JP2021196868A - Operation management system of production line and production line - Google Patents

Abstract

To provide an operation management system which can contribute to increase of productivity by effectively utilizing operation data.SOLUTION: In an operation management system 90, a processing unit 95 displays stop data and an input form including an input area on a display unit 97. When an operator inputs a cause and handling in the input area, the processing unit 95 stores the stop data and the input contents in a second storage unit 93 in association with each other. When one of machines constituting a production line is stopped, the processing unit 95 extracts the stop data and the input cause and handling from the second storage unit to be displayed on the display unit 97.SELECTED DRAWING: Figure 3

Description

The present disclosure relates to an operation management system in a production line in which a plurality of types of machines are connected.

There is a beverage production line as a production line in which multiple types of machines are connected. As an example of a beverage production line, plastic containers are molded, filling machines that fill the molded containers with beverages (filler), conveyors that temporarily store containers filled with beverages (accumulation conveyors), and labels on the containers. Multiple types of machines, such as a pasting machine (label), make up the line. Each machine that cooperates with each other outputs data related to operation, and the output operation data is aggregated and used for production control. For example, as one example is described in Patent Document 1, the accumulated operation data is utilized for subsequent production control and cost control.

Japanese Unexamined Patent Publication No. 2003-016151

There is always a need to improve productivity by utilizing driving data.
Therefore, an object of the present disclosure is to provide an operation management system that can contribute to the improvement of productivity by more effectively utilizing the operation data.

The operation management system of a production line in which a plurality of machines are connected according to the present disclosure includes a display unit for displaying operation data output by the plurality of machines and a storage unit for storing the operation data.
The storage unit according to the present disclosure stores the operation data in association with the specific unit related to the production line. In addition, the display unit according to the present disclosure displays the operation data in association with the specific unit.

According to the present disclosure, the operation data and the specific unit related to the production line are stored in association with each other, and the operation data and the specific unit are associated and displayed. Therefore, if the operator responsible for the operation of the production line refers to the display in which the operation data and the specific unit are associated with each other, the productivity of the production line can be improved.

It is a figure which shows the schematic structure of the management system of the production line which concerns on embodiment of this disclosure. It is a figure which shows the schematic structure of the production line which concerns on embodiment. It is a figure which shows the structure of the control part in the production line of FIG. This is a display example of the dashboard related to the first function according to the present embodiment. This is another display example of the dashboard related to the first function according to the present embodiment. This is another display example of the dashboard related to the first function according to the present embodiment. This is another display example of the dashboard related to the first function according to the present embodiment. This is another display example of the dashboard related to the first function according to the present embodiment. It is a schematic diagram concerning the 2nd function (self-other integral type) which concerns on this embodiment. It is a part of the flow diagram which concerns on the 2nd function which concerns on this embodiment. It is another part of the flow chart relating to the 2nd function which concerns on this embodiment. It is a figure which shows an example of the self-other integral type which concerns on the 2nd function which concerns on this embodiment. It is a figure which shows another example of the self-other integral type which concerns on the 2nd function which concerns on this embodiment. It is a figure which shows an example of the evaluation in the team unit about the 3rd function which concerns on this embodiment. It is a figure which shows the other example of the evaluation of the team unit about the 3rd function which concerns on this embodiment. It is a figure which shows an example of the evaluation of the machine unit with respect to the 3rd function which concerns on this embodiment. It is a figure which shows an example of the evaluation of the product unit about the 3rd function which concerns on this embodiment. It is a figure which shows the other example of the evaluation of the product unit about the 3rd function which concerns on this embodiment. It is a figure which shows an example of the evaluation in the time unit about the 3rd function which concerns on this embodiment. It is a figure which shows the other example of the evaluation in the time unit about the 3rd function which concerns on this embodiment.

Hereinafter, embodiments will be described with reference to the accompanying drawings.
[Overall configuration: FIG. 1, FIG. 2 and FIG. 3]
In this embodiment, as shown in FIG. 1, the producer PR provided with the production line 1 and the manufacturer MA of the production line 1 are connected so as to be able to share information with each other via the Internet IN. The shared information is stored in the data server DS on the cloud CL. The producer PR includes a factory FA having a production line 1 and an office OF managing the production line 1.
The factory FA, the office OF, and the manufacturer MA in the producer PR each have, for example, computer devices CP1, CP2, CP3 having dashboards (DB1, DB2, DB3) displaying various information acquired from the production line 1. is doing. The various information includes information based on the first function, the second function, and the third function in the present embodiment described later.

[Production line 1: Fig. 2]
As an example of this embodiment, a beverage product production line 1 will be described.
The production line 1 for beverage products is composed of a plurality of machines, and FIG. 2 shows eight elements as the main machines among them. In the production line 1, the resin container PB such as a PET bottle is conveyed in the direction indicated by the white arrow, and is subjected to the corresponding processing by the following machines.

Blow bottle molding machine 10: A machine that manufactures a resin container PB filled with a beverage, and blow-molds the preform PF as a raw material by heating it. In the blow bottle molding machine 10, the preform PF delivered from the preform feeder 13 is blow molded in the blow molding machine 11.
Filler 20: The filler 20 is a machine that sterilizes and cleans the resin container PB and fills the resin container PB with a beverage. After filling the beverage with the filling machine 21, a cap supplied from the cap feeder 23 is attached. , Responsible for closing the resin container PB.

Accum Conveyor 30: Resin containers PB filled with beverages are conveyed by a conveyor, but these are retained in a certain quantity so that the accumulator 30 can continue to operate in the downstream process for a certain period of time even if the filler 20 is stopped. It is a device for making. The resin container PB containing this beverage is still a semi-finished product.

Labeler 40: The labeler 40 is a machine that winds a label displaying a product name on a resin container PB which is a semi-finished product containing a beverage. For example, a label made of a plastic film is supplied from the label feeder 43 to the winding machine 41, and the label is wound around the resin container PB.

Inspection machine 50: The inspection machine 50 is a machine that inspects the position, appearance, tear, etc. of the label wrapped by the labeler 40, and the resin container PB recognized as a rejected product is excluded from the production line 1.
Accum 60: Accum 60 is a machine that retains and aligns a certain number of product resin containers PB and packs them in a box with the case packer 70 in the next process.
Case packer 70: The case packer 70 is a machine for packing a resin container PB in a cardboard box.
Palletizer 80: The palletizer 80 is a machine for stacking corrugated cardboard filled with a resin container PB on a pallet for transporting a forklift. As an example, many cardboard boxes are gripped (adsorbed) by a robot and interlocked, and in a later process, they are tied up with a resin band or wrapped with a shrink film to prevent them from collapsing.
In addition, between the case packer 70 and the palletizer 80, another machine, for example, a machine for inspecting the number (quantity) and sealing a cardboard box, is generally provided, but in the present embodiment, there is a machine. Omit.

As shown in FIG. 1, the production line 1 includes an operation management system 90. The operation management system 90 controls the operation of each device of the blow bottle molding machines 10 to the palletizer 80 constituting the production line 1, and acquires and stores information (operation data) regarding the operation of these devices. The operation data includes information that the operation has been stopped (stop data) and information that an alarm has been issued (alarm data) for each of the blow bottle molding machines 10 to the palletizer 80. Further, the operation data includes information (production quantity data) regarding the number of resin containers PB processed in the blow bottle molding machines 10 to the palletizer 80.

To that end, each of the blow bottle molding machines 10 to palletizer 80 generates operation data including stop / alarm data and production quantity data. The operation data includes data used for the first function, the second function, and the third function, which will be described later. The generated data is sent from each of the blow bottle molding machines 10 to the palletizer 80 to the operation management system 90. The operation management system 90 stores these acquired data and executes the first function to the third function based on the stored data.

As shown in FIG. 3, the operation management system 90 includes a first storage unit 91 and a second storage unit 93. The first storage unit 91 stores data such as a program for controlling the operation of the blow bottle molding machine 10 to the palletizer 80. The second storage unit 93 stores operation data, abnormality / alarm data, and production quantity data. More specific data will be clarified by the following description of the first function to the third function. The second storage unit 93 may be provided with a storage unit having the same contents to which the contents are copied in the data server DS of the cloud CL shown in FIG. 1, or may be provided only in the data server DS.
Further, the operation management system 90 includes a processing unit 95. The processing unit 95 executes the first function to the third function by using various data stored in the first storage unit 91 and the second storage unit 93. The specific contents of the processing to be executed will be clarified by the following description of the first function to the third function.

