JP2019057191A - Production management system and production management program - Google Patents

Abstract

To provide a production management system capable of autonomously determining a cause of production suspension in the event that the production suspension takes place.SOLUTION: The production management system comprises a host computer 71 that, when an inspection line including an X-ray inspection apparatus 30, a metal detection apparatus 40, a weight inspection apparatus 50, and a classifier 60 is suspended, determines based on a frequency at which an article W flows, pieces of information detected by a lighting sensor 72 and a humidity sensor 73, and a production plan, whether suspension of the inspection line is scheduled suspension or unscheduled suspension.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a production management system that manages the production status and the like on a production line that produces, for example, meat, fish, processed foods, pharmaceuticals, and the like.

  For example, in production lines that produce meat, fish, processed foods, pharmaceuticals, etc., products manufactured on the production line are sent to the inspection line, where they are inspected for contamination and final weight, etc. Products that are judged as non-defective products are shipped as final products.

  Japanese Patent Application Laid-Open No. 2004-133826 stores in advance manufacturing information of articles to be inspected and unique information given to each article, and stores information including inspection results of a plurality of inspection apparatuses on the inspection line in association with the unique information. Describes a management system for managing inspection information.

Japanese Patent No. 4652583

  In such a production management system for managing a production line, when a production line is stopped, knowing whether it is a planned stoppage or a stoppage due to trouble, etc. is whether production is proceeding as planned. It is necessary to judge.

  However, if the cause of the production stop is input manually, there is a risk that input may be forgotten or an input error may occur.

  Accordingly, an object of the present invention is to provide a production management system capable of automatically determining the cause of production stop when a production stop occurs.

  The production management system of the present invention is a production management system for managing a production line including one or more devices. When the production line is stopped, the production line is stopped based on external information of the production line. A host computer for determining whether the system is a planned or unplanned outage.

  With this configuration, the cause of the stop of the production line is determined based on the external information of the production line. For this reason, the cause of the production stop can be automatically determined.

  The production management system of the present invention further comprises an article sensor for detecting an article flowing through the production line, and the host computer plans to stop the production line based on the frequency of the article detected by the article sensor. It is determined whether it is a stopped stop or an unplanned stop.

  With this configuration, the cause of the stop of the production line is determined based on the frequency of articles flowing through the production line. For this reason, the cause of the production stop can be automatically determined.

  The production management system of the present invention further includes an illumination sensor that detects illuminance in the vicinity of the production line, and the host computer is scheduled to stop the production line based on the illuminance detected by the illumination sensor. Or whether it is an unplanned outage.

  With this configuration, the cause of the stop of the production line is determined based on the illuminance detected by the illumination sensor. For this reason, the cause of the production stop can be automatically determined.

  The production management system of the present invention further includes a humidity sensor that detects humidity in the vicinity of the production line, and the host computer is configured to stop the production line based on the humidity detected by the humidity sensor. Or whether it is an unplanned outage.

  With this configuration, the cause of the stoppage of the production line is determined based on the humidity detected by the humidity sensor. For this reason, the cause of the production stop can be automatically determined.

  In the production management system of the present invention, the host computer determines whether the stop of the production line is planned or unplanned based on the production plan of the production line.

  With this configuration, the cause of the stop of the production line is determined based on the production plan of the production line. For this reason, the cause of the production stop can be automatically determined.

  The production management program of the present invention is a production management program for managing a production line including one or more devices. When the production line is stopped on a computer, the production management program is based on external information on the production line. A determination function for determining whether a production line stop is planned stop or unplanned stop is realized.

  With this configuration, the cause of the stop of the production line is determined based on the external information of the production line. For this reason, the cause of the production stop can be automatically determined.

  The present invention can provide a production management system that can automatically determine the cause of a production stop when a production stop occurs.

FIG. 1 is a schematic configuration diagram of a production management system according to an embodiment of the present invention. FIG. 2 is a time chart illustrating an example of determination of a stop cause by an illumination sensor of a production management system according to an embodiment of the present invention. FIG. 3 is a time chart showing an example of determining the cause of a stop by the humidity sensor of the production management system according to the embodiment of the present invention. FIG. 4 is a time chart illustrating an example of determination of a stop cause by a production plan of the production management system according to the embodiment of the present invention.

  Hereinafter, a production management system according to an embodiment of the present invention will be described in detail with reference to the drawings.

  In FIG. 1, the production management system according to an embodiment of the present invention performs inspection of foreign matter contamination and weight inspection of articles W such as food and drink carried out from the conveyor 1 of the production line, and determines the non-defective articles. W is carried out to the conveyor 2 in the subsequent shipping line, and the inspection line is managed so as to exclude articles determined to be defective from the line.

