JP5146648B2 - production management system - Google Patents

Description

  The present invention relates to a production management system, and more particularly to a production management system that records an operator's position as an action history together with the detected time, and records information about the state of the facility as an equipment history along with the time.

2. Description of the Related Art Conventionally, there is known an equipment management system that records information on the state of equipment such as abnormality or event occurring in equipment as equipment history along with time, and uses this equipment history for equipment management (Patent Document 1).
There is also known a work management system for managing the behavior of a worker by causing the worker to carry the position specifying device and detecting the position of the worker from the position of the position specifying device (Patent Document 2). .
Among these, in Patent Document 2, the position of the worker is recorded as a position history together with the time, and from the position history and the equipment history relating to the state of the equipment, the flow line of the movement of the worker on the equipment layout diagram, The incidental information about the event or the like generated in each facility is displayed, and the facility is also managed (see FIG. 17 of Patent Document 2).
JP 2005-11185 A JP 2003-140728 A

However, in the case of Patent Document 2, although the flow line of the worker is shown on the layout drawing of the facility, there is a problem that it is difficult to recognize the causal relationship between the position of the worker and the state of the facility at that time. is there.
For example, when an abnormality occurs in a certain facility, it is possible to confirm where the worker is and the state of the other facilities at that time. It was necessary to identify the position of each worker and to check the state of each facility when an abnormality occurred by browsing the incidental information of each facility.
In view of such problems, the present invention provides a production management system capable of intuitively recognizing the causal relationship between the position of an operator and the state of equipment at a predetermined time.

That is, the production management system according to the present invention includes a layout map storage unit that stores a layout map of equipment, a position detection unit that detects a position on the layout map of an operator who has a position specifying device, and a state of the equipment a facility state detecting means for detecting, equipment and records as action history together with the time position of the detected operator by the position detection means, together with the time information about the state of the equipment detected by the facility state detecting means In a production management system having an operation history management means for recording as a history,
When an input unit for inputting a predetermined time, a display unit for displaying a layout of the equipment stored in the layout map storage means, and a predetermined time are input via the input unit, the operation history An image that displays the position of the worker at the predetermined time and the state of the equipment at the same time on the equipment layout diagram displayed on the display unit from the action history and equipment history recorded in the management means And a display means.

  According to the above invention, the position of the worker and the state of the equipment at a predetermined time input via the input unit are displayed on the facility layout displayed on the display unit. It becomes possible to intuitively recognize the causal relationship between the position of the worker and the state of the equipment at a predetermined time.

Hereinafter, the illustrated embodiment will be described. FIG. 1 shows a container processing line 1 for filling a container such as a plastic bottle with a beverage. The container processing line 1 is installed in a factory 2 and managed by a production management system 3. It is like that.
In the factory 2, in addition to the container processing line 1, a production management room 4 for managing the container processing line 1, a warehouse 5 for storing equipment, and a cold storage room for storing beverages to be filled. 6 is installed.
The container processing line 1 is composed of a plurality of facilities 7a to 7f. From the upstream side, a depalletizer 7a for taking out an empty bottle from a case, a washing machine 7b for washing an empty bottle, a filling machine 7c for filling a bottle with a beverage, a bottle A cap 7d for attaching a cap to the bottle, a labeler 7e for attaching a label to the bottle, and a caser 7f for storing a bottle filled with a beverage in a case.
And in order to operate the said container processing line 1, work, such as a mold change, adjustment, repair, etc. by an operator is required with respect to each said equipment 7a-7f, and an operator goes around regularly and visually. The facilities 7a to 7f are inspected.
The configuration of the container processing line 1 is conventionally known and will not be described in detail.

The production management system 3 can be a conventionally known personal computer PC provided with an input unit 8 such as a keyboard and a mouse and a display unit 9 such as a monitor. It is installed in the room 4.
As shown in FIG. 2, the production management system 3 includes an arrangement map storage unit 11 for storing arrangement drawings of the facilities 7 a to 7 f, a position specifying device 12 possessed by an operator, and each position specifying device 12. The position detection means 13 for detecting the position of the worker based on the information of the above, the equipment state detection means 14 for detecting the information on the state of the equipment 7a to 7f, the position of the worker and the state of the equipment 7a to 7f. The operation history management unit 15 records information together with the time, and the image display unit 16 displays a required image on the display unit 9 according to the operation of the input unit 8.

