JP6625286B1 - Management index calculation system and management index calculation method - Google Patents

Abstract

The management index calculation system (1) includes a plurality of production facilities (310 to 330) each including a device and a control device for controlling the devices, and a production facility (310 to 330) from each of the plurality of production facilities (310 to 330). , Collecting equipment data generated in a first data format unified among a plurality of production facilities (310 to 330), and collecting a second data unified among a plurality of production facilities (310 to 330). The equipment data collected from the plurality of production facilities (310 to 330) is converted into the management data of the plurality of production facilities (310 to 330) by the common processing logic so that the data format becomes the data format. A general controller (20) for converting the data into element data used for calculating the data, and storing the element data in the second data format in the data storage area It comprises a database (10) for calculating a management index in calculation logic for each management indicator using element data in the data storage area, a.

Description

  The present invention relates to a management index calculation system and a management index calculation method for calculating a management index.

  There is a system that collects various data from automated production equipment and calculates a management index of the production equipment using the collected data. In the service information providing system described in Patent Document 1, a data collection device arranged for each production facility collects data from the production facility based on a definition file in which a data collection method is defined, and performs production from the collected data. Event data indicating a state change of equipment is generated and supplied to the remote center device, and the remote center device performs analysis processing and the like. The service information providing system described in Patent Literature 1 uses the same number of setting items to be collected from production equipment by each data collection device, thereby changing the format of a data packet output from each data collection device to the remote center device. We are united.

JP-A-2006-065746

  However, in the technique of Patent Document 1, when the type or format of data accumulated by the monitoring and control system that monitors and controls water and sewage facilities is different, a separate definition file is set for each data collection device, and It was necessary to set a conversion process for generating event data from collected data for each monitoring control system. For this reason, the technique of Patent Document 1 cannot easily calculate a management index for a plurality of production facilities.

  The present invention has been made in view of the above, and an object of the present invention is to provide a management index calculation system capable of easily calculating a management index for a plurality of production facilities.

In order to solve the above-described problems and achieve the object, a management index calculation system of the present invention includes a plurality of production facilities each including an apparatus and a control apparatus that controls the apparatus. Further, the management index calculation system collects equipment data, which is data of the production equipment from each of the plurality of production equipments and is generated in a first data format unified among the plurality of production equipments, and A first data format using processing logic common to each of the equipment data collected from the plurality of production facilities so that the element data used for calculating the management index of the first data format has a second data format unified among the plurality of production facilities. And a general control device for converting the equipment data into element data. Further, the management index calculation system includes a database that stores the element data of the second data format in the data storage area, and calculates the management index by the calculation logic for each management index using the element data in the data storage area. In the first data format, the data storage area, the data format, and the number of digits are unified among a plurality of production facilities for each type of facility data for data items used for calculating a management index in the facility data. In addition, a data area in which a data pattern, a data format, and the number of digits can be freely set for data items unique to the production equipment is provided.

  The management index calculation system according to the present invention has an effect that a management index can be easily calculated for a plurality of production facilities.

The figure which shows the structure of the management index calculation system concerning embodiment. 5 is a diagram illustrating an example of calculation formula information used in the management index calculation system according to the embodiment; FIG. The figure which shows the element information used in the management index calculation system concerning embodiment. The figure which shows the example of the standard time master table definition concerning embodiment. The figure which shows the example of the work input result table definition concerning embodiment. FIG. 5 is a diagram illustrating an example of an operation history record table definition according to the embodiment. The figure which shows the example of the state division | segmentation master table definition concerning embodiment. FIG. 5 is a diagram illustrating an example of a standard time master table according to the embodiment. FIG. 4 is a diagram illustrating an example of a work input result table according to the embodiment; FIG. 4 is a diagram illustrating an example of an operation history record table according to the embodiment. FIG. 7 is a diagram illustrating an example of a working time master table according to the embodiment. FIG. 4 is a diagram for explaining a collection timing of facility data collected by the management index calculation system according to the embodiment. Table showing storage areas allocated to first equipment data sent from the equipment PLC to the general controller according to the embodiment Table showing storage areas allocated to second equipment data sent from the equipment PLC to the general controller according to the embodiment The figure which shows an example of the sequence program used when the supervisory controller concerning embodiment processes data of equipment data. The figure which shows the content information of the equipment data collected by the supervisory controller concerning embodiment. FIG. 9 is a diagram for explaining an operation processing procedure of the management index calculation system according to the embodiment. FIG. 2 is a diagram illustrating an example of a hardware configuration of a database according to the embodiment.

  Hereinafter, a management index calculation system and a management index calculation method according to an embodiment of the present invention will be described in detail with reference to the drawings. The present invention is not limited by the embodiment.

Embodiment.
FIG. 1 is a diagram illustrating a configuration of a management index calculation system 1 according to the embodiment. The management index calculation system 1 is a system that calculates a management index of equipment such as production equipment 310 to 330. The management index calculation system 1 includes a production facility 310 to 330, an overall controller 20, and a database 10. In the management index calculation system 1, the general controller 20 is connected to the database 10 and the production facilities 310 to 330. The database 10 is connected to a display monitor 2 such as a liquid crystal monitor. In the following description, when it is not necessary to identify the production facilities 310 to 330, the production facilities 310 to 330 may be referred to as production facilities.

