JP4711168B2 - Production equipment management system - Google Patents

Description

  The present invention relates to a production facility management system, and more particularly to a production facility management system that manages a production line having a plurality of production facilities.

2. Description of the Related Art Conventionally, a production line composed of a plurality of production facilities includes data collection means for collecting data relating to state changes of each production facility, and data storage means for recording and saving data collected by the data collection means in a data file. The production facility management system manages state changes for each production facility.
As such a production facility management system, operation information, production information, alarm information, etc. of each manufacturing facility are collected in a host computer via a display device provided in each manufacturing facility, and each production is performed using these information. A device that manages the facilities is known. (Patent Document 1)
In addition, a manufacturing history storage unit that stores material information and manufacturing information of each production facility as a manufacturing history and an equipment failure history storage unit that stores manufacturing equipment failure information as an equipment failure history are provided. There is also known a production facility management system including an facility failure history output unit that controls and manages a failure history. (Patent Document 2)
According to these production facility management systems, even if a certain production facility stops due to an abnormality, the stop period can be detected for each cause of the production facility being stopped due to an abnormality based on the collected and accumulated data. I was able to do it.
JP-A-5-138468 JP 2003-241815 A

Here, the above production lines may be composed of production equipment manufactured by different equipment manufacturers. Due to differences in the equipment manufacturer's philosophy and specifications, the production equipment is in the period from when it stops abnormally until it restarts. In addition, there may be a difference in the recognition of the state change of each production facility.
For example, even in a production facility that performs the same work, in a production facility of a certain equipment manufacturer, the operation signal of the reset button is collected, and from the occurrence of an abnormal signal to the production facility until the occurrence of the reset signal, Set as the stop time due to the abnormality, and the production equipment of other equipment manufacturers collects data to that effect every time an abnormality signal occurs, and if another abnormality signal occurs after the abnormality signal is generated in the production equipment Even if the previous abnormality has not been resolved, it may be set to be regarded as a stop time due to a later abnormality.
Therefore, even if an attempt is made to create a production facility outage history from the data collected in this way, the outage period for each production facility is recognized based on a different definition, which is consistent with the handling of the outage period for each production facility. Therefore, even if an attempt was made to calculate the influence of the above abnormality on the operating rate of the entire production line, the result was not necessarily accurate.
In view of such a problem, the present invention can ensure that the stop period of each production facility is consistent even if the production line is composed of production facilities of different equipment manufacturers, and even if there is a difference in the work procedure by the operator. The present invention provides a production facility management system that can be recognized by the state.

That is, the production facility management system of the present invention is a production facility management system for a production line composed of a plurality of production facilities,
The production facility management system is a production facility management system comprising data collection means for collecting state data relating to state changes of each production facility, and data storage means for recording and saving data collected by the data collection means in a data file. ,
As the above status data, the abnormal stop data for abnormal stop of the production equipment and the start data for start of the production equipment are stored. At that time, after the status data is changed from the start data to the abnormal stop data, another abnormality is stored. Even if stop data is received, a state data storage means is provided so that the state data is not rewritten to the other abnormal stop data,
The data collection means detects that the state data in the state data storage means has been rewritten from start data to abnormal stop data and collects this in time series,
The data storage means detects the start data after the first abnormal stop data is collected when the state data collected by the data collection means for the predetermined production facility becomes the abnormal stop data from the start data. The period until the operation is stopped is set as a stop period of the production facility , and the first abnormal stop data in the stop period is set as a cause of the abnormal stop.

  According to the present invention, even if other work is performed between the abnormal stop and the restart, the data storage means sets the period from the abnormal stop of the production facility to the restart of the production facility. Therefore, it is possible to recognize the outage period of each production facility in a consistent state regardless of the difference in ideas between equipment manufacturers and the operator's work procedure, and accurately manage the production history of the production equipment. can do.

