JP2023016147A - Production management system and production management program - Google Patents

Abstract

To provide a production management system capable of grasping at what point on a production line a loss has occurred, and recognizing an improvement notch for loss reduction.SOLUTION: A production management system includes production line configuration apparatuses including a weighing instrument 12, packaging apparatus 13, and inspection apparatus 14, and a host computer 16. Each of the production line configuration apparatuses and the host computer 16 can communicate each other over a network 17. Each of the production line configuration apparatuses transmits processing outcome information, which is information concerning a result of processing by the apparatus, to the host computer 16. The host computer 16 outputs a loss occurrence situation on a production line on the basis of the received processing outcome information.SELECTED DRAWING: Figure 1

Description

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

For example, in a production line that produces meat, fish, processed foods, pharmaceuticals, etc., the manufactured goods are weighed, packaged at a predetermined weight, inspected for contamination by foreign matter, and inspected for final weight. Products determined to be non-defective by inspection are packaged as final products and shipped.

Japanese Patent Laid-Open No. 2004-100003 describes calculating and displaying a loss index representing a loss caused by producing an inspected object, which has been determined as a defective product by an inspection unit, by a production facility in an article inspection apparatus.

Japanese Patent No. 6077764

However, since there are multiple devices in the production line, it is not possible to know which device is causing the loss just by looking at the number of defective products in the inspection device.

SUMMARY OF THE INVENTION Accordingly, it is an object of the present invention to provide a production management system that can grasp where in a production line a loss is occurring and that can grasp an improvement point for loss reduction.

A production management system of the present invention is a production management system for managing a production line including two or more production line constituent devices, comprising a host computer configured to communicate with the production line constituent devices, and comprising: The constituent devices transmit processing result information, which is information about the processing result of the device itself, to the host computer, and the host computer determines the occurrence of losses in the production line based on the received processing result information. This is the output.

With this configuration, the state of loss occurrence in the production line is output based on the processing result information from each production line component device. Therefore, it is possible to grasp where in the production line the loss is occurring, and to grasp the improvement point for loss reduction.

Further, in the production management system of the present invention, the production line component device transmits information indicating the number of products processed by the own device to the host computer as the processing result information, and the host computer receives the processing result information. Based on the result information, the number of product losses between the two or more production line constituent devices is calculated and output.

With this configuration, the number of products lost between production line constituent devices is calculated and output from the number of processed products in the processing result information from each production line constituent device. Therefore, it is possible to grasp where in the production line the loss is occurring, and to grasp the improvement point for loss reduction.

Also, in the production management system of the present invention, the host computer outputs an alarm when the number of product losses exceeds a predetermined threshold.

With this configuration, an alarm is output when the number of product losses exceeds a predetermined threshold. Therefore, it is possible to quickly recognize the situation in which the loss exceeds the threshold, and to grasp the improvement point for loss reduction.

Further, the production management program of the present invention comprises a production line including two or more production line configuration devices, and a host computer configured to communicate with the production line configuration devices, wherein the production line configuration devices are: A production management program for a production management system for transmitting processing result information, which is information about the result of processing of the device itself, to the host computer, wherein the host computer, based on the received processing result information, performs the following operations on the production line: It realizes the function of outputting the occurrence status of losses.

With this configuration, the state of loss occurrence in the production line is output based on the processing result information from each production line component device. Therefore, it is possible to grasp where in the production line the loss is occurring, and to grasp the improvement point for loss reduction.

INDUSTRIAL APPLICABILITY The present invention can provide a production management system that can grasp where in a production line loss is occurring and grasp improvement points for loss reduction.

FIG. 1 is a schematic configuration diagram of a production control system according to one embodiment of the present invention. FIG. 2 is a diagram showing an output example of production progress by the host computer of the production management system according to one embodiment of the present invention. FIG. 3 is a diagram showing an output example of a production progress graph by the host computer of the production management system according to one embodiment of the present invention.

