JPH06282719A - Production management system and data collecting terminal equipment - Google Patents

Abstract

PURPOSE:To more exactly manage production regardless of whether facilities are operated or not. CONSTITUTION:This production management system is a system for summing up production management data from the facilities. This system is provided with data collecting terminals 4 and a host computer 1. The data collecting terminals 4 recognize the operation/stop of productive equipments and judge either an operating state or a non-operating state when the stop of any productive equipment is recognized. When the operating state is judged, an operation stop factor is received. When the non-operating state is judged, a non-operating stop factor is received. The host computer sums up the production management data while receiving the operation/stop and operating/non-operating information from the data collecting terminals 4.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a production management system for collecting production management data from production equipment and a data collection terminal device for collecting production management data from production equipment.

[0002]

[Prior art and its problems] In a factory that employs factory automation, in order to improve productivity, it is necessary to accurately grasp the status of equipment stoppages due to product or equipment malfunctions, and identify the factors that cause equipment stoppages and product defects. It is necessary to identify and improve. A production management system is used in order to grasp the stop situation and to pursue the stop factor and the defect factor. The production management system includes a data collection terminal device that collects production management data from the equipment, and a host computer that collects the production management data collected by the terminal device.

In this type of production control system, a terminal device collects production control data such as equipment operating time, stop time, number of stops, number of products, stop factor, and defect factor. Further, the host computer totalizes the collected production control data, processes the production control data, and creates an operation daily report. This daily operation report is created for each date and equipment and is output in the form of a form.

The daily operation report includes the number of products produced, the number of non-defective products, the number of defective products, the operating ratio, the number of times of stop for each stop factor, and the stop time. Of these, the operating rate is obtained by the ratio of the time that the machine actually operates (hereinafter referred to as operating time) to the time that the machine should operate (hereinafter referred to as operating time).
In the calculation of the operation rate, when the machine stops without the operator's responsibility, this stop time is not included in the operation time. For example, when the work in the previous process is extended and waiting is generated, or when the machine is stopped by cleaning, morning assembly, etc., this stop time is not included in the operating time. Also,
The stop factor here is a stop factor during the operating time, and does not include a stop factor outside the operating time.

In this conventional configuration, the stop time due to a break, waiting, waiting in the morning, cleaning, etc. is not considered to be operating time. This is because these stop times are necessary for safety and hygiene, or because they are unavoidable due to the circumstances of the previous process, they are not the responsibility of the worker of the department in charge. Also, if this kind of downtime is included in the operating time, it is not possible to clearly identify the equipment downtime that requires countermeasures.

However, since the wage cost to be paid to the worker is incurred even when the equipment is stopped outside the operating hours, these stop times are reflected in the product cost. Therefore, in order to study the product cost, it is necessary to understand the downtime outside the operating hours and its factors. An object of the present invention is to enable more accurate production management regardless of the operating / non-operating time of equipment.

[0007]

A production control system according to the present invention is a system for totalizing production control data from production equipment. This system includes a data collection terminal unit and a host unit. The data collection terminal unit has a driving recognition means for recognizing the operation / stop of the production equipment, and an operation / non-operation judgment means for judging whether the production equipment is in operation or not when the operation recognition means recognizes the stop of the production equipment. , Operation
When the non-operation determination means determines that it is in the operating status, the operation stop factor reception means that accepts the operation stop factor, and when the operation / non-operation determination means determines that it is in the non-operation status, It includes non-operation factor reception means for receiving. The host unit operates from the data collection terminal unit.
It receives the stop and operating / non-operating information and performs the production management data totaling process.

A data collection terminal device according to the present invention is a device for collecting production management data from production equipment. This device includes operation recognition means, operation / non-operation determination means, operation stop factor reception means, and non-operation stop factor reception means. The operation recognition means recognizes the operation / stop of the production equipment. The operating / non-operating determining means determines whether the operating state or the non-operating state is recognized when the operation recognizing means recognizes the stop of the production equipment. The operation stop factor receiving means receives the operation stop factor when the operating / non-operation determining means determines that it is in the operating state. The non-working stop factor receiving means receives the non-working stop factor when the working / non-working judging means judges that the work is not working.