  In the management index calculation system 1 of the present embodiment, the supervisory controller 20 collects equipment data, which is data of the production equipments 310 to 330, from the production equipments 310 to 330 in a unified first data format, and The data processing logic converts the equipment data into element data of the second data format used for calculating the management index of the production equipment 310 to 330. In the management index calculation system 1, since the data format of the equipment data collected from the production equipments 310 to 330 is unified, it is possible to convert the data into element data with a single processing logic. The general controller 20 transmits the unified element data of the second data format to the database 10 and causes the database 10 to store the element data. That is, the element data sent from the general controller 20 to the database 10 has a unified data format, not the format of the data packet sent to the database 10. The database 10 stores element data in a unified second data format, and calculates a management index using element data with a single calculation logic for each management index. In the management index calculation system 1, the element data necessary for the management index is stored in a predetermined data format, so that it is easy to assemble the calculation logic. In the following description, a unified data format may be referred to as a unified format.

  The production facility 310 includes a facility PLC (Programmable Logic Controller) 31 and a device 41 controlled by the facility PLC 31. Similarly, the production facility 320 includes a facility PLC 32 and a device 42 controlled by the facility PLC 32, and the production facility 330 includes a facility PLC 33 and a device 43 controlled by the facility PLC 33. In the following description, when it is not necessary to identify the devices 41 to 43, the devices 41 to 43 may be referred to as devices.

  The equipment PLCs 31 to 33 are examples of control equipment arranged in the production equipment 310 to 330 that performs automated production. The equipment PLCs 31 to 33 control the operations of the devices 41 to 43, which are the controlled devices, arranged in the production equipment 310 to 330. An example of the controlled device is a robot.

  The equipment PLCs 31 to 33 control the devices 41 to 43 connected to each other using various data, and hold data indicating the states of the devices 41 to 43. The equipment PLCs 31 to 33 send the equipment data requested by the general controller 20 to the general controller 20. That is, the facility PLC 31 transmits the facility data acquired by the device 41 to the general controller 20, the facility PLC 32 transmits the facility data acquired by the device 42 to the general controller 20, and the facility PLC 33 acquires the The obtained equipment data is transmitted to the overall controller 20. The number of the equipment PLCs included in the management index calculation system 1 is not limited to three of the equipment PLCs 31 to 33, and may be two or four or more. Further, each of the facilities PLCs 31 to 33 may control a plurality of devices.

  The overall controller 20 collects equipment data from the equipment PLCs 31 to 33. The general controller 20 collects various pieces of equipment data in a unified format from the equipment PLCs 31 to 33 and converts the equipment data into a specific format. The general controller 20 includes a communication unit 21 and a data processing unit 22.

  The communication unit 21 performs data communication with the equipment PLCs 31 to 33. The communication unit 21 performs data communication with the database 10. The communication unit 21 receives the equipment data from the equipment PLCs 31 to 33 and transmits to the database 10 element data to be described later, which is data after data processing by the data processing unit 22.

  The data processing unit 22 performs data processing on the equipment data sent from the equipment PLCs 31 to 33 so that the data can be stored in a specific format in the database 10, and stores the data after the data processing in the performance table 103 as element data. The result table 103 will be described later.

  The database 10 receives and stores the element data from the general controller 20 from the general controller 20. The database 10 calculates the management index of the production equipment 310 to 330 in which the devices 41 to 43 are arranged, using the element data and the master data registered in advance. The database 10 lists the collected element data based on the table definition of the master table 102 and the table definition of the performance table 103, and calculates the management index from the list according to the management index calculation logic for calculating the management index. I do. The table definition defines a format when the master table 102 and the result table 103 are stored in the table storage unit 12. The master table 102 will be described later.

  The database 10 outputs the calculated management index to an external device. Here, the database 10 outputs the management index to the display monitor 2 and causes the display monitor 2 to display the management index. The database 10 may output the calculated management index to an information processing terminal (not shown). An example of the information processing terminal is a computer that manages a management index.

  The database 10 includes a table storage unit 12, a combining unit 13, a calculating unit 14, and an output unit 15. Each process by the combining unit 13, the calculating unit 14, and the output unit 15 is executed by a database application program. In other words, the database application program is an application program that executes the operation of the database 10.

  The table storage unit 12 stores a master table 102 and a performance table 103. The master table 102 is a table that defines the format of element data to be collected and the like, and is stored in the table storage unit 12 in advance. The table storage unit 12 stores table definitions of the master table 102 and the result table 103. The result table 103 is a table for storing element data sent from the general controller 20. The equipment data is converted into element data by performing data processing according to the table definition of the performance table 103. This element data is stored in the result table 103. Therefore, the performance table 103 is a table that stores the element data generated according to the table definition of the performance table 103. The table definition of the master table 102 is also used when converting the code of the element data into a list recognizable by the user.

  The combining unit 13 extracts element data necessary for calculating the management index requested by the user from the element data sent from the general controller 20. Further, the combining unit 13 extracts, from the master table 102, master data necessary for calculating the management index requested by the user.

  The combining unit 13 combines the master data of the master table 102 with the extracted element data. The combining unit 13 combines the master data and the element data in the master table 102 to associate the contents of the element data with the element data codes defined in the master table 102. Thereby, the content of the element data is specified.

  The calculating unit 14 calculates a management index requested by the user based on the data combined by the combining unit 13. The process of calculating the management index will be described later. The output unit 15 outputs the management index calculated by the calculation unit 14 to an external device such as the display monitor 2. Note that the calculation unit 14 and the output unit 15 may be arranged outside the database 10.

  The database 10 can receive a request for a management index from a web application or an exe application of an information processing terminal operated by a user. Further, when the database 10 calculates the requested management index, the database 10 can output the management index to the web application or the exe application that has received the request. Therefore, the display monitor 2 may be provided in the information processing terminal of the user.