  The inspection line includes an X-ray inspection device 30, a metal detection device 40, a weight inspection device 50, and a sorter 60. The inspection line may be composed of any one of the X-ray inspection device 30, the metal detection device 40, the weight inspection device 50, and the sorter 60, or may be composed of any two or more. May be.

  The X-ray inspection apparatus 30 includes a conveyor 31, an article sensor 32, an X-ray detection unit 33, and a determination unit 34.

  The conveyor 31 receives the article W carried out from the conveyor 1 of the production line on one end side and conveys it to the other end side.

  The article sensor 32 is disposed immediately before the X-ray detection unit 33, detects the entry of the article W into the X-ray detection unit 33, and outputs the detection signal to the determination unit 34. The article sensor 32 is composed of, for example, a transmission type photoelectric sensor including a pair of light projectors and light receivers (not shown) arranged to face the conveyor 31 so as to straddle the width direction (front and back directions in FIG. 1).

  The X-ray detection unit 33 irradiates the article W detected by the article sensor 32 with a wide X-ray parallel to the surface orthogonal to the conveying direction of the conveyor 31, and the X-ray transmitted through the article W is X-rayed. A signal that is detected by the line sensor and represents the transmission amount at each position is output to the determination unit 34.

  Based on the signal output from the X-ray detection unit 33, the determination unit 34 creates image data representing the difference in the amount of X-ray transmission for each position of the article W as the article W is moved by the conveyor 31. Based on the data, the presence or absence of foreign matter or a defect is determined for the article W.

  The determination unit 34 outputs information including the determination result and image data detected by the X-ray detection unit 33 to the subsequent metal detection device 40 as inspection information.

  The metal detection device 40 is for inspecting whether or not a metal foreign object is mixed in the article W carried out from the X-ray inspection device 30, and includes a conveyor 41, an article sensor 42, a magnetic detection unit 43, and the like. The determination unit 44 is included.

  The conveyor 41 receives the article carried out from the conveyor 31 at one end side and conveys it to the other end side. The conveyor 41 can be shared with the conveyor 31 of the X-ray inspection apparatus 30.

  The article sensor 42 is disposed immediately before the magnetic detection unit 43, detects the article W entering the magnetic detection unit 43 immediately before, and outputs the detection signal to the determination unit 44. For example, the article sensor 42 includes a transmission photoelectric sensor that includes a pair of light projectors and light receivers (not shown) disposed so as to face the conveyor 41 across the width direction (front and back in FIG. 1).

  The magnetic detection unit 43 generates a magnetic field on the conveyor 41 and detects a change in the magnetic field due to the article W passing through the magnetic field. The metal detection device 40 may be configured to magnetize the metal contained in the article W with a magnetizer such as a magnet and detect the residual magnetism of the magnetized metal with a magnetic sensor.

  The determination unit 44 determines whether or not a metal foreign matter is mixed in the article W based on a signal output from the magnetic detection unit 43 with respect to the article W detected by the article sensor 42.

  The determination unit 44 combines the determination result and the determination target value obtained from the signal output from the magnetic detection unit 43 with the inspection information received from the X-ray inspection apparatus 30, and new inspection information of the article W that has been inspected. Is output to the subsequent weight inspection apparatus 50.

  The weight inspection device 50 is for inspecting the weight of the weight of the article W carried out from the metal detection device 40, and includes a conveyor 51, an article sensor 52, a weighing unit 53, and a determination unit 54. Composed.

  The conveyor 51 is arranged so that the weighing unit 53 functions as a weighing table for weighing the load of the article W by the load sensor, receives the article W carried out from the preceding conveyor 41 at one end side, and conveys it to the other end side. .

  The article sensor 52 detects the article W carried into the conveyor 51 and outputs a detection signal to the determination unit 54. The article sensor 52 includes, for example, a transmission type photoelectric sensor including a pair of light projectors and light receivers (not shown) arranged to face the conveyor 51 so as to straddle the width direction (front and back directions in FIG. 1).

  The weighing unit 53 outputs a weight signal corresponding to the load of the article W detected by the article sensor 52 and placed on the conveyor 51 to the determination unit 54.

  The determination unit 54 obtains the weight of the article W based on the weight signal output from the weighing unit 53 after the article W detected by the article sensor 52 is completely carried into the conveyor 51, and the obtained weight is acceptable. It is determined whether it is within the range.

  The determination unit 54 generates new inspection information of the inspected article W by combining the determination result, the obtained weight value, and the like with the inspection information received from the metal detection device 40, and outputs the new inspection information to the subsequent sorter 60. And output to the host computer 71 via the computer network 70.

  The sorter 60 is for removing, from the line, the articles W carried out from the weight inspection apparatus 50 that have been determined to be defective by the respective inspection apparatuses in the previous stage, and includes a conveyor 61, an article sensor 62, and an exclusion. The apparatus 63 and the determination part 64 are comprised.

