JP2024005142A - Operation state management system, operation state management device, program, and operation state management method - Google Patents

Abstract

To provide an operation state management system capable of grasping a preparation state in a production interval between a previous production and a next production in a production line, an operation state management device, a program, and an operation state management method.SOLUTION: An operation state management system 100 comprises a production device 130, an operation state management device 110 acquiring data from the production device, and a display device 120 displaying the information acquired from the operation statement management device. The operation state management device comprises delay rate storage means 112 for storing a relationship between a work process conducted in a production interval in the production device and a delay rate influencing a preparation delay in the production interval and a predictive production interval time calculation means 115 for calculating a predictive production interval time on the basis of a required process time, which is a required time of each work process received from the production device and a delay rate of each work process. The display device displays prediction information based on a predictive production time.SELECTED DRAWING: Figure 1

Description

The present disclosure relates to an operating status management system, an operating status management device, a program, and an operating status management method.

Conventionally, various products have been produced (manufactured) using various production lines installed within a factory. A production line combines production equipment that performs various processes. In order to efficiently produce products using such a production line, techniques for managing the operation have been developed (see, for example, Patent Document 1).

Patent No. 4846412

In production equipment that performs high-speed production such as aseptic filling lines for PET bottles, an inter-production state exists between the previous production and the next production after the previous product is produced until the next product is produced. do. During this time between production, the production equipment is cleaned and washed in preparation for the production of the next product. However, during production, work is performed simultaneously in multiple processes and multiple equipment, so it is difficult to grasp the factors that cause the time between production to be delayed and the end time.

Therefore, the present disclosure provides an operating status management system, an operating status management device, a program, and an operating status management method that can grasp the preparation status between productions, which is between the previous production and the next production, on a production line. The challenge is to provide the following.

In order to solve the above problems, in this disclosure,
A production device that produces a product, an operation status management device that acquires data from the production device, and a display device that displays information acquired from the operation status management device, An operating status management system that manages the situation between productions,
The operating status management device includes:
a delay rate storage means that stores a relationship between a work process carried out between the productions in the production apparatus and a delay rate that affects a delay in preparation between the productions;
a predicted inter-production time calculation means for calculating a predicted inter-production time based on the process required time that is the required time for each work process received from the production device and the delay rate of each work process;
The display device provides an operation status management system that displays prediction information based on the predicted production time.

In addition, in the operating status management system of this disclosure,
The operating status management device includes:
Inter-production schedule storage means that stores inter-production schedule information including work processes scheduled between the productions;
Further comprising a scheduled end time calculation means for calculating a scheduled end time using the predicted inter-production time calculated by the predicted inter-production time calculation means and the inter-production time start time which is the start time of the inter-production time,
The display device may display the scheduled end time as the prediction information.

In addition, the operating status management system of the present disclosure is
Process performance storage means storing process performance information in which the process time required for each work process and the inter-production time of the production equipment are recorded in association with the manufacturing lot to be produced;
Delay rate calculation means that refers to the process performance information, executes a simple regression analysis using the inter-production time as an objective variable and the time information of the work process as an explanatory variable, and calculates the delay rate of each work process;
You may further have.

In addition, in the operating status management system of this disclosure,
The delay rate calculation means may perform a simple regression analysis using a process required time, which is a required time of the work process, as the time information of the work process.

In addition, in the operating status management system of this disclosure,
The delay rate calculation means calculates the delay rate in association with any one or more of the product type to be produced, the liquid inside, the bottle shape, the labeler type, the bottle capacity, whether it is acidic or neutral, the cap type, or the label material. You may.

Additionally, in this disclosure,
It is connected to a production device that produces a product and a display device that displays information, acquires production information from the production device, and manages the situation between productions that is between the previous production and the next production in the production device. An operating status management device that
The operating status management device includes:
a delay rate storage means that stores a relationship between a work process carried out between the productions in the production apparatus and a delay rate that affects a delay in preparation between the productions;
A predicted inter-production time calculation means for calculating an estimated inter-production time based on the process time required for each process received from the production apparatus and the delay rate for each process type,
The display device provides a working status management device that displays prediction information based on the predicted production time.

Additionally, in this disclosure,
It is connected to a production device that produces a product and a display device that displays information, acquires production information from the production device, and manages the situation between productions that is between the previous production and the next production in the production device. A program used for a computer that
The computer,
a delay rate storage means that stores a relationship between a work process carried out between the productions in the production apparatus and a delay rate that affects preparation delays between the productions;
Predicted inter-production time calculation means for calculating the estimated inter-production time based on the process time required for each process received from the production equipment and the delay rate for each process type;
Provide a program to function as

Additionally, in this disclosure,
The operation status includes an inter-production schedule storage means that stores inter-production schedule information of production equipment, and a delay rate storage means that stores the relationship between work processes for each process type and delay rates that affect work delays in inter-production time. An operating status management method in which a management device manages the status of the production equipment,
calculating a predicted inter-production time based on the process time required for each work process received from the production equipment and the delay rate for each process type;
calculating a scheduled end time using the predicted production time;
Provided is an operating status management method having the following functions.

