JP5836595B2 - Production system - Google Patents

Description

  The present invention relates to a plurality of production devices constituting a production line, a control device provided in each production device and provided with a display device capable of controlling each production device and displaying a production state, and communicates with each control device. The present invention relates to a production system equipped with a possible overall control device.

  For example, Patent Document 1 discloses a production system (production line) having a monitoring function. This production system is provided with a large display device of a size that can be easily seen from any position around the system. When the information from the sensors that detect the operating status of each production device (equipment) indicates an abnormality (trouble) in the production device, the production system displays the production device in which the abnormality occurred and the details of the abnormality on a large display device. indicate. If the abnormality is duplicated, the production apparatus in which the abnormality has occurred and the content of the abnormality are displayed on the large-sized display device in accordance with the preset work priorities for the abnormality recovery and inspection.

JP-A-61-178160 (second page, upper right view, line 15 to lower right column, line 2, FIG. 2)

  Since the conventional production system is configured with a single large display device, an operator may have visually recognized the production device in which an abnormality has occurred and headed for the production device, but mistakenly changed it to another production device. There is a risk of going. In particular, if there are duplicate abnormalities, there will be a delay in the recovery work for abnormalities with high work priorities, which may result in production loss and in some cases significant damage to production. In addition, depending on the work position or work state of the worker, the visual field may be blocked by a device on the production floor or some sort of shielding object, and it may be delayed to notice the occurrence of an abnormality.

  The present invention has been made in view of the above circumstances, and an object of the present invention is to provide a production system capable of quickly recognizing a production apparatus in which an abnormality has occurred and promptly starting a processing operation to cope with the abnormality. There is to do.

In order to solve the above-described problem, the structural feature of the invention according to claim 1 is that a plurality of production devices constituting a production line, and each production device is controlled by each production device and in a production state. In a production system comprising: a control device provided with a display device capable of displaying an image; and an overall control device capable of communicating with each of the control devices, the overall control device includes a plurality of the production devices from a plurality of the control devices. Information identifying means for acquiring information indicating a production state including a plurality of different abnormalities of the apparatus and identifying the content of the information; and information indicating the plurality of different abnormalities from the plurality of control devices by the information identifying means. when acquiring, based on the type of abnormality stored in advance, the production apparatus longest cycle to a plurality of different processing operations to address each of a plurality of said different abnormal is executed And priority determining means for determining the priority in consideration of whether running a bottleneck process or other process is a time, depending on the priority determined by the priority order determination means, a plurality of the Priority execution order determination means for determining the priority execution order of processing work, the processing work having the highest priority execution order among the priority execution orders determined by the priority execution order determination means, and the processing work are executed Priority processing information display means for displaying priority processing information indicating the production device to be displayed on each display device of the plurality of control devices, and dealing with an abnormality other than the abnormality with the highest priority execution order among the plurality of different abnormalities And misordered work prevention means for prohibiting the execution of the processing work.

A structural feature of the invention according to claim 2 is that in claim 1, the misordering work prevention means performs processing work for dealing with an abnormality other than an abnormality having the highest priority execution order among the plurality of different abnormalities. In response to execution, a warning is displayed on the display device .

  The structural feature of the invention according to claim 3 is that, in claim 1 or 2, each display device comprises a light emitting means provided in the production device so as to be recognizable from the outside and capable of emitting different colors. The control device includes a light emission control unit that emits light by changing a light emission color between the light emitting unit of the production apparatus on which the processing operation with the highest priority execution order is to be executed and the light emitting unit of the other production apparatus. That is.

According to the first aspect of the invention, the overall control device has a bottle having the longest cycle time for the production apparatus on which each processing operation is performed according to the priority execution order of the plurality of processing operations that respectively deal with a plurality of different abnormalities. Priority is determined in consideration of whether the neck process or other processes are being executed , and the priority indicating the processing work with the highest priority execution order among the priority execution orders, and the production apparatus on which the processing work is to be executed Processing information is reported to a plurality of control devices, and each control device displays it on its own display device. Therefore, for example, the worker can prioritize processing work to deal with an abnormality that occurred in the process with the longest cycle time, can prevent a reduction in production efficiency, and all the production devices in which an abnormality has occurred Can be accurately recognized in the production apparatus, and processing operations for dealing with abnormalities can be quickly started. And, it is prohibited to execute in the order different from the priority execution order. Therefore, there is no delay in recovery work for an abnormality having a high priority execution order, and production loss can be reduced.

