JP3089628B2 - Process control system - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION [Industrial Application Field] The present invention relates to a process management system for managing a lot process procedure and a lot input sequence of lots in a lot production system in a manufacturing industry, and in particular, each cell is independent. The present invention relates to a process management system that manages a lot production process managed by a controller.

[Conventional technology]

In recent manufacturing shops, the controller of each cell has become intelligent because of the need to automate the flow of information, and has an interface to LAN.
Achieve automation by communicating information via

In the conventional process management system, lot information is centrally managed in the lot management host system, or a lot management table for managing lots is updated and the lot management information is updated. The defined process information generally uses the same file or table.

In controlling the automatic guided vehicle, the host computer manages the status in the loader / unloader using a photoelectric tube or the like, and further tracks the position of the automatic guided vehicle in the shop one by one.

[Problems to be solved by the invention]

The conventional process management system described above has the advantage that software can be developed efficiently because lots are centrally managed in the lot management host system, but if the host system goes down, it spreads to the entire shop, and the processing is processed by the host system. There is a disadvantage that the response speed when requests are concentrated at one time is not guaranteed.
In order to overcome this, there is a method in which the host system has a duplex or dual configuration. However, in general, the host system is expensive and has drawbacks such as being incompatible with small and medium-sized manufacturing shops.

On the other hand, in the distributed processing method, in the process shop, a controller for each cell and a controller for controlling the shop are connected to each other via a LAN, and a controller for controlling the shop generates a lot management table describing a process procedure when a lot is input. To the controller of the first process via LAN, and at the end of the first process, the first
A controller that fills in the end information of the process by the controller of the first process, passes the lot management table to the controller of the next process via the LAN, repeats the process in order, and repeats the lot management table after the end of the final process. Although there is a management method such as returning to a lot, this method has a drawback that the progress of the lot cannot be monitored in real time by the same terminal until the lot has completed all processes.

Furthermore, in the control of the automatic guided vehicle, the load was concentrated because the host computer performed tracking of the automatic guided vehicle and status management of the loader and unloader,
In addition, since tracking of the automatic guided vehicle is performed, there is a disadvantage that trouble processing is complicated.

[Means for solving the problem]

The process management system of the present invention manages a process procedure in a job shop, which describes an order in which a lot having one or more buckets, which are transport units in the shop, walks over a plurality of processes, and carries in a bucket before processing. A shop management controller that has a loader conveyor and an unloader conveyor that carries out unloading of buckets after processing, a shop management controller that manages loading into multiple cells, and a cell controller that controls the loader conveyor and unloader conveyor of cells and manages the lot of each process in the cell And a transport controller that controls the automatic guided vehicle to carry out logistics transport in the shop, and a buffer controller that manages a buffer device that temporarily stores transported goods overflowing between cells in the shop. It has a LAN that connects the controllers to each other, and the shop management controller It has a lot management table that describes the process procedure of the lot and a cell-by-cell input plan that describes the procedure for starting the lot for each cell that has the relevant process, and is created using the process procedure of the lot management table and the lot-start procedure of the cell-based input plan. Instructs the cell controller to input lots based on the input input plan, updates the lot management table at the end of each bucket, which is one transport unit of the product, and updates the lot management table as well as the final transported product. Input management means for recognizing the end of the lot by providing the final conveyed product flag, and reserve the bucket to be conveyed in advance for the lot supply request from the corresponding cell after the input instruction to the relevant cell controller, and instruct the buffer controller to take out. Transfer management means for instructing the transfer control controller on the transfer destination of the product to be delivered.

