JP4782497B2 - Operation analysis device, production facility, operation analysis method and program - Google Patents

Description

  The present invention relates to an operation analysis apparatus that analyzes an operation state of a production line.

  Conventionally, an operation analyzer that analyzes the operating state of a production line that produces a production object by performing production operations with a plurality of production facilities according to a predetermined order, and identifies factors that are reducing the production capacity of the production line Has been proposed (see, for example, Patent Document 1).

  The operation analysis apparatus of Patent Document 1 detects a state in which the production facility with the longest cycle time (hereinafter referred to as the longest facility) is stopped, and the stop of the longest facility is caused by the tool change of the facility itself. It is determined whether it is caused by the fact that the other production facilities (hereinafter referred to as front and rear facilities) have stopped (so-called “waiting for loading / unloading” or “waiting for pre-process and post-process”). Then, when the operation analyzer determines that the front and rear facilities are stopped, as described above, the stop of the front and rear facilities is caused by the tool change of the facilities itself, or other production facilities are stopped. It is judged whether it was caused by doing.

As described above, the operation analysis apparatus of Patent Document 1 searches for the stop factor of the longest facility so as to follow other production facilities in order from the longest facility, and reduces the stop factor to reduce the production capacity of the production line. To identify as a factor.
Japanese Patent Laid-Open No. 5-200657

  However, the operation analysis apparatus of Patent Document 1 has a problem that it is not possible to appropriately specify the factor that is reducing the production capacity of the production line.

  That is, in the production line, the cause of stoppage of each production facility is related to each other and is generated at the same time. Therefore, as in the operation analysis device of Patent Document 1 described above, the cause of stoppage of the longest facility is simply specified. However, it is impossible to identify factors that actually have a large influence on the decline in production capacity such as production time of the entire production line.

  Therefore, the present invention has been made in view of such a problem, and an object thereof is to provide an operation analysis apparatus that can appropriately specify a factor that is reducing the production capacity of a production line.

  In order to achieve the above object, an operation analysis apparatus according to the present invention is an operation analysis apparatus that analyzes an operation state of a production line that produces a production object by a plurality of production facilities performing production operations according to a predetermined order. The actual value specifying means for specifying the actual value of the production capacity of the production line from the operation result of the production line, and the stop factor of each production facility where the production work is stopped during the operation of the production line are detected. For each stop factor detected by the stop factor detecting means and the stop factor detecting means, an estimated value of the production capacity of the production line when the stop factor has not occurred is obtained, the relevance of each stop factor and the An estimated value calculating means for calculating based on the actual value; and an estimated value presenting means for presenting an estimated value for each stop factor calculated by the estimated value calculating means. And features.

  As a result, for each stop factor of each production facility, an estimated value of the production capacity of the production line when the stop factor has not occurred is calculated and presented. Thus, it is possible to appropriately identify factors that have a large influence on the decline in production capacity of the entire production line.

  Further, the operation analysis apparatus further includes, for each stop factor detected by the stop factor detecting unit, an actual value specified by the actual value specifying unit and an estimated value calculated by the estimated value calculating unit. Difference calculating means for calculating the difference and difference presenting means for presenting the difference calculated by the difference calculating means in ascending order or descending order may be provided. For example, the actual value specifying means specifies, as the actual value, an actual production time required for the production line to produce a unit quantity of the production target, and the estimated value calculation means The estimated production time required to produce a product by the unit quantity is calculated as the estimated value, and the difference calculating means calculates the difference by subtracting the estimated production time from the actual production time. Alternatively, the actual value specifying means specifies an actual production quantity of a production object produced by the production line within a unit time as the actual value, and the estimated value calculating means includes the production line within the unit time. The estimated production quantity of the produced production object is calculated as the estimated value, and the difference calculating means calculates the difference by subtracting the actual production quantity from the estimated production quantity.

  As a result, the difference between the estimated value and the actual value for each stop factor is presented in ascending / descending order, so that the factor having a great influence on the decline in the production capacity of the entire production line can be identified more appropriately and quickly. be able to.