  The conveyor 61 receives the article W carried out from the preceding stage conveyor 51 at one end side, conveys it to the other end side, and carries it out to the conveyor 2 on the shipping line. In addition, this conveyor 61 can also be shared with the conveyor 2 of a shipping line.

  The article sensor 62 is arranged immediately before the rejection device 63, detects the article W carried into the conveyor 61 immediately before the rejection device 63, and outputs a detection signal to the determination unit 64. The article sensor 62 is composed of a transmission type photoelectric sensor including a pair of light projectors and light receivers (not shown) disposed so as to face each other across the conveyor 61 in the width direction (front and back directions in FIG. 1), for example.

  Each time the rejection device 63 receives a failure signal from the determination unit 64, the rejection device 63 excludes the articles W on the conveyor 61 from the line.

  As this exclusion device 63, one that blows air from the side of the conveyor 61 to the article W to remove it from the conveyor 61, or one that guides and removes the article W by turning or sliding the lever to the side of the conveyor 61. Etc. can be used.

  The determination unit 64 extracts information on the determination result of the quality of the article from the inspection information received from the weight inspection apparatus 50, and when any of the determination results includes a determination result of a defect, the determination unit 64 Then, a defect signal is output, and the article W detected by the article sensor 62 is removed from the conveyor 61.

  Each apparatus of the inspection line having such a configuration can communicate with the host computer 71 via the computer network 70, and the host computer 71 collects and manages information on each apparatus.

  The host computer 71 is composed of a computer unit including a CPU (Central Processing Unit), a RAM (Random Access Memory), a ROM (Read Only Memory), a hard disk device, and an input / output port (not shown).

  Various sensors such as an illumination sensor 72 and a humidity sensor 73 are connected to the host computer 71 via a computer network 70.

  The illumination sensor 72 detects and outputs the illuminance near the inspection line. The humidity sensor 73 detects and outputs the humidity near the inspection line.

  The host computer 71 stores and manages the inspection information and operation history of each device on the inspection line in the hard disk device.

  The host computer 71 can refer to the production plan created by the host system. The production plan includes information on a stop plan for performing maintenance work by stopping the production line including the inspection line.

  The host computer 71 monitors the operating state of each device on the inspection line. When the inspection line stops, the host computer 71 automatically determines the cause of the stop and stores it in the hard disk device for management.

  When the determination unit 34, the determination unit 44, the determination unit 54, and the determination unit 64 detect that the own device has stopped, the determination unit 34, the determination unit 44, and the determination unit 64 transmit the fact that the own device has stopped to the host computer 71 via the computer network 70. At this time, the determination unit 34, the determination unit 44, the determination unit 54, and the determination unit 64 simultaneously detect the detection frequency of the article W immediately before the article sensor 32, the article sensor 42, the article sensor 52, and the article sensor 62 of the respective devices are stopped. Send. The determination unit 34, the determination unit 44, the determination unit 54, and the determination unit 64 calculate, for example, the number of detections of the article W within a predetermined time as the detection frequency, and the latest detection frequency when the own apparatus is stopped is calculated as the host computer 71. Send to.

  When the host computer 71 receives information indicating that the own apparatus has stopped from the determination unit 34, the determination unit 44, the determination unit 54, and the determination unit 64, the host computer 71 determines that the inspection line has stopped.

  When the host computer 71 determines that the inspection line has stopped, it affects the detection frequency of the article W immediately before the stop, the detection result of the illumination sensor 72, the detection result of the humidity sensor 73, and the stop of the inspection line such as the production plan. The cause of the stoppage is determined based on external information that is information related to the received operating environment.

  When the detection frequency of the article W immediately before the inspection line stops is equal to or less than a preset threshold value, the host computer 71 determines that the inspection line is stopped as a planned stop, and the article immediately before the inspection line stops. If the W detection frequency is greater than a preset threshold value, it is determined that the inspection line is stopped unplanned.

  At the end of production, since the raw material of the filling machine is reduced and the production amount per unit time is reduced, the conveyance frequency of the article W as the inspection object is lowered. Further, at the end of production, the inspection line is stopped after confirming the passage of all the articles W including the post-process of the inspection line, so the articles W do not flow for a certain time immediately before the stop.

  For this reason, the threshold value which can determine the planned stop as described above as the planned stop is set in advance, and the planned stop and the unplanned stop are determined based on the detection frequency of the article W immediately before the inspection line stops. be able to.

  When the illuminance detected by the illumination sensor 72 is lower than a preset threshold, the host computer 71 determines that the inspection line is stopped as a planned stop, and the illuminance detected by the illumination sensor 72 is a preset threshold. In the above case, it is determined that the inspection line is stopped unplanned.