According to the present disclosure, it is possible to grasp the preparation status between productions, which is between the previous production and the next production, on the production line.

FIG. 1 is a configuration diagram showing an operating status management system according to an embodiment of the present disclosure. FIG. 1 is a diagram showing an operating status management device 110 according to an embodiment of the present disclosure. It is a figure which shows an example of the process performance information memorize|stored in a process performance storage means. FIG. 3 is a diagram illustrating an example of a delay rate that does not depend on product information. It is a figure which shows an example of the delay rate for each product type. It is a figure which shows an example of the delay rate for every bottle shape. It is a figure which shows an example of the delay rate for each bottle capacity. It is a figure which shows an example of the schedule information between productions memorize|stored in the schedule storage means between productions. FIG. 3 is a diagram showing product information including product types. 2 is a diagram showing a hardware configuration of a display device 120. FIG. 3 is a flowchart showing processing operations of the operating status management system. 3 is a diagram showing a display image on the display device 120. FIG. 7 is a diagram showing another example of process performance information stored in process performance storage means 111. FIG. 7 is a diagram showing still another example of process performance information stored in process performance storage means 111. FIG. It is a diagram showing an example of a work process in an aseptic filling line for PET bottles.

Hereinafter, preferred embodiments of the present disclosure will be described in detail with reference to the drawings.
<System configuration>
FIG. 1 is a diagram showing an operating status management system using an operating status management device according to an embodiment of the present disclosure. In FIG. 1, 100 is an operation status management system, 110 is an operation status management device, 120 is a display device, 130 is a production device, 140 is a gateway device, and 150 is a network. The operating status management device 110, display device 120, and gateway device 140 are connected to a network 150 such as the Internet, and are capable of data communication with each other. The production device 130 is connected to the gateway device 140 for data communication. The gateway device 140 transmits data such as production information received from the production device 130 to the operating status management device 110 via the network 150. The display device 120 accesses the operating status management device 110 via the network 150, receives data from the operating status management device 110, and displays the data.

In the example of FIG. 1, only one display device 120 is shown for convenience of explanation. However, in reality, the operating status management device 110 can be used from a large number of display devices 120 via the network 150. Further, in the example of FIG. 1, for convenience of explanation, three production apparatuses 130, which are production equipment, are shown. However, in reality, more production devices 130 are usually installed at a production site. The operating status management system 100 according to the present embodiment is particularly useful when the production line has a large number of production devices and the entire production line has a complicated configuration.

FIG. 2 is a diagram showing details of the operating status management device 110. Of these, FIG. 2A is a hardware configuration diagram of the operating status management device 110. The operating status management device 110 can be realized by a general-purpose server computer. Specifically, as shown in FIG. 2, the hardware configuration of the operating status management device 110 includes a CPU (Central Processing Unit) 110a, a RAM (Random Access Memory) 110b which is the main memory of the computer, and a CPU. A large-capacity storage device 110c (for example, hard disk, flash memory, etc.) for storing programs and data to be executed, an input I/F (interface) 110d that accepts input from input devices such as a keyboard and a mouse, and an external A data input/output I/F (interface) 110e for data communication with a device (data storage medium, etc.), a display output I/F (interface) 110f for sending information to a display device (liquid crystal display, etc.), The communication unit 110g includes a communication unit 110g for performing network communication with other devices such as the display device 120 and the gateway device 140 via the network 150. These elements are connected to each other via a bus. Further, the operating status management device 110 implemented by the server computer has an internal clock (not shown), and the CPU 110a can obtain the current time from the internal clock.

FIG. 2(b) is a functional block diagram of the operating status management device 110. In the hardware configuration shown in FIG. 2(a), the CPU 110a reads the program stored in the storage device 110c into the RAM 110b and executes it, so that the operating status management device 110 can operate the various means shown in FIG. 2(b). It becomes possible to make it function. As shown in FIG. 2(b), the operation status management device 110 includes a process performance storage unit 111, a delay rate storage unit 112, an inter-production schedule storage unit 113, a delay rate calculation unit 114, a predicted inter-production time calculation unit 115, It has scheduled end time calculation means 116.

