JPH08126942A - Production line operation management method and device thereof - Google Patents

Abstract

PURPOSE: To provide the operation management method capable of enhancing the operation factor computing accuracy of each production line and its each operation factor, and the device thereof. CONSTITUTION: In each production line formed out of a plurality of production units M1 through Mn, various data of information on the failures, cutting tool replacement, arrangement, start-up and the like of each production unit are collected, and the time chart for the failures, cutting tool replacement, arrangement, start-up and the like of each production unit is computed based the aforesaid information. However, when the periods of failures are piled up in a plurality of the production units, the failure time chart of each production line is computed without convolutionally counting the periods of suspended operations. Besides, the net time chart of each production line for cutting tool replacement, arrangement, and start-up shall be computed in such a way that cutting tool replacement, arrangement and start-up during the period of each suspended operation are excluded. The operation factor of each production line is thereby computed by using the time thus computed for cutting tool replacement, arrangement and start-up.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an operation management method for a production line including a plurality of production apparatuses and an apparatus therefor.

[0002]

2. Description of the Related Art Conventionally, in an automobile manufacturing plant or the like, an automated production line including a plurality of production devices is provided,
The workpieces are supplied to the plurality of production apparatuses, the machining and assembly of the workpieces that are shared by the respective production apparatuses are executed, and after the processing and the assembly are completed, the workpieces are sequentially supplied to the production apparatuses on the downstream side for production. I do. In a recent production line, the work is conveyed from upstream to downstream together with the pallet in a state of being set on the pallet, but the movement of the work between the respective production devices is configured to be commonly or independently executable. The cycle time in is often set to a predetermined short cycle time on the order of tens of seconds. In addition, a work pool may be provided between a production device that is likely to wait for work to be unloaded and the next production device.

Conventionally, in order to manage the operation in the production line as described above, data relating to the operation state (data such as failure, cutting tool exchange, setup, start-up, etc.) is collected for each production apparatus and based on the data. For each production device, the operating rate of the entire production line, failure time, cutting tool replacement time, setup time, start-up time (time from start of work to start of device), etc. It analyzes monthly and manages the operation of the production line. In the case of calculating the operation rate of the production line, conventionally, the operation stop time of a plurality of production devices is simply summed to calculate the total operation stop time of the production line, and the total operation stop time and the production line The operation rate was calculated based on the total load time.

Here, for example, Japanese Patent Laid-Open No. 5-200657.
In the official gazette, an operating state detecting means for detecting the operating state of the production device in each production device, an information collecting means for collecting information on the operating state of each production device in a preset period,
A stop state search means for searching a preset stop state of the production device to be checked, a stop analysis means for analyzing a cause device and a stop factor of the cause of the stop, and a stop time for each cause device and stop factor There is described a production line operation analysis device provided with a stop time accumulating means for categorizing and accumulatively calculating, and an output means for outputting the calculation result to the outside.

[0005]

In the conventional production line operation management method, when the operation rate of the production line is calculated, the operation stop times of a plurality of production apparatuses are simply summed to obtain the total production line total. The operation stop time is calculated, and the operation rate of the production line is calculated using this total operation stop time.
However, if the operation stop time of multiple production equipment partially or totally overlaps, the overlapped operation stop time is recorded in a superimposed manner, and the operation stop time longer than the actual production line stop time is added. Since the operating rate is calculated using this, there is a problem that the accuracy of calculating the operating rate decreases.

Therefore, according to the conventional operation management technology for the production line, even if the cutting tools are replaced or the equipment is repaired in each production device while the operation of the production line is stopped, the operation management statistics are obtained. There is no effect on the utilization rate of the data. Therefore, in the conventional operation management, during the operation suspension period of the production line, management to promote the exchange and repair of cutting tools in each production device is not executed at all, and it is determined by the worker's voluntary judgment. In rare cases, cutting tools are only replaced or repaired during the operation stoppage of the production line. An object of the present invention is to provide an operation management method capable of increasing the calculation accuracy of the operation rate of a production line, an operation management method capable of increasing the operation rate, and an operation management device capable of increasing the operation rate.

[0007]

According to a first aspect of the present invention, there is provided an operation management method for managing the operation of a production line, which comprises a plurality of production apparatuses, in which data relating to the operation state of each production apparatus is collected. , When calculating the operating rate of the production line based on the data on the operating state, if the operating stoppage periods of a plurality of production equipments overlap, the operation stoppage period of the production line is not added up. The operation rate is calculated.

