JPH06274209A - Production management displaying system - Google Patents

Abstract

PURPOSE:To display the number of parts stored in respective processes of a production line and to quickly cope with lack in parts by computing the number of parts in each loading part based upon a detection signal, judging an abnormal state in the operated number of parts, outputting abnormal data based upon the abnormal state, and displaying the number of parts. CONSTITUTION:Inlet side sensors 14a, 14b are fixed to the parts carrying-in side of loading parts 12b, 13b arranged on the 1st and 2nd processes 12, 13 of the production line and outlet side sensors 15a, 15b are fixed to the parts carrying-out side. A programmable controller(PC) 7 computes the number of parts W stored in the loading parts 12b, 13b based upon detection signals outputted from the sensors 14a, 14b and 15a, 15b. When the number is less than a normal value, the PC 7 outputs an abnormal data signal. A 'DELAY' display or the like is additionally executed based upon the signal. Consequently the worker can easily confirm lack in the number of parts W in respective processes 12, 13.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a production management display system introduced into a production line in a factory, and more specifically, displays the state of the number of parts held on a mounting portion in each process of the production line. Regarding technology.

[0002]

2. Description of the Related Art The applicant of the present invention installs a display device in which LEDs are arranged on a display board to form a dot matrix in a factory, and the production targets, current achievements and stoppages are set on the dot matrix of the display device. By displaying production management information such as time, and equipment information (so-called "Andon" information) regarding the presence or absence of abnormalities in each process of the production line,
We are proposing a production control display system that transmits various information in the factory.

At this time, each process is provided with a work place for the worker to carry out work, and a placement section for temporarily stocking the finished work parts for delivery to the next process. Has been formed. Then, when there are no parts on the mounting part, the display device displays information indicating that the parts are missing and information indicating the process based on an abnormal signal from a process in which the parts are missing on the mounting part. Has become. That is, when the unloading work of the parts is stopped from the previous process and there is no part stocked in the placement part in the process of loading the parts from the previous process, the process in which the parts of the placement part are lost in the display device Information about the loss of the part is displayed.

[0004]

However, when some abnormality occurs in the previous process and the unloading work of the components in the previous process is stopped, the placing part of the process in which the components are loaded from the previous process is stopped. Abnormality in the previous process is confirmed only after the remaining number of stocked parts is exhausted. Therefore, even if an abnormality occurs in a certain process and the unloading work from that process is stopped,
The process by which the worker carries in parts from that process (next process)
There is a problem that it is not possible to notice until the parts of the mounting part in the above are exhausted, and the response to the abnormality is delayed. Further, there is a problem that the production line is stopped because the worker does not notice abnormally until there are no parts stocked on the placing part.

The present invention has been made in order to solve the above problems, and displays the state of the number of parts stocked in each process of a production line so that when the parts are quickly run out, The purpose is to deal with.

[0006]

In order to solve the above problems, the present invention provides a display device for displaying information regarding the presence or absence of an abnormality in each process of a production line, and a stock device provided in each process to stock parts. A mounting portion for carrying out, an inlet side component detecting means provided on a component carrying-in side of the placing portion, an outlet side component detecting means provided on a component carrying-out side of the mounting portion, and an inlet side component detecting means, Calculates the number of parts stocked on the mounting part based on the detection signal from the outlet side part detection means,
Based on the calculation result, an abnormal state of the number of parts in the mounting portion is determined, and a first control unit that outputs various abnormal data signals based on the abnormal state and a first control unit from the first control unit. The gist of the present invention is that the display device is provided with a second control means for displaying the state of the number of the parts based on the abnormal data signal.

[0007]

Therefore, according to the present invention, each step of the production line is provided with a mounting portion for stocking parts. The inlet-side component detection means provided on the component loading side of the placement section detects the components loaded into the placement section and inputs the detection signal to the first control means. Further, the outlet-side component detecting means provided on the component unloading side of the placing part detects the component delivered from the placing part, and inputs the detection signal to the first control means. At this time, the first control means calculates the number of parts stocked in the mounting portion based on the detection signals from the inlet-side component detecting means and the outlet-side component detecting means, and mounts based on the calculation result. The abnormal state of the number of parts in the storage unit is determined, and various abnormal data signals are output based on the abnormal state.

