JP7046020B2 - Operation management device and operation management method - Google Patents

Description

The present invention relates to an operation management device, and more particularly to an operation management device of a production system including a plurality of manufacturing devices and a transfer device for transporting products between the manufacturing devices.

In a production system consisting of multiple manufacturing devices and a transfer device that transports products between manufacturing devices, if a failure occurs in the manufacturing device or the transfer device, the operation instruction is changed based on the work failure information. The system to do is known.

For example, when a work failure occurs, it is determined whether the cause is due to the manufacturing equipment or the product, and if it is caused by the manufacturing equipment, an operation instruction is given not to use the manufacturing equipment that causes it, and if it is caused by the product Is known as a system (Patent Document 1) that does not give an operation instruction to a failed product. Further, there is known a system (Patent Document 2) in which when a work failure due to a product occurs, the work by another manufacturing apparatus is not performed on the failed product.

Japanese Unexamined Patent Publication No. 2005-346482 Japanese Unexamined Patent Publication No. 60-067056

Patent Document 1 has a problem that when the production system becomes large-scale and the time required for changing the operation plan after the work failure becomes long, the waiting time for waiting for the work instruction of the production system is extended and the production efficiency is lowered.

In Patent Document 2, since all other work for the product in which the work has failed is skipped and the product is lot-out, the work cannot be replanned and executed for the product in which the work has failed, and the production efficiency is lowered. There is a problem to do. In the case of assembly work, even if work failure due to parts occurs, if there is a margin in parts inventory and product delivery date, it is possible to improve production efficiency by changing parts and re-executing. desired.

The present invention has been made to solve the above-mentioned problems, and an object of the present invention is to realize operation management in which a decrease in production efficiency is suppressed even when a work failure occurs.

The operation control device according to the present invention is an operation control device that transmits an operation instruction to a production system that produces a product based on an operation plan, and is designated according to the work order of a plurality of devices constituting the production system. A work information database that stores the work information of the device specified in the operation plan, including the work number, the work failure product identification number that identifies the target product that failed the work, and the final work that determines the work skip. The work failure information database that stores the work failure information including the work skip final number specified by the number, and the product identification number of the product that was the work target in the work when the device completes the work abnormally are identified as the work failure product identification. Work failure information addition processing that adds the work failure information to the work failure information database, which is a number and does not specify the work skip final number, and an operation plan corresponding to the work failure information from the scheduler that formulates the operation plan. Upon reception, the work failure information update process for updating the work skip final number of each device stored in the work information database at the time of reception to the maximum value of the work number of each device , and transmission to the production system. When the product identification number of the work target product in the work information matches the product identification number in the work failure information and the final work skip number is equal to or higher than the work number in the work information, the transmission is performed. It is provided with a functional unit that executes a work skip determination process of deleting work information from the work information database without transmitting the work information to the apparatus.

According to the operation management device according to the present invention, even if the scheduler for formulating an operation plan and the operation management device for transmitting operation instructions are asynchronous production systems, when a work failure occurs, the work related to the work failure occurs. It has the effect of increasing the operating rate of the production system by skipping.

It is a figure which shows an example of the operation schedule of a job shop production system schematically. It is a figure which shows the structure of the production system provided with the operation management apparatus which concerns on this invention. It is a functional block diagram which shows the structure of the operation management apparatus of Embodiment 1 which concerns on this invention. It is a flowchart explaining the reception process in the operation plan receiving part of the operation management apparatus of Embodiment 1 which concerns on this invention. It is a flowchart explaining the response process in the work information acquisition request response part of the operation management apparatus of Embodiment 1 which concerns on this invention. It is a flowchart explaining the reception process in the work completion information receiving part of the operation management apparatus of Embodiment 1 which concerns on this invention. It is a flowchart explaining the transmission process in the operation information transmission unit of the operation management apparatus of Embodiment 1 which concerns on this invention. It is a flowchart explaining the work failure information addition process. It is a flowchart explaining the work skip determination process. It is a flowchart explaining the work skip process. It is a functional block diagram which shows the structure of the operation management apparatus of Embodiment 2 which concerns on this invention. It is a flowchart explaining the reception process in the work completion information receiving part. It is a flowchart explaining the response process in the work information acquisition request response part of the operation management apparatus of Embodiment 3 which concerns on this invention. It is a flowchart explaining the reception process in the work completion information receiving part of the operation management apparatus of Embodiment 3 which concerns on this invention. It is a flowchart explaining the response process in the work information acquisition request response part of the operation management apparatus of Embodiment 4 which concerns on this invention. It is a flowchart explaining the reception process in the work completion information receiving part of the operation management apparatus of Embodiment 5 which concerns on this invention.

<Introduction>
Prior to the description of the embodiment, a job shop production system using an AGV (Automatic Guided Vehicle) will be described.

The AGV is a vehicle that automatically transports products and parts in the factory. Recently, the AGV (AGV) that can be moved to any position in the factory by self-position estimation and cartography technology such as Slam (Simultaneous Localization and Mapping). Transport device) has been developed.

A job shop is a manufacturing device that independently performs some work, having a plurality of certain functions such as a product or part input function, a work such as processing or assembly, and a product payout. The job shop production system using AGV is a production system in which AGV transports products between job shops and the products are completed via a plurality of job shops. The manufacturing equipment and AGV are collectively referred to as "equipment". There are multiple job shops with equivalent functions, and you have the freedom to choose which job shop to work on the product.

In order to operate the job shop production system efficiently, the operation schedule of the AGV and the manufacturing equipment is important. The schedule creation of the production system is generally carried out based on the production capacity of the manufacturing equipment, the working time of the manufacturing equipment in each operation instruction, and the operation capacity information such as the movement time of the AGV. For order data that includes the type and number of products to be manufactured, create an optimal operation schedule based on driving ability information.

Here, the objective function to be determined to be optimal includes that the production time in the entire production system is short, the total operating time of each manufacturing apparatus is short, and the in-process time of the in-process product is short. In addition, if the order contains delivery date information, priority information, or both, there may be restrictions such as keeping the delivery date and keeping the priority.

The delivery date information may be expressed by the production completion time in the factory instead of the delivery date to the customer. By appropriately setting the operation schedule, the operating rate of the device can be increased, the operation time can be shortened, and the production cost can be reduced.

