JP5080013B2 - Work support system for field process status and work support method for field process situation - Google Patents

Work support system for field process status and work support method for field process situation Download PDF

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JP5080013B2
JP5080013B2 JP2006055680A JP2006055680A JP5080013B2 JP 5080013 B2 JP5080013 B2 JP 5080013B2 JP 2006055680 A JP2006055680 A JP 2006055680A JP 2006055680 A JP2006055680 A JP 2006055680A JP 5080013 B2 JP5080013 B2 JP 5080013B2
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敏広 山田
政文 岡田
良和 石井
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    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
    • Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
    • Y02P90/30—Computing systems specially adapted for manufacturing

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Description

本発明は、生産管理システムと製造現場を監視・制御する現場プロセス状況対応作業支援システム及び方法に関する。   The present invention relates to a production management system and an on-site process status corresponding work support system and method for monitoring and controlling a manufacturing site.

食品製造工場（会社）等においては、人手にて作業を行う工程での誤投入防止を図る為、また、新人作業員でも間違いなく作業が出来るよう標準作業手順（ＳＯＰ）をマスタ登録し、その作業手順を現場端末に表示し、オペレータの作業支援を実施している。このような標準作業手順に関する技術は、例えば、特開２００２−２２２２４８号公報に記載されている。   In food manufacturing factories (company), etc., standard work procedure (SOP) is registered as a master so that new workers can work without mistakes in order to prevent mistakes in the manual work process. The work procedure is displayed on the field terminal, and the operator's work support is carried out. A technique related to such a standard work procedure is described in, for example, Japanese Patent Application Laid-Open No. 2002-222248.

特開２００２−２２２２４８号公報JP 2002-222248 A

しかしながら、上記の背景技術では、生産システムが順調に動作しているのであれば良いが、例えば、現場状況が時々刻々と変化したときに、これに応じた適切な作業手順を現場等に指示することができなかった。また、作業手順を変更する場合には、システム管理者が手作業でロジックを変更することになり、マスタ登録作業に多大な労力を費やすこととなる。例えば、同じ品種を製造する作業手順でも対象物の製造過程での状態変化等に対し作業手順の変更をしなくてはいけない場合は想定されるパターンに合わせ、マスタの変更や同じようなマスタの追加登録をすることとなり、実質的に対応が困難であった。   However, in the above background art, it is only necessary that the production system is operating smoothly. For example, when the site situation changes from moment to moment, an appropriate work procedure corresponding to this is instructed to the site. I couldn't. Further, when changing the work procedure, the system administrator manually changes the logic, and a great deal of labor is spent on the master registration work. For example, if the work procedure for manufacturing the same product must be changed in response to changes in the state of the object during the manufacturing process, the master change or similar master Additional registration was required, making it substantially difficult to respond.

上記目的を達成するため、本発明では、作業テーブルに作業工程を記憶し、条件判定テーブルに所定の条件に応じた作業テーブルの変更指示を記憶し、現場プロセスの作業状況を検出する検出手段からの出力データを取り込み、出力データに応じて条件判定テーブルを参照し作業テーブルの記憶内容を変更するように構成した。   In order to achieve the above object, in the present invention, from the detection means for storing the work process in the work table, storing the work table change instruction according to the predetermined condition in the condition determination table, and detecting the work status of the on-site process The output data is taken in, and the storage contents of the work table are changed by referring to the condition determination table according to the output data.

現場の作業状況に応じて適切な標準作業手順などに変更することが可能となる。又、全体を管理する現場機器制御装置内の小工程制御の処理順番を作業手順組替え結果に合わせて変更可能にできる。 It is possible to change to an appropriate standard work procedure according to the work situation at the site. Moreover, the processing order of the small process control in the field device control apparatus that manages the whole can be changed according to the work procedure rearrangement result.

ここでは、食品を例に記載する。   Here, food is described as an example.