The production line operation management method according to claim 2 is
In the invention of claim 1, when there is a work pool between the production apparatuses, even if the production apparatus on the upstream side of the work pool stops operating, a work loading wait occurs on the production apparatus on the downstream side of the work pool. Up to, the operation stop of the production equipment on the upstream side of the work pool is not included in the operation stop period. According to a third aspect of the invention, in the production line operation management method of the first aspect, the blades of a plurality of production devices on the production line are exchanged while the production line is not operating. According to a fourth aspect of the present invention, in the production line operation management method of the first aspect, repair of a plurality of production devices of the production line is promoted while the production line is out of operation.

The operation management device for the production line according to claim 5 is:
In an operation management device that manages the operation of a production line consisting of a plurality of production devices, the operation of the production line is based on the data collection means that collects data related to the operating state of each production device and the data collected by the data collection means. A stop state detecting means for detecting a stop state; and a command means for outputting a command for instructing repair to a plurality of production devices on the production line when the operation stop state of the production line is detected by the stop state detecting means. It is a thing.

[0010]

According to the operation management method of the production line of claim 1, in the operation management method for managing the operation of the production line composed of a plurality of production devices, data on the operation state of each production device is collected, When calculating the operating rate of a production line based on this operation status data, if the operation stoppage periods of multiple production equipments overlap, the operation of the production line will be started without superimposing the operation stoppage period. Calculate the rate. Therefore, the accuracy of calculating the operating rate of the production line can be improved by calculating the operating rate using the actual operating stop time of the production line without superposing the operating stop period.

In the operation management method for the production line according to claim 2, the same action and effect as in claim 1 are achieved, but when there is a work pool between the production devices, the work pool upstream side is provided. Even if the production equipment stops operating, the operation stoppage of the production equipment upstream of the work pool is not included in the operation suspension period until the production equipment on the downstream side of the work pool waits for work to be loaded. That is, even if the production device on the upstream side of the work pool stops operating, the production device on the downstream side of the work pool does not stop until the work loading wait occurs in the production device on the downstream side of the work pool, and the production line is substantially Since it is in operation, by not counting the operation stoppage of the production equipment on the upstream side of the work pool, it is possible to improve the accuracy of calculation of the operation rate of the production line and appropriately evaluate the work pool function.

According to the operation control method of the production line of claim 3, the same operation and effect as in claim 1 are exhibited, but while the operation of the production line is stopped, the replacement of the cutting tools of the plurality of production devices of the production line is promoted. To do. If the blades of multiple production devices in the production line are exchanged while the production line is not operating, the operating rate can be increased compared to the case where the active production line is stopped and the blades are exchanged. . However, in that case, although there is a cost increase due to the replacement of the usable cutting tools that are still in service, the replacement of the cutting tools of a plurality of production devices on the production line is promoted while the production line is out of service ( By promoting the replacement of the cutting tool that is approaching, the operating rate can be increased while suppressing the cost increase.

According to the operation control method of the production line of the fourth aspect, the same operation and effect as those of the first aspect are obtained, but repair of a plurality of production devices of the production line is promoted while the operation of the production line is stopped. Therefore, while the production line is out of service,
Since the frequency of repairing a plurality of production devices on the production line increases, the operating rate can be increased.

In the production line operation management apparatus according to the present invention, in order to manage the operation of the production line composed of a plurality of production apparatuses, the data collection means collects data relating to the operation state of each production apparatus and stops the operation. The state detection means detects the operation stop state of the production line based on the data collected by the data collection means. The command means, when the operation stop state of the production line is detected by the stop state detection means,
Outputs a command to repair multiple production devices on the production line. In this way, while the production line is stopped, multiple production devices in the production line are instructed to perform repairs, and the repairs are performed. Improves operating rate.

[0015]

Embodiments of the present invention will be described below with reference to the drawings. This embodiment is an example of the case where the present invention is applied to the production control of one production line for automatically performing a plurality of types of cutting processes on a work by a plurality of production devices in an automobile manufacturing plant. It includes both the production control method and the production control device for the production line.

As shown in FIG. 1, this production line 1 is
A production line in which n production devices M1 to Mn are arranged in a line, and is a production line for automatically performing a plurality of types of cutting processes on a work. Each production device M1-Mn
It is a device that is automatically controlled and automatically cuts. In addition, in the production line 1, the production devices M1 to Mn
The machining cycle time in is a short time such as 45 seconds. The work is conveyed along the conveyance path of the production line 1 while being fixedly mounted on the pallet, the preset cutting process is executed in each of the production devices M1 to Mn, and the work is transferred to the next production device M1 to Mn. To be done.

