WO2017056749A1 - Management system and management method - Google Patents

Abstract

Provided is a management system associated with a manufacturing line including one or a plurality of facilities. Each of the facilities is configured to process each workpiece according to order information including designation by type of objects to be manufactured and designation of the number of objects to be manufactured. The management system includes: a collecting means for collecting event information about a process that takes place in each of the facilities; a classifying means for classifying, on the basis of a generation source and content of each piece of event information, the event information collected by the collecting means, into sets of event information generated due to the same workpiece; a generation means for generating data which represents process circumstances for each workpiece on the basis of the event information belonging to each of the sets classified by the classifying means; and a visualizing means for visualizing process progression circumstances for each workpiece processed according to the order information, on the basis of the data generated by the generating means.

Description

Management system and management method

The present invention relates to a management system and a management method including a plurality of control devices.

With the recent advancement of Information and Communication Technology (ICT), there is a demand for more advanced production management at the manufacturing site.

For example, Japanese Unexamined Patent Application Publication No. 2014-174701 (Patent Document 1) discloses a configuration for more efficiently analyzing various information managed by a control system and image data of a corresponding object.

JP 2014-174701 A

In an actual manufacturing site, a semi-finished product or a product is manufactured by performing a plurality of processes on the same workpiece. Many manufacturing sites are implementing improvements such as refurbishment, remodeling, and expansion of existing facilities, making it difficult to centrally manage multiple facilities that handle a single workpiece. For a work with a low product unit price, production management is not performed for each work, but production management is performed in units called “orders” in which a predetermined number of works of the same type are collected.

In production management in such order units, even if some trouble occurs in a certain order unit, it is easy to grasp which work out of a plurality of works included in the order has trouble. I can't.

Therefore, there is a demand for a management system capable of realizing finer production management even at a manufacturing site where production management is performed in units of orders. There is also a need for a management system that can objectively evaluate and manage each manufacturing site.

According to an embodiment of the present invention, a management system associated with a production line including one or a plurality of facilities is provided. Each of the one or more facilities is configured to process individual workpieces according to order information including designation of the type of the production object and designation of the number of production objects. The management system collects event information related to processing that occurs in each of one or a plurality of facilities, and the event information collected by the collection unit into the same work based on the source and contents of each event information. Classifying means for classifying the set of event information caused by the generation means, generation means for generating data indicating the processing status for each work based on event information belonging to each of the sets classified by the classification means, and generation means Visualizing means for visualizing the progress of the processing for each workpiece processed according to the order information based on the data generated by.

According to the present embodiment, finer production management can be realized even at a manufacturing site where production management is performed in units of orders.

Preferably, the classification means classifies the collected event information according to the configuration of the production line of one or more facilities. By adopting such a configuration, appropriate classification can be performed according to the configuration in the production line.

Preferably, when the event information having the same content is received a plurality of times from the same source, the classification means classifies each event information into event information caused by different works. By adopting such a configuration, it is possible to prevent a plurality of event information caused by different works from being erroneously associated with the same work.

Preferably, the visualization means reproduces the processing progress of each workpiece in the production line on a plane defined by an axis associated with the process and a time axis. By adopting such a configuration, it is possible to grasp the progress of the process at a glance.

Preferably, the visualization means displays a list of event information classified into a set corresponding to the selected work. By adopting such a configuration, the cause investigation can be facilitated when any trouble occurs in any of the workpieces.

Preferably, the generation unit specifies the order number to which the set classified by the classification unit belongs and the work number in the order based on the time information included in the order information. By adopting such a configuration, it is possible to specify to which order each work belongs even if the information on the order number is not held in each equipment.

Preferably, the collection unit further collects field information acquired by one or a plurality of facilities, and the generation unit executes a process of associating the collected field information with a corresponding work.

Preferably, the visualization means displays the associated field information in response to the work selection.

Preferably, the management system further includes monitoring means for monitoring a defect that may occur in the facility by comparing field information associated with each of a plurality of works in the predetermined facility.

According to another embodiment of the present invention, a management method in a production line including one or a plurality of facilities is provided. Each of the one or more facilities is configured to process individual workpieces according to order information including designation of the type of the production object and designation of the number of production objects. The management method includes a step of collecting event information relating to processing that occurs in each of one or a plurality of facilities, and the event information collected in the collecting step to the same work based on the source and content of each event information. A step of classifying the set of event information caused by the step, a step of generating data indicating a processing status for each work based on the event information belonging to each of the sets classified in the step of classifying, and a step of generating Visualizing the progress of processing for each workpiece processed in accordance with the order information based on the data generated in step.