  Here, details of the management index will be described. Management indicators are a set of metrics that help define the degree of achievement of an organization's goals. Management indicators vary depending on the characteristics or strategies of the organization. ISO (International Organization for Standardization) 22400 is a key performance indicator (KPI) in the area of MES (Manufacturing Execution System). Is an international standard for data constituting KPI. ISO22400 defines KPIs in six areas: productivity, quality, capacity, environment, inventory, and maintenance. The management index calculation system 1 calculates a management index for each production facility.

  FIG. 2 is a diagram illustrating an example of calculation formula information 201 used in the management index calculation system 1 according to the embodiment. FIG. 3 is a diagram illustrating the element information 202 used in the management index calculation system 1 according to the embodiment. The element information 202 in FIG. 3 shows the definition of the element shown in FIG. The element information 202 indicates a correspondence between an element name and an element definition. The calculation formula information 201 is created based on the element information 202.

  The calculation formula information 201 is information of a calculation formula used when the calculation unit 14 calculates the management index of each production facility. The calculation formula information 201 includes calculation formulas for the total efficiency, the operation rate, the hourly operation rate, the performance operation rate, and the non-defective product rate, which are the KPIs of the productivity area in the production equipment, and the elements constituting these calculation equations. Shows the relationship. The overall efficiency is the overall efficiency of the production equipment, and the operation rate is the operation rate of the production equipment.

  The time operation rate, the performance operation rate, and the non-defective rate are related to the overall efficiency, and the calculation formula of the overall efficiency is: total efficiency = (time operation rate) × (performance operation rate) × (non-defective rate). The elements of the operation rate are the operation time and the operable time, and the formula for calculating the operation rate is: operation rate = (operation time) / (operable time). The elements of the time operation rate are the operation time and the operation time, and the calculation formula of the time operation rate is: time operation rate = (operation time) ÷ (operation time). The elements of the performance operation rate are the operation time, the standard time, and the input quantity. The formula for calculating the performance operation rate is: performance operation rate = (standard time) × (input quantity) ÷ (operation time). The factors of the non-defective product rate are the number of non-defective products and the input quantity. The formula for calculating the non-defective product rate is: non-defective product rate = (number of non-defective products) / (input quantity)

  The operable time, the operating time, the operating time, the standard time, the input quantity, and the number of non-defective products are factors for each production facility, and thus differ for each production facility. The operable time is a time during which the production facility can be operated, and the operating time is a time during which the production facility must operate among the operable times of the production facility. The operating time is the time during which the production facility is operating, of the operation time of the production facility, and the standard time is the standard time of the production facility. The standard time is a time required for performing a predetermined fixed operation in each production facility. The input quantity is the quantity of works input to the production equipment, and the number of non-defective products is the quantity of works satisfying a specific quality.

  When the web application or the exe application is operated by the information processing terminal, the management index calculation system 1 can display the calculated value of the KPI defined by ISO22400 on a monitor or the like of the information processing terminal. The database 10 included in the management index calculation system 1 executes a KPI calculation formula defined by ISO22400. Further, the management index calculation system 1 has a table created based on a database application program for calculating a KPI and a table definition that defines the storage specification of element data constituting the KPI calculation formula. In the table definition, “data item”, “data type”, “key”, etc. of element data are defined.

  As an example of the method of calculating the management index, a method of calculating the performance availability will be described. In order to calculate the KPI, element data of the standard time, the input quantity, and the operation time of the production equipment for which the KPI is calculated are required. Therefore, the database 10 has a table for storing data necessary for totalizing each element data. Here, the master table 102 and the result table 103 stored in the database 10 will be described.

  FIG. 4 is a diagram illustrating an example of the standard time master table definition 203A according to the embodiment, and FIG. 5 is a diagram illustrating an example of the work input result table definition 204A according to the embodiment. FIG. 6 is a diagram illustrating an example of the operation history record table definition 205A according to the embodiment, and FIG. 7 is a diagram illustrating an example of the state division master table definition 206A according to the embodiment.

  FIG. 8 is a diagram illustrating an example of the standard time master table 203B according to the embodiment, and FIG. 9 is a diagram illustrating an example of the work input result table 204B according to the embodiment. FIG. 10 is a diagram illustrating an example of the operation history record table 205B according to the embodiment, and FIG. 11 is a diagram illustrating an example of the working time master table 207 according to the embodiment.

  The tables stored in the database 10 include a master table 102 that stores data in which data is defined in advance such as standard time and state classification, and devices 41 to 41 such as work input results and equipment operation history. It is divided into a performance table 103 for storing performance data 43. The standard time master table 203B and the working time master table 207 are the master table 102. The work input result table 204B and the operation history result table 205B are the result table 103.

  The standard time master table definition 203A in FIG. 4 indicates the table definition of the standard time master table 203B that stores standard time master data. In the standard time master table definition 203A, the work input result table definition 204A, the operation history result table definition 205A, and the state division master table definition 206A, the “data type”, the presence or absence of a “key”, the “data length”, "Decimal data" and the like are defined. Examples of data items in the standard time master table definition 203A are a device ID (identification) for identifying a device used in each of the production facilities 310 to 330, and a standard time. The standard time in the standard time master table definition 203A is specified, for example, in seconds. The “data type” is a data format, and an example of the “data type” is a character or a numerical value. The “key” is a primary key used for data search or the like. The “data length” is the length of the data, and the “data decimal number” is the number of digits after the decimal point of the data.