FIG. 1 shows a first embodiment according to the present invention. A production line 1 for filling a container with a liquid and a production facility management system 2 for managing and controlling the production line 1 are shown in FIG. Show.
The production line 1 includes a plurality of production facilities 3, and each production facility 3 is controlled by facility control means 4 such as a PLC (programmable logic controller).
The production facility management system 2 includes a data collection control unit 6 connected in series with a facility control unit 4 of each production facility 3 via a communication unit 5 such as a LAN, and communicates with the data collection control unit 6. The terminal device 7 is connected so as to be able to display the state of the production line 1 and the like.
The data collection control means 6 receives a signal relating to the state change of the production equipment 3 from the equipment control means 4 and converts this signal into state data relating to the state change of the production equipment 3. And the production line 1 is managed by creating a data file using the state data.

The production line 1 will be described. As the production equipment 3 constituting the production line 1, in the present embodiment, a filler for filling a container with a beverage, a capper for capping the container, and a position between these equipments are described above. A conveyor for carrying containers is provided.
Each production facility 3 is provided with a sensor (not shown) that transmits various detection signals to the facility control means 4, and this sensor detects the number of processed containers and abnormalities in the production facility 3. ing.
Each production facility 3 has a reset button for releasing an alarm when an abnormality occurs, a start button for starting the production facility 3 that is stopped, a stop button for stopping the production facility 3, and the like. Is provided.
When a signal is received from the sensor or when the button is operated, the equipment control means 4 transmits a bit signal to that effect to the data collection control means 6. 3 is a signal about the content of the abnormality that occurred in 3 and a signal indicating the start of the production facility 3 by the start button.

Next, the data collection control means 6 of the production facility management system 2 will be described. The data collection control means 6 is a signal acquisition means 11 connected in series by the equipment control means 4 and the communication means 5 of each production facility 3. And a bit signal conversion means 12 for converting the received bit signal into the following state data corresponding to the following area code, and a state data storage unit 13 for temporarily storing predetermined state data for each area code. ing.
When the signal acquisition unit 11 receives the bit signal from the facility control unit 4, the signal acquisition unit 11 recognizes the production facility 3 of the facility control unit 4 that has transmitted the bit signal, and sends the production facility name and the bit signal to the signal conversion unit 12. And send.
Next, in the bit signal conversion means 12, an area code indicating the name of the production facility 3 and state data indicating the contents of start and abnormal stop of the production facility 3 corresponding to the area code are registered.
When the signal from the signal acquisition unit 11 is received, the bit signal conversion unit 12 recognizes an area code corresponding to the production facility 3 of the facility control unit 4 that has transmitted the bit signal, and also converts the received bit signal into the area code. It is converted to state data corresponding to.
FIG. 2 shows an example of the area code and status data registered in the bit signal converting means 12, and in this table, the left column is the area code, for example, the area code of the filler as the production equipment 3 is “R17041”.
The right column of the area code indicates the status data, and status data having different contents is set for each production facility 3. For example, an abnormality of the filling controller at the filler is indicated by status data “8”.
The right column of the state data indicates the reason for abnormal stop stored in the abnormality content storage unit 15 to be described later so that the combination of the area code and the state data is the reason for the abnormal stop. It has become.
For all area codes, the status data indicating the startup status of the production facility 3 is set to “0”. In the following description, this “0” status data is used as startup data, and status other than “0” is set. The data is abnormal stop data.

When the state data storage unit 13 receives the state data converted by the bit signal conversion means 12, the state data storage unit 13 stores predetermined state data for each area code.
The predetermined state data stored in the state data storage unit 13 will be described. The state data storage unit 13 is activated when the start data is changed to abnormal stop data for each area code, and then the production facility 3 is restarted. Only when the data changes from the abnormal stop data to the startup data, the state data is rewritten and stored.
That is, even if another abnormal stop data is received after the start data is changed to the abnormal stop data, the state data is not rewritten to the other abnormal stop data.

