JPH05200657A - Operation analyzer of production line - Google Patents

Abstract

PURPOSE:To conduce to an improvement in the operation rate of a production line as a whole by analyzing and grasping a primary factor hindering the operation rate so accurately. CONSTITUTION:An information collection of each production machine is performed by an information gethering means, an information processing means and a storage means 13. On the basis of these information data, a longest process machine is judged by a longest process machine judging means 14, and a stopped state of this machine is detected by a stopped state detection means 21. In succession, a machine or a cause of the stoppage is judged by a cause machine judging means 22, and a stop factor is analyzed by a stop factor analyzing means 23, while a stop time is accumulatively operated by a stop time accumulating means 24, then the result is displayed to the outside by a display means 16 through a data reduction means 25.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a production line equipped with a plurality of machines for executing various processes on a work,
The present invention relates to a device for automatically performing the operation analysis.

[0002]

2. Description of the Related Art Generally, in a production line equipped with a plurality of machines for executing various processes, machine control means such as a sequencer is provided for each machine, and each machine is controlled individually by the machine control means. The process is executed, and the machine control means detects the operating state of each machine, for example, the cycle time of each machine and the stop time due to various hindrance factors. Here conventionally,
The factors that prevent the operation of each machine are analyzed individually, and based on the results, measures are taken to improve the operation rate of each machine individually.

[0003]

Even if the operating rate of each machine is improved as described above, the operating rate of the entire production line is often not effectively improved. This means that even if the loss time due to the obstructing factors of individual machines (for example, failure or tool change) is reduced, the loss time due to the obstructing factors regarding the relationship between the machines, for example, there is no work on the upstream side of a specific machine. The time to wait for the process to be executed until the work is supplied to the machine (that is, the work carry-in waiting time), and the time to wait for the work to be carried out until the work is accumulated because the work is accumulated on the downstream side ( That is, it is because the work unloading waiting time) is not taken into consideration.

In view of the above situation, the present invention is capable of contributing to the improvement of the operating rate of the whole production line by accurately analyzing and grasping the factors that hinder the improvement of the operating rate. The purpose is to provide.

[0005]

[Means for Solving the Problems] Normally, the cycle time of each machine in the above production line is different from each other,
Generally, the machine with the longest cycle time (hereinafter referred to as the longest process machine) becomes a bottleneck in the operation of the entire production line. Therefore, if the machine that causes such a neck is not fully utilized, the improvement of the operating rate of the entire production line cannot be expected, and conversely, if the operation rate of the machine that easily causes such a neck is improved, The overall utilization rate will also be effectively improved.

The present invention has been made in view of such a point, and a production line in which a plurality of machines for performing a predetermined process are arranged side by side on a work, and the work is sequentially conveyed to each machine. In, the operating state detection means provided for each machine to detect the operating state of the machine, and the information collection for collecting and storing information on the operating state of each machine from each operating state detection means in a predetermined period Means, and a stop state search means for searching for a preset state of the machine to be checked from the stored information, and a machine causing the stop and the cause of the stop Stop analysis means, a stop time accumulating means for accumulating and calculating each stop time for each of the cause machine and the stop factor, and an output means for outputting the calculation result to the outside. That (claim 1).

Here, the machine to be checked may be arbitrarily selected from all machines, but it is generally preferable to select the machine having the longest cycle time. In this case, it is more effective if the longest process machine discriminating means for discriminating the machine having the longest cycle time on the basis of the information stored in the information collecting means and setting it as the machine to be checked is provided (claim Item 2).

[0008]

According to the above apparatus, during the operation of the production line, the information about the operating state of each machine detected by each operating state detecting means is fetched into the information collecting means, organized and stored.
After that, a preset state in which the machine to be checked is stopped is retrieved from the stored information on the operating state, and the machine causing the stop and the cause of the stop are analyzed. Then, each stop time is cumulatively calculated for each of the cause machine and the stop factor, and the calculation result is output to the outside. This calculation result includes not only the accumulated stop time caused by the check target machine itself but also the accumulated stop time caused by other machines. It is possible to devise a measure for increasing the operation rate of the check target machine in consideration of the influence of.

According to the second aspect of the present invention, the longest process machine having the longest cycle time is determined based on the information stored by the information collecting means, and this machine is automatically checked. Set on the machine.

[0010]

An embodiment of the present invention will be described with reference to the drawings.

