JP2023158366A - production management system - Google Patents

Abstract

To provide a production management system that can centralize and display information acquired by a PLC in real time, and can also centralize and analyze the information and generate analytical information.SOLUTION: A first program 64 implemented by a management device 60 causes original information output by a PLC 50 to be registered in an original information DB of a memory 74 of a first server 70, which is a Redis server. A second program 65 implemented by the management device 60 causes a terminal device 90 to display the original information in real time. A third program 66 implemented by the management device 60 generates analysis information based on the original information registered in the original information DB, and causes the analysis information to be registered in an analysis information DB of the memory 74. A fourth program 67 implemented by the management device 60 reads the analysis information from the analysis information DB in response to a request from the terminal device 90 and generates analysis information display data, and causes the terminal device 90 to display an analysis information display screen indicated by the analysis information display data.SELECTED DRAWING: Figure 1

Description

The present invention relates to a production management system that manages the manufacturing of products in a manufacturing factory.

BACKGROUND ART In manufacturing factories that process raw materials to manufacture products, PLCs (Programmable Logic Controllers) that control the drive of manufacturing equipment such as processing equipment and inspection equipment are known (for example, see Patent Document 1). This PLC displays information regarding drive control on an attached display and also stores it in an attached memory. Information regarding drive control includes manufacturing time information, error information, and the like. The manufacturing time information includes information such as whether the manufacturing device is powered on, whether it is in a standby state, whether it is in an operating state, and the number of products manufactured since the start of operation. The error information includes an error code indicating the type of error.

Furthermore, a system is known that stores information regarding drive control in a database (for example, see Patent Document 2).

Japanese Patent Application Publication No. 2010-721758 Japanese Patent Application Publication No. 2011-3126

Generally, in manufacturing factories, it is desired to construct a production management system for controlling production in order to improve manufacturing efficiency. However, the PLC does not have the function of a production management system that collectively manages information acquired by multiple PLCs.

The present invention has been made in view of the above-mentioned circumstances, and its purpose is to be able to centrally display information acquired by a PLC in real time, and to centrally analyze the information and generate analysis information. The objective is to provide a production management system that can generate

(1) The production management system according to the present invention includes a plurality of controllers that periodically acquire original information including at least device ID, manufacturing elapsed information, and error information, and a first program, a second program, and a third program. A management device that implements the above, a memory that stores an original information database and an analysis information database, and a terminal device. The controller, the management device, and the terminal device are capable of communicating through a communication network. The first program executes a source information registration process that acquires the source information from the controller and registers the source information in the source information database. The second program includes a generation process that periodically acquires the source information and periodically generates real-time display screen data, and a first transmission process that periodically transmits the real-time display screen data to the terminal device. , execute. The third program includes an error information acquisition process that acquires the date and time of occurrence of the error indicated by the error information from the source information database, and an analysis information generation process that generates analysis information that associates the device ID and the date and time of occurrence. , an analysis information registration process for registering the analysis information in the analysis information database.

Each controller periodically acquires or generates original information at time intervals such as tens of milliseconds, hundreds of milliseconds, or several seconds. The first program acquires original information from each controller and registers it in the original information database. The second program acquires manufacturing elapsed information from each controller, periodically transmits the acquired manufacturing elapsed information to the terminal device, and displays a real-time display screen on the display of the terminal device all at once. The third program acquires error information from the original information database and generates analysis information. The third program registers the generated analysis information in the analysis information database. That is, the production management system according to the present invention can centrally display the information acquired by the controller in real time, and can centrally analyze the information and generate analysis information.

(2) The production management system according to the present invention may further include a fourth program that acquires the analysis information from the analysis information database and generates analysis information display screen data to be transmitted to the terminal device. good.

For example, when the second program generates analysis information display screen data, if the generation of the analysis information display screen data is delayed or a problem occurs, the real-time display of manufacturing elapsed information on the terminal device may also be affected. There is a risk that this may occur. Since the fourth program generates the analysis information display screen data, the analysis information can be displayed on the terminal device without interfering with the real-time display of the manufacturing elapsed information.

(3) The memory further stores a manufacturing schedule database in which at least the product ID, the device ID, and the manufacturing schedule are associated with each other, and the analysis information generation process acquires the device ID and the manufacturing schedule from the manufacturing schedule database. and the analysis information that associates the product ID, the device ID, the error information, the date and time of error occurrence, and the manufacturing schedule based on the analysis information and the manufacturing schedule. It may also include a process of generating.

The analysis information is generated based on the manufacturing schedule and error information of the original information. Therefore, more detailed analysis information can be generated.

(4) The memory may further store a tally database in which tally information that is a tally of the manufacturing time information for each day is registered. The second program further executes a total display screen data generation process that generates total display screen data based on the total information, and a second transmission process that transmits the total display screen data to the terminal device.

The second program allows a daily total to be displayed on the terminal device.

(5) The real-time display screen indicated by the real-time display screen data includes a plurality of device icons, and the second program is associated with the selected device icon based on the selection of the device icon. An instruction process may be further executed in which the device ID and information instructing generation of the analysis information display screen data are passed to the fourth program.

When a device icon is selected by a person in charge of management or the like on the real-time display screen, an analysis information display screen showing the date and time of occurrence of an error is displayed for the device indicated by the selected device icon. That is, a person in charge of management or the like can check details such as the date and time of error occurrence for each device.

(6) A server that expands the source information database to RAM and accesses the source information database, and that sets one key for one piece of the manufacturing time information and registers it in the source information database. You may also have more.

The server with the above configuration is a so-called Redis (registered trademark) server. By using the Redis server, it is possible to register source information in the source information database and read analysis information from the source information database at high speed.

(7) The analysis information display screen data may be web page data displayed by a browser installed in the terminal device.

The production management system according to the present invention can display manufacturing elapsed information in real time, and can register information in a database and generate analysis information without any problems.

FIG. 1 is a diagram showing the configuration and functions of a production management system 10. FIG. 2 is a layout diagram showing the arrangement of manufacturing equipment 30 in manufacturing factory 20. As shown in FIG. FIG. 3(A) is a diagram showing the manufacturing schedule database, and FIG. 3(B) is a diagram showing the original information database. FIG. 4(A) is a diagram showing an analysis information database, and FIG. 4(B) is a diagram showing a total database. FIG. 5 is a flowchart showing the process of registering the manufacturing schedule, original information, and analysis information in the database. FIG. 6 is a flowchart showing a process for displaying a real-time display screen. FIG. 7 is a flowchart showing the process of displaying the total display screen. FIG. 8 is a flowchart showing the process of displaying the analysis information display screen. FIG. 9 is a flowchart showing the process of displaying the current period cumulative total display screen. FIG. 10 is a diagram showing a real-time display screen. FIG. 11 is a diagram showing a real-time display screen. FIG. 12 is a diagram showing a total display screen. FIG. 13 is a diagram showing an analysis information display screen. FIG. 14 is a diagram showing the current period cumulative total display screen.

Preferred embodiments of the present invention will be described below with appropriate reference to the drawings. Note that this embodiment is only one aspect of the production management system according to the present invention, and it goes without saying that the embodiment may be modified without changing the gist of the present invention. For example, the execution order of each process described below may be changed as appropriate without changing the gist of the present invention. Alternatively, some of the processes described below may be omitted as appropriate without changing the gist of the present invention.

FIG. 1 is a configuration diagram showing the configuration of a production management system 10 according to an embodiment of the present invention. Further, FIG. 1 is also a functional block diagram showing the functions of the management device 60, the first server 70, the second server 80, and the terminal device 90 that constitute the production management system 10.

The production management system 10 is a system used for production management in the manufacturing factory 20. Production management refers to a person who manufactures a product or a person who manages manufacturing at the manufacturing factory 20 (hereinafter referred to as a "manager, etc.") to monitor the operating status of the manufacturing equipment 30 and what is currently being manufactured. This means understanding the type of product, the type of product planned to be manufactured, the number of products manufactured, the yield rate, etc. Management personnel use the production management system 10 to grasp the current manufacturing status, identify problems based on past manufacturing history, and improve the current status. Plan future manufacturing schedules based on the information.

In this embodiment, a production management system 10 used for production management in two manufacturing plants 20, a main factory 21 and a local factory 22, will be described. However, the production management system 10 may be used for production management at one or more manufacturing plants 20.

FIG. 2 is a layout diagram showing the arrangement of each manufacturing device 30 installed on the first floor of the manufacturing factory 20. The manufacturing device 30 includes a processing device 31, a coolant device 32, a finishing device 33, a cleaning device 34, and the like. Although not shown in FIG. 2, the manufacturing device 30 also includes an inspection device 35 (see FIG. 1).

The manufacturing factory 20 is divided into a plurality of areas 40 by floors, walls, and the like. Manufacturing equipment 30 for the same purpose is installed in each area 40, respectively. Examples of the same purpose include "processing", "coolant", "finishing", and "inspection". In the example shown in FIG. 2, the first floor of the manufacturing factory 20 has a "cylindrical" area 41, a "coolant" area 42, a "width/outer diameter" area 43, an "inner diameter" area 44, a "finishing" area 45, and a "finishing" area 45. The cleaning area 46 is divided into six areas 40.

The "cylindrical" area 41 is an area whose purpose is, for example, to process raw materials into cylindrical members. The "coolant" area 42 is an area whose purpose is to cool the cylindrical member. The "width/outer diameter" area 43 is an area for processing, for example, drilling, bending, cutting, etc. on the outer part of the cylindrical member. The "inner diameter" area 44 is an area for processing, for example, drilling, bending, cutting, etc., on the inner part of the cylindrical member. The "finishing" area 45 is an area for finishing, such as polishing, the processed member (product). The "cleaning" area 46 is an area for cleaning the finished product.