The process performance storage unit 111 is a storage unit that stores process performance information. The process performance information is information that totals the time required for each work process between productions in each production apparatus 130 for each product manufacturing lot. Therefore, process performance information is recorded in association with the manufacturing lot to be produced. In each production device 130, products are produced (manufactured) at any time. Therefore, once the production of one lot (pre-production) is completed, preparations are made for the production of the next lot (next production). Once the preparations are complete, production of the next lot begins. In this way, preparation time is provided between the production of the previous lot and the next lot. This time is called the inter-production time because it is between the end of the previous production and the start of the next production. Each lot can also be identified by a product number.

FIG. 3 is a diagram showing an example of process performance information stored in the process performance storage means 111. As shown in FIG. 3, the process performance storage means 111 stores the previous production end time, the next production start time, the time between productions, the product type of the previous production, and the required process time as process performance information.

Process performance information is managed for each manufacturing lot of manufactured products. Further, the process performance information is managed in chronological order, and the production lots are arranged in descending order of the previous production end time. The time between the previous production end time, which is the end time of the previous production, and the next production start time, which is the start time of the next production, is the inter-production time. During the inter-production time, multiple work processes take place. Examples of the work process include cleaning and cleaning of the production equipment 130, which is production equipment. Process duration is the time required for a work process. Some work processes may be performed in parallel. In the example of FIG. 3, the required process times are stored for four processes, processes A to D. As shown in the bottom row of FIG. 3, the average inter-production time is calculated for the inter-production time, and the average process time required for each process is calculated and stored.

FIG. 3 shows an example in which products of previous production types a and b were each produced once, and products of previous production type c were produced twice as different manufacturing lots. Furthermore, in FIG. 3, equipment P and equipment Q are production equipment 130. The example in FIG. 3 shows that processes A and B are carried out in equipment P, and processes C and D are carried out in equipment Q.

To explain the top row of FIG. 3 as an example, the previous production end time of the production equipment 130 that produced type a as the previous production is “2021/04/10 21:36”, and the next production of the production equipment 130 Production start time is "2021/04/11 04:58". Therefore, the inter-production time from the previous production end time to the next production start time is "7:22" (7 hours and 22 minutes). Then, four work processes are performed during the inter-production time, and the required times for processes A to D are "1:10" (1 hour and 10 minutes), "0:20" (20 minutes), and "0:45". ” (45 minutes) and “0:35” (35 minutes).
Further, the average inter-production time, which is the average of all inter-production times, is calculated at any time. In the example of FIG. 3, the average of four inter-production times is recorded, but in reality, more averages of inter-production times are usually recorded.

The delay rate storage unit 112 is a storage unit that stores delay rate information. The delay rate is the rate at which each work process delays the start of the next production. That is, the delay rate is a rate that affects preparation delays between productions. Naturally, the impact on delays varies depending on the type of work process. Therefore, the delay rate varies depending on the type of work process. FIG. 4 is a diagram showing an example of a delay rate that does not depend on product information. As shown in FIG. 4, the delay rate storage means 112 stores delay rates in association with each work process.

Although the delay rate shown in FIG. 4 is a delay rate that is not based on product information, a delay rate managed using product information may be used. For example, among product information, delay rates for each product type, bottle shape, and bottle capacity can be used. FIG. 5, FIG. 6, and FIG. 7 are diagrams showing delay rates for each product type, bottle shape, and bottle capacity, respectively. As shown in FIGS. 5, 6, and 7, even in the same type of work process, the delay rate differs depending on the product type, bottle shape, bottle capacity, etc. produced in the previous production.

The inter-production schedule storage unit 113 is a storage unit that stores inter-production schedule information including product numbers and types of previous production and next production, and each scheduled work process. FIG. 8 is a diagram showing an example of inter-production schedule information stored in the inter-production schedule storage means 113. As shown in Figure 8, the inter-production schedule information includes the previous product number indicating the lot number of the previous production, the product to be produced by the previous product number, the next product number indicating the lot number of the next production, and the product to be produced by the next product number. We have varieties and work processes. One or more work processes are scheduled between the production of the previous product number and the next product number. For example, the example in FIG. 8 shows that at least process A and process B are prepared as work processes.

The "product type" used in the process performance information in Figure 3 and the production schedule information in Figure 8 includes product information such as bottle shape, labeler type, bottle capacity, acidic/neutral type, liquid content, cap type, and label material. can be attached. FIG. 9 is a diagram showing an example of product information. In the example of FIG. 9, as product information, bottle shape, labeler type, bottle capacity, acidic/neutral type, liquid content, cap type, and label material are recorded in product type information. Such product information can be stored in a predetermined storage area within the storage device 110c. The product information may include attributes other than those shown in FIG.