The production line shown in the upper part of FIG. 1 comprises a plurality of production machines M1, M2, M3, ...
1, M2, M3, ... Are provided with sequencers (operating state detecting means) SQ1, SQ2, SQ3 ,. These sequencers SQ1, SQ2, SQ3, ... Perform sequence control so that each production machine M1, M2, M3, ... Performs a process corresponding to the machine, and each production machine M1, M2, M3 ,. It is configured to detect the operating state of ... And output an information signal related thereto. Then, these information signals are input to the operation analysis device 10.

The operation analysis apparatus 10 is provided with the information collecting means 1
1, an information organizing means 12, a storage means 13, a longest process machine discriminating means 14, an analyzing means 15, and a display means 16,
The information collecting means 11, the information organizing means 12, and the storage means 13 constitute the information collecting means of the present invention.

The information collecting means 11 is provided for each sequencer SQ.
The information input from 1, SQ2, SQ3, ... Is taken in and output to the information organizing means 12. The information organizing means 12 organizes the collected information into information relating to the cycle time of each machine, the transportation time between machines, the stop time corresponding to various obstructive factors in each machine, and the storage means 13 This organized information is stored. The longest process machine discriminating means 14 is based on the information stored in the storage means 13 and produces all the production machines M1, M.
The machine with the longest cycle time (machine with the longest process) among 2, 2, M3, ...

As shown in FIG. 2, the analyzing means 15 includes a stop state searching means 21, a cause machine discriminating means 22, a stop factor analyzing means 23, a stop time accumulating means 24, and a data organizing means (which constitutes an output means) 25. And the cause machine discriminating means 22 and the stop factor analyzing means 23 constitute the stop analyzing means of the present invention.

The stop state search means 21 is the storage means 1 described above.
The state in which the longest process machine discriminated by the longest process machine discriminating means 14 is searched from the information stored in 3 and is picked up. The causal machine discriminating unit 22 discriminates whether the machine causing the stop is the self machine (that is, the longest process machine itself) or another machine, and outputs the causal machine. Stop factor analysis means 2
3 analyzes the cause of the above stop (for example, tool exchange, failure, etc.) and outputs it. Stop time accumulation means 2
Reference numeral 4 is a cumulative calculation of each stop time for each of the cause machines output from the cause machine determining means 22 and each stop cause analyzed by the stop cause analyzing means 23. The data organizing means 25 organizes the calculation result of the stop time by the stop time accumulating means 24 and other data in a form that is easy to refer to and outputs it to the display means 16.

The display means (constituting the output means) 16 is composed of a printer, a CRT, etc., and displays the data output from the data organizing means 25 to the outside.

Next, the contents of control operation of the production line performed by the operation analysis apparatus 10 will be described with reference to the flowcharts of FIGS.

First, each sequencer SQ1, SQ2, SQ
The information signal relating to the operating state output from 3, ... Is taken in by the information collecting means 11 (step S in FIG. 3).
1) Based on this information, the information is organized into information relating to the cycle time of each machine, the transfer time between machines, the stop time of each machine and the cause of the stop (step S2). And
This information is stored by the storage means 13 (step S
3).

As the above-mentioned obstructive factors, in addition to various abnormalities of each production machine, exchange of cutting tools, etc., factors such as no work (waiting for work carry-in) and full work (waiting for work carry-out) caused by stopping of other machines Is also included.

From the start of such information collection until the lapse of a predetermined information collection period (step S
No in step 4), the information collection in steps S1 to S3 is continued. Then, after the information collection period has elapsed (YES in step S4), that is, after a certain amount of information has been accumulated, the operation analysis of the production line by the operation analyzer 10 is started.

First, based on the collected information, the longest process machine discriminating means 14 discriminates the longest process machine having the longest cycle time (step S5). Then, the operation analysis is performed using this longest process machine as the machine to be checked (analysis routine; step S6).

This analysis routine will be described with reference to the flowcharts of FIGS.

First, the information stored in the storage means 13 is sequentially read (steps S11 and 12).
NO), the state in which the longest process machine is stopped is searched from among these (step S13). When the stopped state of the longest process machine is found (YES in step S13)
S), it is determined whether the stop is due to the own machine (the longest process machine itself) or another machine (step S14), and if it is determined to be due to the longest process machine itself (step S14). YES), the stop time is sequentially accumulated and stored in combination with the item of the cause machine (that is, the longest process machine) and the factors thereof (fault, tool change, etc.) (step S15).

On the other hand, when it is determined that the cause of the stop is not the longest process machine itself (NO in step S14),
Whether the stop is due to waiting for work loading (that is, no work flows into the longest process machine), or waiting for work unloading (that is, work accumulates on the downstream side of the longest process machine and cannot work out of the longest process machine) ) Is determined (step S1)
6).

