it on the display device 14, and ends the present processing routine. This processing routine is repeatedly executed until the operation of the production management apparatus 10 is completed or until the production lines L1 and L2 are stopped. Therefore, after the start of execution of this processing routine, the number of detection signal samples increases as time elapses, and the reliability of the statistical value is improved. FIG. 7 is an explanatory diagram illustrating an example of a display screen of production management information displayed on the display device. In the example of FIG. 7, the set cycle time, the movable rate corresponding to the set cycle time, the actual cycle time, and the movable rate corresponding to the actual cycle time are displayed, but only one of them may be displayed. Based on this production management information, it can be understood that the production lines L1 and L2 are not operating at the set cycle time, and are operating at an actual cycle time of 42 seconds that is 6 seconds later than the set cycle time of 36 seconds. In addition, with the actual values of the current production lines L1 and L2, the movable rate has reached about 93%, and it can be considered that there is little room for improvement as long as the actual cycle time is maintained. Therefore, the reason why the set operation rate is low is that the cycle time is later than the set cycle time, and it can be understood that the production lines L1 and L2 are not stopped or repaired. That is, it can be determined that there is a reason for delay in the operations of the production facilities 31 to 33, or that the current performance of the production facilities 31 to 33 is not compatible with the set cycle time. The actual cycle time is determined using the statistical mode value as described above, and indicates the actual state of the production lines L1 and L2 excluding the disturbance. On the other hand, when the actual cycle time calculated by the statistical process is equal to the set cycle time, there is a problem in the maintenance of the production lines L1, L2 and the production facilities 31 to 33 such as the stop and repair of the production lines L1, L2. It can be identified.

  According to the production management apparatus 10 according to the first embodiment described above, the statistical value of the cycle time is obtained using the detection signal that is output every time the product is fed out from the production line, and the statistical value is used for the realization. The cycle time can be determined. Therefore, when the actual cycle time is later than the set cycle time, it can be understood that the low mobility is not caused by the stop or repair of the production lines L1 and L2. On the other hand, when the actual cycle time is equal to the set cycle time, it is specified that there is a problem in the maintenance of the production lines L1, L2 and the production facilities 31-33 such as the stop and repair of the production lines L1, L2. Can do. As a result, when the production line production management is performed using only the movable ratio as an index, the cause of the low movable ratio or the decreased movable ratio, which could not be easily determined, is the delay of the actual cycle time. Or other factors, for example, whether the stop time is prolonged can be easily determined.

  According to the production management device 10 according to the first embodiment, the actual cycle time is determined through statistical processing. Therefore, the actual cycle time can be determined without being affected by the stop of the production lines L1 and L2 and other disturbances or by reducing the influence of the disturbances.

  According to the production management apparatus 10 according to the first embodiment, the availability using the actual cycle time is displayed as the production management information, so that the administrator can know the availability based on the actual cycle time.

・ Modification:
(1) In the first embodiment, statistical processing is executed using all received detection signals, and the actual cycle time is calculated. On the other hand, the detection interval of the detection signal may be monitored, and the actual cycle time may be calculated by excluding the detection interval of the detection signal exceeding the predetermined determination interval Tir. FIG. 8 is an explanatory diagram showing an exemplary waveform of a received detection signal used in the first modification. The predetermined determination interval Tir corresponds to a time interval corresponding to the delay or stop of the production lines L1 and L2. In FIG. 8, the detection intervals Ti1, Ti2, and Ti4 do not exceed the determination interval Tir, and the detection interval Ti3 exceeds the determination interval Tir. Therefore, by calculating the average value of the cycle times using the detection intervals Ti1, Ti2, and Ti4 excluding the detection interval Ti3, the actual cycle time can be calculated without being affected by delay or stop.

(2) In the first embodiment, the mobility using the actual cycle time is displayed on the display device 14 as the production management information. In addition to this, or instead, when the actual cycle time is shorter than the set cycle time, for example, it is determined that any of the processing steps are not performed and the visual inspection is performed without following the procedure, Warnings such as skipping process skipping and table of contents inspection skipping may be displayed on the display device 14 as production management information. The case where it is shorter than the set cycle time corresponds to, for example, an actual cycle time shorter than 80% of the set cycle time.