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

In FIG. 1, a production management system 1 according to one embodiment of the present invention receives raw materials such as foods, beverages, etc. manufactured and processed in the upstream manufacturing process, and collects them in a predetermined weight in the weighing process and packaging process. In the inspection process, the product is inspected for weight, contamination, and packaging conditions.

The production line includes a weighing device 12, a packaging device 13, and an inspection device 14, each of which performs a different process. Each of these devices is also called a production line configuration device. are placed.

It should be noted that not only the devices (12 to 14) are arranged adjacent to each other as shown in FIG. , the inspection device 14 and the caser (not shown) are arranged adjacent to the product area where the packaged product is handled, and the two divided areas are connected by a conveying means consisting of a belt conveyor and a chute. It may be the case that

The weighing device 12 collects or combines the supplied raw materials so as to have a predetermined weight, and discharges them to the packaging device 13 .

The weighing device 12 temporarily stores the received raw materials in a storage container, disperses them in predetermined amounts into a plurality of weighing containers, and combines and computes the weighed values obtained in each of the weighing containers to obtain a weight within a predetermined weight range. It may have a combination metering means for discharging raw materials.

The packaging device 13 packages raw materials of a predetermined weight discharged from the weighing device 12 with packaging materials and discharges them to the inspection device 14 . The packaging device 13 can, for example, detect the amount of packaging material used from the start of operation of the production line to the present.

The inspection device 14 inspects the weight of the packaged product discharged from the packaging device 13, the presence of foreign matter, etc., and discharges the packaged product that is determined to be non-defective by the inspection.

The host computer 16 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).

Weighing device 12 , packaging device 13 , inspection device 14 and host computer 16 are connected to network 17 . The weighing device 12, packaging device 13, inspection device 14, and host computer 16 can communicate with each other via a network 17. FIG.

In the host computer 16, the arrangement of each device on the production line is set in advance, and information on other devices arranged before and after one device is stored in association with, for example, an ID unique to the device.

In the example shown in FIG. 1, the host computer 16 stores that the weighing device 12 is arranged in the weighing process, the packaging device 13 in the packaging process, and the inspection device 14 in the inspection process in this order.

In addition, if there are a plurality of devices in any process and each device can communicate with the host computer 16, it is possible to set whether each device is arranged in series or in parallel. I hope it is.

The host computer 16 receives inspection information such as inspection results and operation history transmitted from each device on the production line via the network 17 and stores and manages them in the hard disk device.

The operation history of the device here is not limited to the start and stop of operation of each device. It includes detection of the passage of raw materials discharged by the device, detection of the storage amount of supplied raw materials in the weighing device 12, zero set processing of the weighing means (not shown), etc. It includes waiting for stabilization, sheet roll exchange of packaging material, etc., and operation information specific to each device such as detection of incoming goods in the inspection device 14, output of inspection results, reset processing of inspection means (not shown), stabilization waiting period, etc. are included and sent to the host computer 16 as event data.

The event data may be assigned an ID unique to the device, and may be used as identification information for identifying which event data is transmitted from which device on the data.

Furthermore, the host computer 16 may have reception time information addition means for adding the received time information as a time stamp when event data transmitted from each device is received. As a result, even if time information is not included in the event data of any of the devices, time information at approximately the same point in time is recorded in the host computer 16, which limits the functionality of the control software on the device side. can avoid receiving Moreover, even if there is a deviation in the time set in each device, the effect is small.

The weighing device 12 , the packaging device 13 , and the inspection device 14 transmit processing result information, which is information regarding the processing results of each device, to the host computer 16 .

The weighing device 12 receives and weighs the supplied raw materials, collects or combines them so that they fall within a predetermined weight range, and outputs the combined discharge result including the time of discharge and the combined weight as processing result information to the host computer. 16.

The packaging device 13 includes, as a result of packaging, packaging OK (indicating normal packaging) or packaging NG (indicating normal packaging), the time when packaging was completed, the amount of packaging material used, and the like. The packaging result is transmitted to the host computer 16 as processing result information.