  The work input record table definition 204A of FIG. 5 shows the table definition of the work input record table 204B that stores the element data of the input quantity. Examples of data items in the work input record table definition 204A are a device ID and an accounting date and time. The accounting date and time indicates the date and time when the result of the work input is accounted. The accounting date and time in the work input result table definition 204A is defined by, for example, year, month, day, hour, minute, and second.

  The operation history record table definition 205A of FIG. 6 shows the table definition of the operation history record table 205B that stores the element data of the operation time. Examples of data items in the operation history record table definition 205A are a device ID, a state category, a change start date and time, and a change end date and time. The state division indicates the state of the production equipment 310 to 330, the change start date and time indicates the date and time when the state division started to change, and the change end date and time indicates the date and time when the state division ended the change. Examples of the state classification include a state in which the work is being processed, a state in which the work is put in, an abnormal state, and a power-off state. The change start date and time and the change end date and time in the operation history record table definition 205A are specified by, for example, year, month, day, hour, minute, and second.

  The state section master table definition 206A of FIG. 7 shows the table definition of the table that stores the state section master data. Examples of data items in the state section master table definition 206A are a state section, a state section name, and an operation stop section. The state division name is the name of the state division, and the operation stop division indicates the operation or stop of the production equipment 310 to 330. For example, when the production equipments 310 to 330 are stopped, the operation stop division is indicated by “0”, and when the production equipment is operating, the operation stop division is indicated by “1”.

  Data processing according to the result table definitions such as the work input result table definition 204A and the operation history result table definition 205A corresponds to generating element data in a unified format.

  The standard time master table 203B in FIG. 8 is a table for storing standard time element data. The element data in the standard time master table 203B is created based on the standard time master table definition 203A. In the standard time master table 203B, the device ID and the standard time are associated. The standard time in the standard time master table 203B is indicated in seconds in accordance with the standard time table definition 203A.

  The work input record table 204B in FIG. 9 is a table for storing element data of the input quantity. The element data in the work input record table 204B is created based on the work input record table definition 204A. In the work input record table 204B, the device ID and the accounting date and time are associated. The accounting date and time in the work input record table 204B is represented by year, month, day, hour, minute, and second in accordance with the provisions of the work input record table definition 204A.

  The operation history record table 205B of FIG. 10 is a table for storing element data of the operation time. The element data in the operation history record table 205B is created based on the operation history record table definition 205A. In the operation history record table 205B, a state category, a change start date and time, and a change end date and time are registered for each device ID. The change start date and time and the change end date and time in the operation history record table 205B are indicated by year, month, day, hour, minute, and second in accordance with the rules of the operation history record table definition 205A.

  The working hour master table 207 in FIG. 11 is a table for storing element data of working hours. The element data in the working time master table 207 is created based on the master table definition corresponding to the working time master table 207. In the working time master table 207, a working time name, shift start date and time, shift end date and time, operable time, and planned suspension time are registered for each working time ID. The working hour ID is information for identifying working hours, and the working hour name is the name of the working hours. Examples of working hours are day shift and night shift. The shift start date and time is the date and time when the shift work was started, and the shift end date and time is the date and time when the shift work was ended. The planned suspension time is a time during which the production facilities 310 to 330 are suspended according to the plan. In the present embodiment, the description of the master table corresponding to the state division master table definition 206A is omitted, but the table storage unit 12 stores a master table corresponding to the state division master table definition 206A. . In the present embodiment, the description of the master table definition corresponding to the working hour master table 207 is omitted, but the table storage unit 12 stores the master table definition corresponding to the working hour master table 207. .

  FIG. 12 is a diagram for explaining a collection timing of facility data collected by the management index calculation system 1 according to the embodiment. FIG. 12 illustrates the processing of the devices 41 to 43 in the production facilities 310 to 330 and the processing of the general controller 20. In the processing of the devices 41 to 43, a timing chart is shown in which the devices 41 to 43 send the equipment data to the overall controller 20 via the equipment PLCs 31 to 33.

  The devices 41 to 43 detect that the equipment data being handled has changed. Further, the devices 41 to 43 generate word data related to the management of the device operating state, and generate bit data related to the management of the device operating state. The devices 41 to 43 transmit a data change signal indicating whether or not data has changed, word data related to the management of the device operating state, and bit data related to the management of the device operating status at a specific timing. Send to

  The general controller 20 collects the equipment data transmitted from the devices 41 to 43, executes data processing as data processing to generate element data, and stores the element data in the database 10.

  When the general controller 20 is a PLC, the logic of data processing is specified by a sequence program, and the data format when collecting equipment data from the production equipments 310 to 330 is specified by an allocation table of a storage area for storing the equipment data. You.

  FIG. 13 is a table showing storage areas allocated to the first equipment data sent from the equipment PLCs 31 to 33 to the general controller 20 according to the embodiment. FIG. 14 is a table showing storage areas allocated to the second equipment data sent from the equipment PLCs 31 to 33 to the general controller 20 according to the embodiment. FIG. 15 is a diagram illustrating an example of a sequence program 500 used when the overall controller 20 according to the embodiment performs data processing on facility data.

