JP7016505B2 - Production line control system - Google Patents

Description

The present invention relates to a production line control system.

As a conventional production line control system, for example, the one described in Patent Document 1 is known. The control system described in Patent Document 1 is a means for receiving work information from an apparatus, storing the received requested work information, determining the contents of work items, and a means for determining the current status of each worker with specific items. Evaluation storage means that expresses and stores it in evaluation numbers, evaluation storage means that adds weighting to and stores each evaluation item based on the generated work content, and prioritizes work instruction information according to the condition results of the evaluation storage. It is provided with a work instruction means for outputting to a person.

Japanese Unexamined Patent Publication No. 2006-1638889

On the production line, work for maintaining equipment and the like, work for supplying (replenishing and replacing) parts (materials) necessary for production, work for dealing with troubles that occur in the production process, and the like are performed. On the production line, if the number of tasks required is large relative to the number of workers, the response of the workers may not be able to keep up. In this case, since the work cannot be instructed to the worker, the production line must be stopped until the worker can handle the work. Therefore, the production efficiency is lowered. Further, when the product produced on the production line is food, when the production line is stopped, the food is oxidized or deteriorated. In this case, the food must be discarded.

One aspect of the present invention is to provide a production line control system capable of stabilizing the quality of a production object while suppressing a decrease in production efficiency.

The production line control system according to one aspect of the present invention is a production line control system including a plurality of processes, and is a work request for requesting correspondence of work generated in at least a part of the plurality of processes. It is provided with a receiving unit that receives a signal and a control unit that sets work for a worker registered in advance based on the work request signal received by the receiving unit and outputs information instructing the worker to perform the work. If the pre-registered worker cannot process the work required by the work request signal, the control unit reduces the production amount per unit time set in the production line from the currently set amount. Set to do.

In the production line control system according to one aspect of the present invention, the control unit is set per unit time on the production line when the pre-registered worker cannot process the work required by the work request signal. Set the production volume to be less than the currently set volume. As a result, even if there is no worker who can process the work, the production line can be continuously operated without stopping the production line. Therefore, it is possible to stabilize the quality of the production object while suppressing the decrease in production efficiency. Further, when the product is food, the production line continues to operate, so that the amount of food waste due to the deterioration of the food can be reduced as compared with the case where the production line is completely stopped. As a result, in the control system of the production line, the quality of the production object can be stabilized while suppressing the decrease in the production efficiency.

In one embodiment, when the control unit determines that there is no worker who can set the work required by the work request signal, the control unit sets the production amount to be smaller than the currently set amount. May be good. With this configuration, it is possible to appropriately determine whether or not there is a worker who can handle the work.

In one embodiment, the pre-registered worker is associated with work that can be processed, and when the control unit receives the work request signal, the pre-registered worker is currently configurable work. The work that can be processed by the person is compared with the work required by the work request signal, and if the work cannot be processed by the currently configurable worker, the production amount is reduced from the currently set amount. It may be set as follows. In this configuration, the worker is not instructed to perform work that the worker cannot handle. Therefore, it is possible to instruct work according to the ability of the worker.

In one embodiment, the control unit may set the production amount per unit time to be smaller than the currently set amount depending on the current production situation on the production line. In this configuration, since the production amount is set to decrease according to the current production status, it is possible to control according to the status of the production line.

In one embodiment, the control unit may set the production amount per unit time to be reduced by a certain amount from the amount currently set. With this configuration, the production amount per unit time can be surely reduced.

In one embodiment, the control unit may set the production amount per unit time to be smaller than the amount currently set according to the work situation of the worker. In this configuration, since the production amount is reduced according to the work situation of the worker, it is possible to control according to the work situation of the worker. Therefore, it is possible to reliably avoid the situation where the work by the worker cannot keep up and the production line is stopped.

In one embodiment, a plurality of production lines are provided, and when the control unit sets the production amount per unit time in one production line to be smaller than the currently set amount, the other production lines are provided. The production amount per unit time on the line may be set to be higher than the currently set amount. In this configuration, even when the production amount in one production line is decreased, the production amount in the other production line is increased, so that the production amount as a whole can be maintained. Therefore, in the control system of the production line, the quality of the production object can be stabilized while suppressing the decrease in the production efficiency.

According to one aspect of the present invention, the quality of the production object can be stabilized while suppressing the decrease in production efficiency.