Then, for example, a work pool 2 capable of pooling a plurality of works is provided between the production devices M1 and M2, and the works machined by the production device M1 are
After being transferred to the work pool 2, the work pool 2 is transferred to the production apparatus M2. Further, a work pool 3 capable of pooling a plurality of works is provided between the production devices M3 and M4, and the works processed by the production device M3 are
After being transferred to the work pool 3, the work pool 3 is transferred to the production apparatus M4. Then, the transfer of the works in the production apparatuses M1 to Mn is executed substantially in synchronization with the entire production line 1.

The production devices M1 to Mn are respectively provided with sequencer units S1 to Sn. Each of the sequencer units S1 to Sn includes a sequencer 4 composed of a programmable controller, as shown in FIG. It has a CRT display 5 connected to the sequencer 4 and an operation panel 6, and these sequencer units S1 to Sn are connected to a production management sequencer 7 that comprehensively manages the control line 1 so that signals can be transmitted and received, and programmable. The production control sequencer 7 composed of a controller is connected to the production control computer 8 so as to be able to exchange signals, and the production control computer 8 is connected with a keyboard 9, a CRT display 10 and a printer 11. In addition, in the following description, the "cutting tool"
It means a cutting tool for cutting.

The sequencer 4 of each of the sequencer units S1 to Sn has a control program for cutting work, which is shared among them.
General control programs such as a control program for automatic cutting tool exchange control and a control program for workpiece transfer control are input and stored in advance. Further, each sequencer 4 has commands input through the operation of the operation panel 6, sensor signals for detecting the presence / absence of a work pallet, control information associated with execution of a control program for cutting, and automatic cutting tool exchange control. The various signals (at least the various signals shown in FIG. 3) necessary for executing the control peculiar to the present application to be described later are supplied to the production management sequencer 7 based on the control information accompanying the execution of the control program of FIG. Is configured to.

As shown in FIG. 3A, each production device M1
In Mn, if the production device fails, the sequencer 4 outputs a failure start signal Ks to the production management sequencer 7, and when the failure is resolved, the failure end signal Ke.
Is output to the control management sequencer 7. Then, in the production control sequencer 7, the period from the failure start signal Ks to the subsequent failure end signal Ke is determined to be the failure period. In FIG. 3, the failure time chart is a chart including the start time and end time of the failure period and the time calculated from both times.

As shown in FIG. 3 (B), the replacement of the cutting tool is the same as in the case of a failure, and the production devices M1 to Mn are the same.
In, when the cutting tool exchange is started, the cutting tool exchange start signal Hs is output, and when the cutting tool exchange is finished, the cutting tool exchange end signal He is output. Then, the period from the cutting tool replacement start signal Hs to the cutting tool replacement end signal He is determined to be the cutting tool replacement period. As shown in FIG. 3 (C), the setup (preparation work associated with production) is the same as in the case of failure, and when the setup is started in each of the production devices M1 to Mn, the setup is started. The setup start signal Ds is output, and when the setup is completed, the setup end signal De is output. And
The period from the setup start signal Ds to the setup end signal De is determined as the setup period.

As shown in FIG. 3D, the period from the morning start time to the start start time of each production apparatus M1 to Mn, and the afternoon start time to the start start time of each production apparatus M1 to Mn. Although the period is the rising period, the rising start S is automatically calculated in the production management sequencer 7 from the start time, and when the operation of each of the production devices M1 to Mn is started, it coincides with the end of the rising. Start signal Ms
Is output from the sequencer 4. Then, in the production control sequencer 7, the start signal S
The period up to is determined to be the rising period.

As shown in FIG. 3E, each production device M1
In Mn to Mn, although the production devices M1 to Mn are in an operable state, when the work detection sensor is OFF and waiting for work loading, the work loading waiting start signal Wis is output at the start of the work loading When the waiting is canceled, the workpiece carry-in waiting end signal Wie is output. In the production control sequencer 7, the period from the work carry-in waiting start signal Wis to the work carry-in waiting end signal Wie is
It is judged to be the work-in waiting period.