Since creating an operation schedule in a job shop production system is a large-scale optimization problem, it is mainstream to treat operation capacity information such as working time of manufacturing equipment and moving time of AGV as fixed values. Therefore, the operation schedule can be uniquely described by what time and what kind of work is performed by the manufacturing apparatus and the AGV. Further, when the in-process time of the work-in-process is not included in the objective function, it can be described only in the order of the operation instruction. FIG. 1 schematically shows an example of an operation schedule.

FIG. 1 shows the work in the manufacturing apparatus 1 to 3 and the movement schedule in the AGVs 1 to 3. For example, the work 2-2 is performed on the work (product) carried by the AGV1 in the movement 1-1. After that, AGV1 is moved by movement 1-2. Further, the work 3-2 is carried out on the work carried by the AGV2 in the movement 2-1. Further, the AGV3 moves the work that has completed the execution of the work 1-1 by moving 3-2.

Such an operation schedule is created based on the operation time of the manufacturing apparatus and the operation capacity information such as the movement time of the AGV, but the production system cannot be actually operated with such an operation schedule. This is because the working time of the actual manufacturing equipment and the traveling time of the AGV have an error from the luck capacity information. In addition, unpredictable events may occur at the time of creating the schedule, such as work mistakes in the manufacturing equipment due to errors in the input parts, avoidance of other vehicles in the movement of the AGV, traffic jams, and the like. For these reasons, it is not possible to strictly operate the operation schedule specified by time. Therefore, it is necessary to convert the operation schedule specified by the time into an operation plan on the condition that the work is completed, such as executing an operation instruction based on the completion of the work.

In actual operation, it is desirable to combine local optimization and global optimization. As an example of local optimization, assume a situation where both the transfer work between the AGV and the job shop and the machining or assembly work of the parts in the job shop can be performed.

For example, in consideration of improving the operating efficiency of other devices, it may be better to prioritize the transfer work with the AGV rather than the work in the job shop. Specifically, in a certain job shop, if priority is given to work on a product to be passed to a job shop different from the next destination of the AGV, the transfer work to the AGV is not completed, and the start of movement of the AGV is suspended, resulting in As a result, the operating efficiency at the job shop, which is the next destination of the AGV, will decrease. In this way, simple optimization can be realized only with information on the local situation such as the current state in the job shop. Such optimization performed only by spatially or temporally local information such as information in the job shop or the current state in the job shop is called local optimization.

Local optimization has the advantage that it requires less computational resources for judgment and can be realized by the control device of the manufacturing equipment. In many cases, the work priority is set in advance, and the work that satisfies the operation start condition is executed from the work with the highest priority.

Global optimization is an optimization performed based on the entire factory, the entire operation schedule, or both. For example, in order to prioritize the production of products that are close to the delivery date, there is a method of suspending the production of other products and waiting for the production equipment to be vacated. Another method is to set up an operation schedule so that the same work can be performed continuously so that the setup change of the manufacturing equipment is reduced.

Since global optimization has a wide range of information and judgment criteria for optimization, it is often processed by a device that has a dedicated function such as a scheduler and is different from the operation of the production system. In processing, solutions to scheduling problems that have been widely studied in the past can be applied to time-defined operating schedules.

In actual operation, work is delayed due to the operation schedule, so work is started within a range that does not affect global optimization, for example, if conditions are met even if the start time is around, and the work order does not matter. It is preferable to apply local optimization, for example, by not waiting for the completion of no work.

The embodiment according to the present invention described below is a production system including a plurality of manufacturing devices and a transport device for transporting products between the manufacturing devices. In particular, there are many types of products to be manufactured, and a plurality of manufacturing devices are used. It is related to a production system that can handle various types of products and has high redundancy.

However, the manufacturing apparatus does not execute all the processes of the product, but is divided into, for example, parts processing, fitting, caulking, wiring, inspection, and the like. Therefore, the unfinished product is transported between the plurality of manufacturing devices by the transport device, so that the product is completed.

In such a production system, there are fluctuations in working time for each product type and setup change time due to changes in product type. Therefore, the operating rate of the entire production system depends on the operation plan such as which manufacturing equipment each product is used for. It will change a lot. For example, if products that require different operations are mixed and operated in one manufacturing apparatus, the number of setup changes increases and the operating rate decreases. In addition to the operating rate, if different delivery dates are set for each product, the manufacturing equipment is secured for a specific product and put on standby so that the delivery dates of all products are satisfied. You also need to make a plan. Therefore, it is important to take a bird's-eye view of the entire production system and formulate an operation plan with global optimization in order to improve the operating rate of the production system. A non-real-time processing system is suitable because it takes time to formulate an optimum operation plan for the entire production system and requires computational resources. On the other hand, the responsiveness of work instructions to each device affects the operating rate of the production system, so a real-time processing system is suitable.

<Overview of production system>
FIG. 2 is a schematic diagram showing the configuration of the production system 100 provided with the operation management device according to the present invention, and is common to all the embodiments.

As shown in FIG. 2, the production system 100 includes a scheduler 10, an operation management device 20, a plurality of manufacturing devices 31, 32 to 3n, and a transfer device 41, 42 to 4 m. The transport device 41 to 4 m contains the AGV described above.

The scheduler 10 outputs the operation plan D10 based on the equipment information D1 and the order information D2 input from the outside of the production system 100 and the operation information D3 output from the operation management device 20.

The equipment information D1 has information on the capabilities (executable work and its work time, etc.) of the manufacturing apparatus and the transporting apparatus in the production system 100. Hereinafter, the manufacturing apparatus and the transporting apparatus are collectively referred to as "equipment".

The order information D2 has information on the type and number of products to be manufactured, and if necessary, the delivery date.

The operation information D3 is the current operation information of the production system 100 transmitted from the operation management device 20 to the scheduler 10 during the operation of the production system 100, and the details will be described later.

Based on the input information, the scheduler 10 formulates an operation plan including work information of each device in the production system 100 according to an appropriate evaluation standard, and outputs the operation plan to the operation management device 20 at appropriate intervals. The evaluation criteria are general production system evaluation criteria such as whether the ordered delivery date can be met, the overall manufacturing time is short, and the equipment utilization rate is high.