The layout map storage means 11 stores a layout map of the factory 2 and the container processing line 1 as shown in FIG. 3, and a required coordinate system is set in the layout map. And each equipment 7a-7f and a worker's position are recognized as a coordinate value of this coordinate system.
Further, in the layout map storage means 11, for each of the facilities 7a to 7f, a warning generation area 21 where a predetermined warning is generated when an operator enters the surrounding area, and when the worker enters, the facilities 7a to 7f are predetermined. And an entry restriction area 22 for performing a safe driving operation.

The position specifying device 12 is possessed by all workers who work in the factory 2, and is mounted on the waist of the worker, for example.
The position specifying device 12 includes an acceleration sensor that detects a moving speed or a moving distance of the worker, and a magnetic sensor or a gyro sensor that detects a direction in which the worker is facing.
The position specifying device 12 collects position information on the position of the worker in the factory 2 and the movement speed and direction of the worker by the acceleration sensor and the magnetic sensor, and transmits the position information wirelessly at predetermined time intervals. It is supposed to be.

The position detecting means 13 includes at least one antenna 13a, and the antenna 13a receives position information transmitted from the position specifying device 12. In this embodiment, the antenna 13a is provided at three locations in the factory 2 as shown in FIG.
When receiving the position information from the position specifying device 12, the position detecting means 13 recognizes the position of the position specifying device 12 as the position of the worker as the coordinate value of the coordinate system registered in the layout drawing storing means 11.
In addition, unique identification information is given to the position information transmitted by the position specifying device 12 possessed by each worker, so that even if a plurality of workers are working in the factory 2, each work The position can be detected for each person.
Further, an alarm generating means 13b is connected to the position detecting means 13, and the position of the worker detected by the position detecting means 13 is a warning generating area of each equipment 7a to 7f stored in the layout drawing storing means 11. When it is determined that the vehicle 21 or the entry restriction area 22 has been entered, the alarm generation unit 13b transmits a message to that effect to the following control units 17a to 17f of the corresponding facilities 7a to 7f.
As a method for detecting the position of the worker by the position detecting means 13, the radio waves transmitted from the position specifying device 12 are received by a plurality of antennas 13a arranged in the factory 2, and the position specifying device is determined from the difference in arrival time of the radio waves. Methods for detecting 12 locations are also known, and other location specific methods can be used.

The equipment state detection means 14 is connected to control means 17a to 17f provided in the equipments 7a to 7f so as to be communicable by wire or wirelessly, and collects information on necessary equipment from the control means 17a to 17f. ing.
The control means 17a to 17f are provided with an operation panel having a touch panel (not shown), etc., and can control various facilities 7a to 7f and can perform various settings by the operation panel.
Moreover, each control means 17a-17f has a memory | storage part which stores the information which shows the state of each equipment 7a-7f, and the information recorded on this memory | storage part is rewritten with the state change of an installation.
As such information, for example, operations performed on the control means 17a to 17f via the operation panel, the number of containers processed by the facilities 7a to 7f detected by sensors (not shown), and the facilities 7a to 7f There is information about equipment status such as anomalies that have occurred.
Specifically, for example, in the filling machine 7c, in addition to trend information regarding the number of containers that have been filled and the temperature of the filling liquid, alarm information about warnings such as poor filling and abnormal liquid temperature, and the operator There is event information indicating that 7c is started or stopped, or that the setting is changed using the operation panel.
Further, when the operator the warning generation area 21 and entry restriction region 22 set to the filling machine 7c enters, the alarm generating means 13b is adapted to transmit that fact to the control unit 17c, the control unit 17c Then, there is event information indicating that a predetermined warning is issued or the filling machine 7c performs a predetermined safe driving operation, and further such a warning or a safe driving operation is performed.
And the equipment state detection means 14 always monitors the memory | storage part of the control means 17a-17f, and collects the information regarding the equipment state of each equipment 7a-7f from the control means 17a-17f.
For example, the equipment state detection means 14 collects trend information such as the number of treated containers and the temperature of the filling liquid at predetermined time intervals, and collects the alarm information and event information as soon as such information is generated. It has become.