As shown in FIG. 3 (F), each production device M1
In Mn to Mn, although the machining of the work is completed and the work can be transferred to the next production apparatuses M1 to Mn, the work transfer permission signal is not supplied and the work is unloaded at the start when waiting for the work to be unloaded. When the waiting start signal Wos is output and the waiting for unloading the work is canceled, the unloading end signal Woe for the work is output. In the production control sequencer 7, the period from the work unloading wait start signal Wos to the work unloading wait end signal Woe is determined as the work unloading wait period.

In addition, although not shown in FIG. 3, the sequencer 4 of each of the production devices M1 to Mn sends a stop signal Me when the operation of the production device is stopped and each work start signal WPs when the production of each work is started. Further, when the production of each work is finished, each work end signal WPe is supplied to the production control sequencer 7, and when a defective work is generated, a defective product generation signal E is supplied to the production management sequencer 7.

Next, a signal output control routine which is executed by the sequencer 4 of each of the production apparatuses M1 to Mn and overlaps with the above-described contents will be described with reference to FIG.
A brief description will be given with reference to the flowchart of FIG. Incidentally, the reference symbol Si (i = 1, 2, ...) In the flowchart indicates each step. This signal output control is control that is constantly executed from the start of work to the end of work every day. After the control starts, various signals shown in S2 are read (S1), and then S2 is executed. In S2, S1
Based on the various signals read in step S2, various determinations described in the left column of S2 are executed, and various signals described in the right column of S2 are output to the production control sequencer 7.

That is, the failure start signal Ks is output when the failure starts, and the failure end signal Ke is output when the failure ends. A blade tool exchange start signal Hs is output when the blade tool exchange is started, and a blade tool exchange end signal He is output when the blade tool exchange is completed. At the start of setup, the setup start signal Ds is output,
When the setup is completed, the setup completion signal De is output. When the work carry-in waiting is started, the work carry-in waiting start signal Wis is output, and when the work carry-in waiting is finished, the work carry-in waiting end signal Wie is outputted. A work unloading start signal Wos is output at the start of the work unloading wait, and a work unloading end signal Woe is output at the end of the work unloading wait.

Furthermore, when the production devices M1 to Mn are activated (automatic activation or manual activation), the activation signal Ms is output, and when the production devices M1 to Mn are stopped (automatic activation or manual termination), the stop signal Me is output. . When the production devices M1 to Mn fail, the production devices M1 to Mn are stopped, and at the end of the failure, the production devices M1 to Mn are activated. Further, when the setup of the production apparatuses M1 to Mn is started, the production apparatuses M1 to Mn are stopped, and when the setup is completed, the production apparatuses M1 to Mn are started. Then, the production device M is used for exchanging cutting tools, waiting for work loading, and waiting for work removal.
1 to Mn in the operating state (state from start to stop).

Further, for each work, each work start signal WPs is output at the start of production of each work, and each work end signal WPe is output at the end of production of each work. The signals WPs and WPe are applied to calculate the production time of each work. And when defective work occurs,
The defective product generation signal E is output. Although not shown in S2, each sequencer 4 outputs a cutting tool use signal including information specifying the cutting tool to the production management sequencer 7 every time the usage of each cutting tool is started. Next, S after S2
In step 3, it is determined whether or not it is the last closing time of the day. If the result of the determination is No, S1 and subsequent steps are repeatedly executed at each predetermined minute calculation cycle, and if the determination in S3 becomes Yes, this control is executed. finish.

The production control sequencer 7 is provided with a large number of cutting tool machining number counters for counting the number of times of machining (the number of times of use) of all the cutting tools in each of the production apparatuses M1 to Mn. Sequencer 4
A control program for controlling the number of times of processing for counting the number of times of processing (the number of times of use) of the cutting tool is stored in advance by counting the cutting tool use signal supplied from the production management sequencer 7. The control program of the base data collection control shown in FIG. 6, the control program of the recommendation command output control shown in FIG.

Next, the base data collection control routine executed by the production management sequencer 7 will be described.
This will be described with reference to the flowchart of FIG. In this base data collection control, various signals as shown in S2 of FIG. 4 are read from the sequencer 4 of the production devices M1 to Mn, and each item (fault, cutting tool exchange, setup, setup, etc.) for each production device M1 to Mn is read. Etc.) separately, it is a control that creates base data in which the time data of the time when the signal is read is added to the data corresponding to the read signal and stores it in the memory. , Is repeatedly executed every predetermined minute calculation cycle.