Next, the terminal device 7 of the production facility management system 2 detects that the state data of the predetermined area code in the state data storage unit 13 has been rewritten from the start data to the abnormal stop data, and this is time-sequentially. The data collection means 14 to collect, the abnormal content storage unit 15 in which the reason for abnormal stop corresponding to the area code and status data is registered, the name of the abnormally stopped production facility, the reason for abnormal stop, and the abnormal stop time are shown in time series. A data storage unit 16 for recording and storing the data and a monitor 17 for outputting an abnormal stop history from the data stored in the data storage unit 16 are provided.
When the state data is rewritten for the predetermined area code of the state data storage unit 13, the data collection unit 14 collects the state data and provides the terminal device 7 with the time when the state data was rewritten. Collected from the timer.
As described above, the abnormal content storage unit 15 is registered in advance with an abnormal stop reason set for each production facility 3 corresponding to the area code and the abnormal stop data shown in FIG.
Then, the data storage unit 16 searches the abnormal stop data stored in the abnormal content storage unit 15 from the abnormal stop data of the predetermined production facility collected by the data collection unit 14, and the name of the abnormally stopped production facility or the abnormal The reason for the abnormal stop is recorded in the data file 18 together with the stop time. The data file 18 may be a database or other file format.
Further, in the data storage unit 16, when the state data collected by the data collection unit 14 becomes the abnormal stop data from the start data, the period until the start data is detected next is the stop period of the production facility. It is set and the reason for the abnormal stop at that time is recognized as the cause of the abnormal stop.

Hereinafter, the operation of the production facility management system 2 will be described with specific examples. Here, a description will be given of a method of recognizing a filler stop period when an abnormality occurs in the filling controller in the filler as the production facility 3 and the filler stops abnormally.
First, the data collected by the data collecting means 14 will be described.
During the normal operation of the filler, the state data storage unit 13 stores “0” indicating start data as the state data for the area code “R17041” indicating the filler. When an abnormality occurs in the controller, the filler stops abnormally and the equipment control means 4 transmits a bit signal.
This bit signal is converted into “8” which is abnormal stop data for the area code “R17041” by the bit signal conversion means 12, and the status data storage unit 13 changes the status data of the area code “R17041” from “0” to “0”. Rewrite to 8 ”.
Next, when the operator opens the filler door in order to return the filling controller, a sensor provided in the door is activated and the equipment control means 4 transmits a bit signal.
This bit signal is converted into “30” indicating abnormal stop data for the area code “R17041” by the bit signal conversion means 12, but in the state data storage unit 13, the state data for the area code “R17041” is “ 8 ”is not rewritten to“ 30 ”.
Next, when the repair of the filling controller is completed and the operator closes the work door and operates the reset button after operating the reset button, the status data is rewritten from “8” to “0” which is the startup data.
That is, after the activation data “0” indicating that the operation is in progress is rewritten to the abnormal stop data “8” indicating that the filling controller is abnormal, the state data storage unit 13 may perform the operation of the work door between the next activation data “0”. Even if there is an abnormal stop data “30” indicating release, this is ignored.

On the other hand, the data storage unit 16 collects the abnormal stop data “8” collected by the data collection unit 14 and also the abnormal stop reason corresponding to the area code “R17041” and the abnormal stop data “8” from the abnormal content storage unit 15. “Filler filling controller abnormality” is collected and recorded in the data file 18 together with the collected time.
Further, the data storage means 16 sets the time from when the state data for the area code “R17041” is rewritten to “8” to the time until the state data is rewritten to “0” indicating the activation data after that. Record as.
Similarly, for each production facility 3 other than filler, the state data storage unit 13 stores only predetermined state data for the corresponding area code, and the data collecting means 14 collects the reason for abnormal stop corresponding to the state data. By doing so, the data storage means 16 records the period from the abnormal stop of the production facility 3 to the restart thereof in the data file 18 as the stop period of the production facility 3 due to the reason for the abnormal stop. It has become.