  In addition, the operation analyzer further performs processing according to the operation state of the production line in the predetermined period for each elapse of the predetermined period, the actual value specifying unit, the stop factor detecting unit, and the estimated value calculating unit. And updating means for urging each of the estimated value presenting means.

  Accordingly, since the latest estimated value is presented at every predetermined period, it is possible to appropriately identify a factor that has a large influence at the present time on the decline in the production capacity of the entire production line.

  The operation analysis apparatus further includes a determination unit that determines whether or not the estimated value calculated by the estimated value calculating unit is equal to or less than a threshold value, and the estimated value presenting unit further includes: The determination result may be presented when the determination means determines that the value is equal to or less than the threshold value.

  As a result, an estimated value that is equal to or less than the threshold value is clarified, so that a factor that has a great influence on the decrease in the production capacity of the entire production line can be easily identified.

  Note that the present invention can be realized not only as such an operation analysis apparatus but also as a method, a program thereof, and a storage medium for storing the program.

  The operation analysis apparatus according to the present invention has an effect of being able to appropriately identify a factor that is reducing the production capacity of the production line.

  Hereinafter, an operation analysis apparatus according to an embodiment of the present invention will be described with reference to the drawings.

  FIG. 1 is an external view of an operation analysis apparatus according to an embodiment of the present invention and a production line to be analyzed by the operation analysis apparatus.

  The production line L is composed of a plurality of production facilities M1 to M5 arranged in a line, and the plurality of production facilities M1 to M5 perform production operations according to a predetermined order to produce a production object.

  Specifically, each of the production facilities M1 to M5 performs a production work for mounting electronic components on a board carried from the upstream side of the production line L (left side in FIG. 1), and the production work is completed. Then, it carries out to the downstream side (right side of FIG. 1) of the production line L. For example, each production facility M1 to M5 is configured as a solder printing device, an adhesive application device, a component mounting machine, or a reflow furnace.

  Therefore, this production line L sequentially transports the substrate from the upstream production facility to the downstream production facility, and executes the production work corresponding to the respective roles to each of the production facilities M1 to M5 with respect to the transported substrate. Let As a result, a mounting board on which electronic components are mounted is produced as a production object.

  The operation analysis apparatus 100 according to the present embodiment analyzes the operation state of the production line L described above, and appropriately identifies the factor that decreases the production capacity of the production line L. The operation analysis apparatus 100 detects, for example, the operation state of the terminal device 100A, which is a personal computer in which a dedicated application program is installed, and the production facilities M1 to M5 of the production line L, and transmits the detection result to the terminal device 100A. And an operation detector (not shown).

FIG. 2 is a configuration diagram showing the configuration of the operation analysis apparatus.
The operation analyzer 100 includes the operation detector 101 and the terminal device 100A.

  The operation detector 101 is disposed in each of the production facilities M1 to M5, detects the operation state of the production facility, and outputs operation data 101a indicating the operation state at that time to the terminal device 100A every predetermined time. . In other words, the operation detector 101 counts the number of substrates on which production work has been performed by the production facility, detects the execution and stop of the production work, and detects the cause of the stop. Then, the operation detector 101 includes, for each predetermined time, the number of substrates on which production work has been performed at that time (worked number of sheets), the work execution time during which the production work has actually been performed, The operation data 101a indicating the stop time for each stop factor at which the production work has stopped in time is generated and output. That is, the operation detector 101 includes a function as a stop factor detecting unit that detects a stop factor of each of the production facilities M1 to M5 in which the production work is stopped while the production line L is in operation.

  The terminal device 100A includes a memory 102, an actual value specifying unit 103, an estimated value calculating unit 104, a difference calculating unit 105, a determining unit 106, an updating unit 107, a display unit 108, a data acquiring unit 109, The sort presentation unit 110 is provided.

  The data acquisition unit 109 acquires the operation data 101 a from each operation detector 101 and stores the acquired operation data 101 a in the memory 102.