Then, the second control device causes the display device to display the state of the number of parts based on the abnormal data signal from the first control means.

[0009]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT An embodiment embodying the present invention will now be described with reference to FIGS.
It will be described with reference to FIG. FIG. 1 shows a production management display system in a factory using a display device for displaying production management information and facility information and a control personal computer for display.

The production management display system is composed of a first display system 2 connected by a first network 1 and a second display system 4 connected by a second network 3. The second network 3 uses Ethernet, which is a local area network (LAN), as a transmission medium. First network 1
And the second network 3 are connected via a gateway 5. The first display system 2 is a system that is installed in a factory and displays production management information and facility information on a display device 6 installed for each production line.
The second display system 4 is provided in a management office remote from the factory, and can centrally manage the production management information and the equipment information, so that the first display system 2 and the gateway 5 exchange data with each other. It has become.

In the first network 1, a programmable controller 7 as first control means, a display control personal computer (hereinafter referred to as a control personal computer) 8 as second control means, and factory side operation management A personal computer (hereinafter referred to as a factory management personal computer) 9 is connected. The display device 6 is connected to the control personal computer 8.

The second network 3 includes a management office-side management personal computer (hereinafter, management office-side management personal computer) 10 and an operation status data server 11.
And are connected.

FIG. 3 shows a part of the steps constituting the production line in which the production management display system is introduced (first step 1).
2, a second step 13). The first step 12 is a step of performing pretreatment on the part W delivered from the pre-production line. The worker places the work place 12a for the pretreatment and the part W on which the pretreatment has been performed next. A placing portion 12b for temporarily stocking the product for delivery to the process (second process 13) is provided. That is, the worker pre-processes the component W at the work place 12a, and then mounts the pre-processed component W on the mounting portion 12b.

An inlet side sensor 14a as an inlet side component detecting means is provided on the work place 12a side (inlet side) of the placing part 12b and detects the component W carried into the placing part 12b. It is like this. Also, the mounting portion 12b
An outlet side sensor 15a as an outlet side component detecting means is provided on the side of the next process (outlet side) to detect the component W carried out to the next process from the mounting portion 12b.

At this time, depending on the number of parts W stocked on the mounting portion 12b (hereinafter referred to as the number of buffers),
The supply status of parts from the previous process (pre-production line) is confirmed. That is, in the present embodiment, when the number of buffers is four or more, it indicates that the number of buffers on the mounting portion 12b is normal, and that the supply of the component W from the previous process is normal. . When the number of buffers is 2 or 3, it indicates that the number of buffers in the mounting portion 12b has decreased, and that the supply of the component W from the previous process is delayed. When the number of buffers is one or less, it indicates the state immediately before the part W on the placing part 12b is gone or the state where the part W is gone.
It shows a state in which the part W of b is deficient.

The first step 12 includes the first step 1
An abnormal signal output unit (not shown) is provided for outputting an abnormal signal when an abnormality occurs in the second unit. The second step is a step of processing parts, and the first step (preceding step) 12
By handing the part W from the second process 13 into the second process 13, and temporarily placing the robot 13a that performs various kinds of part processing and the part W that has been subjected to the part processing to the next step. Placement part 13b for stocking
And are provided. That is, the robot 13a performs the component processing on the component W, and then the robot 13a mounts the component W on which the component processing has been performed on the mounting portion 13b.

At the work place 12a side (inlet side) of the placing portion 13b, the inlet side sensor 14b is provided as in the first step 12.
Is provided, and the component W carried in to the mounting part 13b is detected. Further, an outlet side sensor 15b is provided on the next process side (exit side) of the placing part 13b so as to detect the component W carried out from the placing part 13b to the next process.

At this time, as in the first step 12, the supply state of the parts from the previous step is confirmed by the number of the parts W stocked in the mounting portion 13b. That is, in the present embodiment, when the number of buffers is 4 or more, the mounting unit 1
It shows that the number of buffers in 3b is normal, and that the supply of the parts W from the previous process (pre-production line) is normally performed. When the number of buffers is 2 or 3, it indicates that the number of buffers in the mounting portion 13b has decreased, and that the supply of the component W from the previous process is delayed. When the number of buffers is one or less, it indicates a state immediately before the component W on the placing portion 13b is gone or a state where the component W is gone, and the placing portion 13b
3 shows a state in which the part W of FIG.