In addition, the cell controller of the process management system according to the present invention, based on input product information instructed by the shop management controller, sets up a corresponding setup standard among a plurality of setup standard information describing setup information of each process in the cell owned by itself. Setup instructing means for retrieving information and instructing each process facility for setup, transport request or collection request means for transmitting a product transport request to the shop management controller based on input product information, loader and unloader control means, and process input The transfer control controller includes execution management including a plan and a lot progress management means for performing progress management in the process, and the transfer control controller loads a load specified by the shop management controller onto the unmanned transport vehicle and a transferred load. Transport control means for instructing a delivery destination for delivering the And a buffer unit control including a storage means for receiving the goods specified by the shop management controller, and dividing the management unit into buckets in the cell controller. The storage container of the bucket holds data such as a barcode that can be read by an automatic device, and supplies the bucket to the loader under the control of the cell controller based on the data, and simultaneously stores the bucket for storage in the unloader. The storage container of the bucket is replaced one by one each time processing is performed in each cell, and each equipment is determined by the shop management controller or the cell controller according to the lot management table, the cell-based input plan, the process input plan, and the lot name. Of product name to search for setup information instructed to A setup index file having setup information and setup information are generated on a file or a table, and communication is performed between the respective controllers via a LAN.

〔Example〕

An embodiment of the present invention will be described below with reference to FIGS.

Second example of production line as target of process management system
It is shown in FIG. Production system in the figure, pantry 23 serving parts or unprocessed products, buffer device 24 for keeping the line balance line, cells that integrate multiple steps X ₁ cell 25, X ₂ cell 26, X ₃ cell 27, X ₄ cell 28
And _five cells consisting of X5 cells 29.

Pantry 23 IN conveyor 30 and OUT conveyor 31, the buffer device 24 IN conveyor 32 and OUT conveyor 33, X ₅ cell 2
9 has an IN conveyor 34 and an OUT conveyor 35, respectively.

Each cell has a loader 36 and an unloader 37, respectively.

Looking at an example of a lot flow, a bucket (a magazine 39 in FIG. 2 (b) is used for storing the bucket in this system) is loaded from a serving room 23 to an unmanned carrier 38 and stored in a buffer device 24. The magazine is transported (arrow 200), and the magazine is temporarily stored in the buffer device 24 until production actually starts. It is supplied to the process carried by the AGV 38 to the loader 36 of the start production X ₁ cells 25 (arrow 201). The processed product is stored in another magazine 39 (if the empty magazine 39 is discharged from the loader in time, the same magazine 39 is transported to the unloader 37 by the automatic guided vehicle 38 and the same magazine 39 One or more copies may be stored), and the magazine 39 from the unloader 37 is X ₄
It is carried to the loader 36 'of the cell 28 by the automatic guided vehicle 38 (arrow 20).
2). The processed magazine 39 is unloaded from the unloader 37 '
_It is carried to ₅ cells 29 (arrow 203). Magazine products processed in the X ₅ cell 29 has been completed is accommodated 39 X from OUT conveyor 35
It is transported to the loader 36 'of the _two cells 26 (arrow 204). X ₂ cell
Magazine 39 the products are accommodated machining has been completed in 26 is conveyed 'from the loader 36 of X ₃ cell 27' unloader 37.
(Arrow 205).

FIG. 1 is a system configuration diagram showing a process management system for controlling the above-mentioned production system. In the figure, the process management system includes a transfer control controller 3 for registering a lot in the serving room 23, registering a magazine corresponding to the lot, and controlling an unmanned transport vehicle 38 in the shop, inventory management 20 of the buffer device 24 or entry / exit management. A buffer controller 2 which performs 21; a cell controller 4 which has an execution management 19 which performs a lot progress management and a loader / unloader management in a cell and a setup instruction of a process (mainly equipment) in a cell; and a shop management which manages a shop. It is composed of a controller 1 and communicates with each other via the LAN 5.

FIG. 3 is a block diagram showing the above-mentioned production flow from an information system perspective. In the figure, the shop management controller 1 which performs transport control in a shop and in-process management and progress management of lots includes an input management 17, a transport management 18, a lot management table 7, a cell-specific input plan 8, a magazine management table 9, and It is composed of a cell-to-cell transfer table 10 and permits the shop management controller 1 to be turned on from the keyboard 6.

The buffer controller 2 includes the buffer device 24 described above.
Inventory management 20 and in / out management 21.

The transfer controller 3 registers a lot in the shop and a magazine 39 corresponding to the lot, and controls the automatic guided vehicle 38 upon receiving a transfer instruction from the shop management controller 1.

The cell controller 4, which controls the process (mainly equipment) in the cell and manages and sets up the progress of the lot, performs execution management 19,
It comprises an input plan management table 13, an equipment state management table 14, a loader management table 15, an unloader management table 16, a setup index file 11, and setup information 12.