[0009]

In the production management system and the data collection terminal device according to the present invention, when the operation recognition means recognizes the stop of the production equipment, the operation / non-operation determination means determines whether the production equipment is in the operation state or in the non-operation state. To judge. When it is determined that the operation is in the operating state, the operation stop factor receiving means receives the operation stop factor. Further, when it is determined that the non-operation stop factor is received, the non-operation stop factor reception means receives the non-operation stop factor.

Here, when the production equipment is stopped, the operation stop factor and the non-operation stop factor are classified and accepted. For this reason, it becomes possible to grasp the breakdown of the factors causing the operation stop and the cause of the non-operation, and it becomes possible to perform more accurate production management regardless of whether the equipment is operating or not.

[0011]

【Example】

[Structure] In FIG. 1, a production management system as an embodiment of the present invention is a system for performing online production management in real time. This production control system includes a host computer 1 and an N connected to the host computer 1 via a line controller 2 and a serial communication line 3.
(16) terminals 4 ₁ to 4 _N.
Terminals 4 ₁ to 4 _N have facilities (production equipment) 5 ₁ to
5 _N are connected separately. For example, equipment 5 _{1 to} 5 ₄
Are press machines A to D, equipment 5 ₅ is a die-casting machine, equipment 5 _{6 to} 5 ₇ are labeling machines A and B, equipment 5 _{N-2 to} 5 _N
Packing machines A to C.

The terminals 4 ₁ to 4 _N are connected to the equipment 5 ₁ to
Acquire production control data from 5 _N. The production management data includes data such as equipment operation / stop, operation / non-operation, stop factor, defect factor, number of productions, and defective product detection. It also includes product data such as product type and lot number. As shown in FIG. 2, a display unit 11 and a key input unit 12 are arranged on the front surface of each of the terminals 4 ₁ to 4 _N (only the terminal 4 ₁ is shown). The display unit 11 is a 7-segment LED
It has an LED display section 13 and an LCD display section 14. The key input unit 12 has a ten-key unit 15, various data input key units 16, a function key unit 17, and a compulsory key unit 18. In the function key section 17, an indicator lamp 19 composed of an LED for displaying operable keys is arranged above each key. The compulsory key unit 18 is for forcibly setting the operating / non-operating state on the terminal side. The setting by this key has priority over the setting of the operating / non-operating state by the signal from the timetable or equipment.

As shown in FIG. 3, each of the terminals 4 ₁ to 4 _N (only the terminal 4 ₁ is shown) has a control calculation section 20. The control calculation unit 20 is composed of a microcomputer including a CPU, ROM, RAM and the like. The control calculation unit 20 includes a parallel input unit 21, an RS232C interface 23, a key input unit 12, a DIP switch 29, a link interface 30, a display unit 11, an internal clock 25,
The data storage unit 26 and the setting data storage unit 27 are connected.

The parallel input section 21 has 20 parallel terminals X1 to X20 for inputting parallel data. Of these, the parallel terminals X11 to X20 are used for inputting a defect factor and a stop factor. In addition, parallel terminals X8, X9, X1
0 is used to input a signal for determining whether the input signal to the parallel terminals X11 to X20 is a defect factor, an operation stop factor, or a non-operation stop factor. Further, the parallel terminal X1 is used for a pause signal input from the equipment 5 to change the setting from the operating state to the non-operating state. The output terminals of the programmable controller 22 attached to the equipment 5 are connected to the parallel terminals X1 to X20.

In the RS232C interface 23,
A barcode reader 24 can be connected. The DIP switch 29 is for setting the state in the control calculation unit 20 on the terminal 4 side, and can be set, for example, to enable or disable the key input of the compulsory key unit 18. The link interface 30 is connected to the line controller 2 via the serial communication line 3. Internal clock 2
5 is used for measuring the operating time and the stopping time and setting the timer.

The data storage unit 26 stores the collected production management data and the processing data as the processing result. The processing data stored in the data storage unit 26 includes state data, total data, direct / lot / product data, time zone data, event data, and message data. The state data is data that determines the state of the terminal. The total data is total data of production management data from the start of operation of the equipment in one day to the present. Direct / lot / product data is direct (working hours in the work system)
It is the aggregated data of the production control data for each lot, each lot, and each product type. The time zone data is aggregated data of production management data for each predetermined time (for example, 5 minutes). The event data is data such as the time of occurrence of an event, the number of events, and the type of the event during facility operation. The message data is data of a message at the time of message input and the time of occurrence.

