TW202230265A - System and method for analyzing availability and abnormality of production line including a real-time lamp signal capturing module, a default rule processing module, a database, a production line analysis module, and a display interface - Google Patents

Abstract

This invention provides a system for analyzing the availability and the abnormality of a production line. The system includes a real-time lamp signal capturing module, a default rule processing module, a database, a production line analysis module, and a display interface. The real-time lamp signal capturing module captures real-time lamp signals of various devices of the production line. The default rule processing module generates serialized data corresponding to a production state and an abnormality cause and stores the serialized data into the database. The production line analysis module is able to learn and read the serialized data, so as to find a time interval when a device on the production line is abnormal under at least one specific condition, and modifies the abnormality cause that the device is abnormal into a final abnormality cause to generate an analysis result stored in the database. The display interface displays the analysis result stored in the database. This invention further provides a method for analyzing the availability and the abnormality of a production line.

Description

Production line utilization and abnormal analysis system and method

The present invention provides a production line utilization rate and abnormal analysis system and method, especially a production line utilization rate and abnormal analysis system and method that can correct the abnormal cause of the production line.

In modern manufacturing, a production line is used to connect multiple equipments to complete the manufacture of products or semi-finished products. The utilization rate is the percentage of the actual working time of the equipment compared to the planned working time. The higher the utilization rate, the closer the operation of the equipment is to the full load, and the higher the natural production capacity. The relative planned working time minus the actual working time of the equipment is the unplanned downtime.

In order to increase the utilization rate of equipment, it is necessary to reduce the proportion of unplanned line stoppages. Traditionally, the period of equipment line stoppage and the reason for line stoppage are recorded manually, and then countermeasures are found through statistical reports for improvement. However, the method of relying on manual log-in is not only labor-intensive, but also prone to omissions and data loss, and the recorded data cannot be analyzed in real time.

In recent years, most production lines are equipped with warning lights for each equipment to display the status. When an abnormality occurs, the corresponding light will light up to remind the on-site personnel to deal with and return. Many manufacturers will use the technology of the Internet of Things to capture the time period when the warning light is on, so as to reduce the burden of on-site personnel. However, the reason for the abnormality of the equipment still needs to be registered manually, so the data obtained can still only be used for post-mortem analysis.

In addition, the abnormal analysis of each device is also prone to blind spots. For example, when an abnormal light signal occurs in a device in the production line, the on-site personnel confirm the time period of the occurrence and use the preset rules to determine the abnormal cause of the device and record it. The reason for the abnormality may be due to the influence of other devices in the same period, such as changing the line. If the production line utilization rate is analyzed with distorted data, it will not be able to effectively eliminate the real abnormal cause to improve the overall production line utilization rate.

The inventor has devoted his mind to research, and then developed a production line utilization rate and abnormal analysis system and method to automatically analyze the real cause of equipment abnormality in the production line, so as to correct the abnormal cause at an early stage, thereby improving the utilization rate.

A first aspect of the present invention provides an utilization rate and abnormality analysis system of a production line, which is suitable for a production line, and the production line has a plurality of equipments, each of which is electrically connected to a plurality of warning lights, and the warning lights are used for each The equipment provides a real-time light signal, and the utilization rate and abnormal analysis system of the production line includes a real-time light signal acquisition module, a preset rule processing module, a database, a production line analysis module and a display interface. The real-time light signal capture module is electrically connected to the warning lights and configured to continuously capture the real-time light signals of each device. The preset rule processing module is electrically connected to the real-time light signal capture module, and the preset rule processing module has preset rules, so as to analyze the real-time signals of the devices according to the preset rules and the sequence of time. The light signal is converted into a serialized operating state and abnormal cause, and then a serialized data is generated. The database is electrically connected to the preset rule processing module to store the serialized data. The production line analysis module is electrically connected to the database, and the production line analysis module has a learning ability, and is configured to read the serialized data to find out the time period during which the equipments in the production line are abnormal under at least one specific situation, and analyze the production line. The abnormal cause of the abnormality of the devices in at least one specific case is modified into a final abnormal cause to generate an analysis result, and then the analysis result is stored back into the database. The display interface is electrically connected to the database and configured to display the analysis result stored in the database.

A first aspect of the present invention provides a method for analyzing the utilization rate and abnormality of a production line, which is applicable to the above-mentioned production line, and includes the following steps: a. Use the real-time signal capture module to continuously capture the real-time signal of each device. b. Convert the real-time lights of each device into serialized operating status and abnormal reasons according to the preset rules and time sequence of the preset rule processing module. c. Store the operating status of each device and the cause of the abnormality in a database. d. Provide a production line analysis module with learning ability, and use the production line analysis module to find out the abnormal period of the production line in at least one specific case, and analyze the abnormality of the equipment in the at least one specific case. The abnormal abnormal cause of the abnormality is modified to a final abnormal cause to generate an analysis result. e. Save the analysis results back to the database.