In the case of waiting for the loading of the work (YES in step S16), the state of the production machine (preceding process machine) in the process immediately before the longest process machine is checked (step S17). Here, when this pre-process machine is installed at the line entrance (that is, when it is installed at the head of the production line) (YE at step S18).
S), it is determined that the machine is stopped waiting for work to be loaded into the machine manually (step S19), and the stop time is accumulated in combination with the stop factor item "waiting for load operation", Remembered.

When the preceding process machine is not installed at the line carry-in port (NO in step S18), it is judged whether or not this preceding process machine is in the stopped state (step S2).
0), if not in the stopped state (N in step S20)
O), the analysis is performed retroactively until reaching the stopped state (step S21).

Then, it is again determined whether or not this stop is due to the own machine (that is, the preceding process machine) (step S22). If it is due to the own machine (YES in step S22), this machine is the cause machine. Then, the stop time is accumulated and stored according to the cause machine and the stop factor (that is, the content of the abnormality) (step S23). If it is not based on the own machine (NO in step S22), the machine that is the cause of the stop is reached (YES in step S22), or the machine installed at the line entrance is reached (step S1).
The analysis is continued by tracing back the machine (returning to step S17) until YES in step 8).

On the other hand, if it is determined in step S16 that the cause of the longest process machine stoppage is waiting for the workpiece to be unloaded (NO in step S16), the state of the machine one step after the longest process machine. Is checked (step S24). Here, when this post-process machine is installed at the line outlet (that is, when it is installed at the tail of the production line) (YES in step S25).
S), and it is determined that the machine is stopped waiting for the work to be unloaded from the machine manually (step S26),
The stop time is accumulated and stored in combination with the stop factor item “waiting for unloading work”.

When the post-process machine is not installed at the line outlet (NO in step S25), it is determined whether or not the post-process machine is in the stopped state (step S2).
7) If not in the stopped state (N in step S27)
O), the analysis is performed retroactively until reaching the stopped state (step S28).

Then, it is again determined whether or not this stop is due to the own machine (that is, the post-process machine) (step S29). If it is due to the own machine (YES at step S29), this machine is the cause machine. Then, the stop time is accumulated and stored for each of the cause machine and the stop factor (that is, the content of the abnormality) (step S30). When not using the own machine (NO in step S29), the machine that causes the stoppage is reached (YES in step S29) or the machine installed at the line entrance (step S1).
Move down the machine until YES in step 8 (step S24).
Return to) Analysis continues.

In this way, while reading data, each stop time is accumulated according to the cause machine and stop factor,
When the data is completed (YES in step S12), the accumulated time and other various analysis results are arranged in a form that can be easily referred to (step S31), which is displayed outside through the display means 16 and the analyzed various inhibitions. A work instruction, which is a countermeasure against the factor, is given (step S7 in FIG. 3).

An example of this data display is shown in FIGS.
This example is provided with a line as shown in FIG. 8, that is, 6 production machines, and shows the results of analysis of a production line that was appropriately merged and split in the middle of the production machines. Two production machines of the same model are selected. In this example, the same type of machine is used for the production machine.

First, in the screen shown in FIG. 6, the result of the operation analysis of the longest process machine is displayed. Specifically, the date, data collection time, model of the longest process machine, its process time (cycle time), total number of products, and other introductions are displayed, and in the center graph, the total elapsed time (2 hours The ratio of actual work time and various types of downtime is shown. Further, in FIG. 7, the stop factors are classified more finely, and each cumulative stop time for each stop factor is displayed in a bar graph as a ratio to the total stop time.

In the figure, "polishing condition" means that when the inner diameter of the actual work is smaller than the inner diameter preset as the grinding condition in the processing of the inner surface grinding machine, the machine is temporarily stopped and the operator is stopped. It means a stop by waiting for confirmation and restart operation, and "circulation abnormality" means that if a production machine does not finish machining within the specified time, it is judged that this machine has an abnormality and It means stopping by stopping the machine and waiting for the operator's confirmation and restart operation.

"Whetstone exchange / loading failure" means that the production machine stops at the same time as the stone is exchanged.
This means that the longest process machine is stopped in the state of waiting for work discharge because the production machine is stopped due to the work jam. In the items waiting after this, the two stop factors are displayed in pairs because, for example, one of the longest process machines, as shown in FIG. This is because, even if the machine or only the machine stops, the work carry-out wait does not occur unless the other production machine stops.