The setting data storage unit 27 stores terminal setting data set by the host computer 1.
For example, when the host computer 1 sets a timetable for data collection, the setting data is stored in the setting data storage unit 27. In addition, the relationship between the function key unit 17 and the processing content assigned to it is also stored.

As shown in FIG. 1, the host computer 1 comprises, for example, a personal computer, and has a computer body 6, a display 7, a keyboard 8 and a mouse 9.
And the printer 10. Further, the host computer 1 has a control calculation unit 31, as shown in FIG. The control arithmetic unit 31 is composed of a microcomputer including a CPU, a ROM and a RAM. The control calculation unit 31 includes a display 7, a keyboard 8, a mouse 9, a printer 10, an RS232C interface 3
2, a floppy disk device 33, and a hard disk device 34 are connected.

The line controller 2 is connected to the RS232C interface 32. In the hard disk device 34, various processed data collected from the terminal 4 and data processed (for example, operating rate and defective rate data) are recorded in daily report units. Further, the totalized results are also recorded in the hard disk device 34. [Operation] Next, the operation of the above-described embodiment will be described. The control operation of the terminal side terminal 4 will be described with reference to the control flowchart shown in FIGS. 5-8.

First, in step S1, initialization is performed. At the time of this initial setting, various setting values are set to initial values.
In step S2, it is determined whether the key input unit 12 has been operated. In step S3, the host computer 1
It is determined whether or not the command from is received. When the key input unit 12 is operated, the process proceeds from step S2 to step S4. In step S4, key input processing corresponding to the operated key is performed. When a command is received from the host computer 1, steps S3 to S5
Move to. In step S5, host command processing according to the input command is executed.

On the other hand, the control arithmetic unit 20 of the terminal 4 has a 3 msec timer interrupt function, and executes a timer interrupt routine shown in FIG. 6 when a timer interrupt occurs. In step S11 of FIG. 6, the parallel input unit 2
1 or the production management data input via the RS232C interface 23 is acquired (described later). Step S
At 12, it is determined whether the acquired production management data includes valid data. If the valid data is included, the process proceeds from step S12 to step S13.
In step S13, the data that needs to be processed is processed and the processed data is stored in the data storage unit 26.

In the data acquisition process of step S11, it is determined whether or not serial data is input in step S21 of FIG. This determination is made by scanning the input buffer provided in the RS232C interface 23, for example. When the serial data is input, the process proceeds from step S21 to step S23. Step S
23, the input serial data is stored in the data storage unit 2
Store in 6.

In step S22, the parallel input unit 21
It is determined whether or not parallel data is input to. This determination is made, for example, by scanning the input buffer provided in the parallel input unit 21. When parallel data is input, step S22 to step S24
Move to. In step S24, the parallel input process shown in FIG. 8 is executed. In this parallel input process, it is determined in step S31 of FIG. 8 whether a defect has occurred. In step S32, it is determined whether the equipment has stopped. In step S33, it is determined whether or not there is another parallel input.

If it is determined that a defect has occurred, step S
The procedure moves from 31 to step S34. In step S34, the defect factor input by the operator is accepted. In step S35, the accepted defect factors and the acceptance time are stored in the data storage unit 26. Step S when equipment stops
The process moves from 32 to step S36. In step S36, it is determined whether or not the equipment is in operation. For example, when a timetable is set for the schedule of operating state / non-operating state, this determination is made based on the operating state indicated by the timetable and the presence or absence of a pause signal input from the equipment 5. Further, when there is an input from the compulsory key unit 18, it is determined depending on which key of the compulsory key unit 18 is in the ON state.

If it is determined that the system is in operation, step S3
The process moves from 6 to step S37. In step S37, the operation stop factor input by the operator is accepted. In step S38, the accepted operation stop factor and its acceptance time are stored in the data storage unit 26. If it is determined that the system is not in operation, the process proceeds from step S36 to step S39. In step S39, the non-operation stop factor input by the operator is accepted. In step S40, the data storage unit 26 stores the accepted non-operation stop cause and its acceptance time.
Remember.