  The actual value specifying unit 103 reads the operation data 101a of each production facility stored in the memory 102, and specifies the actual value of the production capacity of the production line L (hereinafter referred to as production actual value) from the operation data 101a. . That is, the actual value specifying unit 103 is configured as actual value specifying means. For example, the actual value specifying unit 103 includes the actual line tact (actual production time) required for the production line L to produce only one mounting board, and the actual production number of the mounting boards produced by the production line L per unit time. (Actual production quantity) is specified as the production actual value.

  The estimated value calculation unit 104 reads the operation data 101a of each production facility M1 to M5 stored in the memory 102, and the production line when there is no stop factor for each stop factor indicated in the operation data 101a. An estimated value of L production capacity (hereinafter referred to as a production estimated value) is calculated based on the relevance of each stop factor indicated in the operation data 101a and the production result value. That is, the estimated value calculation unit 104 is configured as estimated value calculation means. For example, the estimated value calculation unit 104 selects an electronic component suction error in the production facility M3 configured as a component mounter from among the stop factors indicated by the operation data 101a. Then, the estimated value calculation unit 104 determines that the estimated line tact (estimated production time) that the production line L would require to produce only one mounting board and the suction error when there is no suction error. If not, the estimated production number (estimated production quantity) of the mounted boards that the production line L will produce per unit time is calculated as the production estimated value. Further, the estimated value calculation unit 104 notifies the sorting presentation unit 110 of the production estimated value when there is no stop factor for each of the stop factors.

  The difference calculation unit 105 calculates, for each stop factor, a difference between the production result value specified by the result value specification unit 103 and the production estimated value calculated by the estimated value calculation unit 104, and presents the difference as a sort. Notification to the unit 110. That is, the difference calculation unit 105 is configured as a difference calculation unit. Specifically, the difference calculation unit 105 calculates the difference between the actual production number specified by the actual value specification unit 103 and the estimated production number calculated by the estimated value calculation unit 104 as the estimated increase production number. Further, the difference calculation unit 105 calculates the difference between the actual line tact specified by the actual value specifying unit 103 and the estimated line tact calculated by the estimated value calculation unit 104 as the estimated shortening time.

  The determination unit 106 holds a threshold for the estimated line tact. Then, when the estimated line tact for each stop factor is calculated by the estimated value calculating unit 104, the determination unit 106 compares the estimated line tact with the threshold value so that the estimated line tact below the threshold value is clearly indicated. The sort presentation unit 110 is instructed. That is, the determination unit 106 is configured as a determination unit.

  The sort presenting unit 110 sorts the production estimated values and the differences notified from the estimated value calculating unit 104 and the difference calculating unit 105 in the ascending / descending order and causes the display unit 108 to display them. Further, the sort presentation unit 110 adds a circle to the estimated line tact instructed from the determination unit 106 and causes the display unit 108 to display the circle.

  The display unit 108 lists the estimated line tact and estimated number of production, which are the production estimated values calculated by the estimated value calculating unit 104 for each stop factor, and the estimated shortening time and estimated number of increased production calculated by the difference calculating unit 105. Are displayed together. That is, the display unit 108 is configured as an estimated value presentation unit, and the display unit 108 and the sort presentation unit 110 constitute a difference presentation unit.

  Each time the operation data 101a of all the production facilities M1 to M5 of the production line L is stored in the memory 102, the update unit 107 performs a process on the stored operation data 101a as a result value specifying unit 103, an estimated value calculation unit. 104 and the difference calculation unit 105 are prompted. That is, since each operation detection unit 101 outputs operation data 101a every predetermined time, the update unit 107 prompts the actual value specifying unit 103 to perform processing for new operation data 101a every predetermined time. The result is displayed on the display unit 108. That is, the update unit 107 is configured as an update unit.

FIG. 3 is an explanatory diagram for explaining the contents of the operation data.
The operation data 101a output from the operation detector 101 disposed in the production facility M2 includes, for example, as shown in FIG. 3A, the number of completed works (production number) “x” and the work execution time ( Actual operation time) “A time”, stop factor “wait for subsequent process, equipment setting, recognition error,...” And stop times “a1 hour, a2 hour, a3 time,.