As described above, this apparatus collects and stores information on the operating states of the respective production machines M1, M2, M3, ... From this information, the production that causes a stop of the machine to be checked. The machine and its stop factor are analyzed, and the stop time of the machine to be checked is cumulatively calculated for each of this cause machine and stop factor to organize and output the data, so the analysis result is used. In this way, it is possible to devise appropriate measures to improve the operating rate of the longest process machine, considering not only the stop factor of the longest process machine itself but also the stop factor of other machines. By doing so, the operating rate of the entire production line can be significantly improved. For example, from the above analysis results,
If it is recognized that it takes a long time to replace the grindstone,
It is only necessary to replace the grindstone before operating the line, and if the stop time due to a machine other than the longest process machine is long, check the production machine that causes the stop. You should give importance to it.

Further, as shown in this embodiment, if the work instruction for improving the operating rate is automatically displayed together with the above calculation result, the worker only has to perform the work according to the instruction. , You can aim to improve the utilization rate.

Further, the apparatus of this embodiment is provided with the longest process machine discriminating means 14, which automatically discriminates the longest process machine based on the information stored in the storage means 13 and sets it as the machine to be checked. Therefore, the work for the operator to select the machine to be checked can be omitted, and the work efficiency can be further improved. However, the check target machine in the present invention does not necessarily have to be the longest process machine, and a plurality of production machines may be set as the check target machines as shown in the above embodiment,
A setting means for setting the check target machine from the outside may be provided so that the operator can select a machine to be particularly noticed as the check target machine, even if the machine is not the longest process machine.

Further, in the above embodiment, the data organizing means 2
Although the output contents from 5 are displayed on the outside through the display means 16 as they are, the output signal from the data organizing means 25 is input to another analysis device and provided as data for this analysis. You can

[0040]

As described above, the present invention collects information on the operating state of each machine, analyzes from this information the production machine that causes the machine to be checked and its cause, and The stop time of the machine to be checked is cumulatively calculated for each cause machine and stop factor, and the result is output.By using this analysis result, not only the stop factor of the longest process machine itself It is possible to devise appropriate measures to improve the operating rate of the longest process machine, taking into account the stop factors caused by other machines, and thereby significantly improve the operating rate of the entire production line. There is an effect that can be.

Further, in the apparatus according to the second aspect, since the longest process machine discriminating means for automatically discriminating the longest process machine based on the stored information and setting this as the machine to be checked is provided, the operator The work of selecting the machine to be checked can also be omitted, which has the effect of further improving work efficiency.

[Brief description of drawings]

FIG. 1 is an overall configuration diagram of a production line and an operation analysis device according to an embodiment of the present invention.

FIG. 2 is a block diagram showing a functional configuration of analysis means in the operation analysis device.

FIG. 3 is a flowchart showing an analysis operation by the operation analysis device.

4 is the first half of a flowchart showing the contents of the analysis routine in FIG.

5 is the second half of the flowchart showing the content of the analysis routine in FIG.

FIG. 6 is a diagram showing an example of a display screen of the operation analysis device.

FIG. 7 is a diagram showing an example of a display screen of the operation analysis device.

FIG. 8 is an explanatory diagram showing a flow of a production line regarding the display.

[Explanation of symbols]

10 Operation Analysis Device 11 Information Collecting Means (Constituting Information Collecting Means) 12 Information Arranging Means (Constructing Information Collecting Means) 13 Storage Means (Constructing Information Collecting Means) 14 Longest Process Machine Discriminating Means 15 Analyzing Means 16 Display Means 21) Stop state searching means 22 Cause machine determining means (stop analyzing means) 23 Stop factor analyzing means (stop analyzing means) 24 Stop time accumulating means 25 Data sorting means (output means) M1, M2, M3, ... Production machine SQ1, SQ2, SQ3, ... Sequencer (operating state detection means)

Claims (2)

[Claims] 1. A production line in which a plurality of machines that perform a predetermined process on a work are arranged side by side, and the work is sequentially conveyed to each machine. The machine is provided for each machine and detects the operating state of the machine. Operating state detecting means, information collecting means for collecting and storing information regarding the operating state of each machine from each operating state detecting means in a predetermined period, and preset from among the stored information A stopped state search means for searching the stopped state of the machine to be checked, a stop analysis means for analyzing the cause machine causing this stop and its stop factor, and each stop time for the cause machine and stop factor An operation analysis apparatus for a production line, comprising: stop time accumulating means for performing a cumulative calculation by classifying each operation; and output means for outputting the calculation result to the outside. 2. The production line operation analysis apparatus according to claim 1, wherein a machine having the longest cycle time is determined based on the information stored by the information collecting means, and this is set as a machine to be checked. An operation analysis apparatus for a production line, which is provided with a machine discriminating means.