The operation plan D10 is a collection of work information of the equipment in the production system 100. The work information includes an identification number (device ID) of the device, a work content to be executed, and a work number uniquely set for each device ID.

The operation plan D10 is output at appropriate intervals according to the capacity and operation state of the production system 100. This interval is determined by the time required for re-planning the operation plan due to work failure or production delay from the production plan. For example, it is decided that the interval is longer than the time required from the information of the work failure to the re-planning. Except when troubles such as work failure occur or when it is not necessary to have the manufacturing equipment execute the work, the operation plan should include a sufficient amount of work information so that the work information waiting for each equipment does not occur. That is desirable.

The operation management device 20 transmits operation instructions D21, D22 to D2l for executing the operation plan to the manufacturing device and the transport device while managing the operation state of the production system based on the input operation plan D10. The operation plan may include a plurality of work information for each device, but the operation instruction sends only one work to be performed to each device.

When the work specified by the operation instructions D21 and D22 to D2l is completed, each device sends completion information to the operation management device 20 and sends a request for acquisition of the next work information.

When the manufacturing devices 31, 32 to 3n can execute the work in parallel, the operation management device 20 transmits an operation instruction in parallel to each manufacturing device.

The operation plan D10 also includes information for waiting for the transmission of the operation instruction in order to optimize the operation of the entire production system 100. For example, in a system in which a transport device 41 to 4 m can transport a plurality of products together, it is necessary to start the transport work after all the work on the product to be transported is completed and all the products are ready to be transported. There is. The conditions included in the work information in order to wait for the start of execution of the work, such as waiting for the completion of other work, are hereinafter referred to as guard conditions. Further, the state in which all the work to be waited for is completed and the work can be executed is hereinafter referred to as the guard condition is satisfied.

In the state where no work failure has occurred, the operation management device 20 has the work information included in the operation state and operation plan of the production system 100 and the work information for which the guard condition is satisfied based on the guard condition of the work information. Send operation instructions to each device. The measures to be taken when a work failure occurs will be described later. Further, the operation management device 20 transmits the operation information D3 necessary for drafting the operation plan, such as the completed work information and the progress state of the operation plan such as the work failure, to the scheduler 10.

Here, the problems of a large-scale production system will be described. In a large-scale production system that can handle a wide variety of products and has a high degree of freedom in operation planning, it becomes necessary to asynchronously operate a scheduler that formulates an operation plan and an operation management device that manages the operation of each device. Optimization of the operation plan is important to improve the operating rate of the production system, but in a large-scale production system with a high degree of freedom, optimization requires a lot of computational resources, so it takes time. On the other hand, it is desired that the operation management device transmits an operation instruction to the standby manufacturing device as soon as possible. Therefore, the method of calculating the optimum operation plan on demand and transmitting the operation instruction when the work of each device is completed is unrealistic from the viewpoint of the operating rate.

In addition, when formulating an operation plan, the model is simplified and optimized, such as not considering variations in working hours. However, in the actual operation of the production system, the work progress varies from the assumption of the operation plan because the work time varies. Therefore, it is difficult for the scheduler to accurately predict the operating state of the production system and formulate a production plan. As a result, it is realistic that the scheduler formulates an optimized operation plan in advance on the premise that work failure does not occur, and the operation management device sends operation instructions on demand with a simple judgment. be. Therefore, the scheduler sends an operation plan packed with work information for a certain period or longer to the operation management device, and the operation management device sends an operation instruction to the manufacturing device and the transfer device on demand while queuing the operation plan. The scheduler and the operation management device will be operated asynchronously.

When the scheduler and the operation management device are asynchronous and the operation management device operates the production system while queuing the operation plan, it is a problem to appropriately process the unexecutable work information related to the work failure. If the work information related to the work failure continues to remain, other work not related to the work failure cannot be executed, and the operation rate decreases. On the other hand, if the work is re-executed using the parts planned to be used for other products, a new setup change work may occur due to a shortage of parts and the like, and the optimum operation plan may be lost. Therefore, when the work fails, it is necessary to perform operation management based on the operation plan replanned by the scheduler in consideration of the work failure. As a result, the operation management device does not execute the work information of the operation plan corresponding to the work failure among the work information related to the work failure, and executes only the work information of the operation plan corresponding to the work failure. Is desired. In the embodiments described below, variations of the production system 100 for realizing these will be described.

<Embodiment 1>
<Device configuration>
FIG. 3 is a functional block diagram showing the configuration of the operation management device 20 according to the first embodiment of the present invention.

As shown in FIG. 3, the operation management device 20 includes an operation plan receiving unit 201, a work information acquisition request response unit 202, a work completion information receiving unit 203, and an operation information transmitting unit 204 as a functional unit 200, and serves as a database (DB). , Work information DB 21, work completion information DB 22, and work failure information DB 23. The functional unit 200 can be configured by using a computer, and is realized by the computer executing a program. That is, the functional unit 200 can realize the functions of each unit by executing a program stored in the storage device in a processor such as a CPU (Central Processing Unit) or a DSP (Digital Signal Processor).

The operation plan receiving unit 201 has a function of receiving and processing information such as an operation plan transmitted from the scheduler 10 (FIG. 2). The work information acquisition request response unit 202 has a function of responding to a work information acquisition request from the manufacturing apparatus and the transport apparatus. The work completion information receiving unit 203 has a function of receiving and processing work completion information from the manufacturing apparatus and the transporting apparatus. The operation information transmission unit 204 has a function of transmitting operation information to the scheduler 10.

The work information DB is a database that stores work information and the like included in the operation plan received from the scheduler 10. The work completion information DB 22 is a database for storing information on completed work of the manufacturing apparatus and the transporting apparatus. The work failure information DB 23 is a database for storing information regarding work failures of the manufacturing apparatus and the transport apparatus. Each database is composed of a storage device such as a hard disk.

<Operation>
<Operation in a situation where work failure does not occur>
The operation of each functional unit will be described below. First, the operation of each functional unit in a situation where work failure does not occur will be described.

Each functional unit starts processing in response to an event associated with processing of another functional unit or another device. An event is a well-known term in the field of systems management that refers to actions such as "processing completed", "database updated", and "preset latency updated". be.

FIG. 4 is a flowchart illustrating a reception process in the operation plan receiving unit 201. When the operation plan receiving unit 201 receives the operation plan transmitted from the scheduler 10 (FIG. 2), the operation plan receiving unit 201 updates the work information DB 21 (FIG. 3) and the work failure information DB 23 (FIG. 3).