According to another embodiment of the present invention, a management system associated with a production line including one or more facilities is provided. Each of the one or more facilities is configured to process individual workpieces according to order information including designation of the type of the production object and designation of the number of production objects. The management system actually collects event information generated in each of the one or more facilities, and on each work in each of the one or more facilities based on the event information collected by the collection unit. The load ratio (Allocation ratio) defined as KPI (Key Performance Indicators) based on the calculation means for calculating the processing time and the time required for processing according to the order information and the time calculated by the calculation means Determining means for determining.

According to the present embodiment, each manufacturing site can be objectively evaluated and managed.
Preferably, the calculation means actually processes one or a plurality of workpieces processed according to the same order information from an integrated value of a period from the start of processing at the target facility to completion of the processing. Calculate the time at which By adopting such a configuration, the load degree of each facility can be calculated more accurately.

Preferably, in addition to the degree of load, the determining unit determines another indicator defined as KPI, and the management system further includes a display unit that displays a plurality of indicators determined by the determining unit side by side or in a superimposed manner. . By adopting such a configuration, it is possible to grasp at a glance the operating state of each facility from each of a plurality of indices.

Preferably, the management system is associated with a plurality of production lines, and the display means displays the indicators calculated for each of the plurality of production lines side by side or superimposed. By adopting such a configuration, it is possible to compare the operation states at a glance among a plurality of production lines.

According to another embodiment of the present invention, a management method in a production line including one or a plurality of facilities is provided. Each of the one or more facilities is configured to process individual workpieces according to order information including designation of the type of the production object and designation of the number of production objects. The management method includes a step of collecting event information generated in each of one or a plurality of facilities, and an actual process for each work in each of the one or more facilities based on the event information collected in the collecting step. The load ratio (Allocation ratio) defined as KPI (Key Performance Indicators) based on the step of calculating the processing time, the time required for processing according to the order information, and the time calculated in the calculating step Determining.

According to an embodiment of the present invention, finer production management can be realized even at a manufacturing site where production management is performed in units of orders.

According to another embodiment of the present invention, each manufacturing site can be objectively evaluated and managed.

It is a schematic diagram which shows the structural example of the management system which concerns on this Embodiment. It is a schematic diagram which shows an example of the hardware constitutions of PLC used with the management system which concerns on this Embodiment. It is a schematic diagram which shows an example of the hardware constitutions of the relay server apparatus used with the management system which concerns on this Embodiment. It is a schematic diagram which shows an example of the order information used with the manufacturing line shown in FIG. It is a schematic diagram for demonstrating the process in each installation of the manufacturing line shown in FIG. It is a schematic diagram for demonstrating the individual management process which the management system which concerns on this Embodiment provides. It is a schematic diagram for demonstrating the outline | summary of the individual management process in the management system which concerns on this Embodiment. It is a schematic diagram for demonstrating the pre-processing for implement | achieving the individual management process in the management system which concerns on this Embodiment. It is a schematic diagram for demonstrating the collection process and analysis process for implement | achieving the individual management process in the management system which concerns on this Embodiment. It is a schematic diagram for demonstrating a part of analysis process for implement | achieving the individual management process in the management system which concerns on this Embodiment. It is a schematic diagram for demonstrating the process with respect to the event information set for every workpiece | work identification information shown in FIG. It is a schematic diagram which shows an example which visualized the analysis result provided by the management system which concerns on this Embodiment. It is a figure which shows an example of the log information expand | deployed and displayed from the time chart shown in FIG. It is a schematic diagram for demonstrating the interpolation process for implement | achieving the individual management process in the management system which concerns on this Embodiment. It is a schematic diagram for demonstrating the process using the relevant information in the management system which concerns on this Embodiment. It is a flowchart which shows the process sequence which concerns on the individual management process in the management system which concerns on this Embodiment. It is a schematic diagram which shows an example of the hardware constitutions of PLC which concerns on the collection of the field information used with the management system which concerns on this Embodiment. It is a schematic diagram which shows an example of the field information collected in the management system which concerns on this Embodiment. It is a schematic diagram for demonstrating an example of the correlation process with respect to the field information in the management system which concerns on this Embodiment. It is a schematic diagram which shows an example of the display process of the field information in the management system which concerns on this Embodiment. It is a schematic diagram for demonstrating an example of the tendency monitoring process using the field information in the management system which concerns on this Embodiment. It is a schematic diagram for demonstrating the calculation process of KPI in the management system which concerns on this Embodiment. It is a schematic diagram for demonstrating the calculation method of the actual operation time of the apparatus in the management system which concerns on this Embodiment. It is a schematic diagram which shows the structural example of the management system which concerns on this Embodiment. It is a figure which shows an example of the user interface screen which the management system concerning this Embodiment provides. It is a figure which shows an example of the user interface screen which the management system concerning this Embodiment provides. It is a figure which shows an example of the user interface screen which the management system concerning this Embodiment provides. It is a figure which shows an example of the user interface screen which the management system concerning this Embodiment provides.