Next, the operation management system 90 includes a display unit 97. The display unit 97 displays data related to the first function to the third function. The screen related to this display is displayed on the dashboards DB1, DB2, and DB3 shown in FIG.

The gist of the first function to the third function in the production line 1 of the present embodiment is as follows.
1st function: Production control by linking mechanical data and human data 2nd function: Production control by self-other integral method when machine is stopped 3rd function: Production control through evaluation of productivity in specific unit

[First function: (FIGS. 4 to 8)]
First, the first function will be described.
The first function is to generate information in which mechanical data and human data are linked so that the linked information can be used for production control. The mechanical data referred to here is operation data generated in each of the blow bottle molding machines 10 to the palletizer 80 constituting the production line 1, and is, for example, information that the labeler 40 has stopped at a specific date and time. Applies to. On the other hand, the human-based data cannot be recognized by the machine itself of the blow bottle forming machines 10 to the palletizer 80, so the operator who operates the production line 1 outputs the data corresponding to the operation data of the mechanical system. In the simplest case, for example, the cause when the blow bottle molding machine 10 is stopped and the coping method for releasing the stop are applicable. The first function is to link the above mechanical data and human data, and when any of the blow bottle molding machines 10 to palletizer 80 is stopped later, the information is extracted to take measures against the stop. Allows you to do it quickly. Hereinafter, the first function will be described with reference to specific examples.

[Association of mechanical data and human data: Fig. 4 to Fig. 8]
For example, assume that the labeler 40 has stopped. Stopping here means that the operation is canceled based on a defect, and there are two types of responsibility: self-responsibility for stopping due to the machine itself and other responsibility for stopping due to another machine stopping. .. The suspension of the labeler 40 corresponds to the suspension at its own risk. A method of distinguishing between a stop due to self-responsibility and a stop due to another responsibility will be described in the second function.

[Example of mechanical data related to stoppage: Fig. 4]
FIG. 4 shows an example of mechanical data. This display includes three mechanical data MD1, MD2, MD3 indicating that the accumulator 30 and the inspection machine 50 have also stopped due to the stop of the labeler 40. "Stop information" is written in the upper right corner to indicate that this display is related to the stop of the machine. Further, it is shown that the stop time belongs to the range of 10 to 20 minutes. The mechanical data MD1, MD2, and MD3 can be shown after the production of the beverage is finished, but can also be shown while the production of the beverage is continuing.

The three mechanical data MD1, MD2, MD3 shown in FIG. 4 include the date and time when the stop occurred and the type of the stopped machine. As for the date and time, the same time is shown for all three because the accumulator 30 and the inspection machine 50 are stopped based on the labeler 40, that is, due to another responsibility.
In FIG. 4, the mechanical data MD1 notifying the stop of the labeler 40 is directly displayed as "stop labeler 40", and it can be recognized that the labeler 40 has stopped at its own risk. On the other hand, the mechanical data MD2 and MD3 that notify the stop of the accumulator 30 and the inspection machine 50 have the notation "Labella 40" on the right side of the arrow of the bill, and the accumulator 30 and the inspection machine 50 are responsible for other things. You can recognize that it has stopped.
In the three mechanical data MDs shown in FIG. 4, a button "Write a report" prompting the input of human data is shown in the lower right corner. In the example of FIG. 4, the button in the mechanical data related to the labeler 40 is pressed down to write the human data related to the labeler 40.

[Example of human data input form: Fig. 5]
When the button "Write a report" is pressed down, the form F1 for writing a report is displayed as shown in FIG. Form F1 has a data display area A for displaying stop data which is mechanical data, an input area B1 for entering the cause of the stop, an input area B2 for writing the details of the measures taken for the stop, and a stop. It includes an input area B3 for inputting the contents of the correspondence made with respect to the object. Here, the countermeasure means a measure taken to eliminate the stoppage and restart the operation. In addition, the response means the measures taken to prevent the cause from occurring. The operation cannot be restarted unless measures are taken, but by taking measures, it is possible to prevent the recurrence of the operation stop due to the same cause. Correspondence is an essential input item, but correspondence is an arbitrary input item.

[Example of human data: Fig. 6]
FIG. 6 shows an example of the report written in the input form F1. In other words, the cause of the stoppage of the labeler 40 between 10:05 and 10:20 on 2020/04/13, which is the mechanical data MD1, is "label popping out", and the label popping out "container" as a countermeasure against this stoppage. The fact that "extraction" has been performed is input as human data HD. However, since no "response" was taken this time, it will be reported as blank. After inputting the cause-correspondence, the content of the cause-correspondence is confirmed by pressing the "new post" button in the upper right corner, and is stored in the second storage unit 93. Although not mentioned here, the report may include a title, a message, and the like.
Since the mechanical data MD2 related to the accumulator 30 and the mechanical data MD3 related to the inspection machine 50 are based on other responsibilities, the human data HD is not input.

[Example of integrated data: Fig. 7]
The human data HD is stored in the second storage unit 93, and is stored as integrated data FD in the second storage unit 93 in association with the mechanical data MD1. An example of the integrated data FD stored in the second storage unit 93 is shown. The integrated data FD stored in the second storage unit 93 is the target of the search.
Regarding the stoppage of the labeler 40 between 10:05 and 10:20 on April 13, 2020, the mechanical data (MD) and the human data (HD) are listed side by side in the first line of FIG. ing. Regarding the accumulator 30 and the inspection machine 50, the mechanical data MD includes the suspension due to another responsibility, while the human data HD does not include the cause-correspondence.

[Extraction of past data: Fig. 8]
FIG. 8 shows a form F2 to be input and displayed when extracting specific data from the integrated data FD stored in the second storage unit 93. In FIG. 8, the form F2 includes an input area F21 and a display area F22. Form F2 is displayed on dashboards DB1, DB2, and DB3. However, it is not displayed at the same time on the dashboards DB1, DB2, and DB3.
FIG. 8 shows an example in which "Labeler 40" is input to the "stop machine" in the input area F21, "label popping out" is input to the "stop cause", and the "action extraction" button is pressed down.

The result is shown in the display area F22, and as a past example, there are two countermeasures, "pulling out the container" and "adjusting the label position". The display shows that the ratios of the measures taken are 80% and 20%, respectively.

[Effect of the first function]
According to the operation management system 90, the second storage unit 93 stores the stop data displayed in the data display area A of the input form F1 and the cause input via the input area B1 in association with the applied contents. Will be done. Therefore, when any of the machines constituting the production line is stopped, the stop data, the input cause, and the applied contents can be extracted from the storage unit and displayed on the display unit. The operator can realize the immediate restart of the operation of the production line by referring to the cause displayed on the display unit and the contents of the application.

As shown in FIG. 4, the mechanical data regarding the stop of the machine includes identification information as to whether the stop is due to self-responsibility or other responsibility. Therefore, the operator who refers to this identification information can easily identify the target for inputting the human system information.

When there are a plurality of countermeasures in the display from which the past data is extracted, a plurality of countermeasures are listed as shown in FIG. Therefore, the operator who refers to this display can quickly select a countermeasure even if he / she lacks experience. In particular, as shown in FIG. 8, when the ratio of each countermeasure taken in the past is displayed, it becomes a reference for deciding the order in which the countermeasures should be taken when there are a plurality of countermeasures.

[Second function: Self-other integral method when the machine is stopped (see FIGS. 9 to 13)]
Next, the second function will be described.
The second function is due to the fact that when at least one of the blow bottle molding machines 10 to the palletizer 80 constituting the production line 1 is stopped, the operation is stopped at its own risk, that is, at its own risk, or due to the stop of another person. Then, in other words, it is classified as to whether it was stopped due to another responsibility.
Hereinafter, the gist of the second function (FIG. 9), the procedure of the second function (FIG. 10, FIG. 11), and the actual example of the second function (FIG. 12, FIG. 13) will be described in order.

[Summary of the second function: see Fig. 9]
This will be explained with reference to the gist of the second function. Processing elements such as the "machine operation status collecting unit 95A" and the "machine operation monitoring unit 95B" shown in FIG. 9 are performed by the processing unit 95 of FIG. Further, the mechanical data collected from the production line 1 such as "machine operation status data 93A" and "machine stop data 93B" is stored in the second storage unit 93 of FIG. 3 after collection. Further, the "abnormal stop rule storage unit 91A" and the like are provided in advance in the first storage unit 91 of FIG.