第１図は、本発明のシステム構成図である。管理サーバ９は、製造計画テーブル２，マスタ情報テーブル３，在庫情報テーブル４，製造実績テーブル５，作業手順組替処理部８
（作業手順定義テーブル６，条件判定テーブル７より成る）、工程制御管理処理部１１より成っている。まず、出荷指示テーブル１には、製品の出荷日に対応づけてロットＮo.や製造数量等が登録されている。出荷指示テーブル１に記憶された内容を基本に製造計画が立案される。該立案された製造計画は製造計画テーブル２に記憶される。食品を製造するための製品のレシピ（配合表）等のマスタ情報テーブル３や各工程にて製造を行う為に登録する作業手順定義テーブル６、作業手順の組替を実施する為の条件判定テーブル７を予め管理サーバ９に登録しておく。この管理サーバ９には製造過程で取得する実績を登録する実績テーブル５や在庫データテーブル４も管理している。 FIG. 1 is a system configuration diagram of the present invention. The management server 9 includes a manufacturing plan table 2, a master information table 3, an inventory information table 4, a manufacturing result table 5, and a work procedure reassignment processing unit 8.
(Consisting of a work procedure definition table 6 and a condition determination table 7) and a process control management processing unit 11. First, in the shipping instruction table 1, a lot number, a manufacturing quantity, and the like are registered in association with the product shipping date. A manufacturing plan is drawn up based on the contents stored in the shipping instruction table 1. The produced production plan is stored in the production plan table 2. Master information table 3 such as a recipe (composition table) of a product for manufacturing food, a work procedure definition table 6 registered for manufacturing in each process, and a condition determination table for performing rearrangement of work procedures 7 is registered in the management server 9 in advance. The management server 9 also manages a result table 5 and an inventory data table 4 for registering results obtained in the manufacturing process.

このように動作することで、作業手順定義テーブル６には、例えば、図２に示すように時間の順を追ってなされる、計量，原料投入，調合，…、分析の各工程において、それぞれの詳細工程である計量工程１→計量工程２→…，原料投入工程１→原料投入工程２→…，調合工程１→調合工程２→…，分析工程１→分析工程２→…が記憶される。   By operating in this way, the work procedure definition table 6 includes details in each of the steps of weighing, raw material input, blending,..., Analysis performed in the order of time as shown in FIG. The measurement process 1 → the measurement process 2 →..., The raw material input process 1 → the raw material input process 2 →..., The preparation process 1 → the preparation process 2 →..., The analysis process 1 → the analysis process 2 →.

作業手順定義テーブル６に記憶された内容は監視モニタ１０に表示されると共に、情報共有ネットワーク１２を介して携帯端末１６及び現場端末１７に送られ携帯端末１６のモニタ及び現場端末１７のモニタに表示される。   The contents stored in the work procedure definition table 6 are displayed on the monitor 10 and also sent to the mobile terminal 16 and the site terminal 17 via the information sharing network 12 and displayed on the monitor of the mobile terminal 16 and the monitor of the site terminal 17. Is done.

現場で製造されている製品の状況や現場の状況は、現場センサ１５や計量器１８等の確認装置から情報共有ネットワーク１２を介し管理サーバ９に送信される。送信されたデータを使用して、管理サーバ９内の作業手順組替処理部８が作業手順組替の条件判定テーブル７を参照し、作業手順の組替を実施する。条件判定テーブル７には、例えば、図３に示すように、「調合釜温度が３５０℃以上の場合」のように条件と、「調合工程３と調合工程４を交換する」のような該条件に合致した場合の処理が記憶されている。あるいは「計量器の計量結果が２％以上少なかった場合」に「原料投入１を２％分について追加する」等の処理が記憶されている。作業手順定義テーブル６は、該条件判定テーブルの判定結果に基づいて、テーブルの記憶内容を変更する。   The status of products manufactured at the site and the status of the site are transmitted to the management server 9 via the information sharing network 12 from the confirmation device such as the site sensor 15 and the measuring instrument 18. Using the transmitted data, the work procedure rearrangement processing unit 8 in the management server 9 refers to the work procedure rearrangement condition determination table 7 and rearranges the work procedure. In the condition determination table 7, for example, as shown in FIG. 3, the conditions such as “when the mixing pot temperature is 350 ° C. or higher” and the conditions such as “exchange the mixing process 3 and the mixing process 4”. The process when it matches is stored. Alternatively, a process such as “add raw material input 1 for 2%” when “the weighing result of the measuring device is 2% or less” is stored. The work procedure definition table 6 changes the stored contents of the table based on the determination result of the condition determination table.

このように変換された作業手順定義テーブル６の記憶内容は、組換え結果情報が監視モニタ１０や現場オペレータが使用する現場携帯端末１７や携帯端末１６等に表示される。これらの表示端末からは製造実績を入力したり製造計画を新規登録したり変更することも可能である。これらの表示端末に表示された結果をオペレータ確定操作により組替計画での作業が実施可能となる。また、作業手順の組替えによって発生した余剰品（仕掛品等）は、原料や製品等の在庫テーブル４と製造計画テーブル２と予め登録された製品のレシピ（配合表）等のマスタ情報テーブル３を参照し、転用可能な他製造計画へ余剰品を自動引当する。この引当変更情報も監視モニタ１０や現場オペレータが使用する現場携帯端末
１７や携帯端末１６等に表示されオペレータの確定操作により組替られた計画での作業が実施可能となる。 The storage contents of the work procedure definition table 6 converted in this way are displayed as recombination result information on the monitor 10, the on-site portable terminal 17 or the portable terminal 16 used by the on-site operator. From these display terminals, it is possible to input manufacturing results, register new manufacturing plans, or change them. The result displayed on these display terminals can be carried out in the reassignment plan by the operator confirmation operation. Further, surplus items (work in process etc.) generated by the rearrangement of work procedures are stored in a master information table 3 such as a stock table 4 of raw materials and products, a production plan table 2 and a recipe (composition table) of products registered in advance. Refer to and automatically reserve surplus products to other divertable production plans. This allocation change information is also displayed on the monitoring monitor 10 and the portable terminal 17 and portable terminal 16 used by the field operator, so that it is possible to carry out work in a plan that has been rearranged by the operator's confirmation operation.