The inspection device 14 transmits the inspection result including inspection OK or inspection NG as a result of inspecting the product, the time when the inspection was completed, the weight of the inspection result, etc. to the host computer 16 as processing result information. The inspection device 14 may include a sorting device (not shown) that discharges out of the production line products for which inspection is NG and products for which packaging is NG from the packaging device 13, so that only normal products are sent to the subsequent caser. can be discharged efficiently.

In the present embodiment, the host computer 16, based on the processing result information received from each device, from the amount of raw materials and the planned production quantity set before the start of production line operation, the state of divergence from the planned production quantity, A profit rate is calculated from the occurrence of packaging material loss, the purchase price of raw materials and packaging materials, and the shipping amount, and is displayed on, for example, a display device (not shown) of the host computer 16 .

At this time, the host computer 16 converts the numerical value representing the amount of raw material among the processing result information received from each device into a common unit (eg, kg).

Here, the loss of raw materials and packaging materials means that the raw materials and packaging materials are not good quality and are lost during the operation of the production line. This includes the raw materials and packaging materials of products that have fallen during transportation between devices, the raw materials and packaging materials of products that have been determined to be defective by the inspection device 14, and the materials and packaging materials that have been used for adjustments in the packaging device 13. Packaging materials that were not included.

The host computer 16 can display, for example, a screen as shown in FIG. 2 on the display device as the current production progress.

In FIG. 2, the "raw material" is the mass of the raw material to be supplied, and the "planned production quantity" is the planned number of pieces to be produced from the raw material.

The “measured production amount” is the number of pieces combined and discharged by the weighing device 12 , which is calculated from the combined discharge result of the weighing device 12 . "Total mass" is the sum of the masses combined and discharged by the weighing device 12, calculated from the combined discharge results of the weighing device 12, i.e., the weight of the raw materials weighed to combine or combine into a predetermined weight range. It is the sum of the mass of raw materials that are actually combined or combined out of the value.

Although the predetermined weight range used in the weighing device 12 is usually set in units of grams (g), the "total mass" is converted into kilograms (kg).

The “packaged production quantity” is the number of products packaged by the packaging device 13 and discharged, which is calculated from the packaging result of the packaging device 13 . The “used packaging material amount” is the amount of packaging material used for packaging by the packaging device 13 from the start of the production line to the present, which is calculated from the packaging result of the packaging device 13 .

When the packaging result of the packaging device 12 does not include the amount of packaging material used for packaging, the number of packaged pieces is multiplied by the amount of packaging material per piece, or the packaging material is supplied from the packaging device 13 A pulse signal corresponding to the feeding amount may be received and the number of pulses may be counted to calculate the amount of packaging material.

Although the amount of packaging material used for packaging individual products is usually set in units of millimeters (mm), the "amount of packaging material used" is converted into meters (m).

The “number of non-defective products” is the number of products determined to be non-defective by the inspection device 14 , calculated from the inspection results of the inspection device 14 . The “good product total mass” is the total mass of the products determined to be good products by the inspection device 14, which is calculated from the inspection result of the inspection device 14, and is the sum of the measured values used for the excess/deficiency inspection.

The “number of defective products” is the number of products determined to be defective by the inspection device 14 , calculated from the inspection result of the inspection device 14 . The "defective product total mass" is the total mass of products determined to be defective by the inspection device 14, which is calculated from the inspection result of the inspection device 14, and is the sum of the measured values used for the excess/deficiency inspection.

Normally, values used for excess/deficiency inspection of individual products are set in units of grams (g), but the "good product total mass" is converted into kilograms (kg).

"Raw material loss" is the amount of raw material lost from the start of operation of the production line to the present, and indicates the occurrence of raw material loss.

"Before weighing" is the amount of raw material lost between the supply device 11 and the weighing device 12, and is calculated by subtracting the "total mass" from the "raw material".