FIG. 1 is a diagram schematically showing a production line. FIG. 2 is a diagram showing a control system of a production line. FIG. 3 is a diagram showing an example of data stored in the worker database. FIG. 4 is a diagram showing an example of data stored in the work database. FIG. 5 is a flowchart showing the operation of the control system of the production line. FIG. 6 is a diagram showing an example of a screen displayed on the display device.

Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings. In the description of the drawings, the same or equivalent elements are designated by the same reference numerals, and duplicate description will be omitted.

The production line control system 1 according to the present embodiment controls the production line 100 shown in FIG. In the present embodiment, as the production line 100, a line for producing food (confectionery, etc.) will be described as an example. As shown in FIG. 1, the production line 100 has a main line L and a plurality of (here, three) branch lines L1, L2, and L3 that branch from the main line L. The process P is provided on the main line L. In step P, for example, the food is treated. The food processed in step P is conveyed to each branch line L1 to L3. Food is conveyed, for example, by a belt conveyor. In addition, there may be a further step before the step P.

In the present embodiment, the same steps are performed on the branch lines L1 to L3. The branch line L1 has, for example, a plurality of (here, 6) steps P11 to P16. In step P11, the combination weighing of food is performed by the combination weighing device. In step P12, the food weighed by the combination weighing device is packaged by the packaging device. In step P13, the packaging state of the package is inspected by the packaging inspection device. In step P14, the weight of food is inspected by a weighing device. In step P15, a foreign matter inspection device is used to inspect the presence or absence of foreign matter contamination. In step P16, the package is packed by the packing device. The branch lines L2 and L3 have a plurality of steps P21 to P26 and P31 to P36, similarly to the branch line L1.

In the production line 100, work for maintaining equipment and the like provided in each process, work for supplying (replenishing and replacing) parts (materials) necessary for production, work for dealing with troubles occurring in the production process, etc. Occurs. For example, in step P2, the work of exchanging the film for wrapping the food occurs. When work occurs, the devices provided in each process P, P11 to P16, P21 to P26, and P31 to P36 generate a work request signal requesting the response of the generated work, and receive the work request signal in the receiving unit 3 described later. Send to. The work request signal may include information that identifies the work that needs to be dealt with, information that identifies the process (device) in which the work has occurred, time in which the work (trouble, etc.) has occurred, and the like. The devices provided in each process P, P11 to P16, P21 to P26, P31 to P36 include a generation unit (not shown) for generating a work request signal and a transmission unit (not shown) for transmitting the work request signal. ..

As shown in FIG. 2, the control system 1 of the production line includes a receiving unit 3, a control device (control unit) 5, and a display device 7.

The receiving unit 3 receives a work request signal requesting correspondence of work generated in at least a part of the plurality of processes P, P11 to P16, P21 to P26, and P31 to P36. The receiving unit 3 may receive the work request signal by wire using a cable or the like, or may receive the work request signal wirelessly. When reception by the receiving unit 3 is performed wirelessly, radio waves, infrared rays, or light may be adopted as the transmission medium. The receiving unit 3 outputs the received work request signal to the control device 5.

The control device 5 comprehensively controls the production line 100. The control device 5 manages status information and operation information of various devices provided on the production line 100. The control device 5 is composed of a CPU (Central Processing Unit), a ROM (Read Only Memory), a RAM (Random Access Memory), and the like. The control device 5 has a conceptual part for executing various control processes in the control system 1. The conceptual part can be configured as software in which a program stored in ROM is loaded on RAM and executed by a CPU, for example.

The control device 5 sets the work for the worker registered in advance based on the work request signal received by the receiving unit 3, and outputs the information instructing the worker to work. When the control device 5 receives the work request signal output from the receiving unit 3, the control device 5 acquires the work or the like that needs to be dealt with based on the work request signal. The control device 5 sets a worker required for the work. The worker is registered in the worker DB (database) 9 in advance. Specifically, as shown in FIG. 3, the worker DB 9 stores No (number), the worker, the working state, and the working state in association with each other. The working status is, for example, "1" when the worker is at work (work is available) and when the worker is not at work (work is not possible). Is indicated by "0". The working state is indicated by, for example, "working" when the worker is responding to the work, and "waiting" when the worker is not responding to the work.