In the example shown in FIG. 2, four processing devices 31 that process raw materials into cylindrical members are arranged in a "cylindrical" area 41. Furthermore, one coolant device 32 for cooling is arranged in the "coolant" area 42. Furthermore, two processing devices 31 for processing the outer portion of the cylindrical member are arranged in the "width/outer diameter" area 43. Further, nine processing devices 31 for processing the inner part of the cylindrical member are arranged in the "inner diameter" area 44. Furthermore, two finishing devices 33 that perform finishing are arranged in a "finishing" area 45. Furthermore, one cleaning device 34 for cleaning products is arranged in a "cleaning" area 46. Although not shown in FIG. 2, an inspection device 35 (see FIG. 1) that inspects products is arranged in another area (not shown) in the manufacturing factory 20.

The raw materials are transported in order by a forklift, a conveyor, etc. to a "cylindrical" area 41, a "coolant" area 42, an "outer diameter/width" area 43, and an "inner diameter" area 44. After being processed, etc., it is transported to a "finishing" area 45. After the product is finished by polishing or the like in the "finishing" area 45, it is transported to the "cleaning" area 46 and cleaned. After cleaning, the products are transported to an "inspection" area (not shown) where they are inspected such as dimension measurements.

As shown in FIG. 1, the production management system 10 includes a PLC (Programmable Logic Controller) 50, a management device 60, a first server 70, a second server 80, and a terminal device 90.

The PLC 50, the management device 60, the first server 70, the second server 80, and the terminal device 90 are connected to the communication network 11 by wire or wirelessly. The communication network 11 is a LAN (Local Area Network), a WAN (Wide Area Network), the Internet, or the like. In the example shown in FIG. 1, a LAN is attached to each of the main factory 21 and local factories 22, and the LANs are interconnected through the Internet. Note that, in FIG. 1, illustrations of a gateway device such as a router that connects the LAN and the Internet, a switching hub that performs communication control, and the like are omitted.

The management device 60 communicates with the first server 70, the second server 80, and the terminal device 90 using, for example, a TCP/IP communication protocol. The management device 60, the first server 70, the second server 80, and the terminal device 91 are installed in the head office factory 21, and the management device 60 is connected to the first server 70, the second server 80, and the terminal device 91 through the LAN or WAN. It communicates with the terminal device 90. On the other hand, the terminal device 92 is installed in the local factory 22, and the terminal device 93 is a portable mobile terminal. The terminal devices 92 and 93 communicate with the management device 60 by transmitting an HTTP request and receiving an HTTP response that is a response to the HTTP request.

The PLC 50 is a device that performs drive control of the manufacturing equipment 30 and periodically acquires and accumulates equipment ID, manufacturing elapsed information, error information, etc. for identifying the manufacturing equipment 30 that performs drive control at a predetermined sampling period. . The manufacturing time information is information indicating, for example, whether or not power is supplied to the manufacturing apparatus 30, the number of products processed (manufactured quantity) after power is supplied, the time required for changeover, measurement information, and the like. The time required for setup change is the time required to change from a state that corresponds to the processing or inspection of one type of product to a state that corresponds to the processing or inspection of another type of product, such as replacing accessory parts. be. The measurement information is information obtained by measuring the dimensions of each part of the product when the manufacturing apparatus 30 is an inspection apparatus. The error information is, for example, an error code corresponding to a malfunction occurring in the manufacturing apparatus 30. For example, the PLC 50 acquires or generates a corresponding predetermined error code when a cylinder, motor, or the like of the manufacturing device 30 stops unexpectedly.

The PLC 50 may be built in the manufacturing device 30 in advance, or may be retrofitted to the manufacturing device 30. Furthermore, the PLC 50 may perform drive control of one manufacturing apparatus 30 or may perform drive control of a plurality of manufacturing apparatuses 30. In the example shown in FIG. 1, one PLC 50 is attached to one manufacturing apparatus 30. The PLC 50 corresponds to a "controller" described in the claims.

The PLC 50 includes a display (not shown) that displays manufacturing elapsed information and error information that are periodically acquired, and an attached memory (not shown) that stores the information and device ID. The attached memory has a storage capacity capable of storing, for example, three days' worth of manufacturing time information, error information, and the like. In short, the PLC 50 is capable of accumulating several days' worth of manufacturing time information and error information, but cannot store long-term manufacturing time information and error information such as January. The PLC 50 updates the manufacturing aging information, for example, by overwriting the oldest manufacturing aging information and error information with the newly acquired manufacturing aging information and error information.

The PLC 50 periodically transmits the acquired device ID, manufacturing elapsed information, and error information to the management device 60 as source information in association with the date and time of acquisition. For example, the PLC 50 acquires manufacturing elapsed information and error information at sampling intervals of several hundred milliseconds to several seconds, and transmits the acquired plurality of manufacturing elapsed information and error information collectively at intervals of several seconds to more than ten seconds. Note that the original information transmitted by the PLC 50 does not need to have an acquisition date and time. In that case, for example, the date and time when the original information was received by the management device 60 may be attached to the original information.

The management device 60 is a server, a personal computer, or the like. The management device 60 includes a CPU 61 that is a central processing unit, a memory 62, and a communication interface 63. The communication interface 63 is wired to the communication network 11 through a LAN (registered trademark) cable or the like, or wirelessly connected to the communication network 11 through a wireless LAN such as Wi-Fi (registered trademark).

The memory 62 is a RAM, ROM, hard disk memory, EEPROM, USB (registered trademark) memory, or the like. The memory 62 stores a first program 64, a second program 65, a third program 66, a fourth program 67, an operating system (OS) 68, and a manufacturing schedule database. Note that in FIG. 1, "database" is abbreviated to "DB". The memory 62 corresponds to the "memory" described in the claims.

The first program 64 is a program for transmitting the original information transmitted by the PLC 50 to the first server 70 and registering it in the original information database (see FIG. 3(B)).

The second program 65 is a program for displaying the original information transmitted by the PLC 50 on the display 107 of the terminal device 90 in real time and registering the aggregated data in the aggregated database (see FIG. 4(B)).

The third program 66 is a program for generating analysis information based on the original information transmitted by the PLC 50 and registering the analysis information in the analysis information database (see FIG. 4(A)).

The fourth program 67 is a program for displaying the analysis information on the display 107 of the terminal device 90.

The programming language of the first program 64, second program 65, and third program 66 is, for example, Python. The fourth program 67 is a program for creating web page data or the created web page data itself. Web page data is written in HTML, for example. The HTML may include CSS and JavaScript.

The OS 68 is Windows (registered trademark), macOS (registered trademark), Linux (registered trademark), Unix (registered trademark), ChromeOS (registered trademark), iOS (registered trademark), or the like. The OS 68 includes various DLLs such as a DLL (Dynamic Link Library) for communication and a DLL for display.

FIG. 3A shows an example of a manufacturing schedule database stored in the memory 62. The manufacturing schedule database is created using, for example, EXCEL (registered trademark) or ACCESS (registered trademark).

The manufacturing schedule database is a database in which process codes, factory identification information, product codes, scheduled manufacturing quantities, equipment scheduled to be used, scheduled start dates and times, and scheduled end dates and times are registered in association with each other. Specifically, the manufacturing schedule database has multiple records (rows) and multiple columns (columns). One record is registered in the manufacturing schedule database for one manufacturing schedule. Each column is one of the above "Process code", "Factory identification information", "Product code", "Planned production quantity", "Scheduled equipment used", "Scheduled start date and time", and "Scheduled end date and time". The following items are attached.

In each field of the column corresponding to the item "process code", a process code is registered as identification information for identifying a manufacturing schedule (record). The process code is, for example, a lot number. In the illustrated example, "202111-A001", "202111-A002", and "202111-B001" are registered as process codes.

In each field of the column corresponding to the item "factory identification information", factory identification information that individually identifies the manufacturing factory 20 is registered. In the illustrated example, "001" indicating the main factory and "002" indicating the local factory are registered.

In each field of the column corresponding to the item "product code", a product code is registered as identification information for identifying the type of product. In the illustrated example, "A000002", "B000005", and "C000002" are registered as product codes. The product code may be a product name. The product code corresponds to the "product ID" described in the claims.

In each field of the column corresponding to the item "planned manufacturing quantity", the planned number of products to be manufactured in each manufacturing schedule is registered. In the illustrated example, "2500", "1500", and "2000" are registered as the planned production quantity.

In each field of the column corresponding to the item "device to be used", the device ID of the manufacturing device 30 to be used in each manufacturing plan is registered. In the illustrated example, device IDs such as "A01," "B02," and "C05" are registered as devices scheduled to be used. In addition, in one manufacturing schedule, manufacturing equipment 30 that performs "cylindrical" processing, manufacturing equipment 30 that performs "outer diameter/width" processing, manufacturing equipment 30 that performs "inner diameter" processing, manufacturing equipment 30 that performs "finishing", etc. , a plurality of manufacturing devices 30 can be registered.

In each field of the column corresponding to the item "scheduled start date and time", the date and time when each manufacturing apparatus 30 is scheduled to start manufacturing is registered. In the illustrated example, "2021.11.01 10:15", "2021.11.01 15:00", and "2021.11.01 13:30" are registered as the scheduled start date and time.