"Before inspection" is the amount of raw material lost between the packaging device 13 and the inspection device 14, and is calculated by subtracting the "total mass of non-defective products" and the "total mass of defective products" from the "total mass". In other words, “before inspection” is the amount of raw material lost during transportation from the packaging device 13 to the inspection device 14 .

The "inspected product" is the amount of raw materials lost in the inspection device 14, and is the value of the "defective product total mass".
"Material loss" is calculated by adding "before weighing", "before inspection", and "inspected product".

"Packaging material loss" is the amount of packaging material lost from the start of operation of the production line to the present, and indicates the occurrence of packaging material loss.

The "inspected product" is the amount of packaging material lost in the inspection device 14, and is obtained by multiplying the "number of defective products" by the amount of packaging material used for one product, for example, 0.2 m.

"Before inspection" is the amount of packaging material lost between the packaging device 13 and the inspection device 14, and the value obtained by subtracting the "number of good products" and the "number of defective products" from the "number of packaging production" is added to the value of one product. is calculated by multiplying the amount of packaging material used for In other words, “before inspection” is the amount of packaging material lost during transportation from the packaging device 13 to the inspection device 14 .

"Before packaging" is the amount of packaging material lost in the packaging device 13, and the value obtained by multiplying the "quantity of packaging production" by the amount of packaging material used for one product from the "amount of packaging material used" is calculated. It is obtained by subtracting.
"Packaging material loss" is calculated by adding all "before packaging", "before inspection", and "inspected product".

"Profit rate" is based on the estimated shipping value calculated by multiplying the "number of good products" by the preset unit price information of the product, the estimated cost of the raw materials and packaging materials used, and the operating time of the production line. It is a rough index calculated from the assumed expenses calculated based on the assumed expenses and the assumed profits calculated based on the estimated expenses. The assumed cost may be calculated based on the production plan, or may be calculated based on the production results according to the production progress.

In addition to the "profit rate" shown in the figure, items such as the production progress rate and other information stored in the host computer 16 can be combined, and various indices that can be calculated using other information that has been set and input can be calculated. Names and calculation formulas can be set, and appropriate indicators in the weighing process, packaging process, and weighing process can be grasped according to the production progress.

As another index, for example, based on "raw material loss", the profit that could have been originally obtained from the market price of a product that could not be shipped as a product may be displayed as a loss amount. In this case, the host computer 16 is set with a loss amount per 1 kg of "raw material loss" calculated in advance based on the amount of raw materials per product and the average profit per product. .

For example, as a result of calculating the current production progress, the host computer 16, when the value of "raw material loss" or "packaging material loss" exceeds a predetermined threshold, or when the profit rate falls below a predetermined threshold, A message may be displayed as an alarm on the display device, or may be highlighted by changing the display mode such as color.

Also, the host computer 16 may display, for example, a screen as shown in FIG. 3 on the display device as a current production progress graph.

In the present embodiment, "raw material loss" is expressed in units of kilograms (kg), and "packaging material loss" is expressed in units of meters (m). Alternatively, for example, the packaging material loss may be divided by the length of one roll (roll), converted into a value in units of "rolls", and output.

In this embodiment, even if the inspection device 14 fails the inspection for an inspection item other than the excess/deficiency inspection, the weight value measured for the excess/deficiency inspection is used to calculate the "defective product total mass." However, the inspection device 14 may not be able to measure the weight for some reason.

An example of a weight that cannot be measured by the inspection device 14 is exceeding the measurement range. In this case, the inspection result includes "OVF" (overflow), which indicates exceeding the upper limit of the measurement range. The host computer 16 replaces the "OVF" included in the inspection result with the preset maximum value of the measuring range of the inspection device 14, and totalizes the "number of defective products" and the "total mass of defective products". The difference from the actual weight is an error, but it is within an allowable range in terms of the total loss of raw materials.

Another example in which the weight cannot be measured by the inspection device 14 is a so-called double riding. A double product represents a state in which two products are brought in at short intervals and the individual weights cannot be measured correctly. Such a double product is not determined as inspection NG and is sent to re-inspection. Since neither "mass" can be calculated, the items in FIG.