In order to execute the second function, the processing unit 95 includes a machine operation status collection unit 95A, a machine operation monitoring unit 95B, a machine stop determination unit 95C, a machine abnormality collection unit 95D, and a self-other responsibility classification unit 95E.

The machine operation status collection unit 95A collects machine operation status data 93A from each of the blow bottle molding machines 10 to the palletizer 80 constituting the production line 1. The machine operation status data 93A includes a control device signal, a counter value, a sensor value, a time, and the like.
The machine operation monitoring unit 95B extracts the machine stop data 93B associated with the machine stop by referring to the machine operation status data 93A, and stores the machine stop data 93B in the second storage unit 93. Remember. The machine stop determination unit 95C determines the stop of any of the blow bottle molding machines 10 to the palletizer 80 based on the machine stop data 93B.
On the other hand, the machine abnormality collecting unit 95D extracts the machine abnormality data 93D by referring to the machine operation status data 93A, and stores the machine abnormality data 93D in the second storage unit 93.

When it is determined by the machine stop determination unit 95C that any of the blow bottle molding machines 10 to the palletizer 80 has stopped, the self-other responsibility classification unit 95E compares the machine stop data 93B with the machine abnormality data 93D to perform the self-other responsibility. Judge the responsibility.
At the time of this determination, refer to the abnormal stop rule storage unit 91A, and if there is a description of self-responsibility / other responsibility for the content of the abnormality, and if there is a description of the cause machine name if the cause machine is clear in the case of other responsibility. Based on this, the self-other responsibility is classified and written in the self-other responsibility classification result data 93E.
On the other hand, if there is no description for the abnormality in the abnormal stop rule storage unit 91A, or if there is no abnormality corresponding to the machine stop in the first place, the adjacent machines upstream and downstream are determined with reference to the line structure storage unit 91B, and these machines are stopped. If there is an adjacent machine that has stopped earlier than the own machine, classify the stop of the own machine as another responsibility, and write the cause machine as the adjacent machine in the own / other responsibility classification result data 93E. ..

The data written in the self-other responsibility classification result data 93E is displayed on the display unit 97 of the dashboards DB1, DB2, and DB3.

[Detailed explanation of operation in each part: Fig. 9]
[Machine operation status collection unit 95A]
The machine operation status collecting unit 95A collects data generated by each machine of the blow bottle forming machines 10 to the palletizer 80 from the operation management system 90 of the production line 1 via a communication line. It includes a method of directly communicating with individual machines, a method of communicating with the central control device of the production line 1, and a method of collecting data of each machine collected in the central control device.

The machine operation status data 93A is data related to the operation of the machine, and is the state value of the machine (during stop, operation, standby, etc.) in the control device of each machine, the input quantity of raw materials to the machine, and the production of the machine. Includes data items such as quantity counts (counter values), abnormal signals, alarm signals, sensor signals, and control device clock values (time). The machine operation status data 93A is data collected at regular intervals such as every 0.5 seconds, every 1 second, every 10 seconds, with the values at the same time point of each of these data items as one unit (group). ..

[Machine operation monitoring unit 95B]
The machine operation monitoring unit 95B constantly monitors data items suggesting machine stop with respect to the machine operation status data 93A.
The data item suggesting the machine stop is a data item selected in advance from the machine operation status data 93A. For example, it includes the state of the machine (running / stopped, etc.), an abnormal signal accompanied by the stop of the machine, the count value of the production quantity, and the like. If the count does not increase, the machine is considered to be down.

The machine operation monitoring unit 95B monitors the data defined as described above with respect to the machine operation status data 93A. Then, at the timing when the data item suggesting the machine stop suggests the machine stop, the data item name, the corresponding machine name, the data value, the detected time (= stop start time), etc. are added to the machine stop data 93B. Recorded.

The timing suggesting the stop of the machine is, for example, the timing when the state value of the machine changes from operating to stopped, the timing when the abnormal signal is turned on when the abnormal signal is accompanied by the stop of the machine, and further. , If it is a counter value, it includes the timing when the difference from the previous value becomes zero. The data item name has a concept including a data item uniquely indicating a data item such as a data item number and a data item ID. The corresponding machine name has a concept including a machine number, a machine ID, and the like that uniquely indicate the machine. The data value and the detected time (= stop start time) are referred to as a data number or machine stop data ID that uniquely indicates the data.

The "detected time" is assumed to be the clock value of the operation management system 90 included in the machine operation status data 93A described above, the time stamp of the transmission time of the machine operation status data 93A, the reception time of the data, and the like. .. However, it is preferable that the clock is common to all machines and that there is little delay from the occurrence of an event.
Further, the machine operation monitoring unit 95B monitors the predetermined data for the machine operation status data 93A as described above. Then, when the data item suggesting the stop of the machine returns from the value suggesting the stop to the value suggesting the restart, the time when the restart is detected in the machine stop data 93B of the machine in the above-mentioned machine stop data 93B. Add (= stop end time).

[Machine stop determination unit 95C]
The machine stop determination unit 95C determines the stop of each machine with reference to the machine stop data 93B. Regarding the operation of the machine, there are those that stop for a very short time of less than one second to several seconds and then start again, and those that repeat such a short stop. Therefore, instead of starting the process of self-other responsibility classification when the machine operation monitoring unit 95B detects a stop, a certain threshold value or rule is set, and if the stop continues for a certain period of time, for example, this is determined to be a stop. Then, it is necessary to move on to the next process of self-other responsibility classification. Therefore, in addition to the machine operation monitoring unit 95B that records the machine stop data 93B, a machine stop determination unit 95C that determines the stop of each machine by referring to the machine stop data 93B is provided. The machine stop determination unit 95C determines whether or not the machine is stopped for each data of the machine stop data 93B. Then, a flag indicating that the suspension is determined, that is, the one determined to be subject to the self-other responsibility classification, is attached. The determination of stop is based on, for example, whether or not the length of the stop time is equal to or longer than the threshold value. However, in this case, the end time of the stop (= restart time) does not necessarily have to be added to the data. If the end time of the stop is not added, the latest machine that has been received so far. If the difference between the time associated with the operation status data 93A and the stop start time is equal to or greater than the threshold value, it can be determined to be stopped.

[Machine abnormality collection unit 95D]
The machine abnormality collecting unit 95D constantly monitors the data items suggesting the machine abnormality with respect to the machine operation status data 93A in parallel with the recording and determination of the machine stop described above.
The data item suggesting a machine abnormality is a data item selected in advance from the machine operation status data 93A, and is, for example, a state indicating an abnormality or an abnormality signal among the machine states (operating / stopped / abnormality). , A specific sensor signal indicating an abnormality, etc. are assumed.

As described above, the machine abnormality collecting unit 95D monitors the data items selected in advance with respect to the machine operation status data 93A. Then, at the timing when the data item suggesting the abnormality of the machine suggests the abnormality of the machine, the predetermined data and the data number or the data ID uniquely indicating the data are assigned and recorded as the machine abnormality data 93D.
The timing that suggests a machine abnormality is, for example, the timing when the machine status value changes from normal operation to the abnormality, and the timing when the abnormality signal is turned on for the machine abnormality signal, the sensor value. If so, it includes the timing when the sensor value is ON or exceeds the threshold value determined for each sensor. Further, the predetermined data includes a data item name, a corresponding machine name, a data value, a detected time (= abnormal start time), and the like.

This "detected time" is the same as the above-mentioned stop data.
Furthermore, the machine abnormality collection unit 95D monitors the data defined as described above for the machine operation status data 93A, and the data item suggesting the abnormality of the machine returns from the value suggesting the abnormality to the value suggesting the normality. At the time, the time when normality is detected (= abnormal end time) is added to the machine stop abnormality data of the machine of the above-mentioned machine abnormality data 93D.

[Self-other responsibility classification unit 95E]
For the data determined to be stopped by the machine stop determination unit 95C, the self-other responsibility classification unit 95E is responsible for stopping the machine due to its own machine, or due to another machine. Classify whether it is another responsibility to stop, and in the case of another machine responsibility, identify the machine that directly caused it, that is, the cause machine.
The self-other responsibility classification unit 95E performs self-other responsibility classification with reference to the machine abnormality data 93D, the abnormality stop rule storage unit 91A, and the line structure storage unit 91B.