また、作業手順組替処理部８で組替となった結果に合わせて工程制御管理処理部１１は、現場で製造されている製品の状況や現場の状況を現場センサ１５や計量器１８等の確認装置から送信されるデータを参照し、作業手順組替処理が使用する条件判定テーブル７を使用し現場機器制御装置１３に登録されている現場機器を動作させるロジックを登録した小工程制御１４の制御順番を変更する。   In addition, the process control management processing unit 11 adjusts the status of the product manufactured at the site and the status of the site according to the result of the rearrangement by the work procedure rearrangement processing unit 8 such as the site sensor 15 and the measuring instrument 18. With reference to the data transmitted from the confirmation device, the small process control 14 in which the logic for operating the field device registered in the field device control device 13 using the condition determination table 7 used in the work procedure reassignment process is registered. Change the control order.

作業手順が対象物の状態を判別するものを介し、手順を自動組替できるのでシステム管理者のマスタ登録負荷が低減されるだけでなく、作業手順の自動組替に合わせて製造管理システム側の制御ロジックの組合せまで変更可能であるため、今まで以上に扱いやすく無駄の無い管理が実現できる。   Since the procedure can be automatically reconfigured through what determines the state of the object, not only the master registration load of the system administrator is reduced, but also the manufacturing management system side in accordance with the automatic reconfiguration of the work procedure. Since it is possible to change the combination of control logics, it is easier to handle than ever before, and wasteless management can be realized.

また、基本的な制御手順を登録するテーブルと手順組替要因となる条件判定テーブルを分けて登録することにより、製造プロセスのノウハウ蓄積となる現場側状況による突発的な作業手順変更処理の登録が簡素化可能であり、作業員レベルを意識しない製造が可能となる。   In addition, by registering the basic control procedure registration table and the condition judgment table that causes the procedure reassignment separately, it is possible to register sudden work procedure change processing according to the situation on the site side, which is the accumulated know-how of the manufacturing process. Simplification is possible, and manufacturing without being aware of the worker level becomes possible.

また、製造工場にて現場側の状況を判別するセンサや計量器等の状況確認装置、製造する製品のレシピ（配合表）や各工程にて製造を行う為の製造作業手順等の製造マスタと各工程の製造作業実績情報や在庫情報や現場機器を動作させる為の制御ロジックを持たせるものである。   In addition, a manufacturing master such as a sensor for determining the situation on the site side in a manufacturing factory, a status confirmation device such as a measuring instrument, a recipe (mixing table) of a product to be manufactured, and a manufacturing work procedure for manufacturing in each process It provides control logic for operating manufacturing process performance information, inventory information, and field equipment in each process.

また、作業手順組換え要因となる現場側状況確認装置より自動入力される情報や手動入力された情報を取り込み、作業手順テーブルと条件判定テーブルを使用し、作業手順組換え処理で判別し、作業手順の組換えを実施する。また、組換えにより発生する余剰品（仕掛品等）は予め登録されている製造品のレシピや製造計画より使用可能な他製造計画の投入品として自動で引き当て可能とし、これらの結果を現場端末や携帯端末等に表示、作業者が最終確定するものである。   In addition, information automatically input from the on-site situation confirmation device that is the work procedure recombination factor or manually entered information is imported, and the work procedure recombination process is used to determine the work procedure recombination process. Perform recombination of procedures. In addition, surplus products (work-in-process items, etc.) generated by recombination can be automatically assigned as inputs for other manufacturing plans that can be used from pre-registered manufacturing product recipes and manufacturing plans, and these results are stored on-site. Displayed on a portable terminal or the like, and finalized by the operator.

また、現場状況から作業手順組換えとなった結果を参照可能な工程制御管理装置が制御全体を管理する現場機器制御装置内の小工程制御の処理順番を作業手順組替え結果に合わせて変更可能にするものである。   Also, the process control management device that can refer to the result of the work procedure recombination from the field situation can change the processing order of the small process control in the field device control device that manages the whole control according to the work procedure recombination result To do.