3 to 5 are display examples of the abnormal stop history relating to the production line 1 which is created based on the data recorded and stored in the data file 18 by the data storage means 16 and displayed on the monitor 17. FIG. The abnormality which occurred in each production facility 3 of the production line 1 is displayed together with the abnormality occurrence time and the stop period for each abnormal stop reason.
FIG. 4 shows the number of stops for each abnormal stop reason, the stop period due to the abnormal stop reason, and the stop rate in the production facility affected by the stop period for the entire production line 1 and each production facility 3. is there.
FIG. 5 shows a Pareto diagram regarding the reason for abnormal stop and the stop period for the entire production line 1 and the production facility 3 in which an abnormality has occurred.

Here, as described above, the production line 1 is constituted by a large number of production facilities 3, but these production facilities 3 may be manufactured by different equipment manufacturers.
In such a case, the procedure required for restarting after an abnormality occurs in the production facility 3 may be different for each production facility 3, or the bit signal transmitted by the facility control means 4 may be different. In addition, there may be a difference in the restarting procedure depending on the worker in charge of the production facility 3.
6 (a) and 6 (b) show the steps necessary from the occurrence of an abnormality to the restart in the case where an abnormality occurs in the filling controller at the same time in the fillers manufactured by different equipment manufacturers, and the bit signal conversion means 12. The state data converted by is shown in time series.

First, in the filler of FIG. 6 (a), when the work door is opened, the equipment control means 4 transmits a bit signal. For this reason, the bit signal converting means 12 uses the area code “R17041” indicating the filler. ", The state data is converted as follows.
Until the abnormality occurs in the filling controller, the filler operates normally. Therefore, the status data is “0” which is the start-up data. If an abnormality occurs in the filling controller and the filler stops abnormally, the status data Changes to “8”, which is abnormal stop data indicating “abnormality of filling controller”.
Next, when the operator opens the work door, the status data is changed to the abnormal stop data “30” indicating “work door open” again, and finally the start data “0” indicating “operation state” by operating the start button. To change.

On the other hand, in the filler of FIG. 6B, it is assumed that the reason for stopping is set by the signal generated by the operation of the reset button and that the reason for stopping is canceled by the reset button. Assuming that “1” is “1”, the bit signal converting means 12 converts the state data for the area code “R17041” indicating the filler as follows.
When the status data changes from “0” to “8” due to an abnormality in the filling controller, it changes to “30” by “work door open”, and then changes to “1” by the operation of the reset button. It changes to “0” by the operation.

Furthermore, even in the same production facility 3, the state data may change in different orders depending on the work procedure by the worker.
FIG. 6C shows a case where the same filler as in FIG. 6B is restarted in a different procedure from FIG. 6B. In this figure, the filler has stopped abnormally. At that time, the operator once operates the reset button, and then opens the work door to repair the filling controller.
In this case, if the status data changes from “0” to “8” due to an abnormality in the filling controller, the status data becomes “1” by the operation of the reset button, and the status data becomes “1” by opening the work door. The state data changes from “30” to “1” by further closing the work door and operating the reset button, and then operating the start button to “0”. It changes to.

As described above, when performing a series of operations for restarting the filler from the abnormally stopped state, the state data changes in the order of “0”, “8”, “30”, and “0” in FIG. In (b), the state data changes in the order of “0” “8” “30” “1” “0”. In FIG. 6C, “0” “8” “1” “30” “1” “ The state data changes in the order of “0”.
In this way, even in the case of the same abnormal stop, in order to restart, such a difference can occur in the change of the state data. Therefore, the data file 18 is created using the state data as it is. As a result, a difference occurs in the length of the stop period for each production facility 3.
That is, the stop period due to the “abnormality of the filling controller” in FIGS. 6A and 6B is a period from the abnormal stop time until the work door is opened, and the stop period in FIG. It will be a period from the abnormal stop time due to “abnormality of the filling controller” to the operation of the reset button before performing the recovery operation.
Further, in any of FIGS. 6A, 6B, and 6C, “opening of the work door” necessary for restoring the filler is recognized as the reason for the abnormal stop. For this reason, it becomes impossible to determine whether the abnormality “opening of the work door” has occurred due to the abnormality of the production facility 3 or whether the operator has opened it to restore the filler.
Thus, even if the abnormal stop history as shown in FIGS. 3 to 5 is created without taking consistency with the recognition of the stop period of the production facility 3, the content of the production history created for each production facility 3 is Since they are different from each other, the worker cannot check the production history accurately.