According to the second aspect of the present invention, the control device executes the processing work for dealing with an abnormality other than the abnormality having the highest priority execution order among a plurality of different abnormalities. Also, a warning is displayed on the display device. Thus, the worker, Ru can be abnormal is abnormal or without beside of production equipment that occurred to recognize that it has occurred.

  According to the invention of claim 3, the control device changes the light emission color of the light emission means of the production apparatus to be processed with the highest priority execution order to the light emission color of the light emission means of another production apparatus. ing. Therefore, the worker can surely visually recognize the production apparatus that should start the processing work first, and can further reduce the production loss.

It is a schematic structure figure showing a production system by an embodiment of the invention. It is a functional block diagram which shows the outline of the control apparatus of the production system of FIG. It is a functional block diagram which shows the outline of the integrated control apparatus of the production system of FIG. It is a figure which shows the table data by which the some abnormality which generate | occur | produces in each production apparatus, the kind of each abnormality, the processing operation etc. which each address each abnormality were matched. It is a flowchart for demonstrating operation | movement of the display program at the time of managing the production state in each production apparatus of the production system of FIG. 2 is a flowchart for explaining the operation of a priority determination program when determining the priority of processing work in each production apparatus of the production system of FIG. 1. It is a flowchart for demonstrating operation | movement of the light emission program at the time of managing the production state in each production apparatus of the production system of FIG. It is a flowchart for demonstrating operation | movement of the work program at the time of managing the production state in each production apparatus of the production system of FIG. It is a figure which shows the list | wrist with which the process operation | work of priority execution order order and the production apparatus etc. in which this process operation is performed were matched.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings. As shown in FIG. 1, the production system 1 includes a plurality of production apparatuses 2 constituting a production line, a control apparatus 3 that is provided in each production apparatus 2 and controls each production apparatus 2, and each control apparatus 3. And an integrated control device 4 capable of communication. Each control device 3 is provided with a display device 5 capable of displaying the production state of the production device 2. Each display device 5 is provided with a light emitting device 6 (corresponding to the “light emitting means” of the present invention) capable of emitting different colors so as to be recognized from the outside.

  As shown in FIG. 2, each control device 3 is mainly composed of a computer 30 having a CPU 31, a ROM 32, a RAM 33, an input / output interface (IF) 34 a, a communication IF 34 b, and a bus 35 for connecting them. The drive means 21 of the production apparatus 2 is connected to the input / output IF 34 a via the drive control means 36, the display device 5 is connected via the display control means 37, and the light emitting device 6 is connected via the light emission control means 38. Has been. A transmission / reception control means 39 for communicating with the overall control device 4 is connected to the communication IF 34b. In the ROM 32, for example, a light emission program (see FIG. 7) described later, a work program (see FIG. 8), and the like are stored.

  As shown in FIG. 3, the overall control device 4 is mainly composed of a computer 41 having a CPU 41, a ROM 42, a RAM 43, a communication IF 44, and a bus 45 for connecting them. The communication IF 44 is connected to transmission / reception control means 46 for transmitting control data and the like to each control device 3 and receiving production status information and the like from each control device 3.

  In the ROM 42, a system program for controlling the entire production system 1 and a management program for managing the production state in each production apparatus 2, such as a display program (see FIG. 5) described later, a priority determination program (see FIG. 6), etc. Is remembered. In the RAM 43, for example, as shown in FIG. 4, a plurality of abnormalities occurring in each production apparatus 2, and whether each abnormality is a dangerous abnormality or an abnormality that lowers productivity, other than these Table data D or the like in which an abnormality type indicating whether there is an abnormality and a plurality of processing operations for dealing with each abnormality are stored in advance. For example, “SA1”, “SA2”... As the abnormality of the production apparatus 2 of “MA”, “hazardous”, “decrease in productivity”... ”,“ JA2 ”...,“ SB1 ”,“ SB2 ”... As abnormalities of the production device 2 of“ MB ”,“ Productivity reduction ”,“ Dangerous ”as abnormal types. .., “JB1”, “JB2”,... Are associated as processing operations for dealing with abnormalities. Here, “with danger” is, for example, a case where the movable body may move excessively and collide with the apparatus main body or the like.