When this control is started, various signals are read from each sequencer 4 (S10), and then in S11, the step of creating the base data as described above is executed. For example, when the failure start signal Ks is received, the base data DKs is created. The base data DKs includes information for identifying the production devices M1 to Mn, information indicating a failure, and each production device. The information of the failure number and the information of the failure start time are included, and when the failure end signal Ke is received, the base data DKe is created.
The information includes information for identifying n, information indicating a failure, information about a failure number in each production apparatus, and information about a failure end time. That is, the base data DKs and the base data DK for each failure in each of the production devices M1 to Mn.
The failure time chart shown in FIG. 3A is obtained from e.

The various signals Hs, He, Ds, described above,
De, Wis, Wie, Wos, Woe, Ms, Me, WPs, WP
For e, a time chart will be obtained in the same manner as above. When the defective product generation signal E is received, the defective product counter CE for each of the production devices M1 to Mn is set to 1.
Is incremented only. Next, S12 after S11
In, it is determined whether it is the last closing time of the day. If the determination result is No, S10 and subsequent steps are repeatedly executed at every predetermined minute calculation cycle, and if the determination in S12 becomes Yes, this control ends. To do.

Next, the recommended command output control routine executed by the production control sequencer 7 will be described with reference to the flowchart of FIG. This recommendation command output control is constantly and repeatedly executed every predetermined minute calculation period from the start to the end of work every day. When this control is started, in S20, the base data (DMs, DMe) of all the production devices M1 to Mn are read from the memory, and then in S21, it is determined whether or not the production line 1 is stopped. It in this case,
For each of the production devices M1 to Mn, it can be determined from the base data (DMs, DMe) related to the production device whether or not the production device M1 to Mn is stopped. Is determined to be inactive. If the production line 1 is not stopped, S21 to S20
Returning to step S20 and subsequent steps are repeatedly executed.

When the production line 1 is not in operation, S
In S22 after shifting to 22, the cutting tool exchange recommendation command is output to the corresponding sequencer 4 of the sequencers 4 of the production apparatuses M1 to Mn other than the stopped state. In this case, for each of the production devices M1 to Mn, the count value of the cutting tool counter for the cutting tool currently in use is set to a predetermined ratio of the preset number of times of cutting (for example,
90%) or more, and if it is equal to or more than a predetermined ratio of the limit number of times of machining, the cutting tool exchange recommendation command is output only to the sequencer 4 of the production apparatus M1 to Mn. In the sequencer 4 which has received the cutting tool replacement recommendation command, the cutting tool automatic replacement control is activated, and the cutting tool in use is replaced with the same new cutting tool.

In this case, a tool change recommendation command,
Information such as the count value of the processing number counter, the limit processing number, and the ratio of the count value to the limit processing number is displayed on the display 5. As described above, by executing the cutting tool exchange while the production line 1 is stopped, the frequency of stopping the production line 1 for the cutting tool exchange during the operation of the production line 1 is reduced, and the operation rate of the production line 1 is reduced. Can be increased. Since only the blade having a count value of the number of times of machining equal to or greater than the predetermined ratio of the limit number of times of machining is replaced with a new one, it is possible to suppress an increase in the cost of the blade due to exchanging the blade having a sufficient remaining life.

Next, in S23, a repair recommendation command for recommending repair of the apparatus is output to the sequencer 4 of each of the production apparatuses M1 to Mn other than the stopped state, and then the procedure returns to S20. In this case, each production device M1
In the sequencer 4 of ~ Mn, when the repair recommendation command is received, preset inspection / repair items (lubricating, belt, chain, chip processing mechanism, etc.) are displayed on the display, and the operator is informed of the production device M1.
~ Encourage inspection and repair of Mn. In this way, the production line 1
Since the inspection and repair of the production devices M1 to Mn are urged during the stop of the
It is possible to reduce the frequency of repairing Mn and increase the operating rate of the production line 1.

The production management computer 8 has control programs for daily production management statistical data creation control, weekly production management statistical data creation control, monthly production management statistical data creation control, etc. which will be described below. It is stored in advance. Next, a control routine for creating daily production management statistical data will be described with reference to the flowcharts of FIGS. This production control statistical data creation control is
Based on the daily base data accumulated in the production control sequencer 7, the control is executed in the production control computer 8 after the end of every day or once the next day. When this control is started, first, all failure base data (DKs, DKe) for today are read from the memory of the production management sequencer 7 (S30), and then S31.
In, the failure time chart for each of the production devices M1 to Mn is calculated, and the data is stored in the memory. For example, as shown in FIG. 10, a failure time chart of the production devices M1 to Mn is calculated.