The delay rate calculation means 114 is a means for calculating the delay rate of each work process by referring to the process performance information stored in the process performance storage means 111. Specifically, a simple regression analysis is performed for each target variable, using the time between production as the target variable and the process time required for each work process as the explanatory variable. As the simple regression analysis, for example, the least squares method can be used. Through this simple regression analysis, the p value (reliability) and slope are calculated for each work process. This slope is then taken as the delay rate. In this way, the delay rate calculation means 114 calculates the delay rate of each work process. Note that the delay rate may be calculated by regression analysis other than simple regression analysis. For example, the delay rate calculation means 114 may calculate the delay rate using multiple regression analysis as the regression analysis.

The predicted inter-production time calculation means 115 calculates the predicted inter-production time based on the delay rate calculated by the delay rate calculation means 114. Specifically, the predicted production time calculation means 115 calculates the predicted production time by executing the process according to [Formula 1] below.

[Formula 1]
Predicted inter-production time = Average inter-production time + ((Process A required time - Average process A required time) x α) + ((Process B required time - Average process B required time) x β) + ((Process C required time) - Average process C required time) x γ) +...+ ((Process Z required time - Average process Z required time) x ζ)

In [Formula 1], α, β, γ, and ζ are delay rates corresponding to each work process. In the above [Formula 1], the delay rates α, β, γ, and ζ are the delay rates of processes A, B, C, and Z, which are work processes, respectively. Therefore, when the time required for each work process is greater than the average time required, the predicted inter-production time increases as the delay rate of each work process increases. In the above [Formula 1], when the delay rate of all work processes is 0, the predicted inter-production time=average inter-production time, which is the minimum.

The scheduled end time calculation means 116 calculates the scheduled end time using the predicted inter-production time calculated by the estimated inter-production time calculation means 115. Specifically, the scheduled end time calculation means 116 calculates the scheduled end time by executing processing according to the following [Formula 2].

[Formula 2]
Scheduled end time = Inter-production time start time + Predicted inter-production time

The inter-production time start time in [Formula 2] corresponds to the previous production end time shown in FIG. 3. Therefore, the inter-production time start time is acquired from the process performance information stored in the process performance storage means 111 of the operating status management device 110. As shown in [Equation 2], the scheduled end time is calculated by adding the predicted inter-production time calculated by the predicted inter-production time calculation means 115 to the inter-production time start time.

The operating status management device 110 also executes various processes not included in the above-mentioned means by having the CPU 110a read a program stored in the storage device 110c into the RAM 110b and execute it. The operating status management device 110 may be physically realized by one computer, or may be realized by multiple computers. Further, the cloud system may be implemented as a plurality of distributed cloud systems on the network 150.

The display device 120 is a terminal device that displays information stored and managed by the operating status management device 110. FIG. 10 is a hardware configuration diagram of the display device 120. Display device 120 is realized, for example, by a general-purpose computer incorporating browser software.

As shown in FIG. 10, the display device 120 includes a CPU (Central Processing Unit) 120a, a RAM (Random Access Memory) 120b which is a main memory, and a non-volatile memory for storing programs and data executed by the CPU 120a. A device 120c (for example, flash memory, etc.), an instruction input section 120d such as a keyboard or touch panel, a data input/output I/F (interface) 120e for data communication with an external device (data storage medium, etc.), and a display section. (Liquid crystal display, etc.) 120f, and a communication unit 120g for performing network communication with other computers such as the operating status management device 110 via a network 150, and are connected to each other via a bus.

The display device 120 only needs to be equipped with an arithmetic processing unit such as a CPU, and have a display function, an information processing function, a network communication function, etc., and may be a general-purpose device such as a notebook PC, a tablet, or a smartphone. It is possible. In this embodiment, the display device 120 includes a web browser, and uses the web browser to access the operating status management device 110, which has a function as a web server. Thereby, the display device 120 can acquire and display information managed by the operating status management device 110.

The production device 130 is equipment for producing a predetermined type of product. Each production device 130 is equipped with a PLC (programmable logic controller), various sensors, and a communication device, and acquires production information and transmits it to the gateway device 140. In this embodiment, signals indicating the end of the previous production and the start of the next production are also transmitted to the gateway device 140 as a type of production information. Furthermore, the production device 130 also transmits signals indicating the start and end of each work process to the gateway device 140 as a type of production information.

The gateway device 140 aggregates production information acquired from a plurality of production devices 130. The aggregated production information is then transmitted to the operation status management device 110 via the network 150. The timing of transmitting the production information to the operating status management device 110 may be at regular intervals (for example, every 5 minutes), or may be transmitted in real time every time it is received from each production device 130. In this embodiment, signals indicating the end of the previous production, starting the next production, and signals indicating the start and end of each work process are also transmitted to the operation status management device 110 via the gateway device 140 as part of the production information. Note that the production device 130 may be directly connected to the network 150 and may transmit production information directly to the operating status management device 110 without going through the gateway device 140.