FIG. 4 shows a format 7a showing the structure of the lot management table 7, which is composed of a "number of registered lots" 7a-1, a "management record" 7a-2, and a "process definition" 7a-3.
Here, "lot registration number" 7a-1 represents the number of lots registered in the shop.

FIG. 5 is a detailed format of the management record 7a-2 in FIG. 4, which includes a "data definition pointer" 7b-2, a "number of processes per cell", a "lot status flag", a "lot ID",
“Product name code” 7b-1, “Start date and time”, “Shipping date and time”,
It consists of “planned number” and “magazine width”.
The "data definition pointer" 7b-2 indicates the start address of the process definition record 7a-3 in FIG.

The “number of steps per cell” indicates how many steps (cells) the rod requires.

The "lot status flag" indicates whether the main record part of the file is "null: 0 (flag)", "the lot is registered but not yet input: 1 (flag)", or "this lot is started to be input." Status: 2 (flag) "or" production completed for this lot: 3 (flag) ".

“Lot ID” 7b-3 indicates a daily lot after the order is divided, and is distinguished from other lots.

 “Product name code” is a code representing the model of the product.

The “start date and time” is the scheduled start date and time of the lot, the “ship date and time” is the scheduled date and time when the production of the lot is completed and shipped,
The “planned number” indicates the planned number of productions of the lot.

The “magazine width” indicates the width of the magazine because the width of the magazine can be changed according to the width of the substrate.

FIG. 6 is an explanatory diagram showing the process definition record 7a-3 in FIG. In the drawing, the “execution status flag” indicates whether the lot has been input “unstarted status: 0”, “started status: 1”, or “completed: 2”.

"Cell code" indicates the code of the unique cell in the shop, CC11 the cell code of X ₁ cell, X ₂ cell: CC12, X ₃
Cell: CC 13, X ₄ cell: CC 14, and X ₅ cells: a CC15.

The "process code" is a code for identifying the order of flowing cells in the production of the lot, the number of times when the same product flows through the same cell again, and the front and back of the substrate.

The loader magazine information relates to the magazine transported to the loader of the corresponding cell.
It consists of a “bar code” and a “final flag”. Here, the “confirmed flag” indicates that the magazine is stored in the buffer and can be inserted at any time, and the “final flag” indicates the last magazine when a lot is flown.
"0: Normal magazine", "1: Last magazine of lot".

The unloader magazine information is related to the magazine transported to the unloader of the corresponding cell, and is composed of a “fixed flag”, a “barcode”, and a “final flag”.

FIG. 7 shows the structure of the input plan 8 for each cell, which comprises a cell management section 8a-1 and a cell data section 8a-2.

FIG. 8 is an explanatory diagram showing details of the cell management unit 8a-1. In the figure, the cell management section 8a-1 has a directory 8b indicating a registered lot for each cell and a data section 8c.

FIG. 9 shows the detailed format of the cell data section 8a-2, which includes "lot ID", "process code", "planned number", "permission flag", "instruction flag", "start time", and "completion time". It consists of. The “planned number” indicates the planned number of productions of the lot. The “permission flag” is a flag that permits the lot to be put into the cell, and “0: not permitted”
Indicates "1: permission". The "instruction flag" is a flag for issuing an instruction to the lot that is currently in process in the corresponding cell and is completed or immediately before completion, and is permitted to be input to the next lot. ". "Disclosure time" indicates the time at which the input was started. "Completion time" indicates the time at which production ended.

FIG. 10 shows a transport reservation magazine management table 15b of the cell controller. The transfer reservation magazine management table 15b is a reservation table for managing reservation of the magazine 39 to be transferred by the automatic guided vehicle 38 from now on. This magazine reservation is composed of “lot ID”, “process code”, “pitch”, “magazine width”, “number of supplies”, “barcode”, and “final flag”. Here, the “supply number” indicates the number of products stored in the magazine. The “bar code” is a magazine identification code unique in the shop.