  The operation data 101a output from the operation detector 101 disposed in the production facility M3 includes, for example, as shown in FIG. 3B, the number of completed works (production number) “x” and the work execution time ( Actual operation time) “B time”, stop factor “suction error, component shortage, recognition error,...” And stop time “b1 hour, b2 hour, b3 time,.

  The operation data 101a output from the operation detector 101 disposed in the production facility M4 includes, for example, as shown in FIG. 3C, the number of completed works (production number) “x” and the work execution time ( Actual operation time) “C time”, stop factor “wait for previous process, recognition error, equipment setting,...” And stop time “c1 hour, c2 hour, c3 time,.

  The actual value specifying unit 103 specifies the actual production number of the mounted boards produced by the production line within the unit time from the number of completed operations indicated by the operation data 101a. Further, the actual value specifying unit 103 specifies the above-described actual line tact by dividing the unit time by the actual production number.

FIG. 4 is an explanatory diagram for schematically explaining the operation of the estimated value calculation unit 104.
For example, the estimated value calculation unit 104, for each production facility, based on the operation data 101a output from the operation detector 101 of each production facility M1 to M5, the work execution time in the actual line tact and the stop of each stop factor Calculate time. Then, the estimated value calculation unit 104 selects the stop factors one by one in the order of the stop factor of the production facility M1 to the stop factor of the production facility M5, and the estimated line tact of the production line L when there is no stop factor. Is calculated. That is, when the estimated value calculation unit 104 selects a stop factor, the estimated value calculation unit 104 specifies the relationship between the stop factor and another stop factor. Then, the estimated value calculation unit 104 calculates how the actual line tact changes based on the absence of the selected stop factor and the identified relevance.

  Specifically, when the “suction error” is selected as the stop factor of the production facility M3, the estimated value calculation unit 104 says that if the “suction error” disappears, the stop factor “wait for the post process” of the production facility M2 disappears. The relevance and the relevance that part of the stop factor “waiting for the previous process” of the production facility M4 disappears are specified. Then, the estimated value calculation unit 104 calculates the estimated line tact in consideration of such relevance.

FIG. 5 is a diagram illustrating a list displayed by the display unit.
In this list, a rank column A1 in which the rank is displayed, a facility column A2 in which the identification information of the production facility corresponding to the rank is displayed, and a factor in which the stop factor of the production facility corresponding to the rank is displayed. The column A3, the tact column A4 in which the estimated line tact when there is no stop factor is displayed, the shortened time column A5 in which the estimated shortening time corresponding to the estimated line tact is displayed, and the stop factor are not present In this case, there are a number field A6 in which the estimated production number is displayed and a production increase number field A7 in which the estimated increase number corresponding to the estimated production number is displayed.

  For example, when the estimated line tact time when there is no stop factor “adsorption error” of the production equipment M3 is the shortest (estimated shortening time is the longest), the first place is displayed at the top of the ranking column A1, and the equipment column A2 “M3” is displayed as identification information of the production facility M3 at the top, and a stop factor “adsorption error” is displayed at the top of the factor column A3. The estimated line tact “6 hours 54 minutes 12 seconds” when there is no stop factor “adsorption error” is displayed at the beginning of the tact column A4, and the estimated line tact is displayed at the beginning of the shortened time column A5. The estimated shortened time “42 minutes 21 seconds” that is the difference between the actual line tact and the actual line tact is displayed. Further, an estimated production number “512 sheets” when there is no stop factor “adsorption error” is displayed at the top of the number field A6, and the estimated production number and the actual production number are displayed in the increased production number field A7. The estimated number of increased production “52 sheets” that is the difference is displayed. In addition, when the threshold value held in the determination unit 106 is “7 hours”, for example, the estimated line tact “6 hours 54 minutes 12 seconds” is shorter than the threshold value. A circle is displayed. Thereby, the estimated line tact is specified.

  And as for the stop factors of other production facilities, the rank, production facilities, stop factors, etc. are displayed in the respective columns in the order of shortest estimated line tact (in order of long estimated shortening time). The

  From such a list, it can be easily identified that the factor that has a great influence on the decrease in the production capacity of the entire production line L is the stop factor “adsorption error” of the production facility M3.