<Collection of process performance information>
Next, the collection of process performance information in the operating status management system shown in FIG. 1 will be described. As shown in FIG. 1, the production device 130 is capable of transmitting data to the operation status management device 110 via the gateway device 140 and the network 150. Therefore, in the production device 130, the attached PLC transmits production information detected by an attached sensor or the like to the operation status management device 110. In the operation status management device 110, the collected production information is stored in the process performance storage means 111.

Regarding the previous production end time and next production start time, the production equipment 130 transmits information and time indicating that when the previous production ends and the next production starts, and the operation status management device 110 transmits the acquired time information to the previous production time. It is stored as the production end time and next production start time. As the product type, information on the previous production type acquired from the production device 130 is stored.

For each work process, at the start and end timings of the work process in each production device 130, the PLC installed in the production device 130 determines the type of work process and whether it is started or ended via the gateway device 140. The information is sent to the status management device 110. Then, the operating status management device 110 calculates the required process time based on the acquired start time and end time of the work process. The operation status management device 110 stores the calculated process required time in the process performance storage unit 111 in association with each lot.

As described above, various information from the previous production end time to the next production start time is sent from each production device 130 to the operation status management device 110, and process performance information is accumulated in the process performance storage means 111. To go. When the next production starts and the next production start time is determined, the operation status management device 110 calculates the inter-production time from the difference between the previous production end time and the next production start time. The operation status management device 110 stores the calculated inter-production time in the process performance storage means 111 in association with each lot. Further, the operating status management device 110 calculates the average of the inter-production times and stores it as the average inter-production time.

<Calculation of delay rate>
When the next production starts for a certain manufacturing lot and the inter-production time is determined, in the operation status management device 110, the delay rate calculation means 114 calculates the delay rate of each work process for each type. Specifically, the delay rate calculation means 114 executes a simple regression analysis using the inter-production time and the process required time of each work process from the process performance information shown in FIG. Calculate the p-value and slope.

The calculated p-value represents the reliability of the numerical value. If this p value is not small enough, the reliability of the data is low. Therefore, a predetermined threshold is set, and if the p value is larger than this threshold, it is excluded from the recruitment data. Therefore, if the p value is greater than the threshold, the delay rate is not calculated and the delay rate is zero. In this way, each calculated delay rate is stored in the delay rate storage means 112. As shown in FIG. 4, the delay rate calculation means 114 can also calculate a delay rate that does not depend on product information, but as shown in FIGS. 5, 6, and 7, The delay rate may be calculated for each capacity. Furthermore, the delay rate may be calculated for other attributes that are the attribute information shown in the product information in FIG. For example, the delay rate calculation means 114 calculates the delay rate in association with any one or more of information such as product type, bottle shape, labeler type, bottle capacity, acidic/neutral classification, liquid content, cap type, and label material. You may.

<Calculation of scheduled end time>
As described above, the delay rate is calculated using the latest process performance information, and the delay rate of each work process in the delay rate storage means 112 is always updated to the latest one. In the operation status management system according to the present embodiment, the predicted inter-production time and scheduled end time are calculated as prediction information at the time of product production or between productions. The operational status is managed by obtaining predictive information in this way. For this purpose, inter-production schedule information of the product to be produced is prepared in the inter-production schedule storage means 113. The inter-production schedule information is as shown in FIG. 8, as described above.

FIG. 11 is a flowchart showing the operating status management method according to this embodiment. When the production apparatus 130 starts production with the delay rate and inter-production schedule information prepared, the production apparatus 130 transmits the production information to the operation status management apparatus 110 in the same manner as in the above case. The operating status management device 110 acquires production information from the production device 130, as in the case described above (step S1). The received production information is accumulated in the process performance storage means 111.

The predicted inter-production time calculation means 115 calculates the predicted inter-production time at a predetermined timing while the production apparatus 130 is in operation (step S2). The predetermined timing can be set to various timings, such as when a predetermined unit time has elapsed or when a delay occurs. At a predetermined timing, the predicted inter-production time calculation means 115 calculates the predicted inter-production time. Specifically, the predicted production time calculation means 115 calculates the predicted production time by executing the process according to [Formula 1] above.

The predicted inter-production time calculation unit 115 obtains the process time required for each work process in order to execute the process according to the above [Formula 1]. Further, the predicted production time calculation means 115 acquires the delay rate of each work process from the delay rate storage means 112 for each work process. Then, using the process required time and delay rate of each work process, the process according to the above [Formula 1] is executed to calculate the predicted production time.

Once the predicted inter-production time is calculated, the scheduled end time calculation means 116 calculates the scheduled end time using the predicted inter-production time (step S3). Specifically, the scheduled end time calculation means 116 calculates the scheduled end time by executing the process according to the above [Formula 2].