Embodiments of the present invention will be described in detail with reference to the drawings. Note that the same or corresponding parts in the drawings are denoted by the same reference numerals and description thereof will not be repeated.

<A. Configuration example of management system>
First, a configuration example of the management system according to the present embodiment will be described. FIG. 1 is a schematic diagram illustrating a configuration example of a management system according to the present embodiment. With reference to FIG. 1, the management system 1 is associated with a production line 100 including a plurality of facilities, and provides a production management function in the production line 100. The production line 100 shown in FIG. 1 shows an example in which facilities 101 to 105 are arranged along a conveyor 110 for conveying workpieces as an example. In FIG. 1, the facilities 101 to 105 are also referred to as “equipment 1” to “equipment 5”. Operations of the facilities 101 to 105 are controlled and monitored by PLCs (Programmable Logic Controllers) 111 to 115 which are examples of control devices. In FIG. 1, the PLCs 111 to 115 are also referred to as “PLC1” to “PLC5”.

The PLCs 111 to 115 are connected so as to be able to perform data communication via the local network 116, and transmit various data such as event information to the relay server device 200 on the local network 116 in accordance with pre-specified conditions.

The relay server device 200 performs predetermined preprocessing on the event information received from each of the PLCs 111 to 115 and transmits the preprocessed information to the collection analysis server device 250.

The collection analysis server device 250 collects information received from the relay server device 200 and analyzes the collected information. The collection analysis server apparatus 250 outputs an analysis result in response to a request from the terminal apparatuses 300-1 and 300-2 (hereinafter sometimes collectively referred to as “terminal apparatus 300”).

In FIG. 1, as a typical example, each of a plurality of facilities installed on a single production line 100 is provided with a PLC, and each PLC is connected to the relay server device 200 via the same local network 116. However, the present invention is not limited to this. For example, a configuration in which a plurality of PLCs are directly connected to the collection analysis server device 250 without arranging the relay server device 200 may be employed. In this case, each PLC transmits necessary information to the collection analysis server apparatus 250.

Alternatively, a plurality of relay server devices 200 may be provided. In this case, a relay server device 200 relays data exchange between some PLCs and the collection analysis server device 250, and another relay server device exchanges data exchanges between the remaining PLCs and the collection analysis server device 250. 200 may be relayed.

<B. Example of PLC hardware configuration>
Next, a hardware configuration example of the PLC will be described. The plurality of PLCs arranged in the production line 100 shown in FIG. 1 do not have to be the same model, but rather, it is assumed that manufacturers and models are not unified. The management system 1 according to the present embodiment is equipped with a function that absorbs such differences between PLC manufacturers and models. In the following, a typical PLC hardware configuration is illustrated.

FIG. 2 is a schematic diagram illustrating an example of a hardware configuration of the PLC used in the management system 1 according to the present embodiment. Referring to FIG. 2, the PLC includes an arithmetic unit 120 and one or a plurality of functional units 130. The arithmetic unit 120 is an arithmetic device that executes a user program stored in advance, acquires field information (details will be described later) from the functional unit 130, and outputs a necessary control signal through the functional unit 130.

The arithmetic unit 120 includes a processor 122 that executes a user program, a memory 126 that stores a user program, an operating system (OS: Operating System), various data, and a bus that controls exchange of data via the internal bus 136. A controller 124 and a communication interface 128 are included. The memory 126 may be configured by combining a volatile storage device such as a DRAM (Dynamic Random Access Memory) and a nonvolatile storage device such as a flash memory.

The communication interface 128 may be provided with one or a plurality of communication ports depending on a target device for exchanging data. For example, it supports a communication port conforming to Ethernet (registered trademark) for connecting to the local network 116 (see FIG. 1), a communication port conforming to USB (Universal Serial Bus) for connecting to a personal computer, a serial line and a parallel line. A communication port or the like may be implemented.