The operation history management means 15 sequentially records the position information on the worker's position detected by the position detection means 13 and the movement speed and direction of the worker as the action history together with the detected time. Information on the state of each facility 7a-7f collected by the state detection means 14 is sequentially recorded as facility history together with the time when the information was collected.
The image display means 16 is connected to the layout map storage means 11 and the operation history management means 15, and the layout diagram of the factory 2 and the container processing line 1 recorded in the layout map storage means 11 as shown in FIG. Can be displayed on the display unit 9, and the operation history of the container processing line 1 can be managed by displaying the state of the facilities 7a to 7f and the position of the operator on the layout drawing. .

More specifically, the image display means 16 first displays a menu screen as shown in FIG.
On this menu screen, an operator input field 23a, a start date / time input field 23b, and an end date / time input field 23c are displayed, and the operator uses the input unit 8 to enter these input fields 23a to 23c as appropriate. Make input.
In this embodiment, as an example, all workers are selected, the start date and time is “13:10:00”, and the end date and time is “13:15:00”. In the operator input field 23, not only all workers who have been working in the factory 2 but also only specific workers can be selected.
When the input is completed in the input fields 23a to 23c as described above, the worker selects either “simulation” or “trajectory display” on the right side of the figure.

When “Simulation” is selected, the image display means 16 displays an image as shown in FIG. 3 on the display unit 9, and this image includes a layout diagram of the facilities 7 a to 7 f and a position below the layout diagram. And the equipment history to be displayed.
A status frame 24 is displayed on the upper left of the layout diagram, and the display date and time are displayed in addition to the worker, start date and time, and end date and time entered on the previous menu screen. Here, for the sake of explanation, the display date and time is “13:12:22”, but the display date and time of the screen that is actually displayed first on the display unit 9 is the input start date and time “13:10:00. "
Also, below the status frame 24, buttons 25 for performing operations of “turn back”, “play”, “pause”, and “fast forward” are displayed.
The positions of the status frame 24 and the buttons 25 can be appropriately moved to positions that do not interfere with the layout drawing.

On the other hand, when a predetermined item is entered in the input fields 23a to 23c and “simulation” is selected, the image display means 16 determines from the action history and equipment history recorded in the operation history management means 15 that “13:10: The information on the position information of the worker and the state of the equipment in “00” to “13:15:00” is collected.
Then, the image display means 16 displays the equipment history at the bottom of the layout drawing, and the equipment history includes the start date and time “13:10:00” to the display date and time “13:12:22”. In addition, the states of the respective facilities 7a to 7f collected by the facility state detecting means 14 from the respective control means 17a to 17f are displayed.
Here, the state of each equipment 7a-7f displayed on this equipment history can be displayed by narrowing down the kind, and here, all "alarm information" regarding "all equipment" is displayed. It is like that.
As the “alarm information”, the “equipment name” where the error occurred, the “occurrence date and time” when the error occurred, the “recovery date and time” recovered from the abnormal state, and the “alarm name” indicating the content of the error are displayed on the screen. If it cannot be displayed, it can be scrolled as appropriate.
Here, the “occurrence date” of the “alarm information” is the time when the equipment state detection means 14 collects the alarm information from the control means of the equipment where the abnormality occurred, and the “recovery date” is the time when the operator This is the time when the equipment state detection means 14 has collected event information indicating that the operation is performed normally on the touch panel or the like in a state where normal operation is possible.