When the reception process in the operation plan reception unit 201 is started as shown in FIG. 4, the operation plan reception process is first executed (step S1).

The operation plan reception process is a process of receiving the operation plan transmitted from the scheduler 10. Following the operation plan reception process, the work failure information update process is executed (step S2).

The work failure information update process processes information related to the response to the work failure information from the scheduler 10 included in the operation plan, and the details of the process will be described later. In the situation where no work failure has occurred, the work failure information update process is not executed.

After that, the work information storage process is executed (step S3). The work information storage process adds the work information included in the received operation plan to the work information DB 21. The work information includes a device ID for performing work, a work number, a product ID for work, guard conditions, and the like.

The device ID for performing the work is an ID for identifying the device instructing the operation of the work. The work number is a number uniquely assigned to each work information, and the work is executed in ascending order of the work numbers at least in each device. As the work number, a unique number may be assigned to the entire production system, or a unique number may be assigned to each device in which the work is performed.

The guard condition is information used to execute the work after waiting for the work completion of another device, and includes information such as a device ID and a work number that can specify the work information to be waited for completion. ..

The work information DB 21 manages unfinished work information of each device, and the work information of each device is stored in the order of work numbers.

When the addition of the work information by the work information storage process is completed, the series of processes of the operation plan receiving unit 201 is completed.

FIG. 5 is a flowchart illustrating the response process in the work information acquisition request response unit 202. The work information acquisition request response unit 201 transmits work information to be started by each device to each device in response to a work information acquisition request from each device. If the device that sent the work information acquisition request has no work to start immediately, the work information is not sent. Each device transmits a work information acquisition request to the operation management device 20 (FIG. 2) when there is no work instruction and the work is not being executed.

As shown in FIG. 5, when the work information acquisition request response unit 202 starts the response process in the reception event of the work information acquisition request, first, in the work information request acquisition process, the device that transmits the work information acquisition request ( Identify the device ID of the requesting device) (step S11).

Next, in the work information acquisition process, the work information having the smallest work number among the work information of the requesting device from which the device ID is identified is acquired from the work information DB 21 (FIG. 3) (step S12).

Next, in step S13, it is determined whether or not the work information of the requesting device is stored in the work information DB 21, and if none of the work information is stored (in the case of No), the work information response process in step S20 is performed. Transition. On the other hand, when the work information of the requesting device is stored in the work information DB 21 (in the case of Yes), the process proceeds to the guard condition determination process in step S14. At this time, the work information in the work information DB 21 is stored in the work information DB 21 as it is.

In the guard condition determination process of step S14, the guard condition of the work information acquired in the work information acquisition process (step S12) is confirmed, and it is determined whether or not the guard condition is satisfied. As a result of checking the guard condition, if the guard condition is not set or the work specified in the guard condition has already been completed (in the case of Yes), it is determined that the guard condition is satisfied (step). S15). On the other hand, if the work specified by the guard condition has not been completed yet (in the case of No), it is determined that the guard condition has not been satisfied, and the process proceeds to the work information response process in step S20.

Whether or not the work specified in the guard condition has been completed is determined by the work completion final number of each device stored in the work completion information DB 22 (FIG. 3) and the work number of the work information acquired in the work information acquisition process. Judgment by comparing. If the guard condition is satisfied, the process proceeds to the work information failure information collection process in step S16.

If the work failure information DB 23 (FIG. 3) does not include the work failure information, the work failure information collection process does nothing and shifts to the work skip determination process in step S17.

In the subsequent work skip determination process, it is confirmed whether or not the work failure information has been acquired in the work failure information collection process, and if there is no work failure information, an execution determination is made (step S18), and the work information response process (step S20). ).

When the execution is determined in the work skip determination process, in the work information response process, the work information acquired in the work information acquisition process in step S12 is transmitted to the requesting device to complete a series of processes.

If the work information cannot be obtained in the work information acquisition process (step S12), or if the guard condition is not satisfied in the guard condition determination process (step S14), the work in the work information response process (step S20) is performed. Responds to the requesting device as no information and completes a series of processes.

FIG. 6 is a flowchart illustrating a reception process in the work completion information receiving unit 203. The work completion information receiving unit 203 updates the work information DB 21 (FIG. 3), the work completion information DB 22 (FIG. 3), and the work failure information DB 23 (FIG. 4) according to the work completion information from each device.

When each device completes the work, the work completion report is transmitted to the operation management device 20. The work completion report includes information on the work number for identifying the completed work, information for identifying the completion status, and the like. The information for identifying the completed state includes information for identifying what kind of abnormality is in the case of abnormal completion, in addition to identifying whether it is normally completed or abnormally completed.

As shown in FIG. 6, when the work completion information receiving unit 203 starts the process in the work completion information reception event or the like, first, the process of receiving the work completion information in the work completion information receiving process is executed (step). S21). Then, it is determined whether the work completion information received in step S22 is normal completion or abnormal completion, and if it is normally completed, the work completion information update process is subsequently executed (step S23).

The work completion information update process updates the work completion final number of the device that has executed the work stored in the work completion information DB 22 with the work number of the work completion information received in step S21. After that, the work information DB 21 is updated by the work information update process in step S24.

In the work information update process, the work information specified by the work completion information is deleted from the work information DB 21, and a series of processes of the work completion information receiving unit 203 are completed.

As a result, the work acquired in the work information acquisition process (S12) of the work information acquisition request response unit 202 moves to the next work. On the other hand, the work failure information addition function executed when it is determined to be abnormally completed in step S22 will be described later.

FIG. 7 is a flowchart illustrating a transmission process in the operation information transmission unit 204. The operation information transmission unit 204 transmits the operation information of the production system 100 (FIG. 2) to the scheduler 10 (FIG. 2).

As shown in FIG. 7, the operation information transmission unit 204 starts processing at an event such as the elapse of a certain time or the update of the work completion information DB 22 (FIG. 3) or the work failure information DB 23 (FIG. 3), and the work is completed. The information collection process is executed (step S31). The work completion information collection process collects information to be transmitted to the scheduler from the work completion information DB 22, the work failure information DB 23, or both, collects them as operation information, and proceeds to the operation information transmission process in step S32. The information to be collected includes the work completion final number of each device, work failure information, and the like.