For exceptional products whose weight cannot be measured by the inspection device 14, as described above, a management rule may be set for each production line, which can be detected by the inspection device 14, or based on information included in the inspection result. Different processing may be performed by the host computer 16 within a range that can be identified by the host computer 16, so that the functionality of the inspection device 14 can be improved.

In addition, not only the inspection device 14 but also the exception products generated in the weighing device 12 and the packaging device 13 are subject to management rules determined for each production line, and different processing is performed by the host computer 16 within an identifiable range. It may be carried out, and by doing so, it is possible to cope with functional improvement of the weighing device 12 and the packaging device 13 .

The host computer 16 can add or omit items from the output shown in FIG. 2 by operating a keyboard or the like (not shown) so as to correspond to the management rules defined for each production line. can.

In addition, the host computer 16 controls the output shown in FIG. 2 by manipulating a keyboard (not shown) so as to match the layout of the production line and to emphasize items to be managed intensively. You can change the display mode.

Furthermore, the host computer 16 can aggregate and output the progress information of a plurality of production lines on one screen. In this case, among the output items as shown in FIG. 2, the set specific items can be aggregated and output.

By doing so, it is possible to easily confirm that the amount of packaging material used has increased, or that the number of products produced or the number of non-defective products has decreased.

Thus, in the above-described embodiment, the weighing device 12, the packaging device 13, and the inspection device 14 transmit the processing result information including the contents set in their own devices to the host computer 16, and the host computer 16 receives Based on the processing result information, output the loss occurrence status in the production line.

As a result, the processing result information from the weighing device 12, the packaging device 13, and the inspection device 14 is used to output the state of loss occurrence in the production line. Therefore, it is possible to grasp where in the production line the loss is occurring, and to grasp the improvement point for loss reduction.

In addition, the weighing device 12, the packaging device 13, and the inspection device 14 transmit information indicating the number of products processed by the self device to the host computer 16 as processing result information, and the host computer 16 receives the processing result information. to calculate and output the number of product losses between devices.

As a result, the number of products lost between devices is calculated and output from the number of processed products in the processing result information from the weighing device 12, the packaging device 13, and the inspection device 14. FIG. Therefore, it is possible to grasp where in the production line the loss is occurring, and to grasp the improvement point for loss reduction.

Also, the host computer 16 outputs an alarm when the number of lost products exceeds a predetermined threshold.

As a result, an alarm is output when the number of lost products exceeds a predetermined threshold. Therefore, it is possible to quickly recognize the situation in which the loss exceeds the threshold, and to grasp the improvement point for loss reduction.

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

1 Production control system 12 Weighing device (Production line component device for weighing process)
13 packaging equipment (production line configuration equipment for packaging process)
14 inspection equipment (production line configuration equipment for inspection process)
16 host computer 17 network

Claims (4)

A production management system (1) for managing a production line including two or more production line configuration devices (12, 13, 14),
A host computer (16) configured to communicate with the production line configuration device,
The production line component device transmits processing result information, which is information related to the processing result of its own device, to the host computer;
A production management system in which the host computer outputs a loss occurrence situation in the production line based on the received processing result information. The production line component device transmits information indicating the number of products processed by the device to the host computer as the processing result information,
2. The production management system according to claim 1, wherein the host computer calculates and outputs the number of product losses between the two or more production line constituent devices based on the received processing result information. 3. The production management system according to claim 2, wherein said host computer outputs an alarm when the number of lost products exceeds a predetermined threshold. A production line including two or more production line configuration devices (12, 13, 14), and a host computer (16) configured to communicate with the production line configuration devices, wherein the production line configuration devices are: A production control program for a production control system that transmits processing result information, which is information about the result of processing of the device itself, to the host computer,
A production management program for realizing a function of outputting a loss occurrence situation in the production line to the host computer based on the received processing result information.

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