  FIGS. 13 and 14 show allocation tables of storage areas for facility data transmitted and received between the production facilities 310 to 330 and the general controller 20. Specifically, FIG. 13 shows an address in the first allocation area of the memory device as an equipment data allocation area for each device, and FIG. 14 shows an address of the memory device as an equipment data allocation area for each apparatus. The addresses in the second allocation area are shown. In FIG. 13, (1) indicates that the area is within the first allocation area, and in FIG. 14, (2) indicates that the area is within the second allocation area. Therefore, (1) 000 to 0FF indicates the range of 000 to 0FF in the first allocation area, and (2) 000 to 0FF indicates the range of 000 to 0FF in the second allocation area.

  In the allocation table of the storage area of the equipment data shown in FIGS. 13 and 14, the data contents of the equipment data, the range in the storage area for storing the equipment data, the score of the equipment data to be stored, and the like are set. The range in the storage area for storing the equipment data is defined by the address of the storage area for storing the equipment data. It can be said that the range in the storage area for storing the equipment data defines the data amount of the equipment data. The data amount of the facility data corresponds to the number of digits of the facility data. The data content of the facility data is the purpose of the facility data, and is indicated by the functions used in the devices 41 to 43 and the like. Collecting the equipment data according to the allocation tables in FIGS. 13 and 14 corresponds to generating the equipment data in a unified format. The allocation table of FIG. 13 is an allocation table for storing equipment data as bit data, and the allocation table of FIG. 14 is an allocation table for storing equipment data as word data. Bit data is represented by “0” or “1”, and word data is represented by 16 bits.

  The sequence program 500 is a program used when generating element data for calculating a performance operation rate by data processing. The equipment data used in the sequence program 500 is obtained by the equipment PLCs 31 to 33 from the devices 41 to 43 in the production equipment 310 to 330, and is transmitted from the equipment PLCs 31 to 33 to the general controller 20 in the format shown in FIG. Sent. The equipment data specified in FIG. 13 is sent to the general controller 20 as bit data, and the equipment data specified in FIG. 14 is sent to the general controller 20 as word data. The equipment data sent from the equipment PLCs 31 to 33 to the general controller 20 is equipment data of the functions of the devices 41 to 43. The facility data for each function includes facility data input to the function and facility data output from the function. Examples of the equipment data input from the integrated controller 20 to the equipment PLCs 31 to 33 are data of the time synchronization function, and examples of the equipment data sent from the equipment PLCs 31 to 33 to the integrated controller 20 are data of the input result collection function and quality information. This is the data of the collection function.

  The time synchronization function is a function of synchronizing the internal clocks of the devices 41 to 43 and the internal clock of the general controller 20. The input result collection function is a function of collecting the result information of the work input into the devices 41 to 43. The quality information collecting function is a function of collecting quality information of the work processed by the devices 41 to 43.

  Further, the assignment table of FIG. 13 includes a bit data storage address for storing equipment data necessary for the sequence program 500. The equipment data necessary for the sequence program 500 is equipment data related to the preparation for operation of the A1 device and the A2 device, the system lock, and the like. The bit data storage addresses of the equipment data related to the operation preparation of the A1 apparatus, the system lock, etc. are (1) 010 to 01F allocated to the equipment data of the operation state management function, and the operation preparation of the A2 apparatus, the system lock, etc. The bit data storage addresses of the equipment data related to (1) are (1) 110 to 11F assigned to the equipment data of the operating state management function. The A1 device and the A2 device are each one of the devices 41 to 43.

  Further, the assignment table of FIG. 14 includes a device ID storage address (not shown) for storing a device ID for identifying the devices 41 to 43.

  In the allocation tables of FIGS. 13 and 14, for the devices 41 to 43, the number of addresses at which facility data is registered and the range of addresses at which facility data is registered are set. Further, for each function, the number of addresses at which facility data is registered and the range of addresses at which facility data are registered are set. For example, facility data input to each function of the A1 apparatus has 16 addresses set therein, and facility data input to the entire function of the A1 apparatus has 256 addresses set. As described above, in the management index calculation system 1, the allocation position of the equipment data to each function is set.

  The devices 41 to 43 send the equipment data in the unified format shown in FIGS. 13 and 14 to the overall controller 20 via the equipment PLCs 31 to 33. The user of the management index calculation system 1 determines a uniform format for the facility data of each function shown in FIG. 13 or FIG. 14 so that the management index calculation system 1 calculates the management index. This unified format is set in the devices 41 to 43. Accordingly, the devices 41 to 43 can send the set equipment data in the unified format to the general controller 20. Therefore, the general controller 20 collects the equipment data from each of the devices 41 to 43 in the same data format. be able to.

  Here, the contents of the equipment data collected by the general controller 20 will be described. FIG. 16 is a diagram illustrating the content information of the equipment data collected by the general controller 20 according to the embodiment. FIG. 16 shows the correspondence between the address in the second allocation area shown in FIG. 14 and the contents of the equipment data registered at this address. The devices 41 to 43 send the equipment data to the general controller 20 according to the correspondence shown in FIG.

  Addresses 830 to 835 shown in FIG. 16 are areas in which equipment data of the quality information collection function is stored. For example, the determination result flag corresponding to the characteristic 1 of the quality information collection function is stored in the address 830 in the second area. This determination result flag indicates a result determined for characteristic 1 related to the quality information collection function.

  In the present embodiment, collected data items such as a determination result flag, the number of continuous tests, and a result value as a characteristic value are patterned. In the present embodiment, data items are collected in the same pattern for each quality characteristic. The number of continuous tests is the number of continuous tests in the quality test. The characteristic value is a result of a quality test, and indicates a characteristic of a work as a product.