In the operation information transmission process, the operation information collected in the work completion information collection process is transmitted to the scheduler 10 (FIG. 2). When the operation information is transmitted to the scheduler 10 in the operation information transmission process, the operation information transmission unit 204 completes a series of processes.

When the work is normally completed, the operation management device 20 transmits an operation instruction to each device based on the operation plan and is completed by the production system 100 to the scheduler 10 as in the process described above. The work done is sent as driving information.

<Operation when work failure occurs>
Next, the operation of each functional unit when a work failure occurs will be described. The work failure described in the present embodiment will be described for the failure caused by the product. A work failure caused by a product is a work failure that occurs due to a manufacturing error of a part, etc., and is a work failure that can continue production if the product that failed the work and the work instruction to the product are excluded, and is generally called a chocolate stop. It is a failure.

When a product-induced work failure occurs, it is desirable to temporarily eliminate work instructions for the product and automatically continue production. In the entire production system, work failures caused by products occur in various places and may occur continuously on the same device or products that have resumed production, so special measures are taken to eliminate and resume work instructions. Is required.

First, when a work failure occurs, the work completion information of the abnormal completion is transmitted from the device in which the failure has occurred to the operation management device 20. Then, the abnormal completion is received in the work completion information reception process (step S21) of the work completion information receiving unit 203 of the operation management device 20.

After that, in the work failure information addition process (step S25), the work failure information is updated or added to the work failure information DB 23 (FIG. 3) based on the work completion information. The work failure information includes a work failure information ID, a work failure product ID for identifying which product the work has failed, and a work skip final number for each device ID included in the production system 100.

In the work failure information addition process, a new number is assigned to the work failure information ID, the work failure product ID of the work failure information is set by the work failure product ID included in the work completion information, and the work skip final number is the work skip. It is defined as the final work number for carrying out the determination, and is set to a value that is not used as the work number of the work information such as NULL, and is not specified.

Then, it is confirmed whether the work failure information having the same work failure product ID as the work failure product ID of the set work failure information is stored in the work failure information DB 23. If it is saved, the work failure information ID and the work skip final number of the saved work failure information having the same work failure product ID are updated with newly set values. If it is not saved, the newly set work failure information is added.

The flow chart of FIG. 8 shows the flow of the work failure information addition process described above. When an abnormal completion is received in the work completion information receiving process of the work completion information receiving unit 203, the work failure information addition processing is started, and first, a new number is assigned to the work failure information ID to add new work failure information. (Step S161).

Next, it is confirmed whether the work failure information having the same work failure product ID as the work failure product ID of the newly created work failure information is saved in the work failure information DB 23 (step S162).

When it is saved in the work failure information DB 23 (in the case of Yes), the work failure information ID and the work skip final number of the work failure information having the same work failure product ID saved are updated (step S163). Ends a series of processes.

On the other hand, when the work failure information DB 23 is not saved (in the case of No), the work failure information is newly added (step S164), and a series of processes is terminated.

After the work failure information is added, the work to the work failure product ID in all the devices is skipped by the process described below until the operation plan corresponding to the work failure is transmitted from the scheduler 10.

When the work failure information collection process (step S16) of the work information acquisition request response unit 202 is executed while the work failure information is stored in the work failure information DB 23, the work failure information collection process first performs the work information. It is determined whether the work information (hereinafter referred to as the corresponding work information) acquired from the work information DB 21 by the acquisition process (step S12) includes the product ID that specifies the product to be worked.

For example, in the case of work on a product, the corresponding work information includes information on the product ID of the work target. However, if the work does not target the product, such as the setup change work due to the change of the product type, the information of the product ID of the work target is not included in the corresponding work information. When the product ID is included in the work information, the work failure information collection process collects the work failure information in which the product ID of the work information and the work failure product ID match from the work failure information DB 23.

Subsequently, in the work skip determination process (step S17), it is determined whether or not to skip the corresponding work information based on the work skip final number for each device ID of the work failure information collected in the work failure information collection process.

In the determination, first, the work skip final number of the device ID that matches the device ID included in the corresponding work information included in the work failure information is acquired. When the acquired work skip final number is not specified as a value that is not used as the work information work number such as NULL, or when the work number of the corresponding work information is less than or equal to the work skip final number. , Judge that the corresponding work information is skipped.

On the contrary, when the work number of the corresponding work information is larger than the work skip final number, it is judged (execution judgment) that the corresponding work information is executed.

The flow chart of FIG. 9 shows the flow of the work skip determination process described above. In the work failure information collection process (step S16), when the work skip determination process is started by collecting the work failure information in which the product ID of the corresponding work information and the work failure product ID match from the work failure information DB 23, the work failure information becomes the work failure information. Acquire the work skip final number of the device ID that matches the device ID included in the corresponding work information (step S171).

Next, it is determined whether or not the work number of the corresponding work information is larger than the work skip final number acquired in step S171 (step S172).

Then, when the work number of the corresponding work information is larger than the work skip final number (in the case of Yes), the execution determination of the corresponding work information is performed (step S173). On the other hand, when the work number of the corresponding work information is equal to or less than the work skip final number (in the case of No), it is determined that the corresponding work information is skipped (step S174). A series of processes is terminated by the execution judgment or the skip judgment.

When a skip determination is made in the work skip determination process, the work skip process (step S19) is executed. The work skip process deletes the corresponding work information from the work information DB 21, and updates the work completion final number of the device ID of the corresponding work information in the work completion information DB 22 with the work number of the corresponding work information.

The flow of the work skip process described above is shown in the flowchart of FIG. When the work skip process is started by the skip determination in the work skip determination process, the corresponding work information is deleted from the work information DB 21 (step S191).

Next, the work completion final number of the device ID of the corresponding work information in the work completion information DB 22 is updated with the work number of the corresponding work information (step S192), and a series of processing is completed.

After that, the work information acquisition request response unit 201 shifts to the work information acquisition process (step S12). By these series of processes, the work on the product in which the work failure has occurred is skipped until the work number of the work information becomes larger than the work skip final number. In addition, the work completion final number of each device is updated with the skipped work number.