The control device 5 determines whether or not there is a worker who can handle the work among the workers registered in advance in the worker DB 9. The control device 5 refers to the worker DB 9, and when there is a worker whose attendance state is "1" and whose work state is "standby", the worker can handle the work. Judge that there is. The control device 5 refers to the worker DB 9 and can handle the work when the worker's attendance state is "1" and the work state is only the worker who is "working". Judge that there are no workers.

When the control device 5 determines that there is a worker who can handle the work, the control device 5 generates instruction information for instructing the worker to handle the work. The instruction information includes the process in which the work has occurred, the work content, information indicating the worker, and the like. The control device 5 outputs the generated instruction information to the display device 7.

When the control device 5 determines that there is no worker who can handle the work, the control device 5 sets the production amount per unit time set in the production line 100 to be smaller than the currently set amount. do. The production amount per unit time of the production line 100 is arbitrarily set by, for example, a worker (responsible person). The control device 5 sets the production amount per unit time to be smaller than the currently set amount according to the current production status in the production line 100. For example, when the production amount of the production line 100 at the present time is larger than the planned production amount, the control device 5 reduces the production amount per unit time more than the reference amount. When the production amount of the production line 100 at the present time is less than the planned production amount, the control device 5 reduces the production amount per unit time to be less than the reference amount. The reference amount is a preset value and may be set by the operator or may be set automatically.

In the present embodiment, when the work occurs in any of the branch lines L1 to L3, the control device 5 currently sets the production amount per unit time set in the branch lines L1 to L3 in which the work occurs. Set to be less than the amount that is being used. When the control device 5 is set so that the production amount per unit time in one branch line is set to be smaller than the currently set amount, the production amount per unit time in the other branch line is currently set. Set to increase more than the amount. For example, when the control device 5 reduces the production amount per unit time on the branch line L1, the control device 5 increases the production amount per unit time on the branch lines L2 and L3.

When the control device 5 determines that there is no worker who can handle the work, the control device 5 acquires the progress status of the work currently being performed. Specifically, in the present embodiment, the control device 5 acquires the work time required for the work supported by the worker. The working time is registered in advance in the working DB 11. Specifically, as shown in FIG. 4, the work DB 11 stores the "process", the "work" that may occur in the process, and the "work time" of the work in association with each other. .. The working time is set, for example, based on past work results.

The control device 5 refers to the work DB 11 and acquires the work time according to the work. The control device 5 may set the working time based on the proficiency level (years of experience, etc.) of the worker. Specifically, the control device 5 sets the work time to "10 min", for example, when the work time acquired from the work DB 11 is "15 min" and the proficiency level of the worker currently performing the work is high. Set to. That is, the control device 5 shortens the working time required for the work when the proficiency level of the worker is high. Further, the control device 5 may lengthen the working time when the proficiency level of the worker is low. The proficiency level is set in advance for each worker, for example.

When the control device 5 acquires the work time, the control device 5 acquires the progress status of the work based on the time when the worker starts the work. The time when the worker started the work can be obtained by various methods. For example, the time when the work is started may be automatically transmitted from the device when the worker starts the work in the device, or may be transmitted by the operation of the worker.

The control device 5 calculates the remaining work time based on the work time and the work start time. Specifically, the control device 5 calculates the remaining work time based on the following equation.
Remaining work time = work time- (current time-work start time)
The control device 5 acquires the progress status of the work by calculating the remaining time of the work. The control device 5 calculates the end time of the work based on the progress of the work. The work end time also includes the time for the worker to move to a position where the instruction of the next work can be confirmed on the display device 7. The travel time may be set based on the average travel time from the position where the work was performed to the position where the display device 7 is arranged, and information that can identify the position of the worker (GPS information, RFID). It may be set based on information etc.).

When the control device 5 calculates the end time of the work, the control device 5 resets the production amount of the production line 100. The control device 5 resets the production amount per unit time of the production line 100, which is set to decrease when the work end time is reached. Specifically, the control device 5 sets, for example, the production amount per unit time set in the production line 100 to the original production amount (production amount at the start of production, etc.). The control device 5 may increase the production amount per unit time set in the production line 100 from the original production amount. The end time of the work may be obtained by another method. For example, the end time of the work may be automatically transmitted from the device when the work is completed, or may be transmitted by the operation of the operator.

When the control device 5 calculates the end time of the work, the control device 5 generates instruction information instructing the worker who finishes the work to respond to the work. The control device 5 outputs the generated instruction information to the display device 7.

The display device 7 displays based on the instruction information output from the control device 5. The display device 7 is, for example, a display (monitor). The display device 7 is provided one or more in the production line 100. The display device 7 is arranged at a position visible to the operator.