  The operation at the time of managing the production state in each production apparatus 2 of the production system 1 having the above-described configuration will be described with reference to the table data D shown in FIG. 4 and the flowcharts shown in FIGS. As shown in the display program in FIG. 5, the overall control device 4 acquires information indicating the production status of the plurality of production devices 2 from the plurality of control devices 3, and the contents of each production status information, for example, an abnormality has occurred. The name and process of the production apparatus 2 and the contents of the abnormality that occurs or is resolved are identified (steps 1 and 2, corresponding to the “information identification means” of the present invention). Then, it is determined whether each production state information includes an abnormality or abnormality cancellation (step 3). If each production state information includes an abnormality, the abnormality is registered in the abnormality list (step 4). ).

  The overall control device 4 determines the priority order of the processing work for dealing with the registered abnormality (step 5). That is, as shown in the priority order determination program of FIG. 6, the overall control device 4 acquires a process that becomes a bottleneck among the production processes in each production apparatus 2 (step 31). As a calculation method of this bottleneck process, there are a method of calculating from an actual cycle time and a method of calculating from a theoretical cycle time.

First, a calculation method from an actual cycle time will be described. Since the cycle time is generally considered to follow the normal distribution N, the production apparatus 2 uses a newly averaged value excluding the cycle time exceeding μ ± 3σ (where μ: average cycle time, σ ² : variance). Cycle time. The production process of the production apparatus 2 with the longest averaged cycle time is defined as a bottleneck process.

  According to this calculation method, the bottleneck process does not change sequentially due to the redundancy of the cycle time due to temporary downtime, and the true bottleneck process that must be focused on can be determined. Cycle time redundancy due to temporary downtime can be recovered during production if it is an event other than a bottleneck process.

  Next, a calculation method from the theoretical cycle time will be described. Of the theoretical cycle times of the production process of each production apparatus 2 calculated by the cycle time simulator, the production process of the production apparatus 2 having the longest theoretical cycle time is defined as a bottleneck process. In the present embodiment, one of a calculation method from an actual cycle time and a calculation method from a theoretical cycle time is used.

  The overall control device 4 acquires the operating rate of the production process in each production device 2 (step 32). This operation rate decreases when the frequency of failure of the production apparatus 2 is high and it takes time to repair or restore the production apparatus 2. The overall control device 4 acquires the abnormality information registered in the abnormality list (step 33), and determines whether or not the acquired abnormality is dangerous with reference to the table data D (step 34).

  When the overall control device 4 determines that the acquired abnormality is dangerous, the overall control device 4 determines the priority of the abnormality as “1” (step 35). On the other hand, when it is determined in step 34 that the acquired abnormality is not dangerous, it is determined with reference to the table data D whether or not the acquired abnormality decreases productivity (step 36). . When it is determined that the acquired abnormality is a decrease in productivity, it is determined whether or not the acquired abnormality is in the bottleneck process (step 37). When it is determined that the acquired abnormality is in the bottleneck process, the priority of the abnormality is determined as “2” (step 38).

  On the other hand, if the overall control device 4 determines in step 37 that the acquired abnormality is not in the bottleneck process, it determines whether or not the acquired abnormality is in the low operation rate process (step 39). ). When it is determined that the acquired abnormality is in a process with a low operation rate, the priority of the abnormality is determined as “3” (step 40), and the acquired abnormality is not in a process with a low operation rate. Is determined as “4” (step 41).

  On the other hand, if the overall control device 4 determines in step 36 that the acquired abnormality does not reduce productivity, it determines whether or not the acquired abnormality is in the bottleneck process (step 42). . When it is determined that the acquired abnormality is in the bottleneck process, the priority of the abnormality is determined as “5” (step 43).