Subsequently, the process until the operation plan D10 corresponding to the work failure is transmitted from the scheduler 10 and the work on the product in which the work failure has occurred is restarted will be described.

The operation information transmission unit 204 (FIG. 3) includes the work failure information of the work failure information ID, which is included in the work failure information DB 23 and has not been transmitted to the scheduler 10, in the operation information and transmits the work failure information to the scheduler 10.

When the scheduler 10 receives the operation information including the work failure information, the scheduler 10 re-formulates the operation plan corresponding to the work failure. At this time, if the operation is such that the work order of each product is fixed, the scheduler 10 can determine which work is skipped in the already transmitted operation plan from the work failure information. Therefore, it is possible to formulate an operation plan D10 following the transmitted operation plan D10. When the scheduler completes the re-planning of the operation plan D10 corresponding to the work failure, the corresponding work failure information ID list, which is the information of the work failure information ID for which the correspondence is completed, is added to the operation plan and transmitted to the operation management device 20. .. The operation plan receiving unit 201 (FIG. 3) of the operation management device 20 processes the corresponding work failure information ID list in the work failure information update process.

In the work failure information update process, the work skip final number of each device is set to the work failure information corresponding to the work failure information ID included in the corresponding work failure information ID list, and the work skip final number of each device included in the current work information DB 21 is set. Update with the maximum work number. After that, when the work number of the work information becomes larger than the work skip final number by the work skip determination process of the work information acquisition request response unit 202 (FIG. 3), the work skip of each device to the work failure information ID is completed, and the product Work on will be resumed.

Here, the work skip determination process determines whether the work number of the work information is larger than the work skip final number in all the devices, and if it is large, even if the corresponding work failure information is deleted from the work failure information DB 23. good.

As described above, according to the operation management device 20 of the first embodiment, the work failure information includes the work failure product ID and the work skip final number of each device, and an operation plan corresponding to the work failure is formulated. And the work skip final number is updated, and among the work information in which the work failure product ID and the work target product ID match, the work with the work number up to the updated work skip final number is skipped and the work skip final number is skipped. Work information with a later work number can send an operation instruction to the device. As a result, even if the scheduler for making an operation plan and the operation management device 20 for transmitting an operation instruction to the device based on the operation plan are asynchronous production systems, the work failure is related to the work failure. It has the effect of skipping work and increasing the operating rate of the production system, as well as being able to continuously shift to an operation plan that responds to work failures.

In the present embodiment, the job shop production system using the AGV has been described, but the form of the transfer device and the device is not limited to this. Other machines such as a conveyor may be used as the transport device. Further, the manufacturing apparatus may not be a job shop having a plurality of functions, but may be a machine having only a single function or a machine having other forms.

<Embodiment 2>
Information on the surplus parts may be included in the operation plan, and if there are surplus parts, the same operation instruction may be sent to the device in which the work failure occurs when the work failure due to the parts occurs.

Even if the work caused by the supplied parts fails in the assembly work or the like, if there are surplus parts, the operation plan can be continued by using the surplus parts. Re-planning the operation plan of the entire production system requires a large amount of computational resources, and if the frequency of re-planning requests is high, problems such as the re-planning of the operation plan corresponding to all the requests may not be completed. be. Therefore, if there is a high possibility that the work can be re-executed using the surplus parts and the operation plan can be continued, the operation management device does not request the re-planning of the operation plan, but within the range of the surplus parts. It is desirable to re-execute the work. In the second embodiment, an operation management device capable of such operation management will be described.

<Device configuration>
FIG. 11 is a functional block diagram showing the configuration of the operation management device 20A according to the second embodiment of the present invention.

As shown in FIG. 11, the operation management device 20A includes an operation plan receiving unit 201, a work information acquisition request response unit 202, a work completion information receiving unit 203A, and an operation information transmitting unit 204 as functional units, and serves as a database (DB). It includes a work information DB 21, a work completion information DB 22, a work failure information DB 23, and a surplus product information DB 24. In FIG. 11, the same components as those of the operation management device 20 described with reference to FIG. 3 are designated by the same reference numerals, and duplicate description will be omitted.

FIG. 12 is a flowchart illustrating a reception process in the work completion information receiving unit 203A. In the reception process of the work completion information receiving unit 203A, the function re-execution determination process (step S26) is performed prior to the work failure information addition process (step S25).

The scheduler 10 (FIG. 2) includes the surplus information of the parts used in the work in the operation plan D10 (FIG. 2) and transmits the information to the operation management device 20A. For example, information on the number of surplus parts to be supplied in the setup change is added to the work information such as the setup change work of the parts and transmitted.

When the work information storage process (FIG. 4) in the operation plan receiving unit 201 of the operation management device 20A stores the work information in the work information DB 21, if the work information includes information on the number of surplus items, the information is surplus. Stored in the product information DB 24. When a work failure due to a component occurs in the work of the apparatus, the work completion information receiving unit 203A receives the work completion information of the abnormal completion, and the re-execution determination process (step S26) is executed.

In the re-execution determination process, the number of surplus parts used in the abnormally completed work stored in the surplus product information DB 24 is confirmed. Then, when it is determined that there is a surplus product, it is determined to be re-executed (step S27), the number of surplus products stored in the surplus product information DB 24 is reduced, and the processing of the work completion information receiving unit 203A is completed. do. At this time, unlike the case of normal completion, the work information included in the work information DB 21 is not deleted by the work information update process (step S24). Therefore, when the work information acquisition request response unit 202 (FIG. 11) acquires the work information request from the device that failed the work, the work information acquisition request response unit 202 (FIG. 11) responds with the same work information as the failed work information.

On the other hand, when the re-execution determination document processing confirms the surplus product information DB 24, if it is determined that there is no surplus product, it is determined that the abnormality is completed (step S27), and the work failure information addition processing is performed as in the first embodiment. Is executed, and it is required to skip the work for the same product and re-plan the operation plan to the scheduler.

In addition to associating the surplus product information with the parts and storing it in the surplus product information DB 24, there is also a method of designating the number of re-executable times in each work information. In this case, the surplus product information DB 24 is not required, and the re-execution determination process of the work completion information receiving unit 203A refers to the number of re-executable times included in the work information, and the re-executable number of times re-executed the work. If it is larger than the number of times, it will be determined to be re-executed.