Subsequently, the operation of the control system 1 of the production line will be described with reference to FIG. Each process P, P11 to P15, P21 to P25, P31 to P35 of each line L, L1 to L3 transmits a work request signal requesting the correspondence of the work when the work occurs.

As shown in FIG. 5, the receiving unit 3 receives the work request signals transmitted from the steps P, P11 to P15, P21 to P25, and P31 to P35 (step S01). Next, the control device 5 acquires the work based on the worker request signal (step S02). Subsequently, the control device 5 determines whether or not there is an operator who can perform the work (step S03). When the control device 5 determines that there is a worker who can perform the work (step S03: YES), the control device 5 proceeds to step S04. When the control device 5 determines that there is no worker capable of performing the work (step S03: NO), the control device 5 proceeds to step S07.

In step S04, the control device 5 determines a worker who performs the work. When the control device 5 determines the worker, the control device 5 generates instruction information for instructing the worker to work, and outputs the instruction information to the display device 7 (step S05). Upon receiving the instruction information output from the control device 5, the display device 7 displays a work instruction (step S06).

As shown in FIG. 6, for example, "line state" and "work" are displayed on the display device 7. For example, "line No.", "state" of the line, "time until work occurs", and "presence / absence of work" are displayed in correspondence with each other in the state of the line. In the example shown in FIG. 6, in the "line No.", the main line L is indicated by "1", the branch line L1 is indicated by "2", the branch line L2 is indicated by "3", and the branch line L3 is indicated by "4". FIG. 6 shows that work is occurring at line No. 2 (branch line L1).

In the work, "line No.", "work", and "worker" are displayed correspondingly. In the example shown in FIG. 6, it is shown that the film replacement work is occurring in the line No. 2 and the worker “0003” is instructed to handle the work. The number indicating the worker corresponds to the number associated with the worker in the worker DB9. In the "work" column of the display device 7, the work that occurs in the line where the work has not occurred may be displayed based on the priority of the work. The work priority is set based on the time until the work occurs.

As shown in FIG. 5, in step S07, the control device 5 sets the production amount. The control device 5 sets the production amount per unit time set in the production line 100 to be smaller than the currently set amount. Subsequently, the control device 5 acquires the progress status of the work (step S08). The control device 5 acquires the end time of the work based on the progress of the work, and resets the production amount according to the end time (step S09). After that, the control device 5 determines an operator (step S04) and outputs instruction information (step S05).

As described above, in the production line control system 1 according to the present embodiment, the control device 5 is set to the production line 100 when the worker registered in advance cannot process the work required by the work request signal. The production amount per unit time is set to be smaller than the currently set amount. As a result, even if there is no worker who can process the work, the production line 100 can be continuously operated without stopping the production line 100. Therefore, it is possible to stabilize the quality of the production object while suppressing the decrease in production efficiency. Further, as in the present embodiment, when the product produced on the production line 100 is food, the production line 100 continues to operate, so that the food due to deterioration of the food is compared with the case where the production line 100 is completely stopped. The amount of waste can be reduced. As a result, the control system 1 of the production line can stabilize the quality of the production object while suppressing the decrease in the production efficiency.

In the production line control system 1 according to the present embodiment, the control device 5 reduces the production amount per position time from the amount currently set according to the current production status in the production line 100. Set. In this configuration, since the production amount is set to decrease according to the current production status, control according to the status of the production line 100 becomes possible.

In the production line control system 1 according to the present embodiment, the production line 100 is provided with a plurality of branch lines L1 to L3. When the control device 5 is set so that the production amount per unit time in one branch line is set to be smaller than the currently set amount, the production amount per unit time in the other branch line is currently set. Set to increase more than the amount. In this configuration, even when the production amount in one branch line is decreased, the production amount in the other branch line is increased, so that the production amount as a whole can be maintained. Therefore, in the production line control system 1, the quality of the production object can be stabilized while suppressing the decrease in production efficiency.

Although the embodiments of the present invention have been described above, the present invention is not necessarily limited to the above-described embodiments, and various modifications can be made without departing from the gist thereof.

In the above embodiment, the embodiment in which the production line 100 has a plurality of lines L, L1 to L3 has been described as an example. However, the form of the production line is not limited to this. For example, the number of production lines may be one.