(3) In the first embodiment, three production facilities are arranged in each of the production lines L1 and L2, but may be one or two, and four or more are provided. Also good. Also, the number of production lines may be 1 and 2 lines, or 3 lines or more.

(4) In the first embodiment, the production management apparatus 10 and each of the operation state acquisition apparatuses 20a to 20c communicate with each other by wireless communication, but may be performed by wired communication. For example, when a wired local area network (LAN) connection port is prepared in the vicinity of each of the production facilities 31 to 33, the use of the connection port saves the trouble of new wiring, which is the same as wireless communication. Thus, the production management system 100 according to the first embodiment can be easily introduced.

(5) In the first embodiment, the detection signal is converted into a pulse signal, that is, converted into a digital signal in each of the operating state acquisition devices 20a to 20c, but may be executed in the production management device 10. That is, an analog signal may be transmitted from each of the operation state acquisition devices 20a to 20c to the production management device 10, and the above-described pulse signal generation may be performed in the production management device 10.

  As described above, the present disclosure has been described based on the embodiments and the modified examples. However, the above-described embodiments of the present invention are for facilitating understanding of the present disclosure, and do not limit the present disclosure. The present disclosure can be modified and improved without departing from the spirit and scope of the claims, and the present disclosure includes equivalents thereof. For example, the technical features in the embodiments and the modifications corresponding to the technical features in each embodiment described in the summary section of the invention are to solve some or all of the above-described problems, or In order to achieve part or all of the effects, replacement or combination can be performed as appropriate. Further, if the technical feature is not described as essential in the present specification, it can be deleted as appropriate.

  DESCRIPTION OF SYMBOLS 10 ... Production management apparatus, 11 ... CPU, 12 ... Memory | storage device, 13 ... Transmission / reception part, 14 ... Display apparatus, 15 ... Input device, 16 ... Bus, 20a ... 1st operation state acquisition apparatus, 20b ... 2nd Operating state acquisition device, 20c ... third operating state acquisition device, 21a ... detection unit, 21b ... controller, 30 ... transport mechanism, 31 ... first production facility, 32 ... second production facility, 33 ... third 100 ... Production management system, L1 ... First production line, L2 ... Second production line, PD1, PD2 ... Terminal device, WP ... Finished product, P1 ... Actual cycle time determination program, P2 ... Production Management information generation program

Claims (9)

A production management device for managing the production status of a production line,
A detection signal acquisition unit for acquiring a detection signal output each time a product is drawn out from the production line;
An actual cycle time determination unit that determines a statistical value of a cycle time using the acquired detection signal, and determines an actual cycle time that is an actual cycle time using the calculated statistical value;
A production management information generating unit that generates production management information using the actual cycle time;
A production management device. The production management device according to claim 1,
The actual cycle time determination unit is a production management device that obtains a mode value of a cycle time as the statistical value and determines a cycle time corresponding to the mode value as the actual cycle time. The production management device according to claim 1,
The actual cycle time determination unit is a production management device that determines an average value of total values of cycle times at a predetermined ratio from the shortest cycle time among the cycle times as the statistical value as the actual cycle time. In the production management device according to any one of claims 1 to 3,
The production management information generation unit generates, as the production management information, information on a movable rate calculated using a target production number calculated using the actual cycle time and an actual production number actually produced. Production management equipment. In the production management device according to any one of claims 1 to 4,
The production management information generation unit generates display information for displaying the actual cycle time and a preset cycle time as the production management information. The production management device according to any one of claims 1 to 5, further comprising:
A production management device comprising a display unit for displaying the production management information. The production management device according to any one of claims 1 to 6, further comprising:
A detection unit that outputs the detection signal every time a product is drawn out from the production line,
The said detection signal acquisition part is a production management apparatus which acquires the said detection signal from the said detection part. A production management system for managing the production status of a production line,
The production management device according to any one of claims 1 to 7,
A production management system comprising: a terminal device that receives and displays the production management information output from the production management device. A production management method for managing the production status of a production line,
Obtain a detection signal that is output every time a product is paid out from the production line,
Using the obtained detection signal to obtain a statistical value of the cycle time, using the obtained statistical value to determine an actual cycle time that is an actual cycle time,
Generating production management information using the actual cycle time.

Images