In each field of the column corresponding to the item "scheduled end date and time", the date and time when each manufacturing apparatus 30 is scheduled to end manufacturing is registered. In the illustrated example, "2021.11.03 18:00", "2021.11.02 9:15", and "2021.11.03 11:00" are registered as the scheduled end date and time.

Registration of a new record in the manufacturing schedule database, that is, registration of a new manufacturing schedule, is performed by a management person or the like. A person in charge of management or the like plans (drafts) a manufacturing schedule based on the product name, order quantity, delivery date, etc. written in the order form for receiving the order, and registers it in the manufacturing schedule database. Note that the first program 64, the second program 65, or a program not shown may automatically generate a new manufacturing schedule based on the order form or other manufacturing schedule and register it in the manufacturing schedule database.

The manufacturing schedule database shown in FIG. 3(A) is an example, and the manufacturing schedule database may have columns with items other than those shown in FIG. 3(A). Alternatively, some of the columns labeled with the items shown in FIG. 3(A) may not be included. Further, the manufacturing schedule database may be stored in a memory 72, a memory 74, a memory 82, or a memory 84, which will be described later.

As shown in FIG. 1, the first server 70 includes a CPU 71 that is a central processing unit, a memory 72, and a communication interface 73.

The memory 72 is a RAM, ROM, hard disk memory, EEPROM, USB (registered trademark) memory, or the like. The memory 72 stores an OS (not shown) that is an operating system and a first server program 75. This OS is Windows (registered trademark) or the like like OS68. The memory 72 corresponds to the "memory" described in the claims.

The first server 70 is, for example, an in-house server installed in a server room at the head office. The first server 70 may be a web server that publishes a URL.

The first server 70 is a so-called Redis (registered trademark) server. The Redis server refers to a server that operates a key-value store type database that operates on memory. The Redis server enables high-speed access to the database by expanding all information registered in the database into memory (RAM) and processing (reading/writing) the information. Further, the Redis server operates a key-value store type database in which one key is set and registered for one piece of information. That is, the Redis server can register information in various data formats in the database.

A memory 74 is connected to the first server 70 . The memory 74 may be a hard disk or a storage server. Further, the memory 74 may be part of the memory 72. The memory 74 corresponds to the "memory" described in the claims.

The memory 74 stores an original information database and an analysis information database. The original information database is developed on the memory 72 (RAM) and accessed by the first server program 75 of the first server 70. That is, the source information database allows high-speed reading and writing of information. Note that the analysis information database may also be expanded on the memory 72 (RAM) and accessed by the first server program 75 of the first server 70.

The original information database is a database in which original information transmitted by the PLC 50 is registered. The registration of the original information in the original information database is performed by the first program 64 and the first server program 75.

FIG. 3(B) shows an example of the original information database. The original information database is created using, for example, EXCEL (registered trademark) or ACCESS (registered trademark).

The original information database is a database in which device IDs, process codes, product codes, and manufacturing elapsed information are registered in association with each other. Each record in the source information database is individually identified by a device ID or a process code. That is, manufacturing elapsed information is registered for each manufacturing device 30 that is individually identified by the device ID and for each manufacturing lot that is individually identified by the process code.

The original information database has multiple records (rows) and multiple columns (columns). Each column is assigned one of the following items: "apparatus ID," "process code," "product code," and "manufacturing time information."

In each field of the column corresponding to the item "device ID", a device ID, which is identification information attached to the manufacturing device 30, is registered. In the illustrated example, "A01" is registered.

In each field of the column corresponding to the item "process code", a process code, which is identification information for identifying a manufacturing lot, is registered. Each sub-record registered in the source information database is individually identified by this process code. In the illustrated example, “202111A-001” is registered.

In each field of the column corresponding to the item "product code", a product code, which is identification information for identifying a product, is registered. In the illustrated example, "A000001" is registered.

The item "manufacturing time information" has a plurality of subcolumns (subcolumns). Each of the plurality of sub-columns is assigned one of the following items: "Date and Time", "Error Flag", "Error Code", "Power Supply Flag", "Operation Flag", and "Manufacturing Quantity".

In each field of the subcolumn corresponding to the item "date and time", the date and time when the PLC 50 transmitted the original information or the date and time when the management device 60 received the original information are registered.

In each field of the subcolumn (subcolumn) corresponding to the item "error flag", an error flag included in the original information transmitted by the PLC 50 is registered. The error flag is information indicating whether an error (abnormality) has occurred. For example, an error flag of "ON" indicates that an error has occurred, and an error flag of "OFF" indicates that no error has occurred.

In each field of the subcolumn (subcolumn) corresponding to the item "error code", an error code included in the original information transmitted by the PLC 50 is registered.

The error code is information indicating the type of error (abnormality) that has occurred. The types of errors include, for example, "air pressure abnormality", "emergency stop", "continuous leak test failure", "continuous laser test failure", etc. Note that a correspondence table that associates error codes with error types is stored in advance in the memory 62 or the like.

In each field of the subcolumn (subcolumn) corresponding to the item "power supply flag", the power supply flag included in the original information transmitted by the PLC 50 is registered. The power supply flag is information indicating whether or not power is being supplied to the manufacturing apparatus 30. For example, a power flag of "ON" indicates that power is being supplied to the manufacturing apparatus 30, and a power flag of "OFF" indicates that power is not being supplied to the manufacturing apparatus 30.

In each field of the subcolumn corresponding to the item "operation flag", the operation flag included in the original information transmitted by the PLC 50 is registered. The operation flag is information indicating whether the manufacturing apparatus 30 is in operation and is in a state of manufacturing, inspecting, etc. a product (commodity). For example, an operation flag of "ON" indicates that the manufacturing equipment 30 is manufacturing or inspecting a product, and an operation flag of "OFF" indicates that the manufacturing equipment 30 is manufacturing or inspecting a product. Indicates that it has not been performed.

For example, if power is being supplied to the manufacturing equipment 30, but it is in the preparation period for changing the product to be manufactured (no error has occurred), "ON" is registered in the item "power flag", and the item “OFF” is registered in the “operation flag” and “OFF” is registered in the item “error flag”. In addition, if power is being supplied to the manufacturing equipment 30, but an error occurs and the emergency stop is performed, "ON" is registered in the item "power flag" and "OFF" is registered in the item "operation flag". "ON" is registered in the item "Error flag". That is, it is possible to analyze the state of the manufacturing apparatus 30 based on information registered in the item "power flag", the item "operation flag", the item "error flag", and the like. The third program 66 installed in the management device 60 identifies the state of the manufacturing device 30 based on the information registered in the original information database, and also identifies the type of error, date and time of occurrence, date and time of resolution, and error status. The specified information is registered as analysis information in the analysis information database (FIG. 4(A)). That is, the original information is analyzed and registered in the analysis database. Note that the source information database shown in FIG. 3(B) is an example, and the source information database may have columns with items other than those shown in the figure. , may not have all of the columns labeled with the items shown in the figure.

FIG. 4(A) shows an example of the analysis information database. The analysis information database is created using, for example, EXCEL (registered trademark) or ACCESS (registered trademark).

Registration of analysis information in the analysis information database is performed by the third program 66 and the first server program 75.

The analysis information database is a database in which device IDs, process codes, product codes, and analysis information are registered in association with each other. Each record in the analysis information database is individually identified by a device ID. That is, analysis information is registered for each manufacturing device 30 that is individually identified by the device ID. Furthermore, each record in the analysis information database is also individually identified by a product code. That is, analysis information is registered for each manufacturing lot.

The analysis information database has multiple records (rows) and multiple columns (columns). Each column is assigned one of the following items: "apparatus ID," "process code," "product code," and "analysis information." The item "apparatus ID", the item "process code", and the item "product code" are the same as the item "apparatus ID", the item "process code", and the item "product code" in the source information database.

The item "analysis information" has a plurality of subcolumns (subcolumns). Each of the plurality of subcolumns is labeled with one of the following items: "Date", "Status", "Error Type", "Start Point Time", "End Point Time", and "Period".

A date is registered in each field of a subcolumn corresponding to the item "date". In the illustrated example, "2021.11.01" is registered.

In each field of the subcolumn corresponding to the item "Status", "stop", "preparation", "operation", "abnormal stop", etc. indicating the state of the manufacturing apparatus 30 are registered. “Stopped” indicates a state in which power is not supplied to the manufacturing apparatus 30. "Preparation" indicates that preparations are being made to switch from manufacturing one product to manufacturing another product. “Operating” indicates a state in which the manufacturing apparatus 30 is manufacturing, inspecting, etc. a product. "Abnormal stop" refers to a state in which product manufacturing or inspection is stopped due to an error such as "air pressure abnormality", "emergency stop", "continuous leak inspection failure" or "continuous laser inspection failure". show.

In each field of the subcolumn corresponding to the item "error type", the type of error that has occurred is registered. The types of errors include "air pressure abnormality", "emergency stop", "continuous leak test NG", "continuous laser test NG", etc. Note that the "Error type" is registered only in the field corresponding to the subrecord whose "Status" is "Abnormal stop", and the "Error type" is registered only in the field corresponding to the subrecord whose "Status" is "Abnormal stop". “-”, “none”, etc. are registered in the field.

“Time” is registered in each field of the subcolumn (subcolumn) corresponding to the item “start point time”. The registered "time" indicates the time when the manufacturing apparatus 30 enters a stopped state, a preparation state, an operating state, an abnormally stopped state, or the like.