The image display means 16 displays the layout of the factory 2 recorded in the layout map storage means 11 on this image. In addition to the container processing line 1 installed in the factory 2, the image display means 16 A management room 4, a warehouse 5, a cold room 6 and the like are also displayed, and a layout diagram is displayed in the same layout as the actual factory 2.
Each facility 7a-7f has a warning generation area 21 and an entry restriction region 22 displayed thereon, and a state display unit 26 for displaying numerical values and the like is provided at a position adjacent to each facility 7a-7f. .
The state display unit 26 displays the state of each facility 7a-7f at the display date and time, and here, the number of containers processed in each facility 7a-7f is displayed.
Specifically, the image display means 16 extracts trend information regarding the number of processing of each equipment 7a to 7f at "13:12:22" from the equipment history stored by the operation history management means 15, and displays a status display section. 26 is displayed.
In addition to this, for example, the remaining amount or temperature of the beverage in the tank in the filling machine 7c can be displayed on the state display unit 26, and a plurality of items can be displayed.
The facilities 7a to 7f are each surrounded by a frame 27, and are displayed in different colors according to the state of the facilities. Specifically, the inside of the frame 27 is displayed in green (colorless in FIGS. 3 and 5) when the facilities 7a to 7f are operating normally, and yellow (hatched in FIGS. 3 and 5) in the standby state. When the stop button of the equipment 7a to 7f is pushed or stopped due to an abnormality, it is displayed in red (colored in FIGS. 3 and 5).
The colors of the frames 27 also display the states of the facilities 7a to 7f at “13:12:22” which is the display date and time.

Further, the image display means 16 extracts the position information of each worker at “13:12:22” which is the display date and time from the action history recorded in the operation history management means 15 and is recorded in the position information. All workers are displayed on the layout drawing as icons 28a and 28b based on the coordinate values.
Since the position information is provided with identification information for each worker, the image display means 16 displays the name of the worker on each of the icons 28a and 28b indicating the worker. Yes.
Further, since the position information includes the orientation of the worker, the image display means 16 displays the orientation of the worker on the icons 28a and 28b indicating the worker by arrows. Yes.
Furthermore, when the image display means 16 searches the action history for a predetermined time from the display date and determines that the worker has not moved for a predetermined time, the color of the icons 28a and 28b indicating the worker changes from green to red. To change.

In this way, when the image display means 16 indicates the state of each facility 7a to 7f at the start date and time and the position of each worker by the icons 28a and 28b on the layout drawing, the operator designates the “playback” button 25. To do.
Then, the image display means 16 displays the state of each equipment 7a-7f from the equipment history of each equipment 7a-7f collected by the operation history management means 15 while changing the state of each equipment sequentially in time series, and the behavior of the operator. From the history, the position of each worker is displayed while being sequentially moved in time series.

Specifically, in FIG. 5, when 8 seconds have elapsed from “13:12:22” in FIG. 3, the “pause” button 25 is operated, and the display time becomes “13:12:30”. The time screen is shown.
Here, in the equipment history in FIG. 3, alarms such as “abnormal air pressure” and “reject error” occur in the filling machine 7c and the capper 7d at the time of “13:12:21”. The frame 27 surrounding the capper 7d was displayed in red. Moreover, the washing machine 7b is in a standby state for stopping the filling machine 7c on the downstream side, and the frame 27 is displayed in yellow.
Further, at time “13:12:21” in FIG. 3, the worker A (icon 28a) faces the filling machine 7c in the vicinity of the filling machine 7c, and the worker B (icon 28b) has a caser 7f in the vicinity of the caser 7f. I was facing.

At the time “13:12:30” in FIG. 5, in the equipment history, the filling machine 7 c recovers from the abnormal state to “13:12:26”, and in the layout diagram, the frame 27 of the filling machine 7 c is It is displayed in yellow indicating the standby state.
Specifically, the image display means 16 extracts from the equipment history collected by the equipment history management means 15 that event information indicating that the filling machine 7c has been restored is recorded at “13:12:26”. This information is displayed as the recovery date and time in the alarm information, and the frame 27 is changed from red to yellow.
In addition, the operation is continued in the labeler 7e and the caser 7f that are located downstream of the capper 7d from FIG. 3 to FIG. 5, and the number of processes displayed on the status display unit 26 is the labeler 7e. It can be seen that from “6242” to “10065”, the caser 7 f changes from “3132” to “5055”.
On the other hand, since the capper 7d is in an abnormally stopped state, there is no change in the number of processing in the status display section 26 of the capper 7d, and even if normal operation is possible, the filling machine 7c and the washing machine located upstream of the capper 7d. It can be seen that there is no change in the number of processing lines 7b.