When other parallel data is input, the process proceeds from step S33 to step S41. Step S4
At 1, the other input parallel data is stored in the data storage unit 26. For example, consider a case where a timetable as shown by a solid line in FIG. 12B is set as the operation schedule of the equipment 5 and an operation record as shown in FIG. 12A actually occurs. Here, the operation record is 11
From 7 minutes to 861 seconds, a stop due to hydraulic pressure abnormality occurred,
There was a 10-minute wait from 10:30, a lunch break from 12:00 to 45 minutes, a 5 minute lunch stop from 12:45, and a setup change from 13:00 to 205 seconds. To do. Of these, the operator pushes the pause button when waiting and waiting for lunch, so the control calculation unit 20 accepts the pause input. When the pause input is accepted, the working time becomes the non-working state as shown by the dotted line in FIG.

Since the first stop (stop from 11:07) in the operation record shown in FIG. 12A is a stop in the operating state, the determination in step S36 becomes YES and the process shifts to step S37. Then, a factor for stopping the operation of the hydraulic pressure abnormality is received from the operator. The accepted stop factor is stored in the data storage unit 26 together with the time of 11:07.

The second stop from 11:30 is a waiting stop, and it is judged in step S36 that the operator is not operating due to a pause input by the operator.
To Step S39. And step S39
Then, the waiting non-operation stop factor is accepted. The third stop is a lunch break, and steps S36 to S3
Move to 9. In addition, in the case of a stop at a time determined by a schedule, reception of the non-working stop factor in step S39, for example, a table showing the relationship between the stop time and the non-working stop factor is provided in the setting data storage unit 27. It can be automated by setting.

The fourth stop is the stop following the lunch break,
It's a stop for lunch. In this case, it is determined that the operator is not in a working state according to the pause input, and the process proceeds from step S36 to step S39. In step S39, the non-working factor of the luncheon is accepted. The fifth stop is a stop due to a setup change. Since the state at this time is the operating state, the process proceeds from step S36 to step S37. Then, the operation stop factor of the setup change is accepted from the operator.

Here, the operation stop is twice as shown in FIG. 12C, and the non-operation stop is three as shown in FIG. 12D. Conventionally, data was collected only when the operation was stopped as shown in FIG. 12C, and the contents of the non-operation stop could not be grasped. In the present invention, this can be surely grasped. Note that, as shown in FIG.
Since labor costs are incurred except for lunch breaks, cost reduction can be realized by grasping the factors of non-operation stoppage and improving efficiency. The operation of the host-side host computer 1 will be described with reference to the control flowchart shown in FIGS. 9 to 11.

In the host computer 1, initial setting is performed in step P1 of FIG. In step P2, the operation menu is displayed. In steps P3 to P8, it is determined which process is designated from the operation menu.
In Step P3, it is determined whether the online monitor process is designated. In step P4, it is determined whether the print process is designated. In step P5, it is determined whether the system settings have been designated. In step P6, it is determined whether the terminal data collection process is designated. In step P7, it is determined whether or not another process is designated. In step P8, it is determined whether or not an end command has been issued.
The process returns to step P2 until the end command is issued, and the process ends when the end command is issued.

When the online monitor process is designated, the process proceeds from step P3 to step P9. Step P9
In executes data collection display process for displaying and collecting data from each terminal 4 ₁ to 4 _N. When the printing process is designated, the process proceeds from step P4 to step P10. In step P10, print processing is executed using various forms (described later).

When system settings are specified, step P5
To P11. In Step P11,
For example, to perform a setting for the terminal 4 of the setting of the terminal 4 ₁ to 4 _N data collection time, the setting processing for accepting a setting for this software. When the setting regarding the terminal 4 is accepted in this setting process, a setting request is transmitted to each terminal together with the setting data in step P12. This setting data is stored in the setting data storage unit 27.

When the terminal data collection process is designated, the process moves from step P6 to step P13. Step P13
In each terminal 4 ₁ to 4 _N, it is requested to send all the data collected. In step P14, it is determined whether or not the correct reception is performed, and if it is correct, the process proceeds to step P15. In step P15, it transmits a deletion request to each terminal 4 ₁ to 4 _N. Further, all the acquired data are recorded in the hard disk device 34 as a daily report file.

When another process is designated, the process moves from step P7 to step P16. In Step P16, general processing such as data conversion and various utilities is performed.
In the print process of step P10, the process of step P2 of FIG.
1 displays the print menu. In the display of this print menu, a plurality of print items including daily report print and pallet diagram print are displayed. In Step P22, it is determined whether or not the daily report printing process is designated. In Step P23, it is determined whether or not the Pareto chart printing process is designated. Step P
At 24, it is determined whether another printing process is designated.
In step P25, it is determined whether the end is designated. Until the end is designated, the process returns from step P25 to step P21. When the end is designated, the process returns to the main routine.