“Time” is registered in each field of the subcolumn (subcolumn) corresponding to the item “end point time”. The registered "time" indicates the time when the manufacturing apparatus 30 transitions from a stopped state, a preparation state, an operating state, an abnormally stopped state, etc. to another state.

“Period” is registered in each field of the subcolumn corresponding to the item “Period”. The registered "period" indicates a period during which the manufacturing apparatus 30 was in a stopped state, a preparation state, an operating state, an abnormally stopped state, or the like. In the illustrated example, "30 minutes", "2 hours and 42 minutes", etc. are registered. In the illustrated example, the registered "period" is in "minutes," but the registered period may be in "seconds."

The second server 80 shown in FIG. 1 is, for example, an in-house server installed in a server room at the head office. The second server 80 may be a web server that publishes URLs.

The second server 80 has a CPU 81 that is a central processing unit, a memory 82, and a communication interface 83. The memory 82 is a RAM, ROM, hard disk memory, EEPROM, USB (registered trademark) memory, or the like. The memory 82 stores an OS (not shown) that is an operating system and a second server program 85. This OS is Windows (registered trademark) or the like like OS68.

A memory 84 is connected to the second server 80. The memory 84 may be a hard disk or a storage server. Further, the memory 84 may be a part of the memory 82. Memories 82 and 84 correspond to "memory" described in the claims.

Memory 84 stores an aggregate database. The total database is a database in which the daily number of products manufactured by the manufacturing apparatus 30 (manufactured quantity), etc. are registered. Registration of the total information in the total database is performed by the second program 65 and the second server program 85.

FIG. 4(B) shows an example of a total database. The total database is created using, for example, EXCEL (registered trademark) or ACCESS (registered trademark).

The summary database is registered in association with date, factory identification information, equipment ID, product code, operating time, production quantity, target achievement rate (%), operating ratio (%), power ON time, and power OFF time. It is a database. In other words, the operating time, production quantity, target achievement rate (%), operating ratio (%), power ON time, and power OFF time are stored in a summary database for each date, manufacturing factory, manufacturing equipment 30, and product. be registered.

The summary database has multiple records (rows) and multiple columns (columns). Each column is "Date", "Factory identification information", "Equipment ID", "Product code", "Operating time", "Production quantity", "Target achievement rate (%)", "Operating ratio ( %),” “power ON time,” and “power OFF time.” Regarding the item "Date", the item "Factory identification information", the item "Device ID", and the item "Product code", the item "Date" and the item "Factory identification information" explained in the above analysis information database and manufacturing schedule database. , the item "device ID", and the item "product code".

Each column to which the item "operating time" and the item "production quantity" are attached has three subcolumns (subcolumns). A plurality of sub-columns included in the item "operating hours" and the item "production quantity" are each assigned one of the following items: "daytime", "nighttime", and "total". Daytime operating hours are registered in each field of the subcolumn corresponding to the subitem "daytime" of the item "working hours." Daytime is, for example, the time from 8:00 to 20:00 (12 hours). Nighttime operating hours are registered in each field of a subcolumn corresponding to the subitem "nighttime" of the item "working hours." Nighttime is, for example, the time (12 hours) from 20:00 to 8:00 the next day. In each field of the subcolumn corresponding to the subitem "total" of the item "working time", the total value of the working time during the day and night is registered. In each field of the sub-column (sub-column) corresponding to the sub-item "daytime" of the item "production quantity", the production quantity during the day is registered. In each field of the sub-column (sub-column) corresponding to the sub-item "nighttime" of the item "production quantity", the nighttime production quantity is registered. In each field of the subcolumn (subcolumn) corresponding to the subitem "total" of the item "production quantity", the total value of the production quantity during the day and night is registered.

In each field of the subcolumn corresponding to the item "target achievement rate (%)", the target achievement rate indicated by the ratio (%) of the current production quantity to the planned production quantity is registered. The target achievement rate (%) is calculated by dividing the manufacturing quantity included in the original information transmitted by the PLC 50 by the planned manufacturing quantity registered in the manufacturing schedule database and multiplying the product by 100.

The column to which the item "operating rate (%)" is attached has two subcolumns (subcolumns). The two sub-columns (sub-columns) are each assigned one of the sub-items "daytime" and "nighttime". In each field of the sub-column corresponding to the sub-item "daytime" of the item "operation rate (%)", the operation rate indicated by the rate (%) at which the manufacturing equipment 30 was operating during the day is registered. be done. The operating ratio is calculated by dividing the daytime operating hours calculated based on the original information by 12 hours (half a day) and multiplying by 100. In each field of the sub-column corresponding to the sub-item "Night" of the item "Operating ratio (%)", the operating ratio indicated by the ratio (%) at which the manufacturing equipment 30 was operating at night is registered. . The operating ratio is calculated by dividing the night operating time calculated based on the original information by 12 hours (half a day) and multiplying by 100.

In each field of the column to which the item "power ON time" is attached, the total value of the time during which the power was turned on in the manufacturing apparatus 30 is registered. The time during which the power was turned on is, for example, the total value of the operating time and the standby time. In each field of the column to which the item "power OFF time" is attached, the total value of the time during which the power was not turned on in the manufacturing apparatus 30 is registered.

As shown in FIG. 1, terminal devices 91, 92, and 93, which are terminal devices 90, are connected to the communication network 11. The terminal device 91 is a personal computer installed in the main factory 21. The terminal device 91 is communicably connected to the management device 60 via, for example, a wired or wireless LAN. The terminal device 92 is a personal computer installed in the local factory 22. The terminal device 92 is connected to the management device 60 through, for example, a wired or wireless LAN and the Internet. The terminal device 93 is a mobile terminal such as a smartphone or a tablet used at the main factory 21 and local factories 22, for example. The terminal device 93 is connected to the management device 60 through, for example, a mobile communication network and the Internet.

The configurations of the terminal device 91 and the terminal device 92 are the same. The terminal devices 91 and 92 include a CPU 101 that is a central processing unit, a memory 102, and a communication interface 103. Note that in FIG. 1, illustration of the CPU 101, memory 102, and communication interface 103 included in the terminal device 92 is omitted.

The memory 102 is a RAM, ROM, hard disk memory, EEPROM, USB (registered trademark) memory, or the like. The memory 102 stores a terminal program 104, a browser 105, and an OS 106. The OS 106 is an operating system, and like the OS 68, it is Windows (registered trademark) or the like.

The browser 105 is Google Chrome (registered trademark), Firefox (registered trademark), Microsoft Edge (registered trademark), Internet Explorer (registered trademark), or the like. The browser 105 causes the display 107 to display a web page indicated by the web page data generated by the fourth program 67, for example, through the OS 106.

The terminal program 104 is a program that causes the display 107 to display a real-time display screen. The terminal program 104 may be an application program separate from the browser 105, a plug-in program for the browser 105, or the browser 105 itself. When the terminal program 104 is a plug-in program for the browser 105, for example, a person in charge of management or the like starts the browser 105 of the terminal device 90 and accesses the URL published by the server 70, 80 or the management device 60, etc. 104 is installed in the terminal device 90.

Further, the terminal program 104 may have a function of registering a manufacturing schedule in a manufacturing schedule database. For example, the terminal program 104 receives a manufacturing schedule input into the terminal device 90 by a person in charge of management or the like, and transmits the received manufacturing schedule together with instructions to the management device 60. The instruction is, for example, a command. The OS 68 or the second program 65 of the management device 60 registers the manufacturing schedule in the manufacturing schedule database according to the received instruction. Note that a management program for registering the manufacturing schedule in the manufacturing schedule database may be installed in the management device 60 separately from the second program 65.

A display 107 and an input device 108 are connected to terminal devices 91 and 92. The input device 108 is a keyboard, a mouse, a microphone for voice input, or the like.

The terminal device 93 is a tablet or the like, and includes a CPU 101 and a memory 102 similar to those of the terminal devices 91 and 92, and a touch panel 109 consisting of a display and a touch sensor (input device).

5 to 9 show the programs 64, 65, 66, 67 installed in the management device 60, the server programs 75, 85 installed in the servers 70, 80, the terminal program 104 installed in the terminal device 90, etc. 3 is a flowchart showing processing executed by each program. That is, FIGS. 5 to 9 show the processes performed in the production management system 10. Specifically, FIG. 5 is a flowchart showing the process of registering the manufacturing schedule, original information, and analysis information in the database. FIG. 6 is a flowchart showing a process for displaying a real-time display screen. FIG. 7 is a flowchart showing the process of displaying the total display screen. FIG. 8 is a flowchart showing the process of displaying the analysis information display screen. FIG. 9 is a flowchart showing the process of displaying the current period cumulative total display screen.

Further, FIGS. 10 and 11 are diagrams showing a part of the real-time display screen displayed on the display 107 or touch panel 109 of the terminal device 90, respectively. Note that FIG. 11 is a portion displayed by operating the scroll bar of the real-time display screen in FIG. 10.

FIG. 12 is a diagram showing a total display screen displayed on the display 107 or touch panel 109 of the terminal device 90. FIG. 13 is a diagram showing an analysis information display screen displayed on the display 107 or touch panel 109 of the terminal device 90. FIG. 14 is a diagram showing a current term cumulative display screen displayed on the display 107 or touch panel 109 of the terminal device 90.

Hereinafter, the processes executed in the production management system 10 will be explained with reference to FIGS. 5 to 14.