  Further, in the allocation table of the equipment data, a storage area which does not have a restriction such as collecting data in the same data format may be secured. In other words, the equipment data allocation table may be provided with a device-specific storage area for storing data that the device wants to collect and that is not related to the management index. For the device-specific storage area, the user can set the device-specific data type, storage address, storage data amount, and data content, so that the general controller 20 collects data unique to each device. It is possible to do. When a device-specific storage area is used, by registering the setting contents in the master table 102, device-specific data collected in the database 10 can be easily confirmed after collection.

  Equipment data of a function such as a quality information collection function or data unique to a device may have a different data amount to be obtained for each device. In this case, the allocation area of the function not used in the apparatus may be deleted, and a part or all of the deleted allocation area may be used as the allocation area of the function used uniquely by the apparatus. That is, the allocation area of each function can be increased or decreased in each device. Alternatively, the allocation area of the function not used in any device may be deleted, and a part or all of the deleted allocation area may be used as the allocation area of another device. Thereby, the allocation area of each device can be increased or decreased. In this manner, by determining the collected data for each device as needed and collecting the data, it is possible to reduce the free area of the allocated area in the general controller 20. Therefore, the number of production facilities that can be connected by one general controller 20 can be increased.

  The general controller 20 executes the sequence program 500 according to the data allocation tables shown in FIGS. The line indicated by (0) in the sequence program 500 is a case where the power of the apparatus is off. The line indicated by (60) in the sequence program 500 is a case where the apparatus is adjusting, and the line indicated by (67) in the sequence program 500 is a case where the apparatus is processing a workpiece.

  The location of “MOV K1 D0” in the sequence program 500 is a process of writing “1” as a decimal number to the area of D0 where the state division is stored. Therefore, when the power of the apparatus is off, “1” is written as the state classification. The location of “MOV K2 D0” in the sequence program 500 is a process of writing “2” as a decimal number into the area of D0 where the state division is stored. Therefore, when the device is being adjusted, “2” is written as the status category. The location of “MOV K3 D0” in the sequence program 500 is a process of writing “3” as a decimal number into the area of D0 where the state division is stored. Therefore, when the apparatus is processing the work, “3” is written as the state classification.

  Next, a procedure in which the production equipment 310 to 330 transmits equipment data to the general controller 20 and the general controller 20 transmits element data to the database 10 will be described. FIG. 17 is a diagram for explaining an operation processing procedure of the management index calculation system 1 according to the embodiment.

  Master table 102 is input to database 10 by a user in advance (step ST100). The equipment PLCs 31 to 33 operate in accordance with the respective sequence programs. That is, the equipment PLCs 31 to 33 control the devices 41 to 43 based on the respective sequence programs. The equipment 41 to 43 acquires equipment data necessary for calculating the management index in the form of an allocation table as shown in FIG. 13 or FIG. 14 as equipment data in a unified format (step ST1).

  The equipment PLCs 31 to 33 transmit the equipment data acquired by the devices 41 to 43 to the general controller 20 according to the data transmission timing chart shown in FIG. 12 (step ST2). Specifically, the facility PLC 31 transmits the facility data acquired by the device 41 to the general controller 20, the facility PLC 32 transmits the facility data acquired by the device 42 to the general controller 20, and the facility PLC 33 transmits The equipment data acquired at 43 is transmitted to the overall controller 20. In this way, the equipment PLCs 31 to 33 transmit the equipment data of their own equipment to the overall controller 20 based on the unified format of the allocation table and the timing chart of FIG. 12 without depending on the management index request from the user. Note that the timing chart used by the equipment PLCs 31 to 33 may be a timing chart in which the production equipment 310 to 330 collects data in response to a data request from the general controller 20.

  The general controller 20 receives the facility data for each production facility from the production facilities 310 to 330 (step ST3). The general controller 20 extracts the equipment data necessary for providing to the database 10 based on the sequence program 500 shown in FIG. 15 from the equipment data in the unified format collected from each of the production equipments 310 to 330.

  The general controller 20 performs data processing in accordance with the table definition of the performance table 103 of the database 10 (step ST4), and transmits the data to each performance table 103 of the database 10 as element data (step ST5). That is, the general controller 20 sets the element data in the form according to the data item, data format, and number of digits determined by the table definition of the performance table 103 in which the database 10 stores the element data for calculating the management index. Data processing is performed on the equipment data and transmitted to the performance table 103 of the database 10. The database 10 receives the element data for each production facility from the general controller 20 (step ST6), and stores it in an area in the performance table 103 corresponding to the element data.

  As an example of data processing by the general controller 20, a process of storing data in the operation history record table 205B of the database 10 will be described. The different types of production facilities 310 to 330 under the supervising controller 20 perform operations according to individual sequence programs. In order to store the element data in the operation history record table 205B of the database 10, the equipment PLCs 31 to 33 convert the device ID data, which is the individual identification management number of the own device, into the device ID storage address of the assignment table described in FIG. Store in the indicated area. Further, the equipment PLCs 31 to 33 transfer the equipment data of operation preparation necessary for the sequence program 500 and the equipment data of bits such as the number of seconds of system lock to the area indicated by the bit data storage address in the allocation table described in FIG. Store.

  The overall controller 20 determines the state classification of each of the production facilities 310 to 330 using the sequence program 500 from the facility data stored by each of the production facilities 310 to 330. The overall controller 20 stores the device ID, the number indicating the state category, the change start date and time, the change end date and time, and other necessary data stored from each of the production facilities 310 to 330, at the timing when the state category changes. And store it in the operation history record table 205B of the database 10.