In one embodiment, the method for analyzing the utilization rate and abnormality of the production line further includes a step of: providing a display interface for displaying the analysis results stored in the database.

In one embodiment, the production line analysis module is configured to receive an initial correction instruction, the initial correction instruction is configured to correct the abnormal cause to the final abnormal cause, and the production line analysis module learns the correction mode of the initial correction instruction The cause of the abnormality that occurred after the continuation correction.

In one embodiment, the learning step of the production line analysis module includes: reading the serialized data; receiving an initial correction command, and correcting the abnormal cause to the final abnormal cause by the initial correction command; Perform feature extraction on the abnormal causes of each device in the time period corresponding to the instruction; and learn the correction mode of the initial correction instruction, so as to continue the abnormal causes that occur after the correction.

In one embodiment, the production line analysis module performs feature extraction on abnormal causes of the equipment in the time period corresponding to the initial correction instruction, so as to learn the correction mode of the initial correction instruction.

In one embodiment, the real-time light signal capturing module captures the digital signal of the real-time light signal of each warning light.

In one embodiment, the real-time light signal capture module, the preset rule processing module, the database and the production line analysis module are installed in a computer device, and the display interface is electrically connected to the display interface. A monitor of a computer device.

Thereby, the system and method for analyzing the utilization rate and abnormality of the production line of the present invention can automatically analyze the real cause of equipment abnormality in the production line, so as to correct the abnormal cause at an early stage, thereby increasing the utilization rate of the production line. In addition, the system and method for analyzing the utilization rate and abnormality of the production line of the present invention can find out the error of the abnormal cause only by analyzing the real-time light signal, and further has the benefit of saving the analysis cost.

In order to fully understand the purpose, features and effects of the present invention, hereby, the present invention is described in detail by the following specific embodiments and in conjunction with the accompanying drawings, and the description is as follows:

Please refer to FIG. 1 , a first aspect of the present invention provides a production line utilization rate and abnormality analysis system 1, which is suitable for a production line (not shown in the figure), and the production line has a plurality of devices (not shown in the figure), each of which is an electrical Connect to multiple warning lights, such as warning light R, warning light Y and warning light G. The warning lights are used to provide a real-time light signal to each of the equipment. The production line utilization rate and abnormal analysis system 1 includes a real-time light signal capture module 10 , a preset rule processing module 11 , and a database 12 , a production line analysis module 13 and a display interface 14 . The real-time light signal capturing module 10 is electrically connected to the warning light R, the warning light Y and the warning light G and is configured to continuously capture the real-time light signal of each device. The preset rule processing module 11 is electrically connected to the real-time light signal capture module 10, and the preset rule processing module 11 has preset rules, so as to The real-time light signal of the device is converted into a serialized operating state and abnormal cause, and then a serialized data is generated. The database 12 is electrically connected to the preset rule processing module 11 to store the serialized data. The production line analysis module 13 is electrically connected to the database 12. The production line analysis module 13 has a learning ability and is configured to read the serialized data to find out the abnormality of the equipment in at least one specific situation of the production line. period, and modify the abnormal cause of the abnormality of the devices in at least one specific case into a final abnormal cause, so as to generate an analysis result, and then store the analysis result back in the database 12 . The display interface 14 is electrically connected to the database 12 and configured to display the analysis results stored in the database 12 . The real-time signal capture module 10 , the preset rule processing module 11 , the database 12 and the production line analysis module 13 are installed in a computer device 3 , such as the real-time signal capture module 10 It may be a circuit installed in the computer device. For example, the preset rule processing module 11 , the database 12 and the production line analysis module 13 may be programming languages installed in a hard disk of a computer device or integrated into a software. For example, the display interface 14 is a display electrically connected to the computer device.

Please refer to FIG. 1 and FIG. 2 , a second aspect of the present invention provides a method for analyzing the utilization rate and abnormality of a production line, for example, applicable to the above-mentioned production line, including the following steps:

Step S101: Use a real-time signal capture module, such as the real-time signal module 10, to continuously capture the real-time signal of each device.

Step S102: According to a preset rule processing module, for example, the preset rule processing module 11 presets a sequence of rules and time to convert the real-time light signals of each device into an active state and an abnormal cause to generate a sequence data.

Step S103 : Store the serialized data in a database, such as the database 12 .