The scheduled end time calculation means 116 acquires each piece of information regarding the start time of the inter-production time and the predicted inter-production time in order to execute the process according to the above [Formula 2]. Since the inter-production time start time is the same as the previous production end time, it is acquired from the process performance information stored in the process performance storage means 111 of the operating status management device 110. The predicted inter-production time uses the current predicted inter-production time calculated by the predicted inter-production time calculation means 115. Then, using each piece of acquired information, the process according to the above [Formula 2] is executed to calculate the scheduled end time.

The operation status management device 110 calculates the predicted inter-production time and scheduled end time as prediction information at any time while the production device 130 is in operation. The calculated value is held together with the calculation time and transmitted in response to a request from the display device 120. The display device 120 then displays the acquired prediction information (step S4). FIG. 12 is a diagram showing a display image on the display device 120.

On the left side of FIG. 12, a thick arrow pointing from top to bottom is shown. This arrow shows the progress of time, and the further down it goes, the more time progresses. In the example of FIG. 12, it is assumed that during production, process A ends at a certain time, and then process B and process C end sequentially. The right side of FIG. 12 shows three screens G1 to G3. Screens G1 to G3 correspond to the progression of time indicated by the downward arrow on the left side of FIG.

As shown in screens G1 to G3 of FIG. 12, during production, the display device 120 displays items such as the scheduled end time and delayed process. A delayed process refers to a process in which a delay has occurred. Furthermore, the estimated delay time may also be displayed. Further, for delayed processes, the extended time of each process and the influence time based on the delay of each process may be displayed.

As the scheduled end time, the scheduled end time calculated by the scheduled end time calculation means 116 is displayed. As the predicted delay time, the value obtained by subtracting the planned end time from the scheduled end time is displayed. As delayed processes, processes that have been delayed up to that point are displayed. The scheduled end time, predicted delay time, and influence time are all prediction information based on the predicted production time.

The time required for each process is determined when it is completed. Then, the delay time is calculated by subtracting the average time required for the process from the determined process time. If this value is a positive value, it directly means a delay time, and if this value is a negative value, it means a shortened time.

At a time point after the start of the inter-production time and before the end of the first work process, the display device 120 displays content as shown in screen G1 in FIG. 12. At the time when screen G1 is displayed, no work process has been completed since the start of the inter-production time. Therefore, the process to be delayed is undetermined, and "No delayed process" is displayed. Further, the planned end time is the time at which the plan will end if it proceeds without delay.

The planned end time is calculated immediately after the start of the inter-production time. The planned end time is the sum of the average inter-production time to the start time of inter-production time (previous production end time). If no process has been completed since the start of the inter-production time, the predicted inter-production time equals the average inter-production time even if the processing according to [Formula 1] above is performed. Therefore, when the process according to [Formula 2] above is performed, the scheduled end time becomes the same as the planned end time. Therefore, on screen G1, the scheduled end time and the planned end time are the same, 4:00.

When process A ends, the time required for process A is determined. Then, the delay time can be calculated from a comparison with the average required time of the work process. In the example of FIG. 12, it is assumed that process A is delayed by one minute. When the delay in the work process is determined, the predicted inter-production time calculation means 115 executes the process according to [Formula 1] to calculate the predicted inter-production time. Furthermore, the process according to [Formula 2] is executed to add the predicted inter-production time to the inter-production time start time to calculate the scheduled end time. Further, the predicted delay time is calculated by subtracting the planned end time from the scheduled end time. It also calculates the impact on the time between production due to delays (extension) in each work process. If there is only one delayed process, the predicted delay time can simply be used as the influence time of the inter-production time. In this way, the content shown on screen G2 is displayed.

When process B ends, the time required for process B is determined. Then, the delay time of process B can be calculated from the comparison with the average required time of the work process. At this point, using the time required for processes A and B and the average time required for processes A and B, the predicted production time calculation means 115 executes the process according to [Formula 1] to produce the predicted production time. Calculate the intermission time. Then, the screen is switched from screen G2 to display a new screen. In FIG. 12, the screen at this point is omitted.

Furthermore, when process C ends, the time required for process C is determined. Then, the delay time of process C can be calculated from the comparison with the average required time of the work process. If the delay time value is negative, the time is shortened. At this point, the predicted production time calculation means 115 executes the process according to [Formula 1] using the process time required for processes A, B, and C and the average time required for processes A, B, and C. Then, calculate the predicted production time. In addition, it is possible to calculate the influence time on the inter-production time due to each delay process. This can be calculated by setting the time required for processes other than the delayed process of interest as the average time required. As a result, a new screen G3 is displayed.