  In addition, since the general controller 20 collects data from a plurality of production facilities 310 to 330 simultaneously and in parallel, a plurality of production facilities may be used as one management unit. That is, the supervisory controller 20 may generate element data in units of a plurality of production facilities from the facility data collected from the production facilities 310 to 330 and store the element data in the database 10. For example, the supervising controller 20 sets the process of the three devices A1, A2, and A3 arranged in different production facilities of the same type as the process A, and the processes of the three devices A1, A2, and A3. The case where the equipment state category is in operation may be regarded as the operation of the process A. In this way, by setting a new sequence program in which a plurality of production facilities are set as one management unit, the supervisory controller 20 generates facility data of the state division of the process A, and generates the production facilities 310 to 330. In the operation history record table 205B as in the case of the operation history.

  The user operates the web application or the exe application from the information processing terminal to obtain information on the management index of the production facility 310 to 330 in the daily management of the production facility 310 to 330, The production facility corresponding to the management index and the period of the management index are designated, and the management index is requested from the database 10 (step ST101).

  When the database 10 receives the request for the management index from the user, the combining unit 13 extracts, from the performance table 103, the element data necessary for calculating the management index of the requested production equipment and period (step ST7). . Then, the combining unit 13 of the database 10 combines the master data of the master table 102 input by the user in advance with the element data (step ST8). Specifically, the combining unit 13 converts the code of the element data into data according to the master data in the master table 102. The linking unit 13 can specify the content of the element data by associating the content of the element data with the content defined in the master table 102. As a result, the content of the element data indicated by the code becomes data of a list that can be confirmed by the user as to the content of the data.

  The calculation unit 14 calculates a management index requested by the user based on the combined data (step ST9). The output unit 15 outputs the calculated value of the management index to the web application or the exe application of the information processing terminal operated by the user (step ST10). Thereby, the management index specified by the user is displayed on the monitor or the like of the information processing terminal.

  Here, a method of totalizing each element data and calculating the KPI based on the element data stored in the performance table 103 will be described. Here, a case where the performance availability of the device 41 from 8:00 to 17:00 on January 10, 2018 is calculated will be described. It is assumed that the device ID of the device 41 is “1”.

  The combining unit 13 of the database 10 extracts element data used for calculating the equipment operation time of the device 41 from the operation history record table 205B based on the operation history record table definition 205A. The combining unit 13 has the device ID “1”, the equipment status category “1” indicating that the device is operating, the change end date and time after 8:00 on January 10, 2018, and the change start date and time 2018. The element data before 17:00 on January 10 is extracted. When an operation stop section is set in the operation history record table 205B, the combining unit 13 may extract element data whose operation stop section is “1” indicating that the operation is in operation.

  The calculating unit 14 uses the element data extracted by the combining unit 13 to set the device ID to “1”, to indicate that the equipment status category is “1”, and to set the change end date and time to January 2018. A total sum of the times of the element data whose change start date and time is after 8:00 on the 10th and before 17:00 on January 10, 2018 is calculated.

  Next, the combining unit 13 extracts element data for calculating the input amount to the apparatus 41 from the work input result table 204B based on the work input result table definition 204A, and the calculation unit 14 determines based on the extraction result. Then, the input quantity to the device 41 is calculated. Here, the combining unit 13 extracts element data whose device ID is “1” and whose work recording date and time is from 8:00 to 17:00 on January 10, 2018, and calculates the number of extracted data. The calculation unit 14 sums up. Each time one work is input, one work accounting date and time is registered, so that the number of data and the input quantity are equal. Therefore, the calculation unit 14 treats the total number of data as the input quantity.

  Next, the combining unit 13 extracts the standard time master data of the device 41 from the standard time master table 203B based on the standard time master table definition 203A. The combining unit 13 here extracts the standard time when the device ID is “1”. Further, the calculation unit 14 calculates the performance operation rate according to the KPI calculation formula using the standard time, the operation time, and the input quantity. Specifically, the calculating unit 14 calculates the performance availability by dividing the product of the standard time and the input quantity by the operating time.

  Here, the hardware configuration of the database 10 will be described. FIG. 18 is a diagram illustrating a hardware configuration example of the database 10 according to the embodiment. The database 10 can be realized by the processor 301 and the memory 302 shown in FIG. An example of the processor 301 is a central processing unit (CPU) (central processing unit, central processing unit, processing unit, arithmetic unit, microprocessor, microcomputer, processor, DSP (Digital Signal Processor)) or system LSI (Large Scale Integration). Examples of the memory 302 are a random access memory (RAM) and a read only memory (ROM).

  The database 10 is realized by the processor 301 reading and executing a database application program for executing the operation of the database 10 stored in the memory 302. In addition, it can be said that this database application program causes a computer to execute the procedure or method of the database 10. The memory 302 is also used as a temporary memory when the processor 301 executes various processes.

  The functions of the database 10 may be partially realized by dedicated hardware, and partially realized by software or firmware. Further, the general controller 20 and the equipment PLCs 31 to 33 may be realized by the processor 301 and the memory 302 shown in FIG.

  As described above, in the management index calculation system 1, the general controller 20 receives various pieces of equipment data in a unified format from each of the production equipment 310 having the equipment PLC 31, the production equipment 320 having the equipment PLC 32, and the production equipment 330 having the equipment PLC 33. To collect. The management index calculation system 1 converts the collected equipment data into a data format according to the master table 102 using a single data processing logic, and stores the converted data as element data of the performance table 103.