[Abnormal stop rule storage unit 91A]
In the abnormal stop rule storage unit 91A, the data item name and machine name of the machine operation status data 93A and the data value (abnormal value) are described in the "abnormal" column for the abnormality defined for the abnormal data collection unit. .. On the other hand, if it is known in advance that the abnormality indicates suspension of self-responsibility, enter "self-responsibility" in the "self-responsibility" column, and if it is known in advance that it indicates suspension of self-responsibility. Is described as "other responsibility", and if the self-other responsibility cannot be classified only from the abnormality concerned, nothing is described. Furthermore, if the machine that causes the abnormality described as "other responsibility" is known in advance, enter the name of the corresponding machine in the "Cause machine" column.

[Line structure storage unit 91B]
The line structure storage unit 91B includes data for specifying a machine name, an upstream machine name, and a downstream machine name for the blow bottle molding machines 10 to palletizer 80 constituting the production line 1. Upstream and downstream are relative definitions defined based on the direction in which the resin container PB flows.
Each of the blow bottle molding machines 10 to palletizer 80 constituting the production line 1 has no cause for itself, that is, even if there is another responsibility, when the upstream machine is stopped and the injection of the resin container PB into itself is interrupted. Or, when the downstream machine stops and the resin container PB cannot be charged from itself, it also stops. Therefore, in the line structure storage unit 91B, information for specifying the upstream machine name and the downstream machine name is stored for each of the blow bottle molding machines 10 to the palletizer 80.

[Procedure for classification of self-other responsibility: Fig. 10, Fig. 11]
Next, the procedure of self-other responsibility classification will be described with reference to FIGS. 10 and 11. 10 and 11 show the self-others performed by referring to the machine abnormality data 93D, the abnormal stop rule storage unit 91A, and the line structure storage unit 91B for the machine stop data 93B executed in the self-other responsibility classification unit 95E. The procedure of responsibility classification is shown.

The self-other responsibility classification unit 95E reads the data that is determined to be stopped by the machine stop determination unit 95C and is flagged as the machine stop data from the data stored in the machine stop data 93B (FIGS. 10 S201, S203). ). If there is machine stop data (S203 Yes), the machine abnormality data 93D is referred to, and it is searched for whether there is machine abnormality data of the machine at the stop start time (S205, S207).

When there is machine abnormality data (S207 Yes), the abnormality stop rule storage unit 91A is read (S209).
If the machine abnormality data of the machine is the description (line) described in the "abnormality" column, if the "self-responsibility" column is "self-responsibility", the machine stop is judged to be "self-responsibility" and the self-other responsibility. Finish the classification (S211 self-responsibility, S231).
If the "self-other responsibility" column is "other responsibility" (S211 "other responsibility") and there is a description of the cause machine in the "cause machine" column (S213 Yes, cause machine = XX), the machine stop data Search 93B to check if the causative machine (○○) has stopped before the machine stopped, and if it has stopped (S215 Yes), determine that the machine stop is another responsibility and call the causative machine " ○○ ”(S233).

On the other hand, in any of the following four cases, the line structure is read from the line structure description unit 91B and referred to, and the upstream machine and the downstream machine for the machine are determined (FIG. 11S217).
Case 1: When there is no machine abnormality data corresponding to the machine stop (S207 No).
Case 2: When there is no record of the stop of the causative machine (○○) in the machine stop data 93B (S213 No).
Case 3: When the cause machine is not described or is not described in the "self-other responsibility" column even if the "self-other responsibility" column of the abnormal stop rule description unit 91A is "other responsibility" (S213 No).
Case 4: When there is no causative machine corresponding to the machine stop (S211 unknown).

When the upstream machine and the downstream machine are determined, it is confirmed whether the upstream machine and the downstream machine are stopped before the machine stop by referring to the machine stop data 93B (FIG. 11S219).
If only the upstream machine is stopped, the machine stop is determined to be "other responsibility" and the causative machine is the upstream machine (S219, only the upstream machine is stopped).
If only the downstream machine is stopped, the machine stop is determined to be "other responsibility" and the causative machine is the upstream machine (S219 only the downstream machine is stopped).
When both the upstream machine and the downstream machine are stopped, the processing is performed as follows (both S221). When the upstream machine is stopped before the downstream machine (S223 Yes), the machine stop is determined to be "other responsibility" and the causative machine is set as the upstream machine (S235). If this is not the case (S223 No), the machine stop is determined to be "other responsibility" and the causative machine is the downstream machine (S237).

If the upstream machine and the downstream machine are determined by referring to the line structure storage unit 91B, refer to the machine stop data 93B, and if both the upstream machine and the downstream machine are not stopped (S219 No), the self-other responsibility It is unknown (S239).

The above determination result is added with the description of "self-responsibility" if it is "self-responsibility" together with the machine stop data (machine name, stop start time, end time, machine stop data ID) in the machine stop data 93B. , Write in the self-other responsibility classification result data, and if it is "other responsibility", the description of "other responsibility" and the cause machine name, the machine stop data of the data indicating the stop of the cause machine found (identified) in the machine stop data 93B Add an ID and write it in the self-other responsibility classification result data. If the self-other responsibility is unknown, add the description of "unknown" and write it in the self-other responsibility classification result data.

The machine stop display unit 97 (FIG. 9) refers to the self-other responsibility classification result data and displays the machine stop and the data classification result in a predetermined description format. For example, the machine name, stop start time, stop end time, abnormality content, and cause machine name may be displayed as a message.
The display unit 97 may display the self-other responsibility classification result data in which the stop time is blank at the time of writing the self-other responsibility classification result data by the self-other responsibility classification unit 95E. When the machine is stopped and restarted, the stop end time may be written in the above message, or a message containing the stop end time may be displayed again.

In addition, the self-other responsibility classification unit 95E showed an example in which only the direct causative machine was identified for each machine stop. However, regarding the stop of a certain machine A, the self-other responsibility classification result data 93E is searched by using the machine name B causing the stop of the machine A and the machine stop data ID. Then, by determining the machine stop recorded by the cause machine name B and the machine stop data ID, and further tracing using the cause machine name C and the machine stop data ID, the root cause machine X (self-responsibility) Can be traced to.

When the number of stops and the stop time of each machine are classified into self-responsibility and total, in the data analysis, the stop is classified according to the description of "self-responsibility" / "other responsibility" in the self-other responsibility classification result data 93E.
In addition, when totaling "other responsibilities" by causal machine, the root causative machine is determined for each machine stop by the above method, and then totaling is performed.

Regarding the self-responsibility classification result data 93E, the self-other responsibility classification unit 95E describes "self-responsibility" / "other responsibility" / "unknown" in some data items of the machine stop data of the machine stop. If it is "other responsibility", the cause machine name and the machine stop data ID of the cause machine stop data are added and written. As a result, even if the self-other responsibility classification result data 93E is not provided, these added portions may be additionally written to the machine stop data 93B instead. In that case, the display unit 97 and the machine stop data 93B are referred to in the data analysis.
Hereinafter, two examples of self-other integrals in the production line 1 performed according to the procedures of FIGS. 9 to 11 will be described. In Case 1, the blow bottle molding machine 10 causes an abnormality and stops, and in Case 2, the labeler causes an abnormality and stops.

[Case of self-other responsibility classification 1: Fig. 12]
An example 1 of self-other responsibility classification in the production line 1 will be described with reference to FIG.
In Case 1, the blow bottle molding machine 10 causes an abnormality and stops. As a result, the preform supply is put into a standby state, and the filler 20 which is a downstream machine of the blow bottle molding machine 10 is also stopped. At this point, the accumulator 30 and the machines downstream of the accumulator 30 continue to operate for the resin container PB (semi-finished product) staying in the accumulator 30.

The stoppage of the blow bottle molding machine 10 is specified based on the value of the production counter provided at the outlet of the blow bottle molding machine 10. That is, the machine operation monitoring unit 95B (FIG. 9) monitors the value of the production counter at the outlet of the blow bottle molding machine 10, and recognizes that the blow bottle molding machine 10 has stopped by stopping the increase of the counter value. , This is recorded in the machine stop data 93B. The following is exemplified as a data group (data group X1) in this case.