  On the other hand, when it is determined in step 42 that the acquired abnormality is not in the bottleneck process, it is determined whether or not the acquired abnormality is in a low operation rate process (step 44). When it is determined that the acquired abnormality is in a process with a low operation rate, the priority of the abnormality is determined as “6” (step 45), and the acquired abnormality is not in a process with a low operation rate. Is determined as “7” (step 46). The above-described steps 31 to 46 correspond to the “priority determination means” of the present invention.

  The overall control device 4 determines whether or not there is a processing operation currently being executed (step 6). If it is determined that there is a processing operation currently being executed, the priority execution order of the processing operations currently being executed is given the highest priority. With the execution order “1”, the priority execution order after “2” of the processing work to deal with the abnormality registered in the list in step 4 is determined according to the determined priority order (step 7, “ Equivalent to “priority execution order determination means”). On the other hand, if it is determined in step 6 that there is no processing work currently being executed, the priority execution order of the processing work for dealing with the abnormality registered in the list is determined according to the determined priority order (step 8, This corresponds to “priority execution order determination means” of the invention). If processing operations with the same priority are duplicated, the priority execution order is determined in the order from the upstream side of the production line or the first-come-first-served basis.

  The overall control device 4 creates a processing work in the determined priority execution order and a list of the production devices 2 on which the processing work is performed (step 9). For example, as shown in FIG. 9, the processing operation “JB2” as the priority execution order “1” and the production apparatus 2 “MB” in which the processing operation “JB2” is executed, and the processing operation “JA3” as the priority execution order “2”. ”And the production apparatus 2“ MA ”on which the processing operation“ JA3 ”is executed are associated with each other.

  The control device 3 displays the content of the processing work with the highest priority execution order in the created list R and the production device 2 on which the processing work is executed on the display device 5 (step 10, “priority processing information” of the present invention). Equivalent to “display means”). The display device 5 may display the priority execution order, for example, the contents of the processing work from “1” to “3” and the production apparatus 2 on which the processing work is executed. The worker can grasp in advance the contents of the next processing work and the contents of the next processing work.

  When the processing operation of the highest priority execution order is completed, the control device 3 of the production apparatus 2 reports the fact to the overall control device 4, and when the overall control device 4 receives the report (step 11), the highest priority execution order is obtained. The abnormality corresponding to the processing work is deleted from the abnormality list (step 12). Then, the presence / absence of remaining abnormalities in the abnormality list is determined (step 13). If there are remaining abnormalities in the abnormal list, the process returns to step 9 to newly execute the priority execution order processing work and the processing work. A list of production apparatuses 2 to be executed is created, and the processes after step 10 are executed. On the other hand, if there is no remaining abnormality in the abnormality list in step 13, the process returns to step 1 and the above-described processing is executed.

  In step 9, the light emission program in FIG. 7 is interrupted. That is, the control device 3 determines whether or not the processing work executed in its own production device 2 has the highest priority execution order (step 21), and the processing work executed in its own production device 2 is performed. If it is the highest priority execution order, the light emitting device 6 of its own emits light in a predetermined color, for example, red (step 22). On the other hand, when the processing work executed in the production apparatus 2 is not the highest priority execution order, the light emitting device 6 is assigned a color other than the predetermined color according to the priority execution order, for example, the priority execution order is “2”. The light emitting device 6 of the production apparatus 2 on which the processing operation “” is executed emits light in yellow, and the light emitting device 6 of the production apparatus 2 on which the processing operation of the priority execution order “3” is executed emits light in purple (step 23). Steps 21 to 23 described above correspond to the “light emission control means” of the present invention.

  In step 11, the work program shown in FIG. 8 is interrupted. That is, when the processing work is started (step 25), the control device 3 determines whether or not the processing work with the highest priority execution order is executed (step 26), and the processing work with the highest priority execution order is executed. If it is determined that the processing has been performed, the processing operation is continued.

  On the other hand, if the control device 3 determines that the processing operation of the highest priority execution order is not executed, it displays a warning to that effect on its display device 5 (step 28). Then, control is performed so that processing work that is not processing work of the highest priority execution order cannot be executed, prohibiting execution of the processing work (step 29), and the processing is terminated. Note that at least one of displaying a warning on the display device 5 and prohibiting the execution may be performed. Further, the warning may be accompanied by sound as well as display. Steps 28 to 29 described above correspond to the “misordered work prevention means” of the present invention.