  As shown in FIG. 2, in the period A and the period B when the inspection line is stopped, the host computer 71 determines that the period A in which the illuminance detected by the illumination sensor 72 is lower than a preset threshold is a planned stop. Then, it is determined that the period B in which the illuminance detected by the illumination sensor 72 is greater than or equal to a preset threshold is an unplanned stop.

  In a planned stop such as a break, the illumination is turned off and the illuminance near the inspection line decreases. In an unplanned stop, the illumination is not turned off, so the illuminance near the inspection line does not decrease.

  For this reason, the threshold value which can determine the planned stop as described above as the planned stop is set in advance, and the planned stop and the unplanned stop can be determined based on the illuminance when the inspection line stops.

  When the humidity detected by the humidity sensor 73 is higher than a preset threshold, the host computer 71 determines that the inspection line is stopped as a planned stop, and the humidity detected by the humidity sensor 73 is a preset threshold. In the following cases, it is determined that the stop of the inspection line is an unplanned stop.

  As shown in FIG. 3, in the period C and the period D in which the inspection line is stopped, the host computer 71 determines that the period C in which the humidity detected by the humidity sensor 73 is higher than a preset threshold is a planned stop. Then, it is determined that the period D in which the humidity detected by the humidity sensor 73 is equal to or less than a preset threshold is an unplanned stop.

  In planned outages such as cleaning, the humidity near the inspection line increases due to water washing. In an unplanned outage, the humidity near the inspection line does not increase because water is not used.

  For this reason, the threshold value which can determine the planned stop as described above as the planned stop is set in advance, and the planned stop and the unplanned stop can be determined based on the humidity when the inspection line stops.

  In short, if there is a change in the environment around the production line due to work performed or an event that occurs when the production line is stopped, the detectable environmental status and the work performed or event that occurred after the line stopped Can be determined to determine whether or not the production line is scheduled to be stopped.

  The host computer 71 determines that the inspection line is stopped as a planned stop when the inspection line is stopped during a production stop period in the production plan created in the host system, and is created in the host system. When the inspection line is stopped during the production period in the production plan, it is determined that the inspection line is stopped unplanned.

  As shown in FIG. 4, in the period E, the period F, and the period G when the inspection line is stopped, the host computer 71 is scheduled for the period E and the period F in which the production is stopped in the production plan created by the host system. It is determined that the stop has occurred, and it is determined that the period G in which production is produced in the production plan created by the host system is an unplanned stop.

  In this way, it is possible to determine a planned stop and an unplanned stop by referring to the production plan created by the host system.

  The host computer 71 only needs to determine a planned stop and an unplanned stop by at least one of the methods described above, or a combination of several methods.

  Moreover, sounds such as chimes at the start and end of production may be detected by a microphone, and a planned stop and an unplanned stop may be determined based on this.

  In addition, when the vicinity of the inspection device is imaged by the camera, people around the inspection device are detected from the captured image, and people gather around the inspection device, it is determined that the stop is unplanned due to a trouble with the inspection device. You may make it do.

  While embodiments of the invention have been disclosed, it will be apparent to those skilled in the art that changes may be made without departing from the scope of the invention. All such modifications and equivalents are intended to be included in the following claims.

DESCRIPTION OF SYMBOLS 30 X-ray inspection apparatus 32 Article sensor 34 Judgment part 40 Metal detection apparatus 42 Article sensor 44 Judgment part 50 Weight inspection apparatus 52 Article sensor 54 Judgment part 60 Sorter 62 Article sensor 64 Judgment part 71 Host computer 72 Illumination sensor 73 Humidity sensor

Claims (6)

A production management system for managing a production line including one or more devices (30, 40, 50, 60),
A production management system comprising a host computer (71) that, when the production line is stopped, determines whether the stop of the production line is a planned stop or an unplanned stop based on external information of the production line. An article sensor (32, 42, 52, 62) for detecting an article (W) flowing through the production line;
The production management system according to claim 1, wherein the host computer determines whether the production line is scheduled to be stopped or unplanned based on the frequency of the article detected by the article sensor. An illumination sensor (72) for detecting illuminance in the vicinity of the production line;
3. The production management system according to claim 1, wherein the host computer determines whether the stop of the production line is a planned stop or an unplanned stop based on the illuminance detected by the illumination sensor. A humidity sensor (73) for detecting the humidity in the vicinity of the production line;
The host computer according to any one of claims 1 to 3, wherein the host computer determines whether the stop of the production line is a planned stop or an unplanned stop based on the humidity detected by the humidity sensor. production management system.   The production according to any one of claims 1 to 4, wherein the host computer determines whether the stop of the production line is a planned stop or an unplanned stop based on a production plan of the production line. Management system. A production management program for managing a production line including one or more devices (30, 40, 50, 60),
A production management program for realizing a determination function for determining whether a stop of the production line is planned or unplanned based on external information of the production line when the production line is stopped in the computer.

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