  As described above, in the present embodiment, the estimated line tact and the estimated shortening time for each stop factor are presented, and therefore, by comparing the presented estimated line tact and the like, the production capacity of the entire production line L is reduced. It is possible to appropriately identify factors that greatly affect In addition, the estimated line tact, estimated shortening time, etc. are displayed in ascending / descending order, or the estimated line tact below the threshold value is clearly indicated, which is a factor that greatly affects the decline in the production capacity of the entire production line L Can be identified easily and quickly.

  Further, since the list as shown in FIG. 5 is periodically updated by the updating unit 107, the factors that have a large influence at the present time on the decline in the production capacity of the entire production line L are appropriately identified. can do.

FIG. 6 is a flowchart showing the operation of the operation analysis apparatus 100 in the present embodiment.
First, the operation analysis apparatus 100 detects an operation state including a stop factor of each of the production facilities M1 to M5 (step S100), and generates operation data 101a indicating the detection result for each production facility (step S102). . Then, the operation analysis apparatus 100 specifies a production result value such as the actual production number from the generated operation data 101a (step S104). Furthermore, the operation analysis apparatus 100 selects any stop factor indicated by the operation data 101a of each production facility M1 to M5 (step S106), and calculates a production estimated value when there is no stop factor (step S106). S108).

  Here, the operation analysis apparatus 100 determines whether or not all the stop factors indicated in the generated operation data 101a of the production facilities M1 to M5 have been selected (step S110). When it is determined that not all have been selected (N in step S110), the operation analysis apparatus 100 repeatedly executes the operations from step S106. When it is determined that all have been selected (Y in step S110), the operation analysis apparatus 100. Calculates the difference between the actual production value specified in step S104 and the estimated production value calculated in step S108 for each stop factor (step S112).

  Then, the operation analysis apparatus 100 sorts the differences and estimated production values for each stop factor in ascending or descending order (step S114), and collectively displays the results in a list (step S116).

  As mentioned above, although the operation | movement analyzer which concerns on this invention was demonstrated using embodiment, this invention is not limited to this.

  For example, in the embodiment, the determination unit 106 instructs the sort presenting unit 110 to clearly indicate an estimated line tact that is equal to or less than the threshold value. However, the determination unit 106 instructs the sort presenting unit 110 to clearly indicate the estimated production number that is equal to or greater than the threshold value. You may instruct. In this case, for example, when the threshold value is 500 sheets, a circle is displayed near “512 sheets” in the number-of-sheets column A6 of the list shown in FIG. Also, when the difference such as the estimated shortening time and the estimated increase in production number calculated by the difference calculation unit 105 is equal to or greater than or less than the threshold, the estimated shortening time and the estimated increase in production number are displayed in the list in the same manner as described above. You may explicitly display it. In this case, the sort presentation unit 110 holds a threshold value. Then, the sort presenting unit 110 compares the estimated shortening time and the estimated number of increased production calculated by the difference calculating unit 105 with the threshold value held by itself, and lists the comparison result as the above-described circle. To display. In the embodiment, the estimated line tact below the threshold is marked with a circle to clearly indicate the estimated line tact. However, other visual methods such as font, color, and size of the estimated line tact are used. Thus, the estimated line tact may be specified. Further, the sort presentation unit 110 may transmit the estimated line tact to another terminal device by e-mail or the like.

  In the embodiment, the operation detector 101 of each production facility M1 to M5 periodically generates and outputs the operation data 101a, but generates and outputs the operation data 101a based on an instruction from the update unit 107. May be. That is, the update unit 107 prompts each operation detector 101 to generate and output the latest operation data 101a. When the operation data 101a is stored in the memory 102, the actual value specifying unit 103, the estimated value calculation The unit 104 and the difference calculation unit 105 are urged to execute processing based on the latest operation data 101a.

  Furthermore, in the embodiment, the terminal device 100A is separated from the production facilities M1 to M5, but may be incorporated in any production facility.

  The operation analysis apparatus according to the present invention has an effect that it is possible to appropriately specify a factor that reduces the production capacity of the production line, and for example, analyzes an operation state of the production line for mounting electronic components on a substrate. It is useful as a device.