For such a problem, the data storage means 16 of the present invention recognizes the stop period by the above-described method, so that it can be produced under the same conditions even if the equipment manufacturer is different or the operator's work procedure is different. The stop period of the equipment 3 can be recognized.
That is, in any of FIGS. 6A to 6C, the data storage unit 16 of the present embodiment has a period from the first detected abnormal stop time of the filling controller to the start time at which the filler is restarted. Recognize as a suspension period. (Fig. 6 (d))
Therefore, even if the equipment manufacturer is different or the operator's work procedure is different, the data is stored under the same conditions, and the abnormal stop history as shown in FIGS. You can know the state accurately.
From the above, it is not necessary to provide a means for ensuring the consistency of the stop period for each production facility, and the bit signals from each facility control means 4 are collectively converted by the data collection control means 6. As a result, it is not necessary to modify each production facility 3, and the production history can be managed at a lower cost.

FIG. 7 shows a second embodiment according to the present invention. In this embodiment, each production facility 3 includes a bit signal conversion means 12 and a state data storage section 13 of the data collection control means 6. The production facility management system 2 is provided with the same data collection means 14, abnormal content storage section 15, data storage means 16, and monitor 17 as the operation terminal.
In this embodiment, the state data storage unit of each production facility 3 and the data collection means 14 of the terminal device are individually connected by the communication means 5.
Even in the case of such a configuration, the state data storage unit 13 rewrites the state data of the production facility 3 for each production facility 3, and the rewritten state data is the data collection means of the production facility management system 2. 14, the same effects as those of the first embodiment can be obtained.

In the above embodiment, the state data storage unit 13 determines the state data to be rewritten. However, the state data storage unit 13 may rewrite all the state data converted by the bit signal conversion unit 12.
In this case, all of the state data is collected by the data collecting unit 14, but the data storage unit 16 does not stop until the next activation data is detected when the state data changes from the activation data to the abnormal stop data. By ignoring the collected abnormal stop data, the same stop period as that in the above embodiment can be obtained.

The layout which shows the production line and production equipment management system in a present Example. The table | surface which showed the content currently recorded on the status data storage part and the abnormality content storage part. A table created by the data storage means for abnormal stops that occurred in the entire production line. A table created by the data storage means for the entire production line and abnormal stop that occurred for each production facility. A parade diagram regarding the abnormal stop of the entire production line and the production facility where the abnormality occurred, created by the data storage means. The figure which showed the status data which the bit signal conversion means converted in time series, and showed recognition of the stop period by a data storage means. The layout which shows the production line and production facility management system concerning a 2nd Example.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Production line 2 Production equipment management system 3 Production equipment 4 Equipment control means 6 Data collection control means 7 Terminal device 12 Bit signal conversion means 13 State data storage part 14 Data collection means 16 Data storage means 18 Data file

Claims (1)

A production facility management system for a production line composed of a plurality of production facilities,
The production facility management system is a production facility management system comprising data collection means for collecting state data relating to state changes of each production facility, and data storage means for recording and saving data collected by the data collection means in a data file. ,
As the above status data, the abnormal stop data for abnormal stop of the production equipment and the start data for start of the production equipment are stored. At that time, after the status data is changed from the start data to the abnormal stop data, another abnormality is stored. Even if stop data is received, a state data storage means is provided so that the state data is not rewritten to the other abnormal stop data,
The data collection means detects that the state data in the state data storage means has been rewritten from start data to abnormal stop data and collects this in time series,
The data storage means detects the start data after the first abnormal stop data is collected when the state data collected by the data collection means for the predetermined production facility becomes the abnormal stop data from the start data. A production facility management system characterized in that a period until the operation is stopped is set as a stop period of the production facility , and the first abnormal stop data in the stop period is set as a cause of the abnormal stop.

Images