In screen G3 of Fig. 12, when process A is extended by 1 minute, the impact time on the inter-production time is +5 minutes (delay), and when process A is extended by 8 minutes, the impact time on the inter-production time is +5 minutes (delay). is +30 minutes (delay), and if process C is shortened by 15 minutes, the impact on the production time will be -5 minutes (shortened).

<Variations of explanatory variables>
In the above explanation, the process time was used as an explanatory variable in the simple regression analysis. As the explanatory variable, things other than the process required time may be used. FIG. 13 is a diagram showing another example of process performance information stored in the process performance storage means 111. In the example of FIG. 13, in addition to the process required time shown in FIG. 3, the difference with the average process time is stored. A positive value indicates that the time was longer than the average time, and a negative value indicates that the time was shorter than the average time. When having process performance information as shown in FIG. 13, the delay rate calculation means 114 uses a simple regression for each objective variable, using the inter-production time as an objective variable and the difference from the process average time of each work process as an explanatory variable. Perform analysis. In this way, the delay rate calculation means 114 calculates the delay rate of each work process.

FIG. 14 is a diagram showing still another example of the process performance information stored in the process performance storage means 111. In the example of FIG. 14, in addition to the process required time shown in FIG. 3, a process start time and a process end time are stored. When having process performance information as shown in FIG. 13, the delay rate calculation means 114 uses the inter-production time as the objective variable, the process start time and process end time of each work process as explanatory variables, and calculates a simple value for each objective variable. Perform regression analysis. In this way, the delay rate calculation means 114 calculates the delay rate of each work process.

As described above, the operation status management system 100 according to the present embodiment includes the production equipment 130 that produces products, the operation status management device 110 that acquires data from the production equipment 130, and the operation status management system 100 that acquires data from the operation status management device 110. A display device 120 that displays information, and an operation status management system that manages the situation between productions that are between the previous production and the next production in the production equipment, and the operation status management device 110 Delay rate storage means 112 that stores the relationship between work processes carried out between productions and delay rates that affect preparation delays between productions, and process required times that are the required times of each work process received from the production equipment. , a predicted inter-production time calculation means 115 that calculates the predicted inter-production time based on the delay rate of each work process, and the display device 120 displays prediction information based on the predicted inter-production time, so that the production On the line, it becomes possible to grasp the preparation status between productions, which is between the previous production and the next production.

Furthermore, the operating status management system 100 according to the present embodiment includes:
The operating status management device 110 stores the inter-production schedule storage means 113 that stores inter-production schedule information including work processes scheduled between productions, the predicted inter-production time calculated by the predicted inter-production time calculation means, and the predicted inter-production time calculated by the predicted inter-production time calculation means. It further includes a scheduled end time calculation means 116 that calculates the scheduled end time using the start time of the inter-production time, which is the start time of the time, and the display device 120 displays the scheduled end time as prediction information, so that the work process If a project ends later than the original completion plan due to a delay, it becomes possible to know the scheduled end time, making it easier to adjust the schedule in subsequent processes.

Furthermore, the operating status management system according to the present embodiment includes:
The process performance storage means 111 stores process performance information in which the process required time of each work process and the production time of production equipment are recorded in association with the manufacturing lot to be produced, and It further includes a delay rate calculation means 114 that calculates the delay rate of each work process by executing a simple regression analysis with time as an objective variable and time information of the work process as an explanatory variable. Relationships can be kept up-to-date, which helps in calculating accurate predicted production time and scheduled end time.

The delay rate calculation means 114 may perform a simple regression analysis using the process required time, which is the required time of the work process, as the time information of the work process. By performing simple regression analysis using the process required time as an explanatory variable, the delay rate can be calculated easily and accurately. The delay rate calculation means 114 may calculate the delay rate in association with any one or more of the product type to be produced, the liquid inside, the bottle shape, the bottle capacity, the cap type, and the label material. In this case, by using the delay rate specialized for each attribute, it is possible to more accurately calculate the predicted production time and scheduled end time.

The operation status management system according to the present disclosure can be applied to any production device that is equipped with means for detecting the state of the production device during the inter-production time between the previous production process and the next production process. Therefore, the present invention can be applied to various products and production equipment, regardless of the type of product to be produced or the production equipment used to produce the product.

For example, the operating status management system according to the present disclosure can be applied to an aseptic filling line for PET (polyethylene terephthalate) bottles. When applied to an aseptic filling line for PET bottles, the production equipment includes equipment that implements a blending process, a liquid treatment process, a molding process, a filling process, or a packaging process. A PLC is installed in these facilities, and the information detected during the inter-production time between the previous production process and the next production process is transmitted to the operation status management device via the gateway device.

FIG. 15 is a diagram showing an example of a work process in an aseptic filling line for PET bottles. Since the work processes of the entire production line are aggregated, there are various work processes as shown in FIG. 15. Each piece of equipment, which is a production device, executes a plurality of work processes within the time between production. In the operation status management system according to this embodiment, by accurately setting the delay rate of the work process based on actual results, it is possible to calculate the predicted production time and scheduled end time, which are difficult to grasp with the senses of the worker. becomes.