Data group X1 (data group related to the shutdown of the blow bottle molding machine 10)
[Data item name] Blow bottle molding machine 10 Production counter [Machine name] Blow bottle molding machine [Value] Counter value xxx
[Stop start time] 2020/03/12 15:14:35
[Stop end time] Blank (= Stopping)
[Machine stop data ID] XXXXXXX1

On the other hand, the abnormality of the blow bottle molding machine 10 is recorded in the machine abnormality data 93D by the machine abnormality collecting unit 95D in parallel with the recording in the machine stop data 93B. In this example, it is assumed that the blow bottle molding machine 10 has an abnormality called "serious failure occurrence", that is, an abnormality signal corresponding to "serious failure occurrence" is turned on. Then, the following data group Y1 is recorded in the machine abnormality data 93D as an example.

Data group Y1 (machine abnormality data 93D)
[Data item name] Machine error [Machine name] Blow bottle molding machine 10
[Data value] Major failure occurred [Time of occurrence] 2020/03/12 15:14:34

After recording in the machine stop data 93B described above, when it is determined by the machine stop determination unit 95C that the blow bottle molding machine 10 is stopped, the self-other responsibility classification unit 95E refers to the machine abnormality data 93D. .. Then, it is searched whether the abnormality of the [machine name] blow bottle molding machine 10 is recorded at the time when the machine is stopped of the blow bottle molding machine 10, and the following data group Y2 is obtained from the above-mentioned data group Y1.

Data group Y2 (machine abnormality data 93D)
[Data item name] Machine error [Machine name] Blow bottle molding machine 10
[Data value] Major failure occurred

Further, the self-other responsibility classification unit 95E refers to the abnormality stop rule storage unit 91A, and refers to the "self-other responsibility" column for the abnormality in which the "abnormality" column is as follows. [Data value] Regarding the occurrence of a serious failure, "self-responsibility" is described (defined) in the "self-responsibility" column of the abnormal stop rule storage unit 91A, and the machine stop of the blow bottle molding machine 10 is "self-responsibility". It is judged.
[Data item name] Machine error [Machine name] Blow bottle molding machine 10 [Data value] Major failure occurred

In parallel with the machine stop determination, abnormality collection, and self-other responsibility classification of the blow bottle molding machine 10, the same processing is performed on the filler 20. An example thereof will be described below.
The stoppage of the filler 20 is specified based on the value of the production counter at the outlet of the filler 20. That is, the machine operation monitoring unit 95B (FIG. 9) monitors the value of the production counter at the outlet of the filler 20, determines that the filler 20 has stopped by stopping the increase of the counter value, and displays the machine stop data 93B. This is recorded. The following is an example of the data group (data group x2) in this case.

Data group x2 (data group related to the stoppage of filler 20)
[Data item name] Filler production counter [Machine name] Filler [Value] Counter value xxx
[Stop start time] 2020/03/12 15:14:36
[Stop end time] Blank (= Stopping)
[Machine stop data ID] XXXXXXX2

The abnormality of the filler 20 is recorded in the machine abnormality data 93D by the machine abnormality collecting unit 95D. In this example, it is assumed that an abnormality called "upstream equipment (blow molding machine) abnormality" has occurred in the filler 20, that is, an abnormality signal corresponding to "upstream equipment (blow molding machine) abnormality" has been turned on. Then, the following data group y1 is recorded in the machine abnormality data 93D as an example.

Data group y1 (machine abnormality data 93D)
[Data item name] Machine error [Machine name] Filler [Data value] Upstream equipment (blow molding machine) error [Occurrence time] 2020/03/12 15:14:34

After recording in the machine stop data 93B described above, when it is determined by the machine stop determination unit 95C that the filler 20 is stopped, the self-other responsibility classification unit 95E refers to the machine abnormality data 93D. Then, it is searched whether the abnormality of the [machine name] filler is recorded at the time when the machine is stopped in the filler 20, and the following data group y2 is obtained from the above-mentioned data group y1.

Data group y2
[Data item name] Machine error [Machine name] Filler [Data value] Upstream equipment (blow molding machine) error

Further, the self-other responsibility classification unit 95E refers to the abnormality stop rule storage unit 91A, and refers to the "self-other responsibility" column for the abnormality in which the "abnormality" column is as follows. Data value] Regarding the abnormality of the upstream equipment (blow molding machine), "other responsibility" is described (defined) in the "self-other responsibility" column of the abnormality stop rule storage unit 91A, and "cause machine name" column is further described as "other responsibility". Blow bottle molding machine 10 "is described (defined).

[Data item name] Machine error [Machine name] Filler [Data value] Upstream equipment (blow molding machine) error

Here, the self-other responsibility classification unit 95E refers to the machine stop data 93B, confirms whether the blow bottle molding machine 10 is stopped when the machine of the filler 20 is stopped, and the data group X1 which is the machine stop data described above. To get.

Data group X1
[Data item name] Blow bottle molding machine 10 Production counter [Machine name] Blow bottle molding machine [Value] Counter value xxx
[Stop start time] 2020/03/12 15:14:35
[Stop end time] Blank = Stopping [Machine stop data ID] XXXXXXX1

As a result, in the self-other responsibility classification unit 95E, the stop of the causative machine described in the abnormal stop rule storage unit 91A was confirmed. Blow bottle molding machine 10 "can be certified. [Machine stop data ID] XXXXXXX1 indicating the machine stop of the blow bottle molding machine 10 is added to these results, and the data is written in the self-other responsibility classification result data 93E together with the data of the stop of the filler 20.

Further, it is assumed that no abnormality has occurred in the filler 20 because it is not recorded in the machine abnormality data 93D. In this case, the machine abnormality data 93D is referred to in the self-other responsibility classification unit 95E. Then, since the abnormality of the [machine name] filler is not recorded at the time when the machine of the filler 20 is stopped, the line structure storage unit 91B is referred to, and the blow bottle forming machine 10 is used as the [upstream machine] and the blow bottle molding machine 10 is used as the [downstream machine]. The accumulator 30 is specified (FIG. 12).

The machine stop data 93B is searched for these machine stops, and in this example, since the accumulator 30 continues to operate, the above-mentioned machine stop data data group X1 of the blow bottle molding machine 10 is obtained.

As a result, the self-other responsibility classification unit 95E determines that the stoppage of the filler 20 is "other responsibility", and sets the causative machine to "blow bottle molding machine 10". [Machine stop data ID] XXXXXX1 indicating the machine stop of the blow bottle molding machine 10 is added to these results, and the data is written in the self-other responsibility classification result data 93E together with the data of the stop of the filler 20.

[Case 2: Classification of self-other responsibility: Fig. 13]
Another case 2 of the self-other responsibility classification in the production line 1 will be described with reference to FIG.
In Case 2, the labeler 40 causes an abnormality and stops. As a result, the accumulator 30 upstream of the labeler 40 is filled with the supply of the resin container PB (semi-finished product) from the filler 20 and is stopped. Further, in conjunction with this stop, the filler 20 and the blow bottle forming machine 10 upstream of the accumulator 30 are stopped. Since the supply of the resin container PB from the labeler 40 is stopped downstream from the accumulator 30, the inspection machine 50 is stopped, but the case packer 70 downstream from the accumulator 60 has the resin container PB on the accumulator 60. Continue to operate until all are spit out.

In the following description, as described in Case 1, the description of the operation of each element is omitted, and the portion after the determination by the machine stop determination unit 95C for each of the blow bottle molding machines 10 to the inspection machine 50. Will be described mainly with the reference data shown below. The explanation will be given in the order of the labeler 40, the accumulator 30, the filler 20, the blow bottle molding machine 10, and the inspection machine 50. Since it is assumed that the machine is stopped continuously, the [machine stop end time] of the machine stop data 93B is blank (= stopped) for each machine.