When the daily report printing is designated, the process proceeds from step P22 to step P26. In step P26, the daily report printing process is executed (described later). When Pareto chart printing is designated, the process proceeds from step P23 to step P27.
In Step P27, Pareto chart printing processing is executed. When another printing process is designated, the process proceeds from step P24 to step P28. In step P28, another printing process is executed.

In the daily report printing process of step P26, the process shown in FIG.
In step P31 of 1, the date of the daily report to be printed is accepted. When the operator inputs the date to be printed, the control calculation unit 31 receives the input date. Here,
It is possible to receive daily reports for multiple days on a daily basis. In step P32, the date / lot /
Read related data such as product data. Step P
At 33, the read data is subjected to various kinds of processing such as operation rate calculation and defect rate calculation. In Step P34, the processed data is output in the designated output format.

The output result is shown in FIG. In the daily report shown in FIG. 13, the data of “1 shift” and “2 shift” are displayed in a list on the first page. Here, the stop factors are described according to the time chart shown in FIG. In particular, there are three output factors for non-operation stoppages: "break", "waiting", and "lunch". Regarding the output stop factor, time and its composition ratio are also output.

As a result, it is possible to understand the breakdown of the stoppage during non-operation, and to know the hidden cost increase factor that is not included in the operation rate. Such data is necessary to control costs and can provide important data for cost analysis. Further, by providing such a totalizing function in the general-purpose production management system, data for cost analysis can be obtained at low cost.

The waiting time is not included in the normal operating time, but can be included in the operating time. In this case, it suffices not to operate the pause button when the waiting is generated.

[0041]

In the production management system and the data collection terminal device according to the present invention, the stop factor is accepted separately for the operation stop factor and the non-operation stop factor, so that more accurate production is possible regardless of whether the equipment is operating or not. You will be able to manage. You can understand the cause of stoppage during non-operation.

[Brief description of drawings]

FIG. 1 is a configuration block diagram of a production management system as an embodiment of the present invention.

FIG. 2 is a plan view showing a panel arrangement of the terminal.

FIG. 3 is a configuration block diagram of a terminal.

FIG. 4 is a configuration block diagram of a host computer.

FIG. 5 is a control flowchart of the terminal.

FIG. 6 is a control flowchart of the terminal.

FIG. 7 is a control flowchart of the terminal.

FIG. 8 is a control flowchart of the terminal.

FIG. 9 is a control flowchart of the host computer.

FIG. 10 is a control flowchart of the host computer.

FIG. 11 is a control flowchart of the host computer.

FIG. 12 is a timing chart showing operation results and operation times.

FIG. 13 is a diagram showing an example of a daily report output format.

[Explanation of symbols]

 1 Host Computer 4 Terminal 20 Control Arithmetic Unit 21 Parallel Input Unit 31 Control Arithmetic Unit

Claims (2)

[Claims] 1. A production management system for collecting production management data from production equipment, comprising: an operation recognition means for recognizing the operation / stop of the production equipment.
When the operation recognition means recognizes the stop of the production equipment, the operation / non-operation determination means for determining whether it is in the operation state or the non-operation state, and when the operation / non-operation determination means determines the operation state A data collection terminal including an operation stop factor receiving means for receiving an operation stop factor, and a non-operation stop factor receiving means for receiving a non-operation stop factor when the operation / non-operation determination means determines that the operation is not in operation A production management system comprising: a unit, and a host unit that receives operation / stop and operation / non-operation information from the data collection terminal unit and performs a production control data totaling process. 2. A data collection terminal device for collecting production management data from a production device, the operation recognition means for recognizing the operation / stop of the production equipment, and the operation recognition means for recognizing the stop of the production equipment. An operating / non-operating determining means for determining whether it is in an operating state or a non-operating state, and an operating stop factor receiving means for receiving an operating stop factor when the operating / non-operating determining means determines that the operating state is in an operating state. A data collection terminal device comprising: a non-working stop factor receiving unit that receives a non-working stop factor when the working / non-working judging unit judges that the work is not working.