Step S104: Provide a production line analysis module with learning ability, such as the production line analysis module 13, so as to find out the abnormal period of the production line in at least one specific situation by the production line analysis module 13, and Modifying the abnormal cause of the abnormality of the devices in at least one specific case into a final abnormal cause to generate an analysis result.

Step S105 : returning the analysis result to the database 12 .

Thereby, the production line utilization rate and abnormality analysis system 1 and method of the present invention can automatically analyze the real cause of equipment abnormality in the production line, so as to correct the abnormal cause at an early stage, thereby increasing the production line utilization rate. In addition, the system 1 and the method for analyzing the utilization rate and abnormality of the production line of the present invention can find out the error of the abnormal cause only by analyzing the real-time light signal, and further has the benefit of saving the analysis cost.

As shown in FIGS. 1 and 2 , in an embodiment of the second aspect of the present invention, a step S106 may be further included: providing a display interface, such as the display interface 14 , to display the data stored in the database 12 Analyze the results.

As shown in FIGS. 1 to 3 , in one embodiment, the production line analysis module 13 is configured to receive an initial correction instruction, and the initial correction instruction is configured to correct the abnormal cause to the final abnormal cause, and the production line analysis module 13 is configured to receive an initial correction instruction. The group learns the cause of the abnormality that occurs after the correction mode of the initial correction command is followed by correction. Specifically, the step of step S105 may include the following steps: S1051 : read the serialized data; S1052 : receive an initial correction command, and use the initial correction command to correct the abnormal cause to the final abnormal cause. S1053: Perform feature extraction on abnormal causes of each device in the time period corresponding to the correction instruction. S1054: Learning the correction mode of the initial correction instruction to follow the abnormal cause that occurs after the correction.

As shown in FIG. 1 to FIG. 4 , in one embodiment, for the equipment A1 , the equipment A2 and the equipment A3 of a production line 2 according to the production sequence, in this embodiment, the default rule processing module 11 is preset. The rule can be as follows: the unmarked normal mode N represents the normal operation time segment of the device; the abnormal time segment E1 represents the device abnormality; the abnormal time segment E2 represents the device standby. In the prior art, abnormal causes are recorded for equipment A1, equipment A2, and equipment A3 respectively. For example, the abnormal time period E1 in the time period TP2 will be recorded as equipment abnormality, so the manufacturer may report from the weekly report. or monthly report data to strengthen equipment maintenance and cannot correct the cause of the real abnormality. However, the production line analysis module 13 of the present invention analyzes all the equipment of the production line 2 in an integrated manner, and finds out that the equipment A2 has changed materials or lines in the time period TP2 through automatic learning, so in the time period TP2 The abnormal time period E1 of the equipment A2 will be remarked as material change or line change, so the manufacturer can ignore the non-real abnormality such as material change or line change, and focus on the abnormal time period of equipment A1 and equipment A3 In E1, the cause of the abnormality of the equipment; it is also possible to concentrate resources on the speed of material change or line change of the equipment A2 at an early stage to improve the overall utilization rate. In this embodiment, the production line analysis module 13 finds out the production line The sequence data of 2 is for material change or line change in time segments TP1, TP2 and TP3. If the correction of the abnormal cause in the time segment TP1 is the initial correction instruction in step S1053, such as a correction instruction from manual marking, the production line analysis module 13 can perform feature extraction on the abnormal cause in the time segment TP1 for learning, so as to In the time periods TP2 and TP3, the abnormal cause can be automatically corrected by learning the experience in the time period TP1.

In one embodiment, the real-time light signal capturing module 10 captures the digital signals of the real-time light signals of the warning light R, the warning light Y, and the warning light G. The warning light R, the warning light Y, and the warning light G respectively output analog signals, and then the analog-to-digital device (not shown) converts the analog-digital signals and sends them to the real-time signal capture module 10 . For example, the real-time light signal corresponding to the warning light R may be a digital signal (1,1,1,1) indicating "on"; the real-time light signal corresponding to the warning light Y may be a digital signal (1,0) indicating "flashing" ,1,0); and the real-time light signal corresponding to the warning light G can be a digital signal (0,0,0,0) indicating "off". But it doesn't stop there.

The present invention has been disclosed above with preferred embodiments, but those skilled in the art should understand that the embodiments are only used to describe the present invention, and should not be construed as limiting the scope of the present invention. It should be noted that all changes and substitutions equivalent to this embodiment should be considered to be included within the scope of the present invention. Therefore, the protection scope of the present invention should be defined by the scope of the patent application.