Next, in S32, all the production devices M
The failure time chart of the production line 1 corresponding to the logical sum of the failure time charts of 1 to Mn is calculated as shown in FIG. 10, and the data is stored in the memory. The failure time chart of the production line 1 is shown in the production devices M1 to Mn.
When the failure time charts of No. 1 are overlapped with each other, the failure period is not calculated in a superimposed manner, and is calculated only once and calculated. That is, the failure time chart of the production line 1 calculated in this way shows the time and time at which the production line 1 is considered to be substantially stopped due to the failure of any of the production devices M1 to Mn.

Next, in S33, all the cutting tool exchange base data (DHs, DHe) for today is read from the memory, and then in S34, the cutting tool exchange time chart for each of the production devices M1 to Mn is calculated. , That data is stored in memory. For example, as shown in FIG. 10, a blade tool exchange time chart of the production apparatuses M1 to Mn is calculated. Next, in S35, the actual cutting tool exchange time chart of the production line 1 corresponding to the logical sum of the cutting tool exchange time charts of all the production apparatuses M1 to Mn is shown in the column of "Production line (actual)" in FIG. And the data is stored in the memory. When the cutting tool replacement time charts of the production apparatuses M1 to Mn are overlapped, the actual cutting tool replacement time chart of the production line 1 is calculated by calculating only once, without superposing the cutting tool replacement period. It The actual cutting tool replacement time chart of the production line 1 shows the time and time at which the production line 1 is considered to have substantially stopped its operation due to the replacement of the cutting tool in the production line 1.

Next, in S36, in consideration of the fact that the operation of the production line 1 does not stop due to the exchange of the cutting tool during the failure period of the production line 1, the failure of the production line 1 is confirmed from the actual cutting tool replacement time chart of the production line 1. The net cutting tool replacement time chart of the production line 1 excluding the cutting tool replacement during the period is calculated as shown in the column of “Production line (net)” in FIG. 10, and the data is stored in the memory.

Next, as in the case of exchanging the cutting tool, the setup base data (DDs, DDe) for today is read (S3
7) Next, the setup time chart for each of the production devices M1 to Mn is calculated and stored in the memory (S38), and then the actual setup time chart of the production line 1 is calculated and stored in the memory (S39). ), Then the net setup time chart of the production line 1 is calculated and stored in the memory (S4
0). Next, as in the case of the cutting tool exchange, today's rising base data (DS, DMs) is read (S41),
Next, the rise time chart of each of the production devices M1 to Mn is calculated and stored in the memory (S42), then the actual rise time chart of the production line 1 is calculated and stored in the memory (S43), and then the production is performed. The net rise time chart of line 1 is calculated and stored in the memory (S4
4).

Next, as in the case of exchanging the cutting tool, today's work-in-waiting base data (DWis, DWie) is read (S45), and then the work-in waiting time chart for each of the production devices M1 to Mn. Is calculated and stored in the memory (S46), then the actual workpiece loading wait time chart of the production line 1 is calculated and stored in the memory (S47),
Next, a net work loading waiting time chart of the production line 1 is calculated and stored in the memory (S48). Next, as in the case of the cutting tool exchange, today's work unloading waiting base data (DWos, DWoe) is read (S49), and then the work unloading waiting time chart of each production device M1 to Mn is calculated. Are stored in the memory (S50), then the actual work unloading time chart of the production line 1 is calculated and stored in the memory (S51), then the net work unloading time chart of the production line 1 is calculated and stored in the memory. (S52).

Next, all the work production time base data (DWPs, DWPe) for all of today's work are read from the memory (S
53) Next, the production delay time for all the works in each of the production devices M1 to Mn and the sum thereof are calculated and stored in the memory (S54). Next, the sum of the production delay times of the production line 1 is calculated and stored in the memory (S5
5). The production delay time of each work is a time obtained by subtracting a predetermined cycle time from the production required time of each work, and the production delay time of all works is the production delay time of all works. That is. Next, the base data (CE) of all defective work for today is read from the memory (S56), and the number of defective work for each of the production devices M1 to Mn is calculated and stored in the memory. (S57). Next, the total number of defective works on the production line 1 is calculated and stored in the memory (S58).