A person in charge of management or the like inputs the manufacturing schedule into the terminal device 90 using the input device 108 or the touch panel 109. The terminal device 90 transmits the input manufacturing schedule to the management device 60. As shown in FIG. 5, the second program 65 of the management device 60 or the management program registers the manufacturing schedule in the manufacturing schedule database based on the fact that the management device 60 has received the manufacturing schedule (S11: Yes). S12). If the management device 60 does not receive the manufacturing schedule (S11: No), the second program 65 or the management program skips the process of step S12.

On the other hand, the PLC 50 acquires the manufacturing time information, stores the manufacturing time information in the attached memory (S31), and sends the manufacturing time information with the device ID and acquisition date and time as original information to the management device 60. (S32). The PLC 50 repeatedly executes the processes of steps S31 and S32 at predetermined time intervals (sampling intervals) until it is determined to be finished (S33: No). The PLC 50 determines to end the process based on, for example, that the power has been turned off or that an end instruction has been input (S33: Yes), and ends the process (End).

The management device 60 receives the original information transmitted by the PLC 50 (S32). The first program 64 of the management device 60 transmits the received original information to the first server 70 along with the registration request (S14). The registration request is, for example, a command. The process in step S14 corresponds to the "original information registration process" described in the claims.

The first server 70 receives the original information and the registration request sent by the management device 60 (S14). The first server program 75 of the first server 70 registers the original information in the original information database according to the received registration request (S15).

On the other hand, the third program 66 of the management device 60 reads the manufacturing schedule from the manufacturing schedule database in order to analyze the original information and generate analysis information (S21). The third program 66 specifies the device ID and process code indicating the manufacturing device 30 to be analyzed from the read manufacturing schedule, and sends a request to the first server 70 for analysis information including the specified device ID and process code. (S22). The request is, for example, a command. The process in step S21 corresponds to the "manufacturing schedule acquisition process" described in the claims.

The first server 70 receives the request sent by the management device 60 (S22). The first server program 75 of the first server 70 identifies a record in the source information database (see FIG. 3(B)) that has a device ID and a process code that match the device ID and process code included in the received request, The manufacturing time information included in the specified record is read out (S23). The first server program 75 sends the analysis information including the read manufacturing elapsed information (original information) and the device ID and process code used to specify the record to the management device 60 as a response to the request received in step S22. A reply is sent (S24).

Note that the manufacturing time information included in the analysis information returned by the first server 70 may be all of the manufacturing time information acquired at each sampling period, or may include some of the manufacturing time information obtained from all of the manufacturing time information. The manufacturing time information may be thinned out manufacturing time information.

The management device 60 receives the analysis information returned by the first server 70 (S24). The third program 66 of the management device 60 generates the analysis information (FIG. 4(A)) based on the received analysis information (S25). Specifically, the third program 66 identifies the state of the manufacturing apparatus 30 based on each flag included in the manufacturing aging information, identifies the error type based on the error code included in the manufacturing aging information, and determines the manufacturing aging information. Identify the start point time, end point time, period, and date based on the date and time included in the information. The process in step S24 in which the third program 66 transmits a request for analysis information (S22) and receives the analysis information corresponds to the "error information acquisition process" described in the claims. The "date and time" of the manufacturing time information included in the analysis information corresponds to the "date and time of error occurrence" described in the claims. The process of step S25 corresponds to the "analytical information generation process" described in the claims.

The third program 66 of the management device 60 transmits a registration request including the generated analysis information and device ID to the first server 70 (S26). The registration request is, for example, a command that instructs to register the included analysis information in the analysis information database. The process of step S26 corresponds to the "analysis information registration process" described in the claims.

Note that the sending of the request for analysis information (S21) and the sending of the request for registering analysis information (S26) may be performed by the first program 64 instead of the third program 66. That is, the first program 64 may communicate with the first server 70 all at once. In that case, for example, the third program 66 instructs the first program 64 to transmit a request for analysis information (S21) and a request to register analysis information (S26) through the OS 68.

The first server 70 receives the registration request including the analysis information (S26). The first server program 75 of the first server 70 generates a new record in the analysis information database and registers the analysis information in accordance with the received registration request (S27).

On the other hand, the second program 65 of the management device 60 calculates the operating time, production quantity, target achievement rate, operating ratio, etc. based on the original information received by the management device 60 in step S32, and registers it in the aggregation database (S28 ).

Next, based on FIG. 6, a process for displaying a real-time display screen on the display 107 or touch panel 109 of the terminal device 90 will be explained.

A person in charge of management or the like starts the terminal program 104 on the terminal device 90 . For example, a person in charge of management or the like selects an icon on a home screen (not shown) displayed on the display 107 or touch panel 109 by the terminal program 104 to instruct display of a real-time display screen.

In response to receiving the selection of the icon instructing the display of the real-time display screen (S41), the terminal program 104 transmits a request for real-time display screen data to the management device 60 (S42). The request is a command including, for example, factory identification information indicating the type of factory (headquarters factory or local factory) and screen identification information indicating the type of screen (real-time display screen).

The management device 60 receives a request for real-time display screen data (S42). The second program 65 of the management device 60 identifies a record having factory identification information that matches the factory identification information included in the request in the manufacturing schedule database (see FIG. schedule) is read out (S43). The second program 65 generates real-time display screen data based on the read manufacturing schedule and the original information received in step S32 (see FIG. 5) (S44). The real-time display screen data is screen data for displaying the real-time display screens shown in FIGS. 10 and 11 on the display 107 or the touch panel 109.

As shown in FIGS. 10 and 11, the real-time display screen includes a plurality of device icons 120. One device icon 120 corresponds to one manufacturing device 30 and has a manufacturing device name that is the name of the manufacturing device 30. In the example shown in FIGS. 10 and 11, the manufacturing equipment names are "A01", "intensive coolant", "B02", "C04", "D02", "washing machine", etc. Note that "A01", "B02", "C04", and "D02" may be the device IDs described above.

The real-time display screen is partitioned into a plurality of display areas 130 by lines or the like. One display area 130 corresponds to one area 40 (see FIG. 2). Specifically, the display area 131 (130) corresponds to the "cylindrical" area 41. Display area 132 (130) corresponds to "coolant" area 42. The display area 133 (130) corresponds to the "width/outer diameter" area 43. The display area 134 (130) corresponds to the "inner diameter" area 44. The display area 135 (130) corresponds to the "finishing" area 45. Display area 136 (130) corresponds to "washing machine" area 46. Each display area 130 is arranged in the real-time display screen at the same arrangement position as each area 40 in the manufacturing factory 20.

A name object 123 indicating "cylinder" is arranged in the display area 131. A name object 124 indicating "coolant" is arranged in the display area 132. A name object 125 indicating “width/outer diameter” is arranged in the display area 133. A name object 126 indicating "inner diameter" is arranged in the display area 134. A name object 127 indicating “finishing” is arranged in the display area 135. A name object 128 indicating "washing machine" is arranged in the display area 136. The name objects 123, 124, 125, 126, 127, and 128 allow a management person or the like to recognize which display area each display area 130 is.

The device icons 120 are arranged in each display area 130, respectively. The device icon 120 is placed in the display area 130 and position corresponding to the area 40 and position in the manufacturing factory 20 where the manufacturing device 30 indicated by the attached manufacturing device name is placed. In the example shown in FIG. 10, the device icon 120 with the manufacturing device name “A01” is placed at the upper left of the display area 131. The manufacturing apparatus 30 (see FIG. 2) having the apparatus ID "A01" is arranged at the upper left of the "cylindrical" area 41 corresponding to the display area 131.

A person in charge of management who visually checks the real-time display screen can intuitively recognize the manufacturing device 30 corresponding to the device icon 120 based on the position where the device icon 120 is displayed. Further, the device icon 120 corresponding to the manufacturing device 30 that the user wants to check can be easily found from among the many device icons 120. That is, the person in charge of management and the like can quickly and accurately check the manufacturing status.

The device icon 120 includes original information and some information about the manufacturing schedule in addition to the manufacturing device name. In the example shown in Figure 10, some of the information in the original information is the name (product code) of the product currently being manufactured (processing, inspection, etc.), operating time, and the manufacturing quantity to date, and the manufacturing schedule. Some of the information is the planned production quantity. In FIG. 10, in the equipment icon 120 with the manufacturing equipment name "A01", the name of the product currently being manufactured is "A000003", the name of the product to be manufactured next is "C000020", and the operating time is " 4:51:15'', the production quantity to date is ``911'', and the planned production quantity is ``3187''.

Further, the device icon 120 has information based on original information and a manufacturing schedule. In the example shown in FIG. 10, the information based on the original information and the manufacturing schedule is the target achievement rate (%). The target achievement rate (%) is the value (expressed as a %) obtained by dividing the production quantity to date by the planned production quantity and multiplying it by 100. In FIG. 10, the target achievement rate (%) of the device icon 120 having the manufacturing device name “A01” is “28.6%”. In addition to the information shown in FIG. 10, the device icon 120 may include other source information, manufacturing schedule, and other information.

The operating time and the current production quantity that the device icon 120 has are the above-mentioned manufacturing elapsed information. That is, the device icon 120 is an object that displays the current status of the manufacturing device 30 in real time. The real-time display screen having a plurality of device icons 120 displays the current status of all manufacturing devices 30 in the manufacturing factory 20 at once.

The device icon 120 is also an object used by a management person or the like to instruct display of the total display screen (see FIG. 12). When the device icon 120 is selected, a total display screen pops up. "Pop-up display" means displaying in a window separate from the real-time display screen.