Although the preferred embodiments of the present disclosure have been described above, the present disclosure is not limited to the above embodiments, and various modifications are possible. For example, in the above embodiment, the predicted production time and scheduled end time are received from the operation status management device via the network and displayed on the display device, but the display output I/F of the operation status management device It may also be displayed on a display device directly connected to.

In addition, in the above embodiment, the operating status management device calculates the predicted inter-production time and the scheduled end time, and displays them on the display device, but the estimated finished time is not calculated or displayed, and only the predicted inter-production time may be calculated and displayed. This is because even if it is not possible to know the scheduled end time, by knowing the predicted production time, it is possible to anticipate a certain amount of time delay.

100... Operating status management system 110... Operating status management device 110a... CPU (Central Processing Unit)
110b...RAM (Random Access Memory)
110c...Storage device 110d...Input I/F
110e...Data input/output I/F
110f...Display output I/F
110g... Communication department 111... Process performance storage means 112... Delay rate storage means 113... Inter-production schedule storage means 114... Delay rate calculation means 115... Predicted inter-production time calculation means 116 ...Estimated end time calculation means 120...Display device 120a...CPU (Central Processing Unit)
120b...RAM (Random Access Memory)
120c...Storage device 120d...Instruction input section 120e...Data input/output I/F
120f...Display section 120g...Communication section 130...Production device 140...Gateway device 150...Network

Claims (8)

A production device that produces a product, an operation status management device that acquires data from the production device, and a display device that displays information acquired from the operation status management device, An operating status management system that manages the situation between productions,
The operating status management device includes:
a delay rate storage means that stores a relationship between a work process carried out between the productions in the production apparatus and a delay rate that affects a delay in preparation between the productions;
a predicted inter-production time calculation means for calculating a predicted inter-production time based on the process required time that is the required time for each work process received from the production device and the delay rate of each work process;
The display device is an operating status management system that displays prediction information based on the predicted production time. The operating status management device includes:
Inter-production schedule storage means that stores inter-production schedule information including work processes scheduled between the productions;
Further comprising a scheduled end time calculation means for calculating a scheduled end time using the predicted inter-production time calculated by the predicted inter-production time calculation means and the inter-production time start time which is the start time of the inter-production time,
The operating status management system according to claim 1, wherein the display device displays the scheduled end time as the prediction information. Process performance storage means storing process performance information in which the process time required for each work process and the inter-production time of the production equipment are recorded in association with the manufacturing lot to be produced;
Delay rate calculation means that refers to the process performance information, executes a simple regression analysis using the inter-production time as an objective variable and the time information of the work process as an explanatory variable, and calculates the delay rate of each work process;
The operating status management system according to claim 1 or 2, further comprising: 4. The operating status management system according to claim 3, wherein the delay rate calculation means executes a simple regression analysis using a process required time, which is a required time of the work process, as the time information of the work process. The delay rate calculation means calculates the delay rate in association with any one or more of the product type to be produced, the liquid inside, the bottle shape, the labeler type, the bottle capacity, whether it is acidic or neutral, the cap type, or the label material. The operating status management system according to claim 3. It is connected to a production device that produces a product and a display device that displays information, acquires production information from the production device, and manages the situation between productions that is between the previous production and the next production in the production device. An operating status management device that
The operating status management device includes:
a delay rate storage means that stores a relationship between a work process carried out between the productions in the production apparatus and a delay rate that affects a delay in preparation between the productions;
A predicted inter-production time calculation means for calculating an estimated inter-production time based on the process time required for each process received from the production apparatus and the delay rate for each process type,
An operating status management device, wherein the display device displays prediction information based on the predicted production time. It is connected to a production device that produces a product and a display device that displays information, acquires production information from the production device, and manages the situation between productions that is between the previous production and the next production in the production device. A program used for a computer that
The computer,
a delay rate storage means that stores a relationship between a work process carried out between the productions in the production apparatus and a delay rate that affects preparation delays between the productions;
Predicted inter-production time calculation means for calculating the estimated inter-production time based on the process time required for each process received from the production equipment and the delay rate for each process type;
A program to function as The operation status includes an inter-production schedule storage means that stores inter-production schedule information of production equipment, and a delay rate storage means that stores the relationship between work processes for each process type and delay rates that affect work delays in inter-production time. An operating status management method in which a management device manages the status of the production equipment,
calculating a predicted inter-production time based on the process time required for each work process received from the production equipment and the delay rate for each process type;
calculating a scheduled end time using the predicted production time;
An operating status management method that has