Next, in S59, various times described below are calculated. Today's load time T (for example,
In the case of an 8 hour working day, 8 hours is calculated from preset data, and the total failure time Kt of all the production devices M1 to Mn is the failure of the production line 1. Calculated from the time chart, and the total cutting tool replacement time Ht for all the production devices M1 to Mn
Is calculated from the cutting tool exchange time chart of the production line 1, and the total setup time Dt for all the production devices M1 to Mn is calculated from the setup time chart of the production line 1 and all the production devices The total rise time Ut for M1 to Mn is calculated from the rise time chart of the production line 1, and all the production devices M1 to Mn.
Is calculated from the work-in waiting time chart of the production line 1, and the total work-out waiting time Wot of all the production devices M1 to Mn is the work-out waiting time of the production line 1. Calculated from the chart. Then, the data of the calculation result is stored in the memory.

However, since there is the work pool 2 between the production devices M1 and M2, even if the production device M1 fails or is set up, the influence of the effect does not result in waiting for the work to be loaded into the production device M2. It can be considered that the production line 1 did not stop operating. Therefore,
When there is a failure or setup of the production apparatus M1, the failure or setup of the production apparatus M1 is recorded in the total failure time Kt or the total setup time Dt until the time when waiting for the work to be brought into the production apparatus M2 due to the influence thereof. I will not do it. Similarly, since the work pool 3 is also provided between the production devices M3 and M4, when there is a failure or setup of the production device M3, the production device M4 waits until a work carry-in wait occurs due to the failure. Total failure time K for failure and setup of M3
t and the total setup time Dt are not included.

Next, in S60, the operating rate η of the production line 1 for today is calculated by the following equation and stored in the memory. η = [T− (Kt + Ht + Dt + Ut)] × 100 / T After the operation rate η of the production line 1 is calculated, the production management statistical data creation control for each day ends. Since the daily production control statistical data calculated as described above is accumulated in the memory, it is possible to easily produce weekly production control statistical data and monthly production control statistical data using these production control statistical data. Can be created.

In the control line 1, since the transfer of the work is executed substantially in synchronization throughout the production devices M1 to Mn, and because the machining cycle time is short, When the cutting tool exchange is executed in any of the production devices, the production line 1 stops operating, and when the setup is executed in any of the production devices, the production line 1 stops operating, and any of the production devices In view of the fact that production line 1 will stop operating during the start-up period in
Is calculated by the above arithmetic expression. Further, since waiting for work loading and unloading occurs during a period of failure in any of the production devices M1 to Mn, blade change, setup, and start-up, the operation rate η includes waiting for work loading and unloading work. The wait is not taken into account.

In the production management method and the production management apparatus described above, when the failure time charts of the production line 1 are calculated, when the failure periods of the plurality of production apparatuses M1 to Mn are overlapped, the overlapping failure periods are overlapped. Since the failure time chart of the production line 1 is calculated only once and not calculated in a superimposed manner, the calculation accuracy of the failure period of the production line 1 can be improved. Then, when the cutting tool replacement time chart of the production line 1 is calculated, when the cutting tool replacement periods of the plurality of production apparatuses M1 to Mn overlap, the overlapping failure periods are not counted in a superimposed manner and only once. Since it is counted and the failure time chart of the production line 1 is calculated,
It is possible to improve the accuracy of calculation of the cutting tool replacement period. Then, since the operating rate of the production line 1 is not affected even if the cutting tool replacement is executed during the failure period of the production line 1, the production line 1 excluding the cutting tool replacement during the failure period of the production line 1 Since the net blade change period is calculated, it is possible to improve the accuracy of calculation of the blade change period that affects production.

The same applies to the calculation of the setup period of the production line 1 and the calculation of the rising period of the production line 1. As described above, the calculation accuracy of the failure period, the blade tool replacement period, the setup period, and the start-up period of the production line 1 is improved, and the production line 1 is used by using the failure period, the blade tool replacement period, the setup period, and the start-up period. Since the operating rate η of is calculated, the accuracy of calculating the operating rate η of the production line 1 can be significantly improved.

Further, regarding a failure or setup in the production apparatuses M1 and M3 on the upstream side of the work pools 2 and 3, due to the influence of the failure or setup, a work-in waiting occurs in the production apparatuses M2 and M4 on the downstream side. Up to production equipment M1, M3
Since the period of failure or setup in 1 is not included in the operation stop period of the production line 1, it is possible to improve the calculation accuracy of the operation rate η of the production line 1.