The second step 13 includes the first step 12
Similarly to the above, an abnormal signal output section (not shown) for outputting an abnormal signal when an abnormality occurs in the second step 13 is provided.

The display device 6 thus constructed is suspended from the ceiling of the factory where the production line is installed so that the operator can easily see the display device 6. Next, the display device 6 introduced into this production line will be described with reference to FIG.

The display device 6 is provided with a display unit 17 on a display board 16 in which LEDs of two colors, red and green, are arranged to form a dot matrix. The display unit 17 displays production management information such as production targets, current results, and stop times, information regarding the presence / absence of abnormality in each process of the production line (so-called "Andon" information), and the like. The display format of the display unit 17 includes a “target” display unit 18,
"Result" display unit 19, "Stop" display unit 20 and "Abnormal"
A display unit 21 is provided.

The "target" display section 18 displays the target number of units to be achieved today on the production line. This target number is input from the management computer 9 on the factory side.

The "actual result" display section 19 is adapted to display the number of units produced by the production line operating up to the present. The number of units produced is displayed based on an operation result data signal, which will be described later, output from the programmable controller 7 on the first network 1.

The "stop" display section 20 is adapted to display how long the production line has been stopped until now. The "stop" display section 20 is displayed based on a data signal of a stop time, which will be described later, output from the programmable controller 7 on the first network 1.

The "abnormality" display section 21 is adapted to display the process name in which the abnormality has occurred, the content of the abnormality, etc., based on an abnormal data signal, which will be described later, output from the programmable controller 7 on the first network 1. There is.

That is, for example, when an abnormality occurs in the first step 12, the name of the step in which the abnormality occurs is "first step".
Is displayed. Further, in the first and second steps 12 and 13, when the number of buffers in the mounting portions 12b and 13b becomes smaller than a predetermined normal value (four or more in this embodiment), "delay" is displayed. To do. Then, in the first and second steps 12 and 13, the mounting portions 12b and 13
When the number of buffers in b becomes equal to or less than the deficiency value (one in this embodiment) which is a value smaller than the normal value, "lack" is displayed.

Similarly, when the number of buffers in each mounting portion becomes smaller than a predetermined normal value in other processes in this production line as well, a "delay" is displayed together with the display of the process name. Be seen. Then, when the number of buffers in each of the mounting portions becomes equal to or less than the depletion value which is a value smaller than the normal value, the process name is displayed and "lack" is displayed.

As shown in FIGS. 1 and 3, the programmable controller 7 is connected to various equipments M such as the robot 13a provided in each process of the production line through signal lines, and controls each equipment M. While performing, an abnormal signal is input from an abnormal signal output section provided in each process. The abnormal signal output section includes an abnormality detector provided in each equipment M, a maintenance time indicator provided in each equipment M, a push button switch 22 used when an operator needs assistance, etc. It is a general term for devices that output a signal indicating that the device is in a state different from the state.

The programmable controller 7 converts the input abnormal signal into data (encodes) according to its type,
The data is stored in a storage device (not shown) built in the programmable controller 7 and is output as various data signals on the first network 1.

The storage device of the programmable controller 7 has a capacity capable of accumulating operation history data for one day of the production line, and the operation history data on the production line day is sequentially stored. The programmable controller 7 calculates the operation record and the stop time of the production line based on the operation record data stored in the storage device, and outputs it as a data signal of the operation record and the stop time on the first network 1. Further, the storage device stores data of the number of buffers in the mounting portion of each process, which is input from the factory management personal computer 9 or the like. Then, the storage device is configured to store the number of buffers in each mounting portion, which has been rewritten by various calculations.

The programmable controller 7 is connected to the inlet side sensors 14a, 14b and the like and the outlet side sensors 15a, 15b and the like respectively provided in each process.
Inlet sensors 14a and 14 provided in each process
When the component W is carried into the mounting portion provided in the process, the component b or the like detects the component W to be carried in and inputs a component detection signal indicating the detection of the component W to the programmable controller 7. ing.