FIG. 11 is an explanatory diagram of a loader magazine management table 15c indicating the location of the loader magazine in the cell. In the figure, the magazine management table 15c includes “state”, “lot ID”, “process code”, “pitch”, “magazine width”, “number of supplies”, “remaining number”, “barcode”, and “final flag”. It is composed of Here, the "state" indicates the position of the loader and the state of the loader by "arrived", "starting supply", "stopping", and the like. The “remaining number” is a number obtained by subtracting the actually used number from the “supply number”, and indicates the number remaining in the magazine.

FIG. 12 shows the structure of the inter-cell transfer table 10a, which includes an “index” 10a-1, a “loader transfer table” 10a.
-2, "Unloader transport table" 10a-3.

FIG. 13 shows the details of the inter-cell transfer table 10a, which includes "Lot ID", "Process code", "Bar code", "Transfer source", "Recovery destination", and "Status" 10b-1.
It is composed of Here, the “transportation source” indicates the position of the magazine that currently exists in the magazine to be transported. The “collection destination” indicates where the magazine received at the “transport source” is to be transported.

The "status" 10b-1 indicates the state of the magazine corresponding to the lot, and includes "storage", "AGV (automatic guided vehicle) start", "AGV availability", "AGV instruction", "cell request". , "Reservation" and the like. The statuses are "1: transfer request / recovery request / no report from cell controller, no report from transfer controller / not instructed to other controllers", "2: waiting for delivery from buffer controller, waiting for receipt of storage" , "3: transfer request / recovery request from cell controller, transfer reserved to cell controller, magazine arrived", and the like.

FIG. 14 is an explanatory diagram showing a magazine table 9a for each lot. In the figure, the magazine table 9a is labeled
An ID, a process code, and a bar code. When the buffer controller reports that the magazine has been dispatched, the record is erased. In addition, "Lot ID", "Process code",
If there is a warehousing report containing a "barcode", the data is described.

FIG. 15 is an explanatory diagram showing a setup change instruction (arrow 117) to the equipment 41 based on the start of supply instruction from the shop management controller 1 and a transfer mechanism when the equipment 41 does not have the data. In the drawing, first, the setup index file 11 and the setup information 12 are stored in advance in the cell controller 4 via a floppy disk 42 or a communication including the setup index file and the setup information.
To be stored.

When the actual production phase has been reached, the shop management controller 1 transmits an input instruction to the cell controller 4 (arrow 103). The cell controller 4 searches the index file 11 of the corresponding model from the “process code” 7c-1 and the “article name code” 7b-1 in the input instruction message, and searches the index file 11 containing the “substrate name” 43 in the index file 11. A replacement instruction is transmitted to the equipment (arrow 117). When the equipment does not hold the setup change data of the corresponding model, the equipment requests the cell controller 4 for the setup data (arrow 300).

The cell controller 4 searches for the equipment setup information file names 44 and 45 in the index file 11, and transfers the corresponding data file to the equipment (arrow 301). The method of searching for the equipment setup information file names 44 and 45 may be generated in the same manner as the method of generating the setup index file name 11.

Next, the flow of information on the operation side of the shop will be described.

Lot ID 7b registered in transfer controller 3
-3 (FIG. 5) corresponding to the magazine identification code (bar code in this system) 7c-2 (FIG. 6) is registered,
On the other hand, the empty magazine is stored in the buffer device 24. When the entry permission for the input lot of the cell data section 42 of the cell-specific input plan 8 is made by the keyboard 6 (or the host computer) of the shop management controller 1 (arrow 102), the cell controller 4 via the LAN 5 of the input management 17. Input plan (“Lot ID” 7b-3, “Product name code” 7b-1, “Scheduled number”
7b-4, "magazine width" 7b-5, "process code" 7c-1, and "magazine pitch" 7c-4) are transmitted (arrow 103). The cell controller 4 writes the received input plan in the input plan management table 13, and the execution management 19 monitors which type of equipment is in the setup setting state and how long the currently operating type of the equipment is to be finished. Equipment status table
Referring to FIG. 14 (arrow 116), if the setup is possible, referring to the setup index file 11 corresponding to the input model held by the cell controller 4 (arrow 104), the interface for determining the model code of the input model for each equipment. Is transmitted to the equipment 41 via the arrow (arrow 117). (At this time, the model code is transmitted from the shop management controller 1 to the cell controller 4 (arrow 103) in some cases in the communication message of the input plan.) Here, the facility 41 owns the setup information 12 of the corresponding product. If not, a data request for the setup information 12 is transmitted to the cell controller 4 (arrow 300).