  As described above, according to the production system 1 of the present embodiment, the overall control device 4 determines the priority execution order of a plurality of processing operations for dealing with a plurality of different abnormalities according to the priority order for each processing operation. Determining and reporting priority processing information indicating the processing work with the highest priority execution order among the priority execution orders and the production apparatus 2 on which the processing work is to be executed to the plurality of control apparatuses 3, and each control apparatus 3 itself Are displayed on the display device 5. Therefore, the operator can accurately recognize the production apparatus 2 in which the abnormality has occurred in all the production apparatuses 2, and can quickly start the processing work to cope with the abnormality.

  In addition, the control device 3 warns the display device 5 in any of the plurality of production apparatuses 2 for executing a processing operation for dealing with an abnormality other than the abnormality having the highest priority in the plurality of different abnormalities. Is displayed. Therefore, the worker can recognize that an abnormality has occurred even if he / she is not near the production apparatus 2 where the abnormality has occurred. In addition, it is prohibited to execute in a different order from the priority execution order. Therefore, there is no delay in recovery work for an abnormality having a high priority execution order, and production loss can be reduced.

  In addition, the control device 3 changes the light emission color of the light emitting device 6 of the production device 2 to be executed with the processing operation having the highest priority execution order to the light emission color of the light emitting device 6 of another production device 2. Therefore, the worker can surely visually recognize the production apparatus 2 that should start the processing work first, and can further reduce the production loss. In addition, the overall control device 4 determines the priority order in consideration of whether the production device 2 on which the processing operation is to be performed is executing a bottleneck process or other processes. Therefore, for example, the worker can preferentially perform the processing work for dealing with an abnormality occurring in the process having the longest cycle time, and can prevent a reduction in production efficiency.

  In the above-described embodiment, the processing work for dealing with the abnormality has been described. However, work order for parts replenishment and maintenance instruction can be instructed in the same priority order. That is, the abnormality that occurs in the production apparatus 2 includes a part-out notice (parts replenishment guide) indicating that the part-out time is approaching, and a maintenance instruction that notifies the maintenance time of the production apparatus 2 and the tool.

  DESCRIPTION OF SYMBOLS 1 ... Production system, 2 ... Production apparatus, 3 ... Control apparatus, 4 ... Overall control apparatus, 5 ... Display apparatus, 6 ... Light-emitting device (light emission means).

Claims (3)

A plurality of production devices constituting a production line, a control device provided in each of the production devices, each having a display device capable of controlling each production device and displaying the production state, and capable of communicating with each control device In a production system equipped with a general control device,
The overall control device is:
Information identifying means for acquiring information indicating a production state including a plurality of different abnormalities of the plurality of production apparatuses from the plurality of control apparatuses and identifying the content of the information;
When the information identifying means acquires information indicating the plurality of different abnormalities from the plurality of control devices, a plurality of different ones respectively dealing with the plurality of different abnormalities based on the type of abnormality stored in advance Priority order determining means for determining the priority order in consideration of whether the production apparatus to be processed is executing a bottleneck process or other process having the longest cycle time ;
Priority execution order determination means for determining a priority execution order of the plurality of processing operations according to the priority order determined by the priority order determination means;
Among the priority execution orders determined by the priority execution order determination means, the processing work having the highest priority execution order, and priority processing information indicating the production apparatus on which the processing work is to be executed are stored in a plurality of control devices. Priority processing information display means for displaying on each display device;
An out-of-order work prevention means for prohibiting the execution of processing work for dealing with an abnormality other than the abnormality having the highest priority execution order among the plurality of different abnormalities;
A production system characterized by comprising: In claim 1,
The out-of-order work prevention means displays a warning on the display device for executing a processing work for dealing with an abnormality other than an abnormality having the highest priority execution order among the plurality of different abnormalities. Production system. In claim 1 or 2,
Each of the display devices includes a light emitting means that is provided in the production device so as to be recognized from the outside and capable of emitting different colors.
The control device includes: a light emission control unit that emits light by changing a light emission color between the light emitting unit of the production apparatus on which the processing operation with the highest priority execution order is to be executed and the light emitting unit of the other production apparatus. Production system characterized by having.

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