Then, the worker A (icon 28a) has moved to a position close to the vicinity of the capper 7d in FIG. Thereby, it can be seen that the worker A is moving from the filling machine 7c to the vicinity of the capper 7d between FIGS.
Also, since the filling machine 7c is recovered from the abnormal state between FIGS. 3 to 5, the worker A who was in the vicinity of the filling machine 7c at the time of “13:12:26” restored the filling machine 7c. It can be determined that the work has been performed.
On the other hand, the worker B (icon 28b) has not moved from the state of FIG. 3 in FIG. 5, and the image display means 16 has changed the icon 28b from green to red, assuming that the worker B has not moved for a predetermined time. It is designed to change to display.

Thus, according to the production management system 3 of the present embodiment, the state of each facility 7a-7f and the position of the operator can be continuously confirmed within the input time range, and the facility 7a-7f. The causal relationship between the state and the worker's position can be intuitively recognized.
In addition, when the equipment history shown in FIG. 3 is displayed, when the occurrence time or recovery time of the required alarm information is selected, the image display means 16 displays the state of the equipment 7a to 7f and the operator at the selected time. Can be displayed on the layout diagram, and the state of the factory 2 at the time of alarm occurrence or recovery can be confirmed.
Further, in the menu screen of FIG. 4, the required date and time is input only at the start time, and the date and time is not input at the end time, thereby confirming the state of the equipment 7a to 7f and the position of the operator at the time input at the start time. can do.
For example, the following can be considered as an example of using such a production management system 3. That is, when an operator circulates the facilities 7a to 7f of the container processing line 1 every hour and the worker performs an operation of filling in a handwritten check sheet, the time actually entered in the check sheet It is possible to confirm whether or not the entry work has been performed.
In addition, when a part of the equipment 7a-7f of the container processing line 1 fails, it is possible to specify which worker was near the failure location when the equipment 7a-7f failed, or before the failure. It is also possible to estimate which worker has performed some work on the equipment 7a to 7f.

When the start date and time and the end date and time are entered in the menu of FIG. 4 and “trajectory display” is selected, the image display means 16 displays the status of all equipment 7a to 7f generated during the inputted period as equipment history. In addition, the trajectory through which each worker has passed is displayed in the layout diagram. This is a screen as shown in FIG. 17 for example in the patent document 2.
According to this screen, it is possible to confirm what route the worker has moved through the factory 2, and this can be used to improve the proper arrangement of the worker. In addition, the production manager can use and analyze the simulation image and the trajectory display image separately for efficient management of the factory.

The layout of the factory in which the container processing line concerning a present Example was installed. The block diagram of a production management system. The figure which displayed the state of an installation and the position of an operator on the layout displayed on the display part. The figure which showed the menu screen. FIG. 4 is a layout after a predetermined time has elapsed from the layout shown in FIG. 3.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Container processing line 2 Factory 3 Production management system 7a-7f Equipment 8 Input part 9 Display part 11 Arrangement drawing storage means 12 Position specification apparatus 13 Position detection means 14 Equipment state detection means 15 Operation history management means 16 Image display means

Claims (3)

A layout map storage means for storing a layout map of equipment, a position detection means for detecting a position on the layout map of an operator having a position specifying device, a facility status detection means for detecting a status of the equipment, and the position and records as action history together with the time position of the detected operator by the detecting means, and a operation history management means for recording as equipment history together with the time information about the state of the detected equipment by the equipment state detecting means Production management system
When an input unit for inputting a predetermined time, a display unit for displaying a layout of the equipment stored in the layout map storage means, and a predetermined time are input via the input unit, the operation history An image that displays the position of the worker at the predetermined time and the state of the equipment at the same time on the equipment layout diagram displayed on the display unit from the action history and equipment history recorded in the management means A production management system comprising display means.   When a predetermined start time and a predetermined end time are input via the input unit, the image display means, on the layout diagram of the facility, the position of the operator and the location of the facility from the start time to the end time. 2. The production management system according to claim 1, wherein a change in state is continuously displayed in time series.   The image display means displays the worker's display different from the display when the worker is moving when the position of the worker does not change for a predetermined time in the action history. The production management system according to claim 1 or 2.

Images