When the equipment changeover is completed, the cell controller 4 refers to the management tables 15 and 16 of the loader / unloader (arrow 116), and if a magazine request has been input (arrow 116), transmits a transport request to the shop management controller 1. (Arrow 105). And the shop management controller 1
The flag 3 is set in the "status" 10b-1 of the inter-cell transfer table 10b with "cell request".

The input management 17 refers to the lot management table 7 (arrow 117),
In the magazine described in the process definition record 7a-3 (FIG. 4) of the lot management table 7 (the bar code 7c-
From the magazine No. 5 in the downward order), a delivery instruction is transmitted to the buffer controller 2 so that the magazine with the "final flag" is the last (arrow 107).
At the same time, a transfer request is sent to the transfer controller 3 from the buffer device exit conveyor 31 (arrow 105).
The transfer instruction is transmitted to the loader 34 (or the unloader 35) (arrow 106).

Further, the shop management controller 1 notifies the cell controller 4 of the barcode of the magazine to be transported from now (arrow 108), and makes a reservation for the cell. The shop management controller 1 manages the current position of the magazine and the "status" 10b-1 in the inter-cell transfer table 10a.

On the other hand, the cell controller 4 registers the above barcode in the magazine reservation management table 44 (details are the barcode 15b-1 in FIG. 10). When the magazine 39 is transferred to the cell by the automatic guided vehicle 38 (arrow 201), the bar code is read at the entrance of the cell loader 34 (or unloader 35), and the loader is loaded until the magazine is discharged from the loader 34 (or unloader 35). The magazine management unit table 15c (FIG. 11) monitors the magazine and monitors the number of sheets supplied in real time to manage the progress of the lot. When the supply or storage of the magazine ends, the cell controller 4 transmits a magazine collection request to the shop management controller 1 (arrow 109).
The transfer management 18 of the shop management controller 1 transmits a storage request including the collection magazine barcode to the buffer controller 2 (arrow 111), and at the same time, the transfer control controller 3 controls the loader 34 (or unloader 3) of the requested cell.
Conveyed from 5) to the buffer inlet conveyor 30. These steps are repeated until the production of the lot is completed.

At this time, the shop management controller 1 reflects the update of the lot production result in the lot management table 7 every time the magazine is collected. Cell controller 4 has "final flag" 7c
When the supply or storage of the magazine having -3 is completed, the end of the lot is recognized, a lot end report is transmitted to the shop management controller 1 (arrow 112), and the shop management controller 1 updates the lot management table 7.

For the setup change in the cell, an input plan is transmitted from the shop management controller 1 to the cell controller 4 (arrow 10).
3) The cell controller 4 uses the “process code” 7c in the message.
An index file name 11 corresponding to the model is generated from -1 and the "product name code" 7b-1. The cell controller 4 searches for the “board name” 43 described in the file,
The “board name” 43 is transmitted to the equipment and used as a setup start instruction (arrow 104). (In this case, it may be added to the input planning message.) [Effects of the Invention] According to the process management system of each of the first to fifth aspects of the present invention, each cell controller has a function of inputting and setting up a lot. Therefore, even when the shop management controller goes down, the equipment can be operated locally in each cell, and the entire shop can be prevented from being stopped.

Further, according to the invention of claim 2, since the result collection, the equipment trouble collection and the quality result collection are stored in the cell computer, the result data is not lost even when the shop management controller goes down.

According to the first to fifth aspects of the present invention, since the loads are distributed to the shop management controller, the cell controller, the transport control controller, and the buffer controller, each of them can be configured by an inexpensive controller and a local area network, A process management system can be realized inexpensively in small and medium-sized manufacturing shops.