The outlet side sensors 15a, 15b and the like respectively provided in the respective processes detect the parts W to be carried out when the parts are carried out from the mounting portion provided in the process, and detect the parts W. The component detection signal shown is input to the programmable controller 7.

At this time, the programmable controller 7
Are the inlet side sensors 14a, 1 provided in each process.
4b and the like and outlet side sensors 15a, 15b and the like, the number of buffers in each mounting portion in each step is calculated based on the detection signals, and the calculation result is stored in a storage device.

When the number of buffers in each process stored in the storage device is smaller than the normal value and larger than the depletion value, the programmable controller 7 sends the data signal of the delay display as the abnormal data signal to the first network. 1
Print on top. Further, when the number of buffers stored in the storage device is equal to or larger than a predetermined value, the programmable controller 7 outputs a buffer-missing data signal as an abnormal data signal onto the first network 1.

For example, in the inlet side sensor 14a provided in the first step 12, when the component W is carried into the mounting portion 12b,
The component W carried in is detected, and a component detection signal indicating the detection is input to the programmable controller 7. Further, when the component is carried out from the mounting portion 12b, the outlet side sensor 15a detects the carried-out component W and inputs a component detection signal indicating the detection to the programmable controller 7.

At this time, the programmable controller 7
When a component detection signal is input from the inlet-side sensor 14a, the calculation unit adds 1 to the number of buffers of the mounting unit 12b stored in the storage device. Then, the programmable controller 7 rewrites the data of the number of buffers of the mounting portion 12b stored in the storage device into the data of the number of buffers plus one.

Further, when the component detection signal is inputted from the outlet side sensor 15a, the programmable controller 7 carries out an operation of subtracting 1 from the number of buffers stored in the mounting portion 12b stored in the storage device. Has become.
Then, the programmable controller 7 rewrites the data of the number of buffers of the mounting portion 12b stored in the storage device into the data obtained by adding 1 to the data.

Further, when the number of buffers of the placing portion 12b stored in the storage device is smaller than the normal value (4 or more) and larger than the depletion value (1), the programmable controller 7 delays display data. The signal is output on the first network 1. In the programmable controller 7, the number of buffers stored in the storage device is a deficient value (1).
In the following cases, the buffer-missed data signal is output on the first network 1.

The control personal computer 8 makes various displays on the display device 6 based on various data signals such as abnormal data signals output on the first network 1. That is, the control personal computer 8 displays the target number of units in the production line to be achieved today on the "target" display section 18 based on the data of the production management information.

The control personal computer 8 displays the number of units produced by the production line operating up to the present on the "actual" display section 19 based on the operation result data signal. The control personal computer 8 displays on the "stop" display section 20 based on the stop time data signal how long the production line has stopped up to the present.

Further, the control personal computer 8 determines the process and "delay" in which the abnormality has occurred based on the delay display data signal.
It is designed to display. Further, the control personal computer 8 is adapted to perform the process in which the abnormality has occurred and the "missing" display based on the data signal indicating the lacking buffer.

The factory-side management personal computer 9 can confirm a data signal output on the first network 1 such as an operation result and a stop time by an operator operating the factory-side management personal computer 9. Further, the factory management personal computer 9 allows the operator to input the number of buffers in the mounting section of each process by operating the factory management personal computer 9. Further, the factory management computer 9 can output various production management information on the first network 1, and the production management information is displayed on the display device 6.

The management personal computer 10 on the management office side includes all the first networks 1 connected to the second network 3.
The operator can confirm the data signals such as the operation results and the stop time output above by operating the management office side management personal computer 10. That is, it is possible to check the operation records and downtime of all the production lines in the factory from the management office by the management office management PC 10. Further, the management office-side management personal computer 10 allows the operator to input the number of buffers in the mounting section of each process by operating the management office-side management personal computer 10. Further, the management office-side management personal computer 10 can output various production management information on the first network 1, and the production management information is displayed on the display device 6. Further, this production management information can be stored as data in the storage device of the programmable controller 7.

The operation status data server 11 is adapted to store the operation history data stored in the storage device of the programmable controller 7. Next, the operation and effect of this production management display system will be described.