The real-time display screen further includes a display switching icon 140. The display switching icon 140 is an object for a management person or the like to input an instruction to switch the display between the real-time display screen and the current period cumulative display screen (see FIG. 14).

Further, the real-time display screen further includes a task completion icon 141. The task end icon 141 is an object for inputting an instruction to the terminal device 90 to end the display of the real-time display screen.

Generation of real-time display screen data (S44) by the second program 65 will be explained in detail. The second program 65 has format data for generating real-time display screen data in advance. The format data may be part of the second program 65 or may be stored in the memory 62 separately from the second program 65. Further, the format data is associated with the screen identification information indicating the real-time display screen.

The format data has a plurality of input fields into which one of the product name, operating time, current production quantity, planned production quantity, and target achievement rate (%) is input. The second program 65 inputs the manufacturing schedule read out in step S43, the original information received in step S32, and the target achievement rate (%) calculated from the manufacturing schedule and the original information into the input field to create real-time display screen data. generate. Note that the format data may be a function that takes a product name or the like as an argument and real-time display screen data as a return value, or may be a class that generates real-time display screen data as an instance. That is, the format data may be any data that becomes the source for generating real-time display screen data.

The second program 65 of the management device 60 returns the generated real-time display screen data to the terminal device 90 as a response to the request received in step S42 (S45).

The terminal device 90 receives the real-time display screen data returned by the management device 60 (S45). The terminal program 104 of the terminal device 90 causes the display 107 or the touch panel 109 to display a real-time display screen indicated by the received real-time display screen data (S46). For example, the terminal program 104 displays a real-time display screen on the display 107 or touch panel 109 by inputting a command including a file path indicating real-time display screen data to the OS 106.

The terminal program 104 periodically transmits, for example, a request for real-time display screen data (S42) to the management device 60, and periodically updates the real-time display screen. Alternatively, based on receiving a request for real-time display screen data, the second program 65 of the management device 60 periodically transmits real-time display screen data to the terminal device 90 until a stop request is issued from the terminal device 90. You may.

Note that the above format data may be stored in the memory 102 of the terminal device 90. In that case, the second program 65 transmits the manufacturing schedule read in step S43, the original information received in step S32 (see FIG. 5), and the target achievement rate (%) calculated from the manufacturing schedule and the original information to the terminal device 90. Send to. The terminal program 104 of the terminal device 90 inputs the received original information, manufacturing schedule, and target achievement rate (%) into the format data, generates real-time display screen data, and displays the data on the display 107 or touch panel 109.

The programs 64, 65, 66, and 67 of the management device 60 repeatedly execute the processes from S11 (see FIG. 5) until an end instruction is input (S49: No). The termination instruction is given, for example, before a business holiday or before maintenance. When the programs 64, 65, 66, and 67 determine that an end instruction has been input (S49: Yes), they end the processing (End). The process of step S44 repeatedly executed by the second program 65 corresponds to the "generation process" described in the claims. The process of step S45 repeatedly executed by the second program 65 corresponds to the "first transmission process" described in the claims.

Similarly, the first server program 75 of the first server 70 executes the operations after S15 (see FIG. 5) until a termination instruction is input or the power of the first server 70 is turned off (S50: No). Repeat the process. The termination instruction is given, for example, before a business holiday or before maintenance. When the first server program 75 determines that the termination instruction has been input (S50: Yes), it terminates the process (End).

Next, a description will be given of a process when a management person or the like selects the device icon 120 on the real-time display screen (see FIG. 10) and a total display screen (see FIG. 12) is displayed as a pop-up.

The terminal program 104 of the terminal device 90 determines whether the device icon 120 or the display switching icon 140 is selected on the real-time display screen (see FIG. 10) (S47). When the terminal program 104 determines that the icons 120 and 140 are not selected (S47: No), the terminal program 104 determines whether a termination instruction has been input (S51). The termination instruction is input to the terminal device 90 by selecting the task termination icon 141 or by selecting the "x" in the upper right corner of the real-time display screen. If the terminal program 104 determines that the termination instruction has not been input (S51: No), it repeatedly executes the processing from step S42 onwards. That is, the terminal program 104 updates and displays the real-time display screen. When the terminal program 104 determines that the termination instruction has been input (S51: Yes), the terminal program 104 terminates the process (End).

When the terminal program 104 of the terminal device 90 determines that the icons 120 and 140 have been selected in step S47 (S47: Yes), the terminal program 104 of the terminal device 90 determines whether the selected icon is the device icon 120 or the display switching icon 140 ( S48). When the terminal program 104 determines that the selected icon is the device icon 120 (S48: device icon), the terminal program 104 executes a process (see FIG. 7) of displaying a total display screen (see FIG. 12) as a pop-up on the display 107 or touch panel 109. Execute.

The total display screen shown in FIG. 12 is a table similar to the total database (see FIG. 4(B)). The total display screen has multiple rows and multiple columns. The plurality of columns are labeled with items such as "date" and "operating hours" similar to those in the aggregation database. Each row of the total display screen is mutually identified by a date such as "2021/10/25". In other words, each row indicates that the manufacturing equipment 30 having the manufacturing equipment name such as "A01" displayed on the equipment icon 120 designated by the person in charge of management, etc. is displayed during the day on each date indicated by "2021/10/25" etc. It shows the operating hours, nighttime operating hours, total operating hours, daytime production quantity, nighttime production quantity, total production quantity, target achievement rate, etc.

Below, items that are not shown in the aggregate database (see FIG. 4(B)), such as the item "operation ratio daytime/nighttime", will be explained.

The column with the item "Occupancy ratio daytime/nighttime" has two sub-columns. Each field in one sub-column displays the ratio (%) of operating time to the total time during the day. Each field in the other sub-column displays the ratio (%) of operating time to the total nighttime hours.

Each field in the column labeled with the item "cumulative abnormal stop time" displays the total amount of time during which the normal operation of the manufacturing apparatus 30 was stopped due to an error, that is, the time during which the manufacturing apparatus 30 was abnormally stopped. Each field in the column with the item ``Normal stoppage cumulative time'' displays the total amount of time that production is stopped, for example, due to preparations for switching from manufacturing one product to manufacturing another product. . Each field in the column to which the item "Number of Abnormal Occurrences" is attached displays the number of times an error (abnormality) has occurred on that day. Each field in the column labeled with the item "first production time" displays, for example, the time required from the start of production until the first product is produced, including warm-up time. Each field in the column labeled with the item "cycle time (seconds)" displays the time required to manufacture one product.

The total display screen further includes a "graph" icon 142 and a "close" icon 143. The "graph" icon 142 is an object that accepts an instruction to display an analysis information display screen (see FIG. 13). The “close” icon 143 is an object that accepts an instruction to close the total display screen. Note that the instruction to close the tally display screen may be accepted by clicking the "x" in the upper right corner of the tally display screen.

With reference to FIG. 7, a process in which the terminal program 104 of the terminal device 90 displays the above-mentioned total display screen on the display 107 or touch panel 109 of the terminal device 90 will be described.

First, the terminal program 104 transmits a request for total display screen data to the management device 60 (S52). The request is, for example, a command for instructing the return of total display screen data. The command includes the device ID corresponding to the device icon 120 selected by the person in charge of management or the like, screen identification information indicating the type of screen (total display screen), and factory identification information.

The management device 60 receives the request sent by the terminal device 90 (S52). The second program 65 of the management device 60 transmits a return request for registration information including the device ID and factory identification information included in the received request to the second server 80 (S54). The request is a command including, for example, a device ID and factory identification information.

The second server program 85 of the second server 80 identifies a record having a device ID and factory identification information that match the device ID and factory identification information included in the received reply request in the aggregate database (see FIG. 4(B)). Then, the information (registration information) possessed by the identified record is read out (S55). The second server program 85 returns the read registration information to the management device 60 (S56).

The management device 60 receives the registration information returned by the second server 80 (S56). The second program 65 of the management device 60 inputs the received registration information into the format data input field indicated by the screen identification information, and generates total display screen data (S57). The second program 65 returns the generated total display screen data to the terminal device 90 as a response to the request received in step S52 (S58). The process in step S57 corresponds to the "total display screen data generation process" described in the claims. The process in step S58 corresponds to the "second transmission process" described in the claims.

Note that the above format data may be stored in the memory 102 of the terminal device 90. In that case, the second program 65 returns the registration information read in step S43 to the terminal device 90 as a response to the request received in step S53. The terminal program 104 of the terminal device 90 inputs the received registration information into the format data and generates a total display screen.

The terminal device 90 receives the total display screen data returned by the management device 60 (S58). The terminal program 104 of the terminal device 90 inputs the received total display screen data to the display 107 or the touch panel 109, and pops up the total display screen (S59).

Next, a description will be given of the processing when the administrator or the like selects the graph icon 142 or the close icon 143 on the total display screen (see FIG. 12).

The terminal program 104 of the terminal device 90 determines whether the graph icon 142 or the close icon 143 is selected on the total display screen (S60). The terminal program 104 continues to display the total display screen (S59) until the icons 142, 143 are selected (S60: No). Note that selection of the close icon 143 also includes selection of the "x" at the top right of the total display screen. When the terminal program 104 determines that the icon 142 or the icon 143 has been selected (S60: Yes), the terminal program 104 determines whether the selected icon closes the icon 143 (or "x") or the graph icon 142 is selected. (S61). When the terminal program 104 determines that the close icon 143 (or "x") has been selected, it closes the total display screen (see FIG. 12) (S62) and displays the real-time display screen (see FIG. 6). ). Note that the terminal program 104 closes the total display screen by inputting a command to the OS 106 instructing to close the total display screen.