BRIEF DESCRIPTION OF THE DRAWINGS It is an external view of the operation analysis apparatus in embodiment of this invention, and the production line used as the analysis object of the operation analysis apparatus. It is a block diagram which shows the structure of the operation | movement analyzer same as the above. It is explanatory drawing for demonstrating the content of the operation data same as the above. It is explanatory drawing for demonstrating roughly operation | movement of the estimated value calculation part same as the above. It is a figure which shows the list displayed by the display part same as the above. It is a flowchart which shows operation | movement of an operation analyzer same as the above.

Explanation of symbols

DESCRIPTION OF SYMBOLS 100 Operation | movement analyzer 100A Terminal device 101 Operation | movement detector 101a Operation | movement data 102 Memory 103 Actual value specific | specification part 104 Estimated value calculation part 105 Difference calculation part 106 Judgment part 107 Update part 108 Display part 109 Data acquisition part 110 Sort presentation part

Claims (8)

An operation analysis device that analyzes an operating state of a production line that produces a production object by a plurality of production facilities performing production work according to a predetermined order,
Actual value specifying means for specifying the actual value of the production capacity of the production line from the operation result of the production line;
Stop factor detection means for detecting a stop factor of each production facility in which production work is stopped during operation of the production line;
For each stop factor detected by the stop factor detecting means, an estimated value of the production capacity of the production line when the stop factor does not occur is calculated based on the relevance of each stop factor and the actual value. Estimated value calculation means for
An operation analysis apparatus comprising: an estimated value presenting unit that presents an estimated value for each stop factor calculated by the estimated value calculating unit. The operation analyzer further includes:
For each stop factor detected by the stop factor detecting means, a difference calculating means for calculating a difference between the actual value specified by the actual value specifying means and the estimated value calculated by the estimated value calculating means;
The operation analysis apparatus according to claim 1, further comprising: difference presenting means for presenting the differences calculated by the difference calculating means in ascending order or descending order. The actual value specifying means specifies, as the actual value, an actual production time required for the production line to produce a production quantity in a unit quantity,
The estimated value calculating means calculates, as the estimated value, an estimated production time required for the production line to produce the production target by the unit quantity,
The operation analysis apparatus according to claim 2, wherein the difference calculation unit calculates the difference by subtracting the estimated production time from the actual production time. The actual value specifying means specifies the actual production quantity of the production object produced by the production line within a unit time as the actual value,
The estimated value calculating means calculates an estimated production quantity of a production object produced by the production line within the unit time as the estimated value,
The operation analysis apparatus according to claim 2, wherein the difference calculation means calculates the difference by subtracting the actual production quantity from the estimated production quantity. The operation analyzer further includes:
A determination means for determining whether or not the estimated value calculated by the estimated value calculating means is equal to or less than a threshold value;
The said estimated value presentation means presents the said discrimination | determination result further, when it discriminate | determines that it is below or above a threshold value by the said discrimination means. The any one of Claims 1-4 characterized by the above-mentioned. Operation analysis equipment. Production equipment included in the production line,
A work execution means for performing a production work for producing a production object;
A production facility comprising: the operation analysis device according to claim 1, which analyzes an operation state of the production line. The operation analysis device is an operation analysis method for analyzing an operation state of a production line for producing a production object by a plurality of production facilities performing production work according to a predetermined order,
The operation analysis device includes an actual value specifying means, a stop factor detecting means, an estimated value calculating means, and an estimated value presenting means,
The actual value specifying means specifies the actual value of the production capacity of the production line from the operation result of the production line;
The stop factor detection means for detecting a stop factor of each of the production facilities in which the production work is stopped while the production line is in operation; and
For each stop factor detected in the stop factor detection step , the estimated value calculation means calculates an estimated value of the production capacity of the production line when the stop factor has not occurred, An estimated value calculating step for calculating based on the actual value;
The estimated value presenting means includes an estimated value presenting step for presenting an estimated value for each of the stop factors calculated in the estimated value calculating step. The program which makes a computer function as a means with which the operation | movement analyzer of any one of Claims 1-5 is provided.

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