[Reference data]
Machine stop data 93B Machine abnormality data 93D Self-other responsibility classification result data 93E
Abnormal stop rule Data example of storage unit 91A Judgment operation of self-other responsibility classification unit 95E

<Stop of Labela 40>
-Machine stop data 93B:
[Data item name] Labeler production counter [Machine name] Labeler [Value] Counter value xxxx
[Stop start time] 2020/03/13 08:28:35 [Stop end time] Blank (= Stopping)
[Machine stop data ID] XXXXXX10
-Machine abnormality data 93D:
[Data item name] Machine error [Machine name] Labeler [Data value] Emission error
[Occurrence time] 2020/03/13 08:28:34

-Abnormal stop rule storage unit 91A:
"Abnormal" column: [Data item name] Machine error [Machine name] Labeler [Data value] Emission abnormality "Self-responsibility" column: "Self-responsibility"

-Operation of self-other responsibility classification unit 95E:
From the description in the "self-other responsibility" column of the above-mentioned abnormal stop rule storage unit 91A, it is determined to be "self-responsibility".
-Self-responsibility classification result data 93E:
Data of the machine stop: [Machine name] Labeler
[Stop start time] 2020/03/13 08:28:35 [Stop end time] Blank (= Stopping)
[Machine stop data ID] XXXXXX10 + "Self-responsibility"

<Stop of Accum Conveyor 30>
-Machine stop data 93B:
[Data item name] Number of passing accumulator bottles [Machine name] Accumulator
[Value] Counter value xxxx
[Stop start time] 2020/03/13 08:28:44 [Stop end time] Blank (= Stopping)
[Machine stop data ID] XXXXXX12
-Machine abnormality data 93D:
No abnormality was recorded in the accumulator 30 (no abnormality).

-Abnormal stop rule storage unit 91A:
It is not referenced because no anomalies have been recorded.
-Operation of self-other responsibility classification unit 95E:
Refer to the machine abnormality data 93D, and since the abnormality of the [machine name] accumulator is not recorded at the time when the machine of the accumulator 30 is stopped, refer to the line structure storage unit 91B, and refer to the [upstream machine] filler, [downstream]. Machine] Get a labeler.

The machine stop data 93B is searched for these machine stops, and the following is extracted for the filler 20 and the labeler 40. Then, comparing the stop start time of the machine stop data of the filler 20 and the machine stop data of the labeler 40, the stop time of the downstream labeler 40 is earlier. Is set to "Labella" and [Machine Stop Data ID] XXXXXX10.
Machine stop data of Filler 20: [Data item name] Filler production counter [Machine name] Filler [Value] Counter value xxxx [Stop start time] 2020/03/13 08:28:46
[Stop end time] Blank (= Stopping) [Machine stop data ID] XXXXXX13 (described later)
Machine stop data of Labeler 40: [Data item name] Labeler production counter [Machine name] Labeler [Value] Counter value xxxx [Stop start time] 2020/03/13 08:28:35
[Stop end time] Blank (= Stopping) [Machine stop data ID] XXXXXX10 (above)

-Self-responsibility classification result data 93E: Accum Conveyor 30
Machine stop data: [Machine name] Accum Conveyor [Stop start time] 2020/03/13 08:28:44 [Stop end time] Blank (= Stopping) [Machine stop data ID] XXXXXX12 + "Other responsibility"
[Cause machine] "Labella" [Machine stop data ID] XXXXXX10

<Fira 20>
-Machine stop data 93B:
[Data item name] Filler production counter [Machine name] Filler [Value] Counter value xxxx
[Stop start time] 2020/03/13 08:28:46 [Stop end time] Blank (= Stopping)
[Machine stop data ID] XXXXXX13
-Machine abnormality data 93D:
[Data item name] Machine error [Machine name] Filler
[Data value] Downstream equipment (accumulate conveyor) is full [Occurrence time] 2020/03/13 08:28:45

-Abnormal stop rule storage unit 91A:
"Abnormal" column: [Data item name] Machine error [Machine name] Filler
[Data value] Downstream equipment (accumulate conveyor) full "Self-other responsibility" column: "Other responsibility"
"Cause machine name": "Accumulator"

-Operation of self-other responsibility classification unit 95E:
Since "other responsibility" is described (defined) in the "self-other responsibility" column of the abnormal stop rule storage unit 91A, and "accumulation conveyor" is described (defined) in the "cause machine name" column. Refer to the stop data 93B. Then, it is confirmed whether the accumulator 30 is stopped when the machine of the filler 20 is stopped, and the following machine stop data is obtained. As a result, the self-other responsibility classification unit 95E confirms that the cause machine described in the abnormal stop rule storage unit 91A is stopped. Therefore, in the self-other responsibility classification result data 93E, the stop of the filler 20 is determined to be "other responsibility", and the causative machine is "accumulate conveyor" and [machine stop data ID] XXXXXX12.

Machine stop data: [Data item name] Number of passing accumulator bottles
[Machine name] Accumulator [Value] Counter value xxxx
[Stop start time] 2020/03/13 08:28:44 [Stop end time] Blank (= Stopping)
[Machine stop data ID] XXXXXX12

Self-other responsibility classification result data 93E:
Machine stop data: [Machine name] Filler [Stop start time] 2020/03/13 08:28:53 [Stop end time] Blank (= Stopping) [Machine stop data ID] XXXXXX13 + "Other responsibility" Cause machine "Accumulator" [Machine stop data ID] XXXXXX12

<Blow bottle molding machine 10>
-Machine stop data 93B:
[Data item name] Blow bottle molding machine 10 Production counter [Machine name] Blow bottle molding machine 10 [Value] Counter value xxxx [Stop start time] 2020/03/13 08:28:48 [Stop end time] Blank (= Stopping) [Machine stop data ID] XXXXXX14
-Machine abnormality data 93D:
[Data item name] Machine error [Machine name] Blow bottle molding machine 10 [Data value] With filler stop signal [Occurrence time] 2020/03/13 08:28:47

-Abnormal stop rule storage unit 91A:
"Abnormal" column: [Data item name] Machine error [Machine name] Blow bottle molding machine 10 [Data value] With filler stop signal "Self-other responsibility" column: "Other responsibility"
"Cause machine name": "Fira"

-Operation of self-other responsibility classification unit 95E:
Since "other responsibility" is described (defined) in the "self-other responsibility" column of the abnormal stop rule storage unit 91A, and "filler" is described (defined) in the "cause machine name" column, the machine is stopped. Refer to data 93B. Then, it is confirmed whether the filler 20 is stopped when the machine of the blow bottle molding machine 10 is stopped, and the following machine stop data is obtained. As a result, the self-other responsibility classification unit 95E confirms that the cause machine described in the abnormal stop rule storage unit 91A is stopped. Therefore, in the self-other responsibility classification result data 93E, the stop of the blow bottle molding machine 10 is determined to be "other responsibility", and the causative machine is "filler" and [machine stop data ID] XXXXXX13.

Machine stop data: [Data item name] Filler production counter [Machine name] Filler
[Value] Counter value xxxx [Stop start time] 2020/03/13 08:28:46
[Stop end time] Blank (= Stopping) [Machine stop data ID] XXXXXX13

Self-other responsibility classification result data 93E:
Machine stop data: [Machine name] Blow bottle molding machine 10
[Stop start time] 2020/03/13 08:28:48 [Stop end time] Blank (= Stopping)
[Machine stop data ID] XXXXXX14 + "Other responsibility" [Cause machine] "Fira"
[Machine stop data ID] XXXXXX13

<Inspector 50>
-Machine stop data 93B:
[Data item name] Inspection machine Bottle inspection count counter [Machine name] Inspection machine
[Value] Counter value xxxx [Stop start time] 2020/03/13 08:28:37
[Stop end time] Blank (= Stopping) [Machine stop data ID] XXXXXX11
-Machine abnormality data 93D:
No abnormality was recorded in the inspection machine 50 (no abnormality).