Moreover, while the production line 1 is stopped, the production tool M1 to Mn which is not in the production stop state, and the production tool M1 to Mn whose blades are about to be replaced, outputs a blade exchange recommendation command to exchange the blades. Therefore, the operating rate η of the production line 1 can be increased, and in this case, only the cutting tool whose count value of the cutting tool processing number counter is equal to or more than the predetermined ratio of the limit processing number is replaced, so that the cutting tool cost is increased. The cost increase can be suppressed. Further, during the operation stop of the production line 1, the production devices M1 to M other than the operation stop
Since the repair recommendation command is output to n to promote the inspection and repair of the production device, the operating rate η of the production line 1 can be increased.

Then, a workpiece loading wait time chart in each of the production apparatuses M1 to Mn, an actual workpiece loading wait time chart of the production line 1, a net workpiece loading wait time chart of the production line 1, and workpieces in each of the production apparatuses M1 to Mn. Data such as the carry-out waiting time chart, the actual work carrying-out waiting time chart of the production line 1, and the net work carrying-out waiting time chart of the production line 1 are also collected, so that these data can be effectively used for the management of the production line 1. In addition, the total production delay time of each of the production devices M1 to Mn, the total production delay time of the production line 1, the number of defective work pieces of each of the production devices M1 to Mn, the total number of defective work pieces of the production line 1, Since such data is also collected, these data can be effectively used for management of the production line 1.

The operation formula of the operating rate η of the production line 1 is merely an example, and the operating rate η is calculated by using an arithmetic expression different from the above arithmetic expression using various data calculated in S59. It may be configured to do so.

[Brief description of drawings]

FIG. 1 is a block diagram showing an overall configuration of a production line according to an embodiment of the present invention.

FIG. 2 is a block diagram showing the contents of a sequencer unit.

FIG. 3A is an explanatory diagram such as a failure time chart,
(B) is an explanatory view of a blade change time chart or the like, (C) is an explanatory view of a setup time chart or the like, (D) is an explanatory view of a rising time chart or the like, and (E) is an explanation of a work loading waiting time chart or the like. FIG. 6F is an explanatory diagram of a work unloading waiting time chart and the like.

FIG. 4 is a flowchart of signal output control by a sequencer of each production apparatus.

FIG. 5 is a flowchart of base data collection control by a production management sequencer.

FIG. 6 is a flow chart of recommendation command output control by a production management sequencer.

FIG. 7 is a part of a flowchart of daily production management statistical data creation control.

FIG. 8 is a part of a flowchart of daily production management statistical data creation control.

FIG. 9 is the rest of the flowchart of production control statistical data creation control for each day.

FIG. 10 is a diagram showing a failure time chart of each production device and a production line and a blade tool exchange time chart of each production device and a production line.

[Explanation of symbols]

 1 Production line M1 to Mn Production device 2,3 Work pool S1 to Sn Sequencer unit 4 Sequencer 7 Production control sequencer 8 Production control computer

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[Procedure amendment]

[Submission date] June 29, 1995

[Procedure Amendment 1]

[Document name to be corrected] Drawing

[Correction target item name] All drawings

[Correction method] Change

[Correction content]

FIG.

[Fig. 2]

[Figure 3]

[Figure 4]

[Figure 5]

[Figure 6]

[Figure 10]

[Figure 7]

[Figure 8]

[Figure 9]

Claims (5)

[Claims] 1. An operation management method for managing the operation of a production line including a plurality of production devices, wherein data relating to the operation state of each production device is collected, and the operation rate of the production line is calculated based on the data relating to the operation state. When calculating, when the operation stoppage periods of multiple production equipments overlap, the operation rate of the production line is calculated without superimposing the operation stoppage periods. . 2. When there is a work pool between the production apparatus and the production apparatus on the upstream side of the work pool stops operating, the production apparatus on the downstream side of the work pool waits until the work is loaded. The operation management method for a production line according to claim 1, wherein the operation stop of the production apparatus on the upstream side of the work pool is not counted in the operation stop period. 3. The operation management method for a production line according to claim 1, wherein replacement of blades of a plurality of production devices in the production line is promoted while the operation of the production line is stopped. 4. The production line operation management method according to claim 1, wherein repair of a plurality of production devices of the production line is promoted while the operation of the production line is stopped. 5. An operation management device for managing the operation of a production line composed of a plurality of production devices, based on data collection means for collecting data on the operation state of each production device, and data collected by the data collection means. A stop state detecting means for detecting an operation stop state of the production line, and when the stop state detecting means detects the operation stop state of the production line, outputs a command for instructing repair to a plurality of production devices of the production line. An operation management device for a production line, which is provided with a command means.