  In the management index calculation system 1, since the plurality of production facilities 310 to 330 transmit equipment data in a unified format to the general controller 20, the general controller 20 transmits the unified format equipment data to the general controller 20. The equipment data may be processed by a single data processing logic and stored in the database 10 as element data. In addition, the database 10 may calculate the management index by a single calculation logic for each management index based on the unified element data regardless of the type of the production equipment 310 to 330 stored by the general controller 20. . Thereby, the burden of data processing and management index calculation is suppressed, and one management index calculation system 1 can easily calculate management indexes of many different types of production equipment.

  Further, the management index calculation system 1 unifies the data storage area, the data format, and the number of digits for the data items required for calculating the management index in the unified data format. On the other hand, the management index calculation system 1 has a fixed data storage area and a fixed data pattern for quality data having different items for each production facility, and the number of data items, the data format, and the number of digits are variable. In addition, the management index calculation system 1 provides a data area in which a data pattern, a data format, a number of digits, and the like can be freely set in a data format for a data item acquired for each production facility and different for each production facility. . As a result, while having a unified data format, not only data items unified for each production equipment required for calculating the management index, but also data items that are partially common and different in other parts between the production equipment, and It is also possible to acquire different non-unified data items for each production facility.

  Furthermore, the general controller 20 can combine various equipment data of the managed production equipment 310 to 330 by collecting and processing various equipment data from the production equipment 310 to 330 in real time. Thus, the central controller 20 can easily generate element data of a process or a line in units of a plurality of production facilities and store the element data in the database 10. The database 10 does not need to generate element data in units of a plurality of production facilities from the stored history data for each production facility, and manages based on the stored element data in units of a plurality of production facilities. The management index can be calculated by the index calculation logic. For this reason, the processing load on the database 10 is suppressed, and the management index can be calculated and output efficiently. In addition, the management index calculation system 1 can be easily constructed by separating the storage function and management function of the facility data, which are the original functions of the database 10, from the management index calculation function.

  As described above, in the embodiment, the general controller 20 collects the facility data generated from the production facilities 310 to 330 in a unified data format, and uses the single data processing logic to convert the facility data to the calculation of the management index. Converted to element data to be used. Further, the database 10 stores the element data from the general controller 20 in the data storage area in a unified data format, and manages the data with a single calculation logic for each management index based on the element data in the data storage area. Index is calculated. Accordingly, the management index calculation system 1 can easily collect the equipment data and easily obtain the element data, and thus can easily calculate the management index.

  The configurations described in the above embodiments are merely examples of the contents of the present invention, and can be combined with other known technologies, and can be combined with other known technologies without departing from the gist of the present invention. Parts can be omitted or changed.

  Reference Signs List 1 management index calculation system, 2 display monitor, 10 database, 12 table storage unit, 13 connection unit, 14 calculation unit, 15 output unit, 20 general controller, 21 communication unit, 22 data processing unit, 31-33 equipment PLC, 41 To 43 devices, 102 master table, 103 result table, 201 calculation formula information, 202 element information, 203A standard time master table definition, 203B standard time master table, 204A work input result table definition, 204B work input result table, 205A operation history Result table definition, 205B Operation history result table, 206A Status section master table definition, 207 Working time master table, 310 to 330 Production equipment, 500 sequence program.

Claims (6)

A plurality of production equipment with equipment and a control device for controlling the equipment,
Collecting data of the production equipment from each of the plurality of production equipment, the equipment data generated in a first data format unified among the plurality of production equipment, and a management index of the plurality of production equipment; The first data format is processed by a common processing logic for each of the equipment data collected from the plurality of production facilities so that the element data used for the calculation has a second data format unified among the plurality of production facilities. An overall control device for converting the equipment data into the element data,
A database that stores the element data of the second data format in a data storage area, and calculates the management index by a calculation logic for each management index using the element data in the data storage area;
Bei to give a,
In the first data format, the data storage area, the data format, and the number of digits of the data item used for calculating the management index in the facility data are different among the plurality of production facilities for each type of facility data. A data area that is unified and that can freely set a data pattern, a data format, and the number of digits for a data item unique to the production facility is provided.
A management index calculation system, characterized in that: In the second data format, a data storage area, a data format, and the number of digits are unified for each type of the element data for data items used for calculating the management index among the element data.
The management index calculation system according to claim 1 , wherein: The general control device generates the element data using the plurality of production facilities as one unit and stores the element data in the database .
The management index calculation system according to claim 1 or 2 , wherein: The management indicator may include a key performance indicator defined by the International Organization for Standardization.
The management index calculation system according to any one of claims 1 to 3 , wherein: The database calculates the management index using definition information and the element data that define the content of the equipment data,
The management index calculation system according to any one of claims 1 to 4 , wherein: Collecting data of the production equipment from each of a plurality of production equipment having an apparatus and a control device for controlling the equipment, the equipment data being generated in a first data format unified among the plurality of production equipment; Collection steps;
Common to each of the equipment data collected from the plurality of production facilities, so that the element data used for calculating the management index of the plurality of production facilities has a second data format unified among the plurality of production facilities. A conversion step of converting the equipment data in the first data format into the element data by processing logic;
Storing the element data of the second data format in a data storage area;
A calculating step of calculating the management index by calculation logic for each management index using the element data in the data storage area;
Only including,
In the first data format, the data storage area, the data format, and the number of digits of the data item used for calculating the management index in the facility data are different among the plurality of production facilities for each type of facility data. A data area that is unified and that can freely set a data pattern, a data format, and the number of digits for a data item unique to the production equipment is provided.
A method for calculating a management index, characterized in that:

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