In the above embodiment, a mode in which the receiving unit 3 and the control device 5 are separately provided has been described as an example. However, the receiving unit 3 and the control device 5 may be composed of one device.

In the above embodiment, the embodiment in which the display device 7 is a display has been described as an example. However, the display device 7 may be, for example, a mobile terminal or the like.

In the above embodiment, the embodiment having the worker DB 9 and the work DB 11 has been described as an example. However, the worker DB 9 and the work DB 11 may be configured by one database. Further, the worker DB 9 and the work DB 11 may have a configuration included in the control device 5.

In the above embodiment, the embodiment in which the control device 5 sets the production amount per unit time to be smaller than the currently set amount according to the current production status on the production line 100 has been described as an example. .. However, the control device 5 may be set so that the production amount per unit time is reduced by a certain amount from the amount currently set. The fixed amount is set arbitrarily. With this configuration, the production amount per unit time can be surely reduced.

Further, the control device 5 may be set so that the production amount per unit time is reduced from the amount currently set according to the work situation of the worker. Specifically, the control device 5 reduces the production amount per unit time by more than the reference amount, for example, when the remaining time of the work is long in the progress of the worker. For example, when the remaining time of work is short in the progress of the worker, the control device 5 reduces the production amount per unit time to be less than the reference amount. In this configuration, since the production amount is reduced according to the work situation of the worker, it is possible to control according to the work situation of the worker. Therefore, it is possible to reliably avoid the situation where the work by the worker cannot keep up and the production line 100 is stopped.

In the above embodiment, the embodiment in which the production line 100 is provided with the main line L and a plurality of branch lines L1 to L3 branching from the main line L has been described as an example. However, the production line may be provided with a plurality of independent lines.

In the above embodiment, a mode in which No (number), a worker, a working state, and a working state are stored in association with each other in the worker DB 9 has been described as an example. However, the work that can be processed may be further associated and stored in the worker DB. That is, the work that can be processed by the ability of the worker may be associated. In the case of this configuration, the control device 5 refers to the worker DB 9 and extracts the worker whose attendance state is “1” and whose work state is “standby”. The control device 5 refers to the worker DB 9 and compares the extracted work that can be processed by the currently configurable worker with the work required by the work request signal. When the currently configurable worker can process the work required by the work request signal, the control device 5 determines that there is a worker who can handle the work. When the currently configurable worker cannot process the work required by the work request signal, the control device 5 determines that there is no worker who can handle the work. In this configuration, the worker is not instructed to perform work that the worker cannot handle. Therefore, it is possible to instruct work according to the ability of the worker.

1 ... Production system control system, 3 ... Receiver unit, 5 ... Control device (control unit), 100 ... Production line.

Claims (7)

A control system for a production line that includes multiple processes.
A receiving unit that receives work request signals from the devices provided in each process, and
A control unit that outputs information instructing work to a pre-registered worker based on the work request signal received by the receiving unit to a display device is provided.
If the control unit determines that there is no worker capable of performing the work requested by the work request signal at present, the control unit continues the operation in the apparatus provided in each process included in the production line. A production line control system that sets the production amount of the device per unit time to be smaller than the currently set amount. The control system for a production line according to claim 1, wherein the display device is a monitor or a mobile terminal that is arranged at a position that can be visually recognized by an operator and gives a work instruction. The production line includes a step of weighing by a combination weighing device, a step of packaging the weighed object with a packaging device, and a step of inspecting the packaging state of the package and the presence or absence of foreign matter in the package with an inspection device. Item 1. The control system for the production line according to Item 1. The pre-registered worker is associated with work that can be processed.
When the control unit receives the work request signal, the control unit compares the work that can be processed by the worker who can currently work among the pre-registered workers with the work required by the work request signal. The production line control system according to claim 1, wherein when the worker who can currently perform the work cannot process the required work, the production amount is set to be smaller than the currently set amount. The production according to claim 1 or 4, wherein the control unit sets the production amount per unit time to be smaller than the amount currently set according to the current production situation in the production line. Line control system. The production according to claim 1, 4 or 5, wherein the control unit sets the production amount per unit time to be smaller than the amount currently set according to the work situation of the worker. Line control system. There are multiple production lines,
When the control unit is set so that the production amount per unit time in one of the production lines is set to be smaller than the currently set amount, the production amount per unit time in the other production lines is currently set. The control system for a production line according to any one of claims 1 to 6, which is set to increase more than the amount of the product.

Images