-Operation of self-other responsibility classification unit 95E:
Refer to the machine abnormality data 93D, and since the abnormality of the [machine name] inspection machine is not recorded at the time when the machine of the inspection machine 50 is stopped, refer to the line structure storage unit 91B, and refer to the [upstream machine] labeler, [ Downstream Machine] Get Accum.
The machine stop data 93B is searched for the stop of these machines, and since the downstream machine Accum 60 continues to operate, the following is obtained.
Machine stop data of labeler 40 of upstream machine: [Data item name] Labeler production counter
[Machine name] Labeler [Value] Counter value xxxx [Stop start time] 2020/03/13 08:28:35
[Stop end time] Blank (= Stopping) [Machine stop data ID] XXXXXX10 (above)

As a result, the self-other responsibility classification unit 95E determines that the stop of the inspection machine 50 is "other responsibility", sets the causative machine as "Labella" and [machine stop data ID] XXXXXX10, and sets the self-other responsibility classification result data 93E. It will be remembered.
Self-other responsibility classification result data 93E:
Machine stop data: [Machine name] Inspection machine [Stop start time] 2020/03/13 08:28:37
[Stop end time] Blank (= Stopping) [Machine stop data ID] XXXXXX11 + "Other responsibility"
[Cause machine] "Shrink labeler" [Machine stop data ID] XXXXXX10

FIG. 13 shows the relationship between the machine stop described above, the self-other responsibility of the self-other responsibility classification result data, and the machine stop data ID of the causative machine.
In the self-other responsibility classification result for the stop of each machine, the adjacent machine that directly caused the machine stop and the machine stop data ID thereof are stored in the self-other responsibility classification result data 93E. In FIG. 13, the direct cause of the machine stop of the filler 20 is the stop of the accumulator 30 ([machine stop data ID] xxxxxx12). However, referring to this in the self-other responsibility classification result data 93E, when the accumulator 30 is stopped ([machine stop data ID] xxxxxx12), the self-other responsibility classification result is "other responsibility" [cause machine] labeler [machine stop]. Data ID] There is a record of XXXXXX10. Further, the stop of the labeler 40 ([machine stop data ID] xxxxxx10) is referred to to obtain a record that this is "self-responsibility". That is, it is recognized that the root cause of the machine stop of the filler 20 is the stop of the labeler 40 ([machine stop data ID] xxxxxx10). Regarding the machine stop of the blow bottle molding machine 10 of FIG. 13, similarly, by referring to the self-other responsibility classification result data 93E, the stop of the labeler 40 ([machine stop data ID] xxxxxx10) is reached as the root cause.

[Effect of the second function]
According to the operation management system 90, when a plurality of machines in the blow bottle molding machine 10 to the palletizer 80 are stopped, the self-other responsibility can be classified, so that the machine that needs to be dealt with and dealt with can be easily specified. As a result, the machines for which measures should be taken in order to improve the operating rate of the production line 1 are clarified, which contributes to the realization of efficient improvement.

In particular, according to the operation management system 90, self-responsibility or other responsibility can be classified based on the operation data generated by the operation of the production line 1. Therefore, according to the operation management system 90, in order to classify self-responsibility or other responsibility, a special signal is added to the analysis of self-other product such as control logic for each machine or interlock between machines, or high-speed data processing is performed. , There is no need to perform arithmetic processing.

[Third function]
Next, the third function will be described.
The third function provides a method for evaluating productivity in a specific unit. There are at least four specific units: team unit, machine unit, product unit, and time unit.
Here, the production line 1 continuously produces beverages, for example, by setting a 24-hour three-shift system. It is assumed that the team is responsible for each of the three shifts, and here, the three teams of team α, team β, and team γ are in charge of production in three shifts. Productivity may differ depending on the team, so if productivity can be shown for each team, it can be used for subsequent production control. Normally, the number of personnel constituting each of team α, team β, and team γ is the same.

Further, the production line 1 includes a blow bottle molding machine 10 to a palletizer 80 and a plurality of machines, but the productivity of each is different. Therefore, if the productivity can be shown for each machine, it can be utilized for the subsequent production control.
Further, the production line 1 produces different beverage products such as beverage X, beverage Y and beverage Z in order. Even if the same production line 1 is used, the productivity may differ between when the beverage X is being produced and when the beverage Y is being produced. Therefore, if the productivity can be shown for each product, it can be utilized for the subsequent production control. The difference between the beverage X, the beverage Y and the beverage Z includes the difference in the size and shape of the resin container PB in addition to the difference in the contents.

Further, the production line 1 continuously produces products, for example, beverage products throughout the year, except during maintenance work. Even if the same operator operates the same production line 1, the productivity may differ depending on the production time. Therefore, if productivity can be shown on an hourly basis, it can be utilized for subsequent production control. The time referred to here has a concept that includes a unit of the month and the like in addition to the time zone in the day. In addition, as an hourly unit, there are evaluations by day of the week, the first half and the second half of the month, and the like.

Hereinafter, examples will be described in order. In this evaluation, the processing unit 95 performs predetermined processing on the operation data including the abnormality / alarm data and the production quantity data stored in the first storage unit 91 of the operation management system 90, and the processing is performed. The evaluation result as a result is displayed on the display unit 97 constituting the dashboard. This operation data also includes the team of operators responsible for production, the type of beverage produced, and the type of resin container PB.

[Evaluation by team: Fig. 14, Fig. 15]
As an example of team-based evaluation, FIG. 14 shows a graph showing the number of outages that occurred for each of team α, team β, and team γ for each of the blow bottle molding machines 10 to palletizer 80. The working hours of team α, team β, and team γ are almost the same.
As shown in FIG. 14, the team α has the highest number of stops in the labeler 40, and by referring to this evaluation result, it can be seen that measures such as work procedures are required for the team α. Further, by referring to FIG. 14, it can be seen that it is necessary to take measures to reduce the number of stops for the labeler 40 having a large number of stops. That is, it can be seen that FIG. 14 is an evaluation result for each machine.
Although the number of stops is shown here as an example on the vertical axis of the graph, other measures such as the stop time may be on the vertical axis, or the value obtained by dividing the stop time by the number of stops may be on the vertical axis.

FIG. 15 shows the evaluation of team α, team β and team γ at the stage of production. In other words, the upper table shows the outage status in later production for the remodeled team α, team β and team γ, and the lower table shows the team α, team β and team γ that undertook the initial production. It shows the suspension situation in the later production. Although the mold change and the initial stage of production are not shown in FIG. 15, each of the blow bottle molding machines 10 to the palletizer 80 is specified. The production of beverage products referred to here is carried out day and night after the production of a specific beverage product is started, but stable production is achieved in the initial stage of production, for example, about 2 hours after the start of production. Not done. Therefore, the operators constituting Team α, Team β, and Team γ adjust the machine, and the skill of the adjustment affects the subsequent production situation.

As shown in FIG. 15, the machine stop status differs depending on the team that performed the type change, and one of the countermeasures is that the other team β and team γ follow the type change work by the team α with the slightest stop. It is listed as one.
In addition, as shown in FIG. 15, the machine stop situation differs depending on the team even in the initial stage of production, and it is a countermeasure that other team β and team γ follow the mold change work by team α, which has the least stop. It is listed as one of.

[Evaluation of machine unit: Fig. 16]
Next, the evaluation of the machine unit will be described with reference to FIG.
As an example of evaluation in machine units, FIG. 16 shows a graph in which the horizontal axis is the stop time and the horizontal axis is the number of stops for each of the blow bottle molding machine 10 and the labeler 40. As an example, FIG. 16 displays only the machines in which the stop time or the number of stops exceeds a certain value among the blow bottle molding machines 10 to the palletizer 80.
From FIG. 16, it can be seen that it is necessary to take measures for the blow bottle molding machine 10 and the labeler 40 displayed, and in particular, the priority of the measures for the labeler 40 having a large stop time and the number of stops is high.

Although only machines whose stop time or number of stops exceeds a certain value are displayed in FIG. 16, all the machines of the blow bottle molding machines 10 to the palletizer 80 can be displayed, and the blow bottle molding machines 10 and the blow bottle molding machine 10 and the machine can be displayed. It is also possible to display other machines except the labeler 40.
As the evaluation of each machine, in addition to the stop time and the number of stops shown in FIG. 16, for example, a comparison between initial production and stable production for each machine, and a machine in which an abnormality alarm is frequently displayed can be displayed. .. The graph shown in FIG. 14 is also an example showing the evaluation of each machine.

[Evaluation of product units: Fig. 17, Fig. 18]
Next, the evaluation of the product unit will be described with reference to FIGS. 17 and 18.
As an example of evaluation of each product, FIG. 17 shows a graph in which the horizontal axis is the stop time and the vertical axis is the stop time for three types of beverage X, beverage Y, and beverage Z having different contents. As shown in FIG. 17, the difference in the beverage X, the beverage Y, and the beverage Z causes a difference in the stop time and the number of stops. Therefore, by referring to FIG. 17, it can be seen that special measures are required for the beverage X.
As another example of product unit evaluation, FIG. 18 shows that the horizontal axis is the stop time and the vertical axis is the vertical axis for three types of containers X (large size), container Y (medium size) and container Z (small size) having different sizes. Is shown in the graph with the stop time as. As shown in FIG. 18, the difference in the container X, the container Y, and the container Z causes a difference in the stop time and the number of stops. Therefore, by referring to FIG. 18, it can be seen that special measures are required for the container X.

17 and 18 show examples in which the contents and the size of the container are different as the product unit, but the size of the label attached to the container and whether or not the contents can be heated are shown. , It can be evaluated in units such as whether or not it contains milk.