As shown in FIG. 3, four parts W are placed on the placing part 13b in the second step 13. At this time, in the first step 12, the pre-processed part W is carried into the mounting portion 13b, and the part W processed in the second step 13 is carried out to the next step. . And
The parts W carried in from the first step 12 and the parts W carried out from the second step 13 are always carried in and out at the same timing. Therefore, in a normal state, the mounting portion 1
Four parts W are always mounted on 3b.

In this state, an abnormality occurs in the first step 12 and the work is delayed, so that the case where the part W is not carried into the second step 13 will be described. First, one component W is carried out to the next process from the mounting part 13b of the second process 13. Then, the exit side sensor 15b detects the component W to be carried out. At this time, the work of the first step 12 is delayed, and the component W is not carried in from the first step 12.

Then, the component W placed on the placing portion 13b.
Will be three. At this time, the programmable controller 7 performs an operation of subtracting 1 from the number of buffers of the mounting unit 13b stored in the storage device. Then, the programmable controller 7 rewrites the data of the placement unit 13b stored in the storage device into data obtained by subtracting 1 from the data of the buffer number. That is, “3” is stored in the storage device as the data of the number of buffers of the mounting portion 13b, and the programmable controller 7 determines that three parts W are mounted on the mounting portion 13b.

At this time, the programmable controller 7
Outputs a delayed display data signal to the first network 1 assuming that the number of buffers of the mounting portion 13b becomes smaller than the normal value.

The control personal computer 8 causes the display device 6 to display the second step as the step name and "delay" based on the delay display data signal output on the first network 1. . That is, “second process delay” is displayed on the display device 6.

At this time, the operator repairs the abnormality in the first step 12 assuming that the abnormality has occurred in the first step 12 due to the delay of the components carried into the second step 13. From this state, the abnormality of the first step 12 is recovered and the second step 13 is repaired.
When the component W is carried into the mounting portion 13b of the above, the entrance side sensor 14b detects the component W to be carried in. Then, the programmable controller 7 performs an operation of adding 1 to the number of buffers in the mounting portion 13b stored in the storage device, based on the detection signal from the inlet side sensor 14b, and outputs the data of the number of buffers stored in the storage device. Is rewritten to the data obtained by adding 1 to the data. When the data of the number of buffers stored in the storage device becomes a normal value (4 or more), the programmable controller 7 outputs a data signal for canceling the delay display on the first network 1, and the control personal computer 8 Based on the data signal for canceling the delay display, the display of "second step delay" on the display device 6 disappears.

Further, the "abnormality" display section 21 displays "second step".
In the state in which "delay" is displayed, the abnormality in the first step 12 is not repaired, the parts W are sequentially carried out from the mounting portion 13b in the second step 13, and the programmable controller 7
When the data of the number of buffers of the mounting unit 13b stored in the storage device of No. 1 becomes less than or equal to the deficiency value (1), the programmable controller 7 outputs a data signal indicating buffer deficiency to the first network 1. To do.

Then, the control personal computer 8 disappears the "second process delay" display on the display device 6 based on the buffer-miss display data signal output on the first network 1, and the "abnormal" display section is displayed. 21st as the process name
A "deficiency" is displayed as a state in which the process and the part W are deficient. That is, the display device 6 displays "second step missing".

Similarly, when an abnormality occurs in the previous production line,
If the unloading work of the part W is delayed or stopped, the first step 12
When the component W is not carried into the container and the number of buffers in the mounting portion 12b becomes smaller than the normal value (4 or more) and larger than the depletion value (1), the display device 6 displays "abnormal". The display of "delay in the first step" is displayed on the section 21.

When the number of buffers on the placing section 12b becomes less than the deficiency value (one), the "abnormal" display section 21 displays
The message "1st process missing" is displayed. Further, also in each of the other steps, when the number of buffers in the placing section becomes smaller than the normal value and larger than the depletion value, the "abnormal" display section 21 of the display device 6 displays the step name and "delay". Is displayed. Then, when the number of buffers in the placing section becomes equal to or less than the deficient value, the "abnormal" display section 21 displays the process name and "missing".