As described above, according to the operation management device 20A of the second embodiment, when the work of the device is abnormally completed, it is determined by the re-execution determination process whether the re-execution is possible, and the re-execution is possible. By executing the same work, it is possible to reduce the number of requests for re-planning the operation plan to the scheduler 10, which has the effect of increasing the operating rate of the production system 100.

<Embodiment 3>
When a failure caused by the device occurs, the work on the product to be transported to the device in which the work has failed may be skipped. A work failure caused by a device is a work failure that occurs due to a failure of the device or the like, and is a work failure in which production cannot be continued until the device is readjusted. When a work failure occurs due to a device, it is produced except for the work instruction to the device that failed the work (hereinafter referred to as the corresponding device) and the work on the product whose operation plan includes the work execution on the corresponding device. It is desirable to continue. In the case of a failure caused by the device, automatic recovery is not performed in the production system, so restarting the failed device is not considered. In the third embodiment, an operation management device capable of such operation management will be described.

<Device configuration>
FIG. 13 is a flowchart illustrating a response process in the work information acquisition request response unit 202B of the operation management device 20B according to the third embodiment of the present invention. In the functional block diagram of the operation management device 20B, in the functional block diagram of the operation management device 20 of the first embodiment described with reference to FIG. 3, the work information acquisition request response unit 202 is used as the work information acquisition request response unit 202B. The configuration is changed and the work completion information receiving unit 203 is changed to the work completion information receiving unit 203B. The same configuration as that of the operation management device 20 described with reference to FIG. 3 is designated by the same reference numerals and duplicated explanations are given. Is omitted.

Further, in the flowchart shown in FIG. 13, in the flowchart of the work information acquisition request response unit 202 of the first embodiment described with reference to FIG. 5, the work failure device transport work confirmation process (work failure device transport work confirmation process) is performed before the guard determination process (step S14). Step S131) has been added.

FIG. 14 is a flowchart illustrating a reception process in the work completion information receiving unit 203B. As shown in FIG. 14, when the work completion information received in the work completion information reception process (step S21) of the work completion information receiving unit 203B is determined to be abnormally completed in step S22, the process proceeds to step S28. It is determined whether the abnormal completion is caused by the product or the device.

Then, if the abnormal completion is caused by the product, the process proceeds to step S25, and the work failure information addition process is executed. On the other hand, if the abnormal completion is caused by the device, the process proceeds to step S29, and the device-induced work failure information addition process is executed.

The device-induced work failure information addition process updates or adds the device-induced work failure information to the work failure information DB 23 (FIG. 3). The work failure information caused by the device includes a work failure information ID, a failure device ID for identifying which device the work has failed, and a failure device work schedule product ID related to the work in the failure device. In the device-induced work failure information addition process, a new number is assigned to the work failure information ID, the failed device ID is set to the work failed device ID included in the work completion information, and the failed device work scheduled product ID is set to empty. do. Then, the work failure information caused by the device set in the work failure information DB 23 is added.

As shown in FIG. 13, in the work failure device transport work confirmation process (step S131) in the work information acquisition request response unit 202B, first, the work information acquired in the work information acquisition process (step S12) (hereinafter referred to as the corresponding work information). Check if the (name) is the transfer work to the device where the work failure caused by the device has occurred. If the corresponding work is a transfer work to a device in which a work failure due to the device has occurred (hereinafter referred to as the corresponding device), a failure device work schedule product of the work failure information caused by the device for which the ID of the corresponding device is set. Add the product ID of the product to be transported in the transport work of the corresponding work to the ID.

Next, the guard condition is collected in the guard condition determination process in step S14, and if it is determined in step S15 that the guard condition is satisfied, the process proceeds to the work failure information collection process in step S16.

In the work failure information collection process, in addition to the work failure product ID included in the work failure information caused by the product, the failure device work scheduled product ID included in the work failure information caused by the device is also confirmed from the work failure information DB 23, and the work is performed. Collect work failure information related to the product ID included in the information.

When the work failure information collection process collects work failures caused by the device, the work skip determination process (step S17) determines the work information as a skip determination.

As described above, according to the operation management device 20B of the third embodiment, when a work failure due to a device such as a device failure occurs, the work information to the product via the device that failed the work is deleted. This does not interfere with the work of other products, and has the effect of improving the operating rate of the entire production system 100.

<Embodiment 4>
When a work failure due to a device occurs, the destination of the work information to be transferred to the device in which the work failure has occurred may be changed. If the upper limit of the transfer work that can be accepted by each device is fixed, the transfer work to the device that has failed due to the device cannot be executed, and the transfer device may stop at another device. Therefore, in the case of the transfer work to the device in which the work failure has occurred, the transfer destination is changed to the transfer to the standby place of the transfer device or the like and executed.

FIG. 15 is a flowchart illustrating response processing in the work information acquisition request response unit 202C of the operation management device 20C according to the fourth embodiment of the present invention. In the functional block diagram of the operation management device 20C, in the functional block diagram of the operation management device 20 of the first embodiment described with reference to FIG. 3, the work information acquisition request response unit 202 is used as the work information acquisition request response unit 202C. The modified configuration is adopted, the same configuration as that of the operation management device 20 described with reference to FIG. 3 is designated by the same reference numerals, and duplicate description is omitted.

Further, the flowchart shown in FIG. 15 is the flowchart of the work information acquisition request response unit 202B of the third embodiment described with reference to FIG. 13, before the work skip determination process (step S17), the transfer work change determination process ( Step S161) has been added.

In the transfer work change determination process, when the work information acquired in the work information acquisition process (step S12) is the transfer work and the transfer destination is registered in the failure device ID in the work failure information caused by the device, the transfer work change determination process is performed. This is a process for changing the destination of work information. In the work information for which the work information is changed, the execution is determined in the work skip determination process (step S17) and the process proceeds to step S20. Send the modified work order to the device.

The change of the transport destination is, for example, a standby place of the transport device. Since the scheduler 10 (FIG. 2) can recognize that the transfer destination of the transfer device is changed from the operation information including the work failure information transmitted from the operation information transmission unit 204 of the operation management device 20C, the transfer destination of the transfer device Redesign the operation plan based on the changed state.

As described above, according to the operation management device 20C of the fourth embodiment, it is planned to move to the corresponding device by changing the transfer destination of the transfer work to the device whose work has failed due to a failure or the like. It has the effect of preventing the transport device from stopping at other devices and improving the operating rate of the entire production system.