[Evaluation by time: Fig. 19, Fig. 20]
Next, the evaluation in units of time will be described with reference to FIGS. 19 and 20.
As an example of time-based evaluation, FIG. 19 is a graph for evaluating downtime / number of outages throughout the year. This evaluation relates to, for example, the suspension of Labela 40, and it can be seen that May peaks. By referring to FIG. 19, necessary measures can be taken when April is approaching.

FIG. 20 shows the evaluation of the time zone at the stage of production. In other words, the upper table shows the outage status according to the time zone when the mold was changed, and the lower table shows the outage status according to the time zone when the initial production was performed. Although the mold change and the initial stage of production are not shown in FIG. 20, each of the blow bottle molding machines 10 to the palletizer 80 is specified.

As shown in FIG. 20, it can be seen that the machine stop status differs depending on the time zone in which the mold is changed, and it is necessary to review the mold change work from 17:00 to 1:00, when the machine is stopped most frequently.
Further, as shown in FIG. 20, even in the initial stage of production, the machine stop status differs depending on the working time zone, and the shift is made so that the initial production can be performed from 9:00 to 17:00, which is the least stopped. You can take measures such as assembling.

[Effect of the third function]
According to the operation management system 90, information for evaluating productivity in a specific unit is provided, and by referring to the information, it can be utilized for later production control. More specifically, it is as follows.

According to the operation management system 90, information for evaluating productivity in a team unit is provided, and by referring to the information, it is possible to accurately evaluate the skill in the team unit and identify the team in need of skill improvement. ..
Further, according to the operation management system 90, information for evaluating the productivity in the machine unit is provided, and by referring to the information, the productivity can be accurately evaluated in the machine unit and the productivity is improved. You can identify the machine to be maintained.

Further, according to the operation management system 90, information for evaluating the productivity in the product unit is provided, and by referring to the information, the productivity can be accurately evaluated in the product unit and the productivity is improved. You can identify the products to focus on.
Further, according to the operation management system 90, information for evaluating the productivity in the time unit is provided, and by referring to the information, the productivity can be accurately evaluated in the time unit, and the productivity can be improved. You can identify the time unit to focus on.

[Additional Notes]
The operation management system 90 of the production line 1 in which the plurality of machines described in the above embodiments are connected is grasped as follows.
(1) A display unit 97 for displaying operation data output by a plurality of machines, and a first storage unit 91 and a second storage unit 93 for storing operation data are provided.
The second storage unit 93 stores the operation data in association with the specific unit related to the production line 1. The display unit 97 displays the operation data in association with the specific unit.
According to the operation management system 90, information for evaluating productivity in a specific unit is provided, and by referring to the information, it is possible to more effectively utilize the operation data and contribute to the improvement of productivity.

(2) The specific unit is a team unit responsible for production on the production line 1, and the display unit 97 displays the operation data in association with the team unit.
As a result, the skill can be accurately evaluated for each team, and the team that needs to improve the skill can be identified.

(3) The specific unit is a machine unit constituting the production line 1, and the display unit 97 displays the operation data in association with the machine unit.
As a result, productivity can be accurately evaluated for each machine, and machines to be maintained for improving productivity can be specified.

(4) The specific unit is a product unit produced on the production line 1, and the display unit 97 displays the operation data in association with the product unit.
This makes it possible to accurately evaluate productivity on a product-by-product basis and identify products that should be focused on improving productivity.

(5) The specific unit is a time unit of production on the production line, and the display unit 97 displays the operation data in association with the time unit.
As a result, productivity can be accurately evaluated on an hourly basis, and time units that should be focused on to improve productivity can be specified.

(6) The operation data is stop data indicating the stop of operation of any of the machines.
By picking up the stop data that has a large influence on the productivity of the production line 1, it is useful for improving the productivity of the production line 1 later.

(7) The operation data is data related to the setup of a plurality of machines constituting the production line.
It is expected that productivity will be improved by being able to recognize the relationship between setup and productivity, which is often overlooked.

(8) The display unit 97 includes a first display unit 97 (dashboard DB1) provided accompanying the production line and a second display unit 97 (dashboard DB2) provided in the management area for managing the operation of the production line. And a third display unit 97 (DB3) provided to the manufacturer involved in the production of the production line.
As a result, appropriate measures can be taken from each position related to the production line 1.

(9) The first storage unit 91 and the second storage unit 93 are provided on the cloud.
As a result, a person in each position related to the production line 1 can easily obtain information on the operation stop even if the person is away from the production line 1.

(10) The production line 1 includes a blow bottle molding machine 10 for molding a resin container PB for beverages, a filler 20 for filling the resin container PB molded by the blow bottle molding machine 10 with a product liquid, and a filler 20. The labeler 40, which attaches a label to the resin container PB filled with the product liquid, the inspection machine 50, which inspects the beverage product whose label is attached to the container, and the inspection machine 50 complete the inspection. It is provided with a case packer 70 for packing beverage products in a box.
Even in this production line 1, which tends to affect the operation of a plurality of other machines arranged upstream or downstream by stopping a specific machine, it is possible to realize an immediate resumption of operation.

In addition to the above, it is possible to select the configuration described in the above embodiment or change it to another configuration as appropriate.

1 Production line 10 Blow bottle forming machine 11 Blow forming machine 13 Preform feeder 20 Filler 21 Filling machine 23 Cap feeder 30 Accumulator 40 Labeler 41 Winding machine 43 Label feeder 50 Inspection machine 60 Accum 70 Case packer 80 Palletizer 90 Management System 91 1st storage unit 91A Abnormal stop rule storage unit 91B Line structure storage unit 93 2nd storage unit 93A Machine operation status data 93B Machine stop data 93D Machine abnormality data 93E Self-other responsibility classification result data 95 Processing unit 95A Machine operation status collection Unit 95B Machine operation monitoring unit 95C Machine stop determination unit 95D Machine abnormality collection unit 95E Self-other responsibility classification unit 97 Display unit 97
A Data display area B1, B2, B3 Input area CP1, CP2, CP3 Computer device DB1, DB2, DB3 Dashboard DS Data server F1 Input form F2 Form F21 Input area F22 Display area FA Factory MA Manufacturer OF Office PR Producer IN Internet CL Cloud ID Machine stop data MD, MD1, MD2, MD3 Mechanical data HD Human data UD Integrated data PB Resin container PF preform

Claims (11)

It is an operation management system for a production line in which multiple machines are connected.
A display unit that displays operation data output by the plurality of machines,
With a storage unit for storing the operation data,
The storage unit is
The operation data and the specific unit related to the production line are associated and stored and stored.
The display unit is
An operation management system that displays the operation data in association with the specific unit.
The specific unit is
It is a team unit responsible for production on the production line.
The display unit is
Displaying the driving data in association with the team unit,
The operation management system according to claim 1.
The specific unit is
It is a machine unit that constitutes the production line.
The display unit is
Displaying the operation data in association with the machine unit.
The operation management system according to claim 1.
The specific unit is
It is a product unit produced on the production line.
The display unit is
Displaying the operation data in association with the product unit.
The operation management system according to claim 1.
The specific unit is
It is a unit of time for production on the production line.
The display unit is
Displaying the operation data in association with the time unit,
The operation management system according to claim 1.
The operation data is
Stop data indicating the stop of operation of any of the machines.
The operation management system according to any one of claims 2 to 5.
The operation data is
Data relating to the setup of a plurality of the machines constituting the production line.
The operation management system according to any one of claims 2 to 7.
The display unit is
The first display unit provided along with the production line and
A second display unit provided in a control area that manages the operation of the production line, and
Including a third display unit provided to a manufacturer involved in the production of the production line.
The operation management system according to any one of claims 1 to 7.
The storage unit is provided on the cloud.
The operation management system according to any one of claims 1 to 8.
The production line
A molding machine that molds beverage containers,
A filler that fills the container molded by the molding machine with the product liquid, and
A labeler that affixes a label to the container filled with the product liquid by the filling machine, and
An inspection machine that inspects beverage products with the label affixed to the container with the labeler.
A case packer for packing beverage products that have been inspected by the inspection machine is provided.
The operation management system according to any one of claims 1 to 9.
It is a production line where multiple types of machines are connected.
The production line, which is the operation management system according to any one of claims 1 to 10, controls the operation of the plurality of types of the machines.

Images