As described above in detail, according to the present embodiment, when the number of the parts W placed on the placing parts 12b, 13b and the like in each step becomes a normal value or less, "abnormal" of the display device 6 occurs. The display unit 21 displays "delay" along with the process name in which the number of parts W has become a normal value or less. For this reason, the operator can easily confirm in which process the part W of the mounting portion is insufficient by visually recognizing the process name and the "delay" display of the "abnormal" display unit 21. At this time, the worker can promptly repair the abnormality in the process of loading the component W, assuming that some abnormality occurs in the process of loading the component W in the process in which the component W is insufficient. Therefore, the worker can recognize the abnormality before the production line is stopped and deal with the abnormality by eliminating the parts W of the mounting portion.

When the number of parts W stocked on the placing part becomes smaller than the normal value, "delay" is displayed on the "abnormal" display part 21 and when the number becomes less than the depletion value. By displaying "missing", it is possible to gradually judge the shortage state of the parts W stocked in the mounting portion.

The present invention is not limited to the above-mentioned embodiment, but may be implemented as follows with a part of the structure appropriately changed without departing from the spirit of the invention. (1) In the above embodiment, the display device 6 also serving as a production control panel for displaying production control information is embodied, but it may be embodied as a display device for displaying only so-called "andon" information.

(2) In the above embodiment, the process name and the content of the abnormality are displayed. However, various messages indicating a coping method for coping with the abnormality may be displayed. (3) In the above embodiment, in particular, the production management display system is configured only by the first network 1 without connecting the first network 1 in the factory and the second network 3 on the management office side. May be.

(4) In the above embodiment, each mounting portion 12b,
Although "delay" and "missing" are displayed according to the number of parts W (insufficient state) in 13b or the like, how many are missing may be displayed. In addition, the mounted component W
You may display the number of.

(5) In the above embodiment, the "abnormal" display section 2
Although the name of the process in which an abnormality has occurred is displayed in 1, various information such as a number and an abbreviation indicating the process may be displayed. (6) In the above embodiment, the programmable controller 7
Various calculations of the number of buffers in the mounting units 12b, 13b, etc. were performed in the control personal computer 8.
The number of buffers in b, 13b, etc. may be calculated.

(7) In the above embodiment, two color LEDs of red and green are used. It may also be used for other types of displays such as plasma displays, electroluminescent displays or liquid crystal displays.

(8) In the above embodiment, the normal value and the deficiency value of the number of buffers in the mounting part of each process stored in the storage device of the programmable controller 7 are used as the management personal computer 9 on the factory side and the management office side. It may be configured so that it can be input from 10 or the like, and can be appropriately set to a desired numerical value.
For example, the depletion value may be set to zero.

[0063]

As described in detail above, according to the present invention, by displaying the state of the number of parts stocked in each process of the production line, it is possible to quickly cope with a shortage of parts. There is an excellent effect.

[Brief description of drawings]

FIG. 1 is an explanatory diagram showing a production management display system installed in a factory and a management office in one embodiment embodying the present invention.

FIG. 2 is a front view showing a display device according to an embodiment.

FIG. 3 is an explanatory diagram showing each step of a production line in which a production management display system is introduced in one embodiment.

[Explanation of symbols]

6 ... Display device, 8 ... Control personal computer as second control means, 12b, 13b ... Mounting part, 14a, 14b ... Entrance side sensor as entrance side component detecting means, 15a, 15b ...
Exit side sensor as exit side component detection means, 7 ... Programmable controller as first control means.

 ─────────────────────────────────────────────────── ─── Continuation of the front page (72) Inventor Noritsugu Ishida 2-chome, Toyota-cho, Kariya city, Aichi Prefecture Toyota Industries Corp.

Claims (1)

[Claims] 1. A display device for displaying information on whether or not there is an abnormality in each process of a production line, a mounting part provided in each process for stocking parts, and a part loading side of the mounting part. On the basis of detection signals from the inlet side component detection means, the outlet side component detection means provided on the component unloading side of the mounting portion, and the inlet side component detection means and the outlet side component detection means. A first number that calculates the number of parts stocked in a unit, determines an abnormal state of the number of parts in the placement unit based on the calculation result, and outputs various abnormal data signals based on the abnormal state And a second control means for displaying the state of the number of parts on the display device based on the abnormal data signal from the first control means.