<Embodiment 5>
If there is a degree of freedom in the work order of the product so that parts independent of each other are assembled, and the work order is not uniquely determined in the operation plan, the operation management device 20 is in the work state at the time when the work caused by the product fails. May be sent to the scheduler 10. If the work order of the product is not uniquely determined, the scheduler 10 cannot grasp the work progress status of the product only from the work failure information. When the operation management device 20 receives the work failure so that the scheduler 10 can determine how the operation plan is processed in relation to the work failure when the scheduler 10 receives the work failure information. The progress status of the entire production system 100 in the above may also be transmitted to the scheduler 10.

FIG. 16 is a flowchart illustrating a reception process in the work completion information receiving unit 203C of the operation management device 20D according to the fifth embodiment of the present invention. In the reception process of the work completion information receiving unit 203C, the work state recording process (step S30) is performed after the work failure information addition process (step S25).

In the functional block diagram of the operation management device 20D, the work completion information receiving unit 203 is changed to the work completion information receiving unit 203C in the functional block diagram of the operation management device 20 of the first embodiment described with reference to FIG. The configuration is adopted, the same configuration as that of the operation management device 20 described with reference to FIG. 3 is designated by the same reference numerals, and duplicate description is omitted.

The work state recording process is a process in which the operation information transmission unit 204 of the operation management device 20D acquires the work number included in the last work information that has been transmitted to each device at the time when the work state recording process is executed. be.

Then, the work failure information of each newly acquired device is added to the work failure information added to the work failure information DB 23 in the work failure information addition process immediately before. The scheduler 10 determines how the already transmitted operation plan is executed from the operation information including the work failure information transmitted from the operation information transmission unit 204 (FIG. 3) of the operation management device 20D, and operates. Re-plan. At this time, the scheduler 10 determines that the work information that has been sent to the device is executed, and that the work information that has not been sent to the device and is related to the work failure is skipped.

As described above, according to the operation management device 20D of the fifth embodiment, the work information of each device at the time when the work failure occurs is transmitted to the scheduler 10 as the work failure information. Therefore, even if the work order of the products is not uniquely determined and the work order has a degree of freedom, the scheduler 10 can determine the processing content of the production system 100 for the already transmitted operation plan. As a result, the scheduler 10 can re-form the operation plan when the work failure information is received, which has the effect of increasing the operating rate of the production system.

<Acknowledgments>
This research was carried out as part of the Innovative Research and Development Promotion Program (ImPACT) led by the Council for Science, Technology and Innovation. "This work was funded by ImPACT Program of Council for Science, Technology and Innovation (Cabinet Office, Government of Japan)."

In the present invention, each embodiment can be freely combined, and each embodiment can be appropriately modified or omitted within the scope of the invention.

10 scheduler, 21 work information DB, 23 work failure information DB, 200 functional parts.

Claims (6)

An operation management device that sends operation instructions to a production system that produces products based on an operation plan.
A work information database that includes work numbers specified according to the work order of a plurality of devices constituting the production system and stores work information of the devices specified in the operation plan.
A work failure information database that stores work failure information including the work failure product identification number that identifies the work failure target product and the work skip final number specified by the final work number that determines work skip, and
When the device abnormally completes the work, the product identification number of the product targeted for the work in the work is set as the work failure product identification number, and the work failure information in which the work skip final number is not specified is used as the work failure information database. Work failure information addition process to be added to
When an operation plan corresponding to the work failure information is received from the scheduler for formulating the operation plan, the work skip final number of each device stored in the work information database at the time of reception is set to the work number of each device. Work failure information update process to update to the maximum value , and
When the product identification number of the work target product in the work information transmitted to the production system matches the product identification number in the work failure information and the work skip final number is equal to or higher than the work number in the work information. Is an operation management device including a functional unit that executes a work skip determination process of deleting the work information to be transmitted from the work information database without transmitting the work information to the device. The functional part is
Prior to the work failure information addition process,
If the device has completed the work abnormally and there is a surplus in the parts used in the work that has completed abnormally, a re-execution determination process for determining that the same work is to be re-executed is performed.
The operation management device according to claim 1, wherein when the same work is re-executed, the operation instruction is transmitted again with the same work information as the abnormally completed work without executing the work failure information addition process. The functional part is
When an abnormal completion of work caused by the device occurs, the device identification number of the device in which the abnormal completion has occurred and the product identification number to be skipped of the work are included in the work failure information. Device-induced work to be added to the failure information database Executes the failure information addition process and
When the work information to be transmitted is the transfer work information to the device in which the abnormal completion has occurred, the work failure device transfer work confirmation process for adding the product identification number to be transferred in the work information to the work failure information. The operation management device according to claim 1. The functional part is
The operation according to claim 3, wherein when the work information to be transmitted is a transfer operation to the device in which an abnormal completion has occurred, a transfer work change determination process for changing the transfer destination to the standby position of the transfer device is executed. Management device. The functional part is
The invention according to any one of claims 1 to 4, wherein the work state recording process for recording the work information for which the operation instruction has been transmitted to the plurality of devices is executed when the abnormal completion of the device is received. Operation management device. It is an operation management method that sends operation instructions to the production system that produces products based on the operation plan.
A work information database that stores work information of the equipment specified in the operation plan, including work numbers specified according to the work order of the plurality of equipment constituting the production system, and a work information database.
Uses a work failure product identification number that identifies the target product that failed work, and a work failure information database that stores work failure information including the work skip final number specified by the final work number that determines work skip. ,
When the device abnormally completes the work, the product identification number of the product targeted for the work in the work is set as the work failure product identification number, and the work failure information in which the work skip final number is not specified is used as the work failure information database. Work failure information addition processing to be added to
When an operation plan corresponding to the work failure information is received from the scheduler for formulating the operation plan, the work skip final number of each device stored in the work information database at the time of reception is set to the work number of each device. Work failure information update processing to update to the maximum value ,
When the product identification number of the work target product in the work information transmitted to the production system matches the product identification number in the work failure information and the work skip final number is equal to or higher than the work number in the work information. Is an operation management method in which a processor executes a work skip determination process of deleting the work information to be transmitted from the work information database without transmitting the work information to the apparatus.

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