[Brief description of the drawings]

FIG. 1 is a computer network diagram showing a shop network, FIG. 2 is a function relation diagram showing mutual relations of shop functions, and FIG. 3 is a flowchart of a lot magazine showing a flow of a lot registered magazine in the shop. , Fourth
The figure shows a schematic format of the lot management table, and FIG.
FIG. 6 is a management record diagram showing detailed items of a management record in the lot management table, FIG. 6 is a process definition record diagram showing a process definition in the lot management table in FIG. 4, FIG. FIG. 8 is format diagram showing a management unit of X ₁ cell, FIG. 9 is format diagram showing a data portion of the X ₁ cell, Fig. 10 format diagram showing the transfer reservation magazine management table of the cell controller, Fig. 11 Is a format diagram showing the loader magazine management unit of the loader, FIG. 12 is a status management format diagram showing the transport status of the magazine, and FIG.
Figure format diagram showing the detailed items of conveying table of X ₁ Seruroda the conveying table between FIG. 12 cells, Fig. 14 format diagram showing a management table indicating the lot-specific magazine bar code, FIG. 15 in the cell controller It is a flowchart which shows a setup method. 1 ... shop management controller, 2 ... buffer controller, 3 ... transport controller, 4 ... cell controller, 5 ... LAN, 7 ... lot management table, 8 ...
... Input planning by cell, 17 ... Input management, 18 ... Transportation management.

──────────────────────────────────────────────────続 き Continued on the front page (58) Field surveyed (Int.Cl. ⁷ , DB name) B23Q 41/08 B65G 43/10 G06F 17/60

Claims (5)

(57) [Claims] In a job shop, a loader conveyor for managing a process procedure describing an order in which a lot having one or more buckets, which are transport units in the shop, walks over a plurality of processes, and loads a bucket before processing. A shop management controller that manages loading into a plurality of cells having an unloader conveyor that unloads a processed bucket, a cell controller that controls a loader conveyor and an unloader conveyor of cells, and manages a lot of each process in the cell, A transport controller that controls the automatic guided vehicle to carry out logistics transport in the shop, a buffer controller that manages a buffer device that temporarily stores buckets overflowing between cells in the shop, and a controller Has a LAN to connect to, shop management controller, lot process A lot management table that describes the procedure, a cell-based loading plan that describes the start procedure of the lot for each cell having the relevant process, a loading management unit, and a transport management unit; The lot controller instructs the cell controller to input a lot based on the input procedure created in the process procedure and the lot start procedure of the input plan for each cell, and reports the progress of the lot in each process to the bucket, which is one transport unit of the product. At the end, the lot management table is updated and the last bucket is provided with a final flag to recognize the end of the lot. When the bucket to be transferred to the buffer device is in the buffer device, the buffer controller is instructed to take out the bucket, and the transfer of the bucket to the transfer controller is performed. Process control system, characterized in that it comprises instructing the transfer destination. 2. The cell controller searches for corresponding setup reference information from a plurality of setup reference information describing setup information of each process in a cell owned by the cell controller according to an input plan instructed by a shop management controller. Setup instruction means for giving a setup instruction to each process facility, transfer request or collection request means for transmitting a bucket transfer request and a collection request to the shop management controller according to the input plan, loader and unloader control means, and process input plan 2. The process management system according to claim 1, further comprising execution management including: and a lot progress management means for managing progress in the process. 3. The transfer control controller according to claim 1, further comprising a transfer control means for instructing a transfer point for transferring the bucket designated by the shop management controller onto the automatic guided vehicle and a delivery destination for delivering the loaded bucket. The process management system according to claim 1 or 2. 4. The buffer controller according to claim 1, wherein said buffer controller includes: a delivery unit for taking out a bucket designated by a shop management controller from said buffer unit; and a storage unit including a bucket designated by said shop management controller to enter said buffer unit. 4. The process management system according to claim 1, further comprising an apparatus control. 5. The cell controller divides a management unit into buckets, and a container of the bucket holds data that can be read by an automatic device. Based on the data, the bucket is transferred to the loader under the control of the cell controller. At the same time, the storage container for storing the bucket is supplied to the unloader, and the storage container of the bucket is replaced one after another for each processing in each cell, and the communication between the controllers is performed via the LAN. The process management system according to claim 1, 2, 3, or 4, wherein the process management system is characterized in that: