JP4348975B2 - Production line operating status analysis device, operating status analysis method, operating status analysis program, and operating status analysis system - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to an operation state analysis apparatus for a production line, and more particularly to an operation state analysis apparatus that analyzes the operation state of a production line composed of a plurality of production facilities using data collected by a data collection device.
[0002]
[Prior art]
In order to continuously perform production according to a production plan in a production line composed of a plurality of processes, it is important to appropriately evaluate the operational state of each process and the operational evaluation of the entire production line. As means for discriminating the state of each process, there is a method of recording a PLC (Programmable Logic Controller) signal for controlling the operation of the equipment constituting each process. However, it is not possible to accurately determine the state of the equipment simply by adding a circuit that outputs a signal representing the state of each equipment in advance to the PLC program and analyzing the recorded signals independently. The state estimation accuracy is increased. For example, in Patent Document 1, a personal computer (PC) is connected to a sequence controller of a facility having a plurality of states on a one-to-one basis, and the operation status of the facility is associated with transition information grasped by the sequence controller. Sampling and determining the transition between the resulting states is disclosed.
[0003]
[Patent Document 1]
Japanese Patent Laid-Open No. 7-104838
[0004]
[Problems to be solved by the invention]
As described above, adding a circuit that outputs a signal indicating the state of each process to the PLC program requires setting and confirming the operation for each process in the field, and for each process. Since the addresses of the internal signals are different, it is necessary to create a dedicated program for each process facility in order to determine the state, which takes time and cost.
[0005]
In addition, even if a circuit and a program are added for each process as described above, these are dedicated to each process, so that the expandability and versatility of the system is poor. For example, because it is difficult to add circuits and programs by expanding to multiple processes, it is possible to further improve the overall status of the related processes or the entire production line from the operating status of each process. Difficult to grasp.
[0006]
In addition, since the circuits and programs provided in each process are not versatile, the output signals are used only for dedicated purposes, and a plurality of signals can be arbitrarily combined to express different states, etc. It is impossible to grasp the operational status.
[0007]
An object of the present invention is to solve the problems of the prior art, a production line that does not require a dedicated circuit or program for each process constituting the production line, and can analyze the operation status based on a signal representing the state of each process Operating condition analyzing apparatus, operating condition analyzing method, operating condition analyzing program and operating condition analyzing system are provided. Another purpose is to provide a highly versatile production line operation state analysis device, operation state analysis method, operation state analysis program, and operation state analysis system that can analyze the operation state by arbitrarily combining multiple signals. is there. Still another object is to provide a production line operating status analysis device, operating status analysis method, operating status analysis program and operating status analysis system that can analyze the operating status across multiple processes without requiring a special circuit or program. Is to provide. The invention described in the following claims is provided to achieve at least one of the above objects.
[0008]
[Means for Solving the Problems]
1. Operating state function
First, the operating state function will be described. The operating state function is a function configured by connecting a plurality of operating states by an operator. ₁ , X ₂ , X _Three X ₁ , X ₂ , X _Three Is a function composed of AND and OR operators such as ₀ = [X ₁ ORX ₂ ] ANDX _Three Etc.
[0009]
Production equipment operating state, X in the above example ₁ , X ₂ , X _Three Is obtained by collecting PLC signals. In addition to the operating state, why operating state function Y ₀ If it is necessary to calculate a new state by the above, it is because the operating state, which is the dynamic state of the equipment, cannot be sufficiently expressed only by the operating state collected from the PLC or the like.
[0010]
For example, as an example, an operation state and an operation state of one cylinder, which is a work element in a production facility, are taken up. Now, if it is desired to grasp the operating state that the cylinder is moving forward, the cylinder advance instruction signal X is sent from the PLC as the cylinder operating state. ₂₀ And the value is 1 (with forward instruction) or 0 (without forward instruction). By the way, cylinder advance instruction signal X ₂₀ If 1 is 1, it is not necessarily the case that the cylinder is moving forward, for example, the case where the cylinder has not started moving forward is included. Therefore, in order to obtain the operating state of forward movement, the cylinder forward end detection signal X is further increased. _{twenty one} And check that the value is 0 (the cylinder advance end is not detected).
[0011]
In this case, two operating states X ₂₀ , X _{twenty one} It is possible to determine whether or not the cylinder is moving forward by checking each independently. ₂₀ And (NOTX _{twenty one} ) With an AND function, and this function is the “forward” operating state function Z ₁ And it is sufficient. "In Progress" Operating State Function Z ₁ Means two operating states X ₂₀ , X _{twenty one} Are combined using the operators OR and NOT. Therefore, the two operating states X from moment to moment ₂₀ , X _{twenty one} Is input as a pair to calculate whether or not the condition (with advance instruction) and (cylinder advance end is not detected) is satisfied, and the operation status data for whether or not "cylinder advance is in progress" is output momentarily. can do.
[0012]
FIG. 1 is an example in which the relationship between the operating state of the cylinder and the operating state of the cylinder is expressed by a ladder circuit diagram. Each operating state X ₂₀ , X _{twenty one} , X _{twenty two} , X _{twenty three} Is indicated by a contact symbol, and the operating state function Z ₁ , Z ₂ Is indicated by a coil symbol. As shown in FIG. ₂₀ And cylinder forward end detection X _{twenty one} The two operating states are connected by an operator and the “in progress” operating state function Z ₁ The cylinder retraction instruction X _{twenty two} And cylinder back end detection X _{twenty three} The two operating states are connected by an operator, and the "backward" operating state function Z ₂ Can be configured.
[0013]
2 shows each operation state X. ₂₀ , X _{twenty one} , X _{twenty two} , X _{twenty three} Is input to the operating state function in time series, and the “in progress” operating state function Z ₁ Output data z ₁ And “backward” operating state function Z ₂ Output data z ₂ It is a figure which shows the example which outputs as a time chart. FIG. 2 (a) shows the operating state of a standard cylinder. (B) Is an example of a problem during “retreating”. From these data, it is possible to perform a quantitative analysis such as “advance time” and “reverse time”, along with extraction of “progressing” problems.
[0014]
In this way, an arbitrary operating state function can be configured by combining a plurality of operating states with an operator, and if a plurality of operating state data is input using this operating state function, the operating state data alone cannot be grasped. Operation status data as a new status can be output.
[0015]
By configuring the function form of the operating state function according to the operating state analysis purpose, desired operating state data can be easily obtained. In addition, if a plurality of operation state data is input in time series, time series operation state data is output, so that more quantitative operation state data can be obtained.
[0016]
Multiple operating states can be collected from the PLC signal of the production facility, and the operating state function can be formed in an arbitrary function form. Therefore, using the operating state function significantly increases the versatility of the operating state analysis. Can be increased. In other words, there is no need to provide a dedicated circuit or a dedicated program for each facility to obtain the desired operating state data. Simply collect the operating state data and input it to the operating state function. Data can be obtained.
[0017]
In addition to configuring the operating state function as a logical operation result of digital data as described above, it can also be a time management function. For example, in the case of FIG. 2, the cylinder retraction time t2 can be determined by a threshold function and output. In this example, if the threshold function is set to 2 sec <t2 <3 sec or the like, 0 can be output as the reverse time operation state data when the reverse time is not within this range.
[0018]
2. Problem solving means
The operation status analysis device according to the present invention is an operation status analysis device that analyzes the operation status of the production line based on the operation status data representing the operation status of each work element of the production line collected by the data collection device, About each of multiple operating states, including actual production status and wasteful waiting status on the production line Based on operating state data Answer In correspondence with a plurality of types of analysis menus to be analyzed, an operating state function storage means for storing in advance an operating state function in which a plurality of operating states are combined by an operator; According to a fixed number of samples or a time series of timing at the end of any operation Data acquisition means for acquiring a plurality of operation state data collected by the data collection device, means for acquiring a user designation for one analysis menu among a plurality of types of analysis menus, and an analysis menu specified by the user The corresponding operating state function is read from the operating state function storage means, and a plurality of operating state data acquired by the data acquiring means is input to the read operating state function, and operating state data representing the operating state of the production line is obtained. According to time series Operating state data calculating means for calculating.
[0019]
With the above configuration, the operating state function described in “1. Operating state function” is used for calculating the operating state data. As for the operation state data input to the operation state function, the operation state data of each work element on the production line is collected by the data collection device. As the operation state data of each work element on the production line, for example, a PLC signal or a sensor signal provided for each process can be used as it is. As described above, since the operating state function is composed of an operating state and an operator, an arbitrary function can be created by changing the type of the operating state or changing the type of the operator. Therefore, the operating state can be analyzed by arbitrarily combining a plurality of signals, and the versatility of the analysis system is high. Further, there is no need for a dedicated circuit or program for outputting a signal representing the operating state.
[0020]
In addition, the operating state data calculation means inputs the operating state data in a plurality of processes including the process and the processes before and after the process to the operating state function in order to analyze the operating state of each process of the production line. It is preferable to calculate process operation state data representing the operation state of each process.
[0021]
The plurality of operation states constituting the operation state function are not limited to only a plurality of operation states in the same process. With the above configuration, operation state data in a plurality of processes including the process and preceding and following processes are input to the operation state function, and process operation state operation data for each process is calculated. The operation status function in this case is configured by combining operation states in a plurality of processes by an operator. Therefore, it is possible to analyze the operating state over a plurality of processes without requiring a special circuit or program.
[0022]
The operating state data calculating means Depending on the analysis menu specified, As the operating status of each process, actual production status indicating actual production, abnormal stop status indicating abnormal stop, tool change status indicating tool change, quality check status indicating quality check status, or after It is preferable to calculate the process operation state data for any one of the process operation states of the post-process full state indicating the waste state where the process work is clogged or the pre-process empty state indicating the waste state where no work is present in the previous process.
[0023]
Each process has a plurality of operating states. The operation state of each process can be divided into a plurality of operation states such as an actual production state, an abnormally stopped state, a tool replacement state, a quality check state, a post-process full state, and a pre-process empty state. The operation state of each process can be quantitatively grasped by analyzing the ratio of each of these operation states to the whole. For example, it is possible to analyze that a certain process has a high ratio in the actual production state and the operation status is smooth, and that another process has a high ratio in the abnormally stopped state and becomes a bottleneck process.
[0024]
With the above-described configuration, the operation state data in a plurality of processes including the process and the preceding and following processes is input to the operation state function and calculated for at least one process operation state data among the plurality of process operation states. All of the plurality of process operating states may be calculated by an operating state function. By using the operation state function, the process operation state can be calculated only by inputting operation state data in a plurality of processes including the process and the preceding and following processes, and dedicated to each process for outputting a signal indicating the operation state of the process There is no need for a special circuit or program that crosses the circuits or programs or processes.
[0025]
The operating state data calculating means When the analysis menu for calculating the actual production state is specified, Actual production status of each process based on a plurality of operation status data including workpiece presence / absence status data in the process, workpiece presence / absence status data in the previous process of the process, and workpiece presence / absence status data in the subsequent process of the process It is preferable to calculate process operation data representing.
[0026]
It is not sufficient to determine the state during actual production only by grasping the state in which there is a workpiece in the process. This is because even if there is a work in the process, the work does not receive actual work such as machining or assembly, so that the subsequent process is waiting because it is a full work, This is because there is a case where the work is kept waiting in the previous process. With the above configuration, the actual production state of the process is calculated based on the operation state data on the presence or absence of the workpiece in the process and the preceding and succeeding processes. Therefore, it is possible to calculate actual production state data that is correctly obtained by analysis over a plurality of processes without using a special circuit or program.
[0027]
The operating state data calculating means When the analysis menu for post-process full state calculation is specified, It is possible to calculate process operation data representing a post-process full state of each process based on a plurality of operation state data including work completion presence / absence state data in the process and work presence / absence state data in the subsequent process of the process. preferable.
[0028]
Regarding the post-process full state, it is insufficient to determine that the post-process is wasteful just by grasping the state in which there is a workpiece in the post-process of the process. This is because even if there is a workpiece in the subsequent process, if the process has not yet completed the actual work, there is no wasted time. With the above configuration, the post-process full state is calculated based on the operation state data in the process and the post-process. Therefore, the post-process full state data correctly obtained by the analysis over a plurality of processes can be calculated without using a special circuit or program.
[0029]
The operating state data calculating means When the analysis menu for calculating the empty state of the previous process is specified, It is preferable to calculate process operation data representing a previous process empty state of each process based on a plurality of operation state data including the work presence / absence state data in the process and the work presence / absence state data in the previous process of the process.
[0030]
It is insufficient to determine that there is waste in the previous process only by grasping the state where there is no workpiece in the previous process of the previous process. This is because even if there is no workpiece in the previous process, there is no dead time if there is a workpiece in the process. With the above-described configuration, the previous process idle state is calculated based on the operation state data on the presence or absence of the workpiece in the process and the previous process. Therefore, it is possible to calculate the pre-process empty state data obtained correctly by the analysis over a plurality of processes without using a special circuit or program.
[0031]
The data acquisition means acquires operation state data according to the time series, and the operation data calculation means calculates operation state data according to the time series based on the acquired operation state data according to the time series. It is preferable to analyze the change over time in the operating state. By analyzing the changes over time, the operating state data can be grasped more quantitatively. Further, it is possible to perform a time series analysis of the operating state without requiring a dedicated circuit and program.
[0032]
The operation status analysis method according to the present invention is an operation status analysis method for analyzing the operation status of the production line based on the operation status data representing the operation status of each work element of the production line collected by the data collection device. And According to a fixed number of samples or a time series of timing at the end of any operation A data acquisition step of acquiring a plurality of operation state data collected by the data collection device; About each of multiple operating states, including actual production status and wasteful waiting status on the production line Based on operating state data Answer A step of obtaining a user designation for one analysis menu among a plurality of types of analysis menus to be analyzed, and an operation state function in which a plurality of operation states are combined by an operator corresponding to the plurality of types of analysis menus are stored in advance. The operation state function corresponding to the analysis menu specified by the user is read from the operation state function storage device, and the plurality of operation state data acquired by the data acquisition step is input to the read operation state function, and the production line Operating status data representing operating status According to time series An operating state data calculating step for calculating.
[0033]
The operation status analysis program according to the present invention is an operation status analysis program for analyzing the operation status of the production line based on the operation status data representing the operation status of each work element of the production line collected by the data collection device. In the operating status analysis device, According to a fixed number of samples or a time series of timing at the end of any operation A data acquisition processing procedure for acquiring a plurality of operation state data collected by the data collection device; About each of multiple operating states, including actual production status and wasteful waiting status on the production line Based on operating state data Answer User specified acquisition processing procedure to acquire user specification for one analysis menu among multiple types of analysis menus to be analyzed, and operation status combining multiple operation states corresponding to multiple types of analysis menus by operators Reads the operation state function corresponding to the analysis menu specified by the user from the operation state function storage device that stores the function in advance, and inputs a plurality of operation state data acquired by the data acquisition processing procedure to the read operation state function Operation status data representing the operation status of the production line According to time series The operation state data calculation processing procedure to be calculated is executed.
[0034]
Moreover, the operation status analysis system according to the present invention is provided for each process of the production line, According to a fixed number of samples or a time series of timing at the end of any operation, Collects operational status data that represents the operational status of each work element that makes up the production line. And out A plurality of data collection devices, a data storage server for receiving and storing data output from each data collection device, About each of multiple operating states, including actual production status and wasteful waiting status on the production line Based on operating state data Answer Corresponding to a plurality of types of analysis menus to be analyzed, an operating state function storage device for storing in advance an operating state function in which a plurality of operating states are combined by an operator, and one analysis menu among a plurality of types of analysis menus Acquires the user's specification, reads the operating state function corresponding to the analysis menu specified by the user from the operating state function storage device, acquires a plurality of operating state data from the data storage server, and acquires the acquired operating state data Is input to the read operating status function, and operating status data indicating the operating status of the production line is obtained. According to time series And an operating state analyzing device to be calculated.
[0035]
With the above configuration, the operation state data of each work element constituting the production line is first collected by the data collection device provided in each process. The data collection device collects, for example, signals of a plurality of control elements that control the operation of the production equipment constituting each process, data of signals of various sensors, and the like as operation state data of each work element. Then, the data collected by the data collection device is stored by the data storage server. Therefore, since the operation state data arranged for each process unit is accumulated by the data accumulation server, the burden on the data accumulation server is reduced. For example, in each process, each time processing on a workpiece is completed, the operation state data can be collectively sent to the data storage server, and data storage with good separation can be performed with a small burden. Even if the configuration of the production line fluctuates, the data collection system can be made flexible because it is divided in units of processes.
[0036]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. In the following, a part production line for producing engine parts for vehicles will be described as an example. However, as a production line, if it is a production line composed of a plurality of production facilities or processes, other than the engine part production line There may be. For example, it may be a production line for parts other than engine parts, an assembly line, an inspection line, or the like, and is not limited to a production line for vehicles.
[0037]
FIG. 3 is a block diagram showing the configuration of the production line operation status analysis system 10. The operation status analysis system 10 is connected to each production facility 20 constituting the production line, an abnormality display device 22 for displaying an abnormal state of each production facility 20, and each production facility 20 and the abnormality display device 22, respectively. It includes a data collection device 30 that collects operational state data, a data storage server 50 that is connected to each data collection device 30 via a network 40, and an operation status analysis device 60 that is also connected to the network 40.
[0038]
Each production facility 20 is composed of various processing machines for completing engine parts, for example, a machining center, a lathe, a drill, an assembly machine for attaching accessory parts, an inspection machine, a work transfer mechanism, etc. Together form an engine parts production line.
[0039]
Each production facility 20 includes a plurality of work elements in order to perform the intended work. The operation of these work elements is controlled by a plurality of control elements, and the positions and the like are detected by a plurality of sensors. For example, when moving workpieces sequentially using multiple cylinder heads, for example, each cylinder head is a working element, and a hydraulic actuator that drives each cylinder head or each relay that turns the motor on / off is controlled. A limit switch or the like that corresponds to an element and detects the position of each cylinder head corresponds to the sensor. Sequence control is performed so that each production facility 20 performs a predetermined operation by the plurality of relays and the like.
[0040]
Each production facility is provided with a PLC 24 for performing sequence control with digital signals. The data of each ON / OFF signal in the PLC 24 is output to the data collection device 30 via the communication line 26 as digital data representing the operation state of the control element that controls the operation of the production facility 20. In addition, various sensors output the data collection device 30 through the analog signal output interface (not shown) and the communication line 28 as analog signals representing the operation states of the work elements of the production facility.
[0041]
The operation state data representing these operation states corresponds to the operation states of each of the plurality of work elements in one production facility 20, for example, the timing at which the workpiece is carried into the production facility, the position or the workpiece from the production facility. It includes production equipment that represents its operating state as one work element, such as the timing and position of unloading. Further, when it is more convenient to form a single process with a plurality of production facilities, the process itself including a plurality of facilities includes what represents the operation state as one work element.
[0042]
The abnormality display device 22 is a device that displays the current status of each process so that it can be seen at a glance. For example, a lamp corresponding to each process is two-dimensionally arranged, and the lamp is displayed with different colors according to the content of the abnormality. A so-called “Andon” that lights up can be used. For example, when the process is abnormally stopped, “red” is lit, and when there is a need for tool change or parts supply, etc., “yellow” is lit and forecasted, and the operator actually performs tool change etc. When the vehicle is stopped, “blue” can be displayed.
[0043]
The lighting of the abnormality display device 22 is controlled by a PLC 24 provided in the abnormality display device 22. Operating state data from each production facility 20 is input to the PLC 24 provided in the abnormality display device 22 via a signal line (not shown). Also, from the PLC 24 provided in the abnormality display device 22, work elements of the abnormality display device 22, for example, ON / OFF signals for the respective lamps are output to the data collection device 30 as operation state data.
[0044]
The data collection device 30 is a device that is provided for each process and collects operation state data of work elements in each process, and can be configured by a general PC. As described above, the data collection device 30 is also connected and provided for the abnormality display device 22. In addition, when one process is composed of one production facility, one data collection device 30 is connected to each production facility, and as described above, a plurality of production facilities constitute one process. When convenient, one data collection device 30 is connected to the process.
[0045]
The data collection device 30 communicates with the corresponding PLC 24 and the analog output interface via the communication lines 26 and 28, collects necessary operating state data, and transfers the collected data to itself to transfer the data. Perform a collection. Data collection is performed by executing a data collection program in accordance with contents registered in a data collection setting file that defines the type of data to be collected, a collection condition setting file that defines a collection period, and the like.
[0046]
The data collection device 30 is a device that transfers the collected operation state data to the data storage server 50 via the network 40 at a predetermined timing, for example, at a certain number of samples or when an arbitrary operation is completed. It can be constituted by a general personal computer or the like. As the predetermined timing, the data collected from the production apparatus 20 can be set, for example, every time processing on the workpiece is completed. Further, the data collected from the abnormality display device 22 may be transferred, for example, at a timing such as when the operation of the production line is completed or when a production lot is switched. Data is transferred by executing the program according to an appropriate file transfer protocol (for example, using File Transfer Protocol: FTP). In order to store untransferred data, the data collection device 30 is provided with a storage device.
[0047]
The data accumulation server 50 is a server that communicates with each data collection device 30 via the network 40 and collects and accumulates operation state data and the like from each data collection device 30. Data transfer with each data collection device 30 is performed by executing the file transfer program as described above. The received data is classified and stored by executing a data server program in accordance with a server setting file that defines the data classification.
[0048]
The operation status analysis device 60 is a device that acquires necessary data from the data storage server 50, processes it, and analyzes the operation status of the production line, and can be configured by a general computer. Specifically, by specifying the analysis menu and setting items desired by the user, necessary operation state data is acquired from the data storage server 50, and processing corresponding to the specified analysis menu is executed to produce It has a function to quantitatively analyze and output the operation status of the line. Software can be used to perform processing corresponding to the analysis menu or the like on the data, and predetermined processing can be performed by executing the corresponding analysis program. A part of the processing can be executed by hardware.
[0049]
The operating state analysis device 60 is analyzed by the CPU 70, the communication control unit 72 that communicates with the data storage server 50 via the network 40, and the input unit 74 such as a keyboard for the user to specify an analysis menu or setting items. An output unit 76 such as a display for displaying the operating status of the production line and an external storage device 78 such as a hard disk for storing the operating state function file 80 are connected to each other via an internal bus.
[0050]
The data acquisition unit 100 in the CPU 70 has a function of requesting the data storage server 50 to transfer necessary data via the communication control unit 72 and acquiring it. The necessary data varies depending on the type of analysis menu specified by the user.
[0051]
The operating state data calculation unit 150 has a function of acquiring necessary operating state data from the data storage server 50 and calculating the operating state data using the operating state function. The actual production state calculation module 152 and the actuator state calculation module 166 in the operation state data calculation unit 150 have a function of calculating each operation state data corresponding to the type of analysis menu specified by the user. The operating state function corresponding to the type of analysis menu specified by the user is read from the file 80 of the external storage device 78. The contents of the calculation of the operating state data will be described using a specific example with reference to FIG.
[0052]
The in-production state calculation module 152 is a function of an operation state analysis process that is executed when the user specifies the menu of “in-production state calculation” and specifies the process. Specifically, it has a function of acquiring operation state data of the process and preceding and following processes and calculating operation state data indicating whether or not actual production is in progress as the operation state of the process.
[0053]
FIG. 4 shows an operation state function Y that outputs an operation state during actual production. ₁ For each operation state, using the same symbols as shown in FIG. ₁ , No work before work X ₂ , Process completion X _Three , Full process X after process _Four During continuous operation X _Five It represents the relationship. As shown in FIG. 4, each operation state is connected by AND, OR, and NOT, and the state (with the corresponding process work) and (with the previous process work), (the process has not been completed yet) and (the post process is not full work) ) Which is one of the states of) and (in continuous operation) ₁ Can be used to calculate actual production.
[0054]
In other words, actual production is an operation state where there is no waste and actual work is being performed, so (during continuous operation) is not sufficient, and (with the relevant process work) and (with the previous process work) It is necessary that there is no waste in relation to the process, (the process has not been completed yet) and (the post process is not a full work) and there is no waste in relation to the post process. In order to grasp the operation state during actual production, it is necessary to monitor five operation state data. ₁ Is used to collect five operating state data in time series, and these are collected into the operating state function Y ₁ Can be output in time series during actual production. FIG. 5 shows each operation state X in time series. ₁ , X ₂ , X _Three , X _Four , X _Five Data and operating state function Y during actual production ₁ An example of output data is shown.
[0055]
The abnormal stop state calculation module 154 is a function of an operation state analysis process that is executed when the user specifies the menu of “abnormal stop state calculation” and identifies the process. Specifically, it has a function of acquiring a plurality of operation state data of the process and calculating operation state data as to whether or not the process is abnormally stopped as the operation state of the process.
[0056]
FIG. 6 shows an operation state function Y that outputs an operation state during an abnormal stop. ₂ In each operation state, during continuous operation X _Five , Abnormal signal X ₆ Is represented by the same notation as in FIG. As shown in FIG. 6, each operation state is connected by AND, and the state of (not in continuous operation) and (abnormal) can be calculated as being in an abnormal stop.
[0057]
In other words, abnormally stopped is an operating state in which the process is stopped due to an abnormality, so the operating state in which an abnormal signal is output is not sufficient, and the operating state in which the process is stopped is not sufficient. . Therefore, an operation state function Y that connects two operation states with AND (not in continuous operation) and represents (abnormal) ₂ And collects two operating state data in time series, and these are collected into the operating state function Y ₂ The operation state data during abnormal stop can be output in time series.
[0058]
The tool change state calculation module 156 is a function of an operation state analysis process that is executed when the user specifies a menu of “tool change state calculation” and identifies the process. Specifically, it has a function of acquiring a plurality of operation state data of the process and calculating operation state data indicating whether or not the tool is being changed as the operation state of the process.
[0059]
FIG. 7 shows an operation state function Y for outputting an operation state during tool change. _Three And as each operation state, tool change forecast X ₇ Individual exchange signal X ₈ Is represented by the same notation as in FIG. As shown in FIG. 7, each operation state is connected by AND, and the state of (with tool change forecast) and (with individual change) can be calculated as the tool being changed.
[0060]
In other words, when the tool is being changed, an operation state in which a tool change forecast is issued is not sufficient because a tool change forecast is issued and the operator or the like is actually changing the tool. Therefore, an operation state function Y representing two operation states connected by AND (with tool change forecast) and (individual change). _Three And collects two operating state data in time series, and these are collected into the operating state function Y _Three , And operating state data during tool change can be output in time series.
[0061]
The quality check state calculation module 158 is a function of an operating state analysis process that is executed when the user specifies a menu of “quality check state calculation” and identifies the process. Specifically, it has a function of acquiring a plurality of operation state data of the process and calculating operation state data indicating whether or not the quality check is in progress as the operation state of the process.
[0062]
In the production line, the process may be stopped in order to check the quality of whether the workpiece is processed or assembled according to the production specification. For example, when a sampling quality check is performed at a rate of one workpiece per 100 workpieces, a quality check forecast is issued in accordance with the sampling timing, and workers etc. go to the process for which the forecast was issued according to the forecast. , Temporarily stop the process and check the quality of the workpiece. Therefore, whether or not a process is in quality check is one of operating state data indicating the operating state of the process.
[0063]
FIG. 8 shows an operation state function Y that outputs an operation state during the quality check. _Four And as each operation state, quality check forecast X ₉ Individual check signal X _Ten Is represented by the same notation as in FIG. As shown in FIG. 8, each operation state is connected by AND, and the state of (with quality check forecast) and (individual check) can be calculated as being under quality check.
[0064]
That is, during the quality check, since the quality check forecast is issued and the worker or the like is actually performing the quality check, the operation state in which the quality check forecast is issued is not sufficient. Therefore, an operation state function Y that represents the (operation check) and (individual check) by connecting two operation states with AND. _Four And collects two operating state data in time series, and these are collected into the operating state function Y _Four And the operation status data during the quality check can be output in time series.
[0065]
The post-process full state calculation module 160 is a function of an operating state analysis process that is executed when the user specifies a menu of “post-process full state calculation” and identifies the process. Specifically, the operation state data of the process and the subsequent process is acquired, and the operation state data indicating whether or not the post process is full as the operation state in which the work is wasted because the work is clogged in the process. It has the function to calculate.
[0066]
FIG. 9 shows an operation state function Y that outputs the operation state of the post-process full state _Five And as each operation state, post-process full work X _Four , Process completion X _Three Is represented by the same notation as in FIG. As shown in FIG. 9, each operation state is linked by AND, and the state of (post process full work) and (the process complete) can be calculated as the post process full state.
[0067]
In other words, the post-process full state is an operating state in which the actual work of the process is completed and the work is jammed because the work is clogged in the post-process even though it is desired to carry the work out to the post-process. Therefore, it is not sufficient that the subsequent process is a full work alone, and it is not sufficient that the actual work of the process is completed. Therefore, an operating state function Y that represents (complete process of the post process) and (completion of the process) by connecting the two operating states with AND. _Five And collects two operating state data in time series, and these are collected into the operating state function Y _Five The operation state data full of the post-process can be output in time series.
[0068]
The previous process empty state calculation module 162 is a function of an operation state analysis process that is executed when the user specifies a menu of “previous process empty state calculation” and specifies the process. Specifically, the operation state data of the process and the previous process is acquired, and the operation state data indicating whether or not the previous process is empty is calculated as the operation state in which the work is wasted because no work is received from the previous process. It has the function to do.
[0069]
FIG. 10 shows an operation state function Y that outputs the operation state in the previous process empty state. ₆ And as each operation state, there is no process work X ₁ , No work before work X ₂ Is represented by the same notation as in FIG. As shown in FIG. 10, each operation state is connected by AND, and the state of (no corresponding process work) and (no previous process work) can be calculated as the previous process empty state.
[0070]
That is, the pre-process empty state is an operating state in which waste is generated in the process because the work does not come from the previous process, so it is not sufficient that there is no work in the previous process, and there is no work in the process. It is not enough. Therefore, an operation state function Y that represents two work states connected by AND (no corresponding process work) and (no previous process work). ₆ And collects two operating state data in time series, and these are collected into the operating state function Y ₆ The operation state data of the previous process vacant can be output in time series.
[0071]
As described above, the operation status of each process includes an operation state such as an actual production state, a state where the process is stopped due to an abnormal stop or the like, and a waste state such as a full post-process state. In order to grasp the operation status of the entire process, it is preferable to grasp the ratio of time occupied by the plurality of operation states and the change in time series thereof. In each process, a so-called volume ratio is used to indicate the time ratio of each operating state in a certain period. This turnover rate can also be calculated by using the operation status function.
[0072]
FIG. 11 is a bar graph of operation time obtained by accumulating the time of each operation state of the process. Here, the turnover rate represents the ratio of each operation state when the total operation time is 1, especially the ratio of the actual working time for producing good products. In addition, as shown in FIG. 11, while calculating a yield rate, the operating state in all the operation hours can be analyzed. For example, the load time and the rate of giving work load to the process, the actual production time and the rate of actually producing parts in the load time, the actual work time of producing good products in the actual production time and The ratio etc. can be calculated | required.
[0073]
In FIG. 11, the difference between the total operation time and the load time is the dead time during which no load is applied to the process, and the time y in the post-process full state. _Five And time y in the previous process empty state ₆ It is. Therefore, these are the operation state functions Y by the functions of the post-process full state calculation module 160 and the pre-process empty state calculation module 162, respectively. _Five = 1 time y _Five And operating state function Y ₆ = 1 time y ₆ Can be obtained as
[0074]
The difference between the load time and the actual production time is the time during which the process is stopped. ₂ , Tool change state time y _Three , Quality check status time y _Four In addition to the time y during the transition stop state ₇ Is included. Time y during the transition stop state ₇ Other than the above, the operation state function Y is determined by the functions of the abnormal stop state calculation module 154, the tool change state calculation module 156, and the quality check state calculation module 158, respectively. ₂ = 1, Y _Three = 1, Y _Four = 1 time y ₂ , Y _Three , Y _Four The time y in the stoppage stop state can be obtained as ₇ For example, manual input data from the input unit 74 can be used.
[0075]
Here, the transition stop state is one of the operating states and is a state in which the process is stopped in order to change the work content of the process. For example, when the parts of the A engine are machined in the morning in the process and the parts of the B engine are machined in the afternoon, a jig for holding the workpiece, a tool for machining the workpiece, a hub in which these are integrated, etc. This is the time required for changeover from the A engine part to the B engine part. Usually, the changeover work is often performed with the power of the process turned off for safety. Therefore, the PLC also temporarily stops operation, and the collection of operation state data is also temporarily stopped. Therefore, the work time data in the change stop state can be manually input as time change stop state data from the input unit 74, and can be used for calculating the output rate. Of course, it is assumed that the power of the process is not turned off during the changeover work, a changeover stop switch or the like is provided in each process, and the changeover stop switch is operated during the changeover work, and the changeover stop signal is generated. It can also be sent to the operation status analyzer via the PLC. Then, the operation state function indicating the changeover stop state is changed into a changeover stop signal and a continuous operation in-progress signal X. _Five You may comprise in combination with these.
[0076]
The difference between the actual production time and the actual work time is the time for producing defective products. That is, actual production time y ₁ Is the production time y ₁₁ And the time of production of defective products ₁₂ And y ₁ = Y ₁₁ + Y ₁₂ It is. The determination of non-defective product and defective product is performed in the inspection process and y in a predetermined period. ₁₁ / Y ₁ X100% is separately calculated as a so-called direct rate. Therefore, the direct rate data is manually input from the input unit 74, and y ₁₁ = Y ₁ X (Direct ratio) x 100% actual working time y ₁₁ Etc. can be calculated and used for the volume ratio calculation.
[0077]
In this way, by inputting the stoppage stop state data and the direct rate data from the input unit 74, the ratio of each operating state in the total operating time in each process, that is, the yield rate is calculated using the operating state function. can do. The volume rate calculation module 164 is a function of an operation state analysis process that is executed when the user specifies a menu of “volume rate calculation” and specifies the process. Specifically, the operation state data in a plurality of steps including the step and the steps before and after the step, the transition stop state time data and the direct rate data of the step in a predetermined period are acquired, and each of the volume ratios It has the function of calculating the operating time and calculating the ratio between them.
[0078]
In the example of FIG. 11, it can be understood that the ratio of the actual production state is less than 50%, and other operating states of the other stopped state or the waste state are generated at substantially the same rate. Note that, as described above, in the volume calculation module, the actual working time y shown in FIG. ₁₁ Actual production time y ₁ , Load time (y ₁ + Y ₂ + Y _Three + Y _Four + Y ₇ ), Or the ratio of these times to the total operating time.
[0079]
FIG. 12 shows the operation state of the process in time series. That is, the change in the operation state of the process from moment to moment is expressed with time on the horizontal axis. A time series overall operational status analysis of such processes can also be added to the analysis menu.
[0080]
The actuator state calculation module 166 is a function of an operation state analysis process that is executed when the user specifies a menu of “actuator state calculation” and identifies a specific actuator of a target process. Specifically, it has a function of acquiring time-series operation state data of the target actuator and calculating the operation state data of the actuator.
[0081]
For example, FIG. 2 which has already been described represents a forward operation state and a reverse operation state of a cylinder as an actuator. As described above, the forward operation state of the cylinder is an operation state function Z representing (forward instruction is present) and (cylinder advance end is not detected). ₁ Similarly, the cylinder reverse operation state is an operation state function Z representing (with a reverse instruction) and (cylinder reverse end is not detected). ₂ Can be used to calculate. The operating states of actuators other than cylinders, such as screw tightening heads, can be calculated in the same manner. In this way, the operating state data of a specific actuator can be calculated using the operating state function.
[0082]
【The invention's effect】
According to the production line operation state analysis apparatus, operation state analysis method, operation state analysis program, and operation state analysis system according to the present invention, each process constituting the production line does not require a dedicated circuit or program. The operating status can be analyzed based on the signal representing the state of the machine. According to the production line operation state analysis apparatus, operation state analysis method, operation state analysis program, and operation state analysis system according to the present invention, an operation state can be analyzed using an operation state function that arbitrarily combines a plurality of operation state signals. . According to the production line operation state analysis apparatus, operation state analysis method, operation state analysis program, and operation state analysis system according to the present invention, the operation state is analyzed across a plurality of processes without requiring a special circuit or program. it can.
[Brief description of the drawings]
FIG. 1 is a diagram illustrating an operating state function according to the present invention.
FIG. 2 is a diagram showing an example of outputting an operation state as a time chart using an operation state function according to the present invention.
FIG. 3 is a block diagram showing a configuration of a production line operation state analysis system in the embodiment according to the present invention.
FIG. 4 is an operation state function Y for outputting an operation state during actual production in the embodiment according to the present invention; ₁ FIG.
FIG. 5 is a diagram showing an example of time-series operation state data and calculated actual production operation state data in the embodiment according to the present invention.
FIG. 6 is an operational state function Y for outputting an operational state during an abnormal stop in the embodiment according to the present invention. ₂ FIG.
FIG. 7 is an operation state function Y for outputting an operation state during tool change in the embodiment of the present invention. _Three FIG.
FIG. 8 is an operational state function Y for outputting an operational state during a quality check in the embodiment of the present invention. _Four FIG.
FIG. 9 is an operational state function Y for outputting the operational state of the post-process full state in the embodiment of the present invention. _Five FIG.
FIG. 10 is a diagram illustrating an operation state function Y for outputting an operation state in the previous process empty state in the embodiment of the present invention. ₆ FIG.
FIG. 11 is a diagram showing a yield rate as an overall operation state of a process using operation state data calculated using an operation state function in the embodiment according to the present invention.
FIG. 12 is a diagram showing the operation state of a process in time series using operation state data calculated using an operation state function in the embodiment according to the present invention.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 10 Operating condition analysis system, 20 Production equipment, 22 Abnormal display apparatus, 30 Data collection apparatus, 50 Data storage server, 60 Operating condition analysis apparatus, 70 CPU, 78 External storage device, 80 Operating state function file, 100 Data acquisition part, 150 operation state data calculation unit, 152 actual production state calculation module, 154 abnormal stop state calculation module, 156 tool change state calculation module, 158 quality check state calculation module, 160 post-process full state calculation module, 162 pre-process free state Calculation module, 164 Volume rate calculation module, 166 Actuator state calculation module.

Claims (10)

An operational status analysis device that analyzes the operational status of a production line based on operational status data representing the operational status of each work element of the production line collected by the data collection device,
Corresponding to a plurality of types of analysis menu analysis based on the operating state data for each of a plurality of operating states including waste state waiting practical production in state and wasted in the production line, a plurality of operating states Operating state function storage means for storing in advance an operating state function combined by an operator;
Data acquisition means for acquiring a plurality of operation state data collected by the data collection device in accordance with a fixed number of samples or a time series of timing for each time point when any operation is completed ;
Means for obtaining a user designation for one analysis menu among a plurality of types of analysis menus;
The operating state function corresponding to the analysis menu specified by the user is read from the operating state function storage means, and a plurality of operating state data acquired by the data acquisition means are input to the read operating state function, and the operating state of the production line and operation status data calculation means for calculating in chronological operation status data representing,
An operating condition analyzing apparatus comprising: In the operation condition analysis device according to claim 1,
In order to analyze the operating state of each process of the production line, the operating state data calculating means inputs the operating state data in a plurality of processes including the process and the processes before and after the process to the operating state function, An operation state analysis apparatus characterized by calculating process operation state data representing an operation state of a process. In the operation condition analysis device according to claim 2,
The operating state data calculating means represents the operating state of each process according to the specified analysis menu, indicating that the actual production is being performed, the abnormally stopped state representing the abnormally stopped state, or the tool is being replaced. Any one of a tool change state, a quality check state indicating that the quality check is in progress, a post-process full state indicating a waste state where a post-process work is clogged, or a pre-process empty state indicating a waste state where no work is present in the previous process An operation state analyzing apparatus for calculating process operation state data with respect to the process operation state. In the operation condition analysis device according to claim 3,
When the analysis menu for calculating the actual production state is specified, the operating state data calculating means
Work presence / absence status data in the process,
Work presence / absence status data in the previous process of the process,
Work presence / absence status data in the subsequent process of the process,
An operation state analysis apparatus that calculates process operation data representing an actual production state of each process based on a plurality of operation state data including: In the operation condition analysis device according to claim 3,
When the analysis menu for calculating the post-process full state is designated,
Whether or not work is completed in the process;
Work presence / absence status data in the subsequent process of the process,
An operation state analyzing apparatus that calculates process operation data representing a post-process full state of each process based on a plurality of operation state data including: In the operation condition analysis device according to claim 3,
The operating state data calculation means, when the analysis menu of the previous process free state calculation is designated,
Work presence / absence status data in the process,
Work presence / absence status data in the previous process of the process,
An operation status analysis apparatus which calculates process operation data representing a previous process empty state of each process based on a plurality of operation status data including: In the operation condition analysis device according to claim 1,
The data acquisition means acquires operation state data according to time series,
The operating data calculating means calculates operating status data according to the time series based on the acquired operating status data according to the acquired time series, and analyzes the temporal change of the operating status. An operational status analysis method for analyzing the operational status of a production line based on operational status data representing the operational status of each work element of a production line collected by a data collection device,
A data acquisition step of acquiring a plurality of operation state data collected by the data collection device according to a certain number of samples or a time series of timing for each time point when an arbitrary operation is completed ,
User for one analysis menu among a plurality of types of analysis menu analysis based on the operating state data for each of a plurality of operating states including waste state waiting practical production in state and wasted in the production line A step of obtaining the specification of
Reads the operating state function corresponding to the analysis menu specified by the user from the operating state function storage device that stores in advance an operating state function in which a plurality of operating states are combined by an operator corresponding to a plurality of types of analysis menus, and obtains data. A plurality of operation state data acquired in the step is input to the read operation state function, and operation state data calculation step for calculating operation state data representing the operation state of the production line according to a time series ,
The operating condition analysis method characterized by comprising. An operational status analysis program for analyzing the operational status of the production line based on operational status data representing the operational status of each work element of the production line collected by the data collection device,
In the operating status analysis device,
A data acquisition processing procedure for acquiring a plurality of operation state data collected by the data collection device according to a certain number of samples or a time series of timing for each time point when an arbitrary operation ends ,
User for one analysis menu among a plurality of types of analysis menu analysis based on the operating state data for each of a plurality of operating states including waste state waiting practical production in state and wasted in the production line User specified acquisition processing procedure to acquire the specification of
Reads the operating state function corresponding to the analysis menu specified by the user from the operating state function storage device that stores in advance an operating state function in which a plurality of operating states are combined by an operator corresponding to a plurality of types of analysis menus, and obtains data. A plurality of operation state data acquired by the processing procedure is input to the read operation state function, and operation state data calculation processing procedure for calculating operation state data representing the operation state of the production line according to a time series ,
The operating condition analysis program characterized by causing Collecting operation state data representing the operation state of each work element constituting the production line according to a certain sample number or a time series of timing for each time point when any operation is completed , provided for each process of the production line , a plurality of data collection devices and out of power,
A data storage server that receives and stores data output from each data collection device;
Corresponding to a plurality of types of analysis menu analysis based on the operating state data for each of a plurality of operating states including waste state waiting practical production in state and wasted in the production line, a plurality of operating states An operating state function storage device for storing in advance an operating state function combined by an operator;
Acquires the user's specification for one analysis menu among a plurality of types of analysis menus, reads the operation state function corresponding to the analysis menu specified by the user from the operation state function storage device, and performs a plurality of operations from the data storage server An operation status analysis device that acquires status data and calculates the operating status data representing the operating status of the production line according to a time series by inputting a plurality of acquired operating status data into the read operating status function;
The operating condition analysis system characterized by including.

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