When the terminal program 104 of the terminal device 90 determines that the graph icon 142 has been selected in step S61 (S61: graph), it executes a process (see FIG. 8) to display the analysis information display screen (FIG. 13).

The analysis information display screen shown in FIG. 13 is a screen that displays analysis information in the form of a graph regarding the manufacturing apparatus 30 specified by the person in charge of management or the like. The analysis information display screen includes a device name object 144 indicating the manufacturing device name, a year/month object 145, and a graph 146. The manufacturing equipment name displayed by the equipment name object 144 is the same as the manufacturing equipment name included in the equipment icon 120 selected by the administrator or the like on the real-time display screen (see FIG. 10). The year/month object 145 displays the current year and month. In the illustrated example, the year/month object 145 is “2021/10” indicating October 2021.

Graph 146 has a vertical axis 147, a horizontal axis 148, and a plurality of bars 149. The vertical axis 147 indicates each date in the month indicated by the year/month object 145. In the illustrated example, October 26th is shown as "10-26" and October 25th is shown as "10-25". A horizontal axis 148 indicates time. "0" at the left end of the horizontal axis in FIG. 13 indicates 0 o'clock, "1" indicates 1 o'clock, "23" indicates 23 o'clock, and "0" to the right of "23" indicates 0 o'clock the next day. shows.

One bar 149 is displayed for each date such as "10-26". That is, one bar 149 indicates analysis information on one date. Moreover, the bar 149 has a plurality of parts, such as a part showing a stopped state, a part showing a preparation state, a part showing an operating state, and a part showing an abnormal stop state. Each part is mutually distinguishable by color, hatching, etc. The stop state, preparation state, operating state, and abnormal stop state are information that match the states registered in the item "state" in the analysis information of the analysis information database (see FIG. 4(A)). In the example shown in FIG. 4(A), in a record in which abnormal stop is registered in the item "Status", "13:12" is registered in the field corresponding to the item "Starting point time", and "13:12" is registered in the field corresponding to the item "Starting point time", and "13:12" is registered in the field corresponding to the item "Starting point time". "13:43" is registered in the field corresponding to the item "period", and "31 minutes" is registered in the field corresponding to the item "period". In that case, in the analysis information display screen shown in FIG. 13, one end (left end) of the part of the bar 149 indicating the abnormal stop state is located at the time indicated by the horizontal axis, which is 13:12, and the other end is located at the time indicated by the horizontal axis, 13:12. The end (right end) is located where the time indicated by the horizontal axis is 13:43. The length of the portion indicating the abnormal stop state is the length corresponding to the period "31 minutes".

The process of displaying the analysis information display screen on the display 107 or touch panel 109 of the terminal device 90 will be described below with reference to FIG. 8.

The terminal program 104 of the terminal device 90 transmits a request for analysis information display screen data to the management device 60 (S71). The request is, for example, a command that instructs to return analysis information display screen data. The command includes the device ID corresponding to the device icon 120 selected by the administrator or the like, and screen identification information indicating the analysis information display screen.

The management device 60 receives the request sent by the terminal device 90 (S71). Based on receiving the request, the second program 65 of the management device 60 starts the fourth program 67 and instructs it to generate analysis information display screen data (S72). For example, the second program 65 inputs a command including a fourth program ID indicating the fourth program 67, a second program ID indicating itself, a device ID, and screen identification information to the OS 68. The OS 68 starts the fourth program 67 indicated by the fourth program ID, and passes the device ID, the screen identification information, and the second program ID to the fourth program 67. The process in step S72 corresponds to the "instruction process" described in the claims. The screen identification information indicating the analysis information screen corresponds to "information instructing generation of analysis information display screen data" described in the claims.

The activated fourth program 67 generates analysis information display screen data indicated by the screen identification information for the manufacturing device 30 indicated by the passed device ID.

To explain in detail, the fourth program 67 transmits a reply request for analysis information to the first server 70 (S73). The reply request is, for example, a command including the device ID.

The first server 70 receives the reply request sent by the management device 60 (S73). The first server program 75 of the first server 70 identifies a record having a device ID that matches the device ID included in the received reply request in the analysis information database (see FIG. 4(A)). The first server program 75 then reads the analysis information possessed by the identified record (S74). The first server program 75 returns the read analysis information to the management device 60 as a response to the reply request received in step S73 (S75).

The management device 60 receives the analysis information returned by the first server 70 (S75). The fourth program 67 of the management device 60 is format data for generating analysis information display screen data, and has in advance format data associated with screen identification information indicating the analysis information display screen. The format data is data in HTML format including CSS and JavaScript, and has an input field into which a manufacturing equipment name and analysis information (see FIG. 4(A)) are input. That is, the analysis information display screen (see FIG. 13) is a so-called Web page. The fourth program 67 inputs the analysis information received in step S75 into the input field of the format data, and generates analysis information display screen data (S76). This format data may be the above function or class.

The fourth program 67 of the management device 60 returns the file path and second program ID indicating the generated analysis information display screen data to the OS 68. The OS 68 passes the above file path to the second program 65 indicated by the second program ID. The second program 65 returns the analysis information display screen data indicated by the passed file path as a response to the request received in step S71 (S77). That is, the second program 65 collectively performs communication with the terminal device 90.

Although an example has been described in which the fourth program 67 transmits a request for analysis information to the first server 70 and acquires the analysis information, the transmission of the request for analysis information to the first server 70 is performed by the third program 66. may go. That is, communication with the first server 70 may be performed by the third program 66 all at once. In that case, the second program 65 that has received the request for analysis information display screen data (S71) passes screen identification information indicating the analysis information display screen to the third program 66. The third program 66 transmits a request for analysis information including the received screen identification information to the first server 70 (S74), and receives the analysis information returned by the first server 70 (S75). The third program 66 passes the file path indicating the received analysis information to the second program 65. The second program 65 starts the fourth program 67 through the OS 68 and passes the passed file path, screen identification information, and second program ID to the fourth program 67. Then, the second program 66 receives a file path indicating the analysis information display screen data generated by the fourth program 67 from the fourth program 67 through the OS 68.

Further, although an example has been described in which the second program 65 returns the analysis information display screen data to the terminal device 90, the fourth program 67 may directly return the analysis information display screen data to the terminal device 90. For example, the fourth program 67 receives a request for analysis information display screen data (web page data) sent by the terminal program 104, generates the analysis information display screen data (web page data), and sends it back to the terminal device 90. Good too. That is, the fourth program 67 may also have a function of communicating with the terminal device 90.

The terminal device 90 receives the analysis information display screen data returned by the management device 60 (S77). The terminal program 104 of the terminal device 90 instructs the browser 105 through the OS 106 to display the received analysis information display screen data on the display 107 or touch panel 109 as a pop-up. The browser 105 causes the analysis information display screen data to be displayed as a pop-up on the display 107 or the touch panel 109 (S78). Note that when the terminal program 104 is a plug-in program for the browser 105, the terminal program 104 directly inputs to the OS 106 an instruction (command) to display the analysis information display screen data as a pop-up on the display 107 or the touch panel 109.

The terminal program 104 of the terminal device 90 determines whether a termination instruction has been input (S79). The termination instruction is input by, for example, an "x" at the top right of the screen. The terminal program 104 causes the analysis information display screen to be displayed on the display 107 or the touch panel 109 (S78) until a termination instruction is input (S79: No). Based on the input of the termination instruction (S79: Yes), the terminal program 104 closes the analysis information display screen (S80) and executes the process from step S59 onward to display the total display screen (see FIG. 7). .

Next, we will explain the current term cumulative display screen (see Figure 14), which is displayed when the administrator etc. selects the display switching icon 140 on the real-time display screen (see Figure 10), and the process of displaying the current term cumulative display screen. is done.

As shown in FIG. 14, the current period cumulative display screen is a screen having the same layout as the real-time display screen (see FIG. 10). The current term cumulative display screen has a device icon 121 instead of the device icon 120 on the real-time display screen. The arrangement position and shape of the device icon 121 are the same as those of the device icon 120. The device icon 121 differs from the device icon 120 in that it displays not the current manufacturing status but the cumulative total for the current period.

To explain in detail, the equipment icon 121 includes the name of the product currently being manufactured (processing, inspection, etc.), the cumulative operating time of this fiscal year, the cumulative manufacturing quantity of this fiscal year, the planned manufacturing quantity of this fiscal year, and the target achievement rate (%) of this fiscal year. are doing. The current term's cumulative operating hours are the cumulative operating hours in a predetermined period (current term) such as a quarter or a half-year. The cumulative production quantity for the current period is the cumulative production quantity for the predetermined period. The planned production quantity for the current period is the cumulative total of the planned production quantity for the predetermined period. The current term target achievement rate (%) is the value (expressed as a %) obtained by dividing the current term's production quantity by the current term's planned production quantity and multiplying it by 100. In the equipment icon 121 with the manufacturing equipment name "A01" in FIG. 14, the name of the product currently being manufactured is "A000003", the cumulative operating time of the current period is "1153:16:57", and the cumulative manufacturing time of the current period is "1153:16:57". The quantity is "175,521", the planned production quantity for this term is "369,692", and the target achievement rate (%) for this term is "47.5%". Note that the device icon 121 may have information other than the cumulative operating time of this term, the cumulative production quantity of this term, the planned production quantity of this term, and the target achievement rate (%) of this term.

The current period operating time and current period production quantity that the device icon 121 has are the above-mentioned manufacturing elapsed information. That is, the device icon 121 is a display object that displays the operating status of the manufacturing device 30 in the current period. Note that when the device icon 121 is selected, a total display screen (see FIG. 12) is displayed on the display 107 or touch panel 109 of the terminal device 90, similarly to when the device icon 120 is selected.

Next, the process of displaying the current term cumulative display screen will be explained. As shown in FIG. 6, when the terminal program 104 of the terminal device 90 determines that the icon selected by the administrator or the like on the real-time display screen (see FIG. 10) is the display switching icon 140 (S48: switching icon) , executes the process shown in FIG. First, the terminal program 104 transmits a request for cumulative display screen data to the management device 60 (S81). The request is, for example, a command that includes screen identification information indicating the current period cumulative display screen and the factory identification information.

The management device 60 receives the request sent by the terminal device 90 (S81). The second program 65 of the management device 60 transmits a reply request for manufacturing schedule to the second server 80 based on the fact that the received request includes screen identification information indicating the cumulative display screen for the current period (S82). The reply request is a command including, for example, the type of requested information and factory identification information.

The second server 80 receives the reply request for the manufacturing schedule (S82). The second server program 85 of the second server 80 identifies a record having factory identification information that matches the factory identification information included in the received reply request in the total database (FIG. 4(B)), and the identified record has Read information. Based on the read information, the second server program 85 calculates and obtains the cumulative operating time of the current period and the cumulative manufacturing quantity of the current period for each manufacturing device 30 (S83). Note that if the pre-calculated cumulative operating hours for this period and the cumulative production quantity for this period are registered in the tally database, the second server program 85 reads and acquires the cumulative operating hours for this period and the cumulative manufacturing quantity for this period from the tally database. (S83). In addition, in step S83 of FIG. 9, the cumulative operating hours of this term and the cumulative manufacturing quantity of this term are collectively described as total information. This tally information may be calculation information for calculating the cumulative operating hours of this term and the cumulative manufacturing quantity of this term. In that case, the current period cumulative operating hours and current period cumulative manufacturing quantity are calculated by the second program 65 of the management device 60 based on the total information.

The second server program 85 of the second server 80 returns the acquired total information to the management device 60 as a response to the reply request received in step S82 (S84). The management device 60 receives the total information returned by the second server 80 (S84).

The second program 65 of the management device 60 identifies, in the manufacturing schedule database, a record having factory identification information that matches the factory identification information included in the request received in step S81. Then, the second program 65 reads information from the identified record, and based on the read information, calculates and obtains the current period's scheduled production quantity for each manufacturing apparatus 30 (S85). Note that, if the planned production quantity for this term is registered in advance in the production schedule database, the second program 65 reads out and acquires the planned production quantity for this term from the production schedule database (S85).

The second program 65 of the management device 60 calculates the current term target achievement rate (%) for each manufacturing device 30 based on the acquired current term cumulative production quantity and current term production planned quantity (S86). The second program 65 generates current period cumulative display screen data based on the acquired current period cumulative operating time, current period cumulative production quantity, current period production schedule quantity, and current period target achievement rate (%) (S87).

To explain in detail, the second program 65 of the management device 60 has format data in advance for generating the current period cumulative display screen data. The format data has input fields for inputting the cumulative operating hours of this term, the cumulative production quantity of this term, the planned production quantity of this term, the target achievement rate (%) of this term, and the like. The second program 65 inputs the current period cumulative operating time, current period cumulative production quantity, current period production schedule quantity, and current period target achievement rate (%) into each input field of the format data to generate current period cumulative display screen data. Note that the format data may be the above-mentioned function or class.

The second program 65 of the management device 60 returns the generated current period cumulative display screen data to the terminal device 90 as a response to the reply request received in step S81 (S88).

The terminal device 90 receives the current period cumulative display screen data returned by the management device 60 (S88). The terminal program 104 of the terminal device 90 inputs the received current period cumulative display screen data to the display 107 or touch panel 109, and causes the current period cumulative display screen to be displayed on the display 107 or touch panel 109 (S89).

The terminal program 104 of the terminal device 90 determines whether a termination instruction has been input (S90). The termination instruction is input to the terminal device 90 by selecting the task termination icon 141 or by selecting the "x" in the upper right corner of the current period cumulative total display screen. When the terminal program 104 determines that an end instruction has been input (S90: Yes), it ends the process (End). When the terminal program 104 determines that no termination instruction has been input (S90: No), the terminal program 104 determines whether the display switching icon 140 has been selected (S91). If the terminal program 104 determines that the display switching icon 140 is not selected (S91: No), it re-executes the processing from step S81 onwards. That is, the current period cumulative display screen is updated and displayed at predetermined time intervals. When the terminal program 104 determines that the display switching icon 140 has been selected (S91: Yes), the terminal program 104 re-executes the process from step S42 (see FIG. 6) onwards for updating and displaying the real-time display screen.

[Operations and effects of embodiment]

In this embodiment, the second program 65 can integrate the original information acquired by the PLC 50 and display it on the terminal device 90 in real time, and the first program 64 and the third program 66 can manage the original information and display it on the terminal device 90 in real time. It is possible to analyze and generate analysis information.

For example, when the second program 65 generates analysis information display screen data, if the generation of the analysis information display screen data is delayed or a problem occurs, the real-time display of manufacturing elapsed information on the terminal device 90 may also occur. Failure may occur. In this embodiment, since the fourth program 67 generates the analysis information display screen data, the analysis information can be displayed on the terminal device 90 without interfering with the real-time display of the manufacturing elapsed information.

In this embodiment, the analysis information displayed on the analysis information display screen (see FIG. 13) is based on the information (manufacturing schedule) registered in the manufacturing schedule database and the manufacturing elapsed information registered in the original information database. generated. Therefore, more detailed analysis information can be generated than when analysis information is generated only based on manufacturing elapsed information.

In this embodiment, the second program 65 can cause the terminal device 90 to display a total display screen having total data compiled for each day.

When a device icon 120 is selected by a person in charge of management or the like on the real-time display screen, an analysis information display screen showing the date and time of occurrence of an error is displayed for the manufacturing device 30 indicated by the selected device icon 120. Therefore, the person in charge of management or the like can confirm details such as the date and time of error occurrence for each manufacturing apparatus 30.

In this embodiment, by using a Redis server as the first server 70, it is possible to register the source information in the source information database and read the analysis information from the source information database at high speed.

In this embodiment, since the analysis information display screen is a Web page, the analysis information display screen can be easily displayed as a pop-up on the terminal device 90 using an existing program or system such as the browser 105.

[Modified example]

In the embodiments described above, an example has been described in which the management device 60 that performs management is one device. However, the management device 60 may be composed of a plurality of devices. The programs 64, 65, 66, and 67 may be distributed and implemented in multiple devices.

10...Production management system 11...Communication network 20...Manufacturing factory 30...Manufacturing equipment 50...PLC
60... Management device 62, 72, 74, 82, 84, 102... Memory 64... First program 65... Second program 66... Third program 67... Fourth program 70 ...First server 75...First server program 80...Second server 85...Second server program 90...Terminal device 104...Terminal program 120...Device icon 121...・Device icon

Claims (7)

a plurality of controllers that periodically acquire original information including at least device ID, manufacturing elapsed information, and error information;
a management device that implements a first program, a second program, and a third program;
a memory for storing a source information database and an analysis information database;
comprising a terminal device;
The controller, the management device, and the terminal device are capable of communicating through a communication network,
The first program above is
Executing a source information registration process that acquires the source information from the controller and registers it in the source information database;
The second program above is
A generation process that periodically acquires the above source information and periodically generates real-time display screen data;
a first transmission process of periodically transmitting the real-time display screen data to the terminal device;
The third program above is
an error information acquisition process that acquires the date and time of occurrence of the error indicated by the error information from the source information database;
an analysis information generation process that generates analysis information in which the device ID and the date and time of occurrence are associated with each other;
A production management system that executes analysis information registration processing for registering the analysis information in the analysis information database. The production management system according to claim 1, further comprising a fourth program that acquires the analysis information from the analysis information database and generates analysis information display screen data to be transmitted to the terminal device. The memory further stores a manufacturing schedule database in which at least a product ID, the device ID, and a manufacturing schedule are associated with each other,
The above analysis information generation process is
a manufacturing schedule acquisition process that acquires the device ID and manufacturing schedule from the manufacturing schedule database;
a process of generating, based on the analysis information and the manufacturing schedule, the analysis information in which the product ID, the device ID, the error information, the date and time of error occurrence, and the manufacturing schedule are associated with each other; , The production management system according to claim 1 or 2. The memory further stores a tally database in which tally information that is a tally of the manufacturing time information for each day is registered;
The second program above is
a tally display screen data generation process that generates tally display screen data based on the tally information;
The production management system according to any one of claims 1 to 3, further executing a second transmission process of transmitting the total display screen data to the terminal device. The real-time display screen shown by the above-mentioned real-time display screen data includes multiple device icons,
The second program above is
Based on the selection of the device icon, an instruction process for passing the device ID associated with the selected device icon and information instructing generation of the analysis information display screen data to the fourth program. The production management system according to claim 2, further performing: A server that develops the source information database in a RAM and accesses the source information database, further comprising a server that sets one key for one piece of the manufacturing time information and registers it in the source information database. The production management system according to any one of claims 1 to 5. 3. The production management system according to claim 2, wherein the analysis information display screen data is web page data displayed by a browser installed in the terminal device.

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