1: Production line utilization rate and abnormal analysis system 10: Real-time signal capture module 11: Default rule processing module 12:Database 13: Production line analysis module 14: Display interface 2: Production line 3: Computer device A1: Equipment A2: Equipment A3: Equipment G: warning light E1: Abnormal time period E2: Abnormal time period TP1: Time segment TP2: Time segment TP3: Time segment R: warning light Y: warning light S101: Steps S102: Steps S103: Steps S104: Steps S105: Steps S1051: Steps S1052: Steps S1053: Steps S1054: Steps S106: Steps

[FIG. 1] is a schematic diagram showing that the utilization rate and abnormality analysis system of the production line of the specific embodiment of the present invention is connected to a plurality of warning lights. [Fig. 2] is a schematic flow chart showing a method for analyzing the utilization rate and abnormality of a production line according to an embodiment of the present invention. [Fig. 3] is a schematic flow chart showing the learning process of the production line analysis module according to the specific embodiment of the present invention. [FIG. 4] is a schematic diagram showing the sequence data of the production line of the specific embodiment of the present invention.

1: Production line utilization rate and abnormal analysis system

10: Real-time signal capture module

11: Default rule processing module

12:Database

13: Production line analysis module

14: Display interface

3: Computer device

G: warning light

R: warning light

Y: warning light

Claims (9)

A production line utilization rate and abnormal analysis system, suitable for a production line, the production line has a plurality of equipment, each of the equipment is electrically connected to a plurality of warning lights, the warning lights are used to provide a real-time light signal to each of the equipment, the The production line utilization rate and abnormal analysis system includes: a real-time light signal capture module, electrically connected to the warning lights and configured to continuously capture the real-time light signals of each device; A preset rule processing module is electrically connected to the real-time light signal capture module, and the preset rule processing module has preset rules, and according to the preset rules and time sequence The real-time light signal is converted into a serialized operating state and abnormal cause to generate a serialized data; a database, electrically connected to the preset rule processing module to store the serialized data; a production line analysis module electrically connected to the database, the production line analysis module has a learning ability, and is configured to read the serialized data to find out the time period during which the equipment is abnormal in at least one specific situation of the production line, Modifying the abnormal cause of the abnormality of the devices in the at least one specific case as a final abnormal cause to generate an analysis result, and then storing the analysis result back into the database; and A display interface is electrically connected to the database and configured to display the analysis result stored in the database. The production line utilization rate and abnormality analysis system according to claim 1, wherein the production line analysis module is configured to receive an initial correction command, and the initial correction command is configured to correct the abnormal cause to the final abnormal cause, and the production line analysis The module then learns the cause of the abnormality that occurs after the correction mode of the initial correction command is followed by correction. The production line utilization rate and abnormality analysis system according to claim 2, wherein the production line analysis module performs feature extraction on abnormal causes of each equipment in the time period corresponding to the initial correction instruction, so as to learn the characteristics of the initial correction instruction Correction mode. The utilization rate and abnormality analysis system of a production line as claimed in claim 1, wherein the real-time light signal capture module captures the digital signals of the real-time light signals of each of the warning lights. The production line utilization and abnormal analysis system as claimed in claim 1, wherein the real-time light signal capture module, the preset rule processing module, the database and the production line analysis module are installed in a computer device Among them, the display interface is electrically connected to a display of the computer device. A method for analyzing the utilization rate and abnormality of a production line, which is applicable to a production line, the production line has a plurality of equipment, each of the equipment is electrically connected to a plurality of warning lights, the warning lights are used to provide a real-time light signal to each of the equipment, the The production line utilization rate and abnormal analysis method includes the following steps: Continuously capture the real-time signal of each device by a real-time signal capture module; Convert the real-time light signals of each device into serialized operating states and abnormal causes through a preset rule processing module and a sequence of time presets to generate serialized data; storing the serialized data in a database; A production line analysis module with learning ability is provided, and the serialized data is read by the production line analysis module to find out the time period during which the equipment is abnormal in at least one specific situation of the production line, and the at least one specific Under the circumstances, the abnormal cause of the abnormality of the equipment is modified to a final abnormal cause to generate an analysis result; and Save the analysis results back to the database. The method for analyzing the utilization rate and abnormality of a production line as described in claim 6, further comprising a step: A display interface is provided to display the analysis results stored in the database. The method for analyzing the utilization rate and abnormality of a production line according to claim 6, wherein the step of the production line analysis module for learning comprises: reading the serialized data; receiving an initial correction command, and using the initial correction command to Part of the abnormal cause in the data is corrected as the final abnormal cause; feature extraction of the abnormal causes of the equipment in the period corresponding to the correction instruction; and learning the correction mode of the initial correction instruction to continue the abnormality that occurs after correction reason. The method for analyzing the utilization rate and abnormality of a production line as claimed in claim 6, wherein the real-time light signal capturing module captures the digital signals of the real-time light signals of each of the warning lights.

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