現場プロセス状況対応作業支援システムのシステム構成図。The system block diagram of an on-site process condition corresponding work support system. 作業手順定義テーブルの詳細図。Detailed view of work procedure definition table. 条件判定テーブルの詳細図。FIG. 5 is a detailed view of a condition determination table.

符号の説明Explanation of symbols

６…作業手順定義テーブル、７…条件判定テーブル、８…作業手順組替処理部、９…管理サーバ、１１…工程制御管理処理部、１５…センサ、１８…計量器。


6 ... Work procedure definition table, 7 ... Condition determination table, 8 ... Work procedure reassignment processing unit, 9 ... Management server, 11 ... Process control management processing unit, 15 ... Sensor, 18 ... Measuring instrument.


Claims (5)

時間の順を追ってなされる作業各工程において詳細工程が記憶される作業手順定義テー
ブルと、現場センサや計量器を含む確認装置から送信されるデータを判定するための条件と該条件に応じた処理が記憶されている条件判定テーブルと、を具備し、現場センサや計量器を含む確認装置から送信されるデータである製品状況や現場の状況により前記条件判定テーブルを参照して前記作業手順定義テーブルの記憶内容を変更する作業手順組替処理部と、該作業手順組替処理部で組替となった結果に合わせて現場機器を動作させるロジックを登録した小工程制御の制御順番を変更する工程制御管理処理部を有することを特徴とする現場プロセス状況対応作業支援システム。 Work procedure definition table in which detailed processes are stored in each process performed in chronological order, conditions for determining data transmitted from a confirmation device including on-site sensors and measuring instruments, and processing according to the conditions Is stored, and the work procedure definition table is referred to the condition determination table according to the product status or the site status, which is data transmitted from a confirmation device including a site sensor and a measuring instrument. Changing the control order of the small process control in which the work procedure reassigning processing unit for changing the stored contents of the device and the logic for operating the field device in accordance with the result of the reassignment by the work procedure reassigning processing unit are registered. An on-site process status work support system characterized by having a control management processing unit. 請求項１において、前記作業手順定義テーブルの記憶内容は、製造する製品の配合表あるいは各工程にて製造を行う為の製造作業手順等の製造マスタ情報、工程の製造実績、在庫データ情報あるいは、製造計画に基づいて定まることを特徴とする現場プロセス状況対応作業支援システム。 In claim 1, the storage content of the work procedure definition table includes a recipe for manufacturing products or manufacturing master information such as manufacturing work procedures for manufacturing in each process, manufacturing results of processes, inventory data information, or An on-site process status work support system characterized by being determined based on a manufacturing plan. 請求項２において、オペレータに対し作業手順を表示する現場端末あるいは携帯端末類
で構成された生産管理システムに前記作業手順を出力する現場プロセス状況対応作業支援
システム。 3. The work support system according to claim 2, wherein the work procedure is output to a production management system including a work terminal or mobile terminals for displaying the work procedure to an operator. 請求項１において、製造途中の工程で作業手順が変更となったことによる、前工程で製
造された仕掛品や事前準備していた投入品あるいは原料を他製造計画へ引当をおこなうこ
とを特徴とする現場プロセス状況対応作業支援システム。 In claim 1, the work procedure is changed in the process in the middle of manufacturing, and the work-in-process manufactured in the previous process and the input or raw material prepared in advance are allocated to another manufacturing plan. Work support system that supports on-site process status. 作業手順定義テーブルに時間の順を追ってなされる作業各工程において詳細工程を記憶
し、条件判定テーブルに現場センサや計量器を含む確認装置から送信されるデータを判定するための条件と該条件に応じた処理を記憶し、作業手順組替処理部により、現場センサや計量器を含む確認装置から送信されるデータである製品状況や現場の状況により前記条件判定テーブルを参照して前記作業手順定義テーブルの記憶内容を変更し、工程制御管理処理部により該作業手順組替処理部で組替となった結果に合わせて現場機器を動作させるロジックを登録した小工程制御の制御順番を変更することを特徴とする現場プロセス状況対応作業支援方法。 A detailed process is stored in each work process performed in the order of time in the work procedure definition table, and a condition for determining data transmitted from a confirmation device including a field sensor and a measuring instrument in the condition determination table and the condition. The work procedure is defined by referring to the condition determination table according to the product status or the site status, which is data transmitted from the confirmation device including the site sensor and the measuring instrument, by the task sequence reassigning processing unit. Change the stored contents of the table, and change the control order of the small process control in which the logic to operate the field equipment is registered according to the result of the reassignment by the work procedure reassignment processing part by the process control management processing part An on-site process status work support method characterized by
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