The functional unit 130 may provide an IO (Input Output) function for exchanging various information with the equipment to be controlled. Specifically, DI (Digital Input) that receives digital signals, DO (Digital Output) that outputs digital signals, AI (Analog Input) that receives analog signals, and AO (Analog Output) that outputs analog signals. May be implemented. Furthermore, special functions such as PID (Proportional Integral Derivative) control and motion control may be implemented.

For example, each of the functional units 130 that provide the IO function includes an IO module 132 and a bus controller 134 for controlling data exchange with the arithmetic unit 120 via the internal bus 136.

In the management system 1 according to the present embodiment, any PLC may be employed as long as it has an interface for outputting internal information to an external device using some communication means. The hardware configuration of the PLC is not limited to that shown in FIG. 2, and any configuration can be adopted.

<C. Hardware Configuration Example of Relay Server Device 200>
Next, a hardware configuration example of the relay server device 200 will be described. The relay server device 200 is typically composed of a general-purpose computer.

FIG. 3 is a schematic diagram illustrating an example of a hardware configuration of the relay server device 200 used in the management system 1 according to the present embodiment.

Referring to FIG. 3, relay server apparatus 200 stores a processor 202 that executes various programs including an operating system (OS) 212 and a processing program 214, and data necessary for program execution by processor 202. A hard disk drive (HDD: Hard Disk Drive) 210 that stores a program executed by the processor 202 in a nonvolatile manner.

The relay server device 200 has an optical drive 216, and stores the stored program from an optical recording medium (for example, a DVD (Digital Versatile Disc)) that temporarily stores a computer-readable program. Read and install in the hard disk drive 210 or the like.

The relay server device 200 further includes an input unit 220 that receives an operation from the user, and an output unit 222 that outputs a processing result and the like to the user. The input unit 220 typically includes a keyboard, a mouse, a touch panel, and the like, and the output unit 222 typically includes a display, various indicators, a printer, and the like.

The relay server device 200 further includes a global communication interface 206 for exchanging data with the collection analysis server device 250 and the like, and a local communication interface 208 for communicating via the local network 116. For these interfaces, hardware corresponding to the target network is adopted.

The above-described components are connected to each other via an internal bus 224. In a typical implementation example, the relay server device 200 can be realized using hardware conforming to a general-purpose architecture, and thus will not be described in further detail here.

Note that the function of the relay server device 200 may be replaced by a PLC, or may be implemented as a dedicated device using an ASIC (Application Specific Integrated Circuit) or the like.

<D. Hardware Configuration Example of Collection Analysis Server Device 250>
As an example of the hardware configuration of the collection analysis server apparatus 250, it may be configured by a general-purpose computer, similarly to the hardware configuration example (see FIG. 3) of the relay server apparatus 200 described above. Since a specific hardware configuration example has been described above, detailed description thereof will not be repeated here.

<E. Overview of individual management process>
The management system 1 according to the present embodiment has a relatively small number of modifications to the production line 100 in which production management is performed in units called “orders” in which a predetermined number of works of the same type are collected. Realize production control for each. Note that the term “lot” is sometimes used as a term similar to “order”, but the term “order” is used in this specification. Such production management for each work is hereinafter also referred to as “individual management”.

The order information includes specification of the type of manufacturing object and specification of the number of manufacturing objects. FIG. 4 is a schematic diagram showing an example of order information 400 used in the production line 100 shown in FIG. Referring to FIG. 4, in order information, a command related to manufacturing is defined for each order. For convenience of explanation, FIG. 4 shows an example in which a plurality of orders commands are included in one order information 400, but the order information 400 may be generated for each single order.

Specifically, the order information 400 includes an order number field 402, a product type code field 404, an option code field 406, and a quantity field 408. The values stored in the product type code field 404 and the option code field 406 correspond to information for specifying the type of manufacturing object, and the value stored in the quantity field 408 corresponds to information for specifying the number of manufacturing objects.

In the order number field 402, identification information for specifying each order is stored. The product type code field 404 stores information for specifying a product to be manufactured. The option code field 406 stores information specified in addition to the information stored in the product type code field 404 (for example, information indicating that the product should be manufactured immediately). The quantity field 408 stores the quantity of products to be manufactured for each order.

The order information 400 as shown in FIG. 4 is obtained from PLCs 111 to 115 (or a controller that controls each facility separately from the PLC) that controls each facility constituting the production line 100 from a production management server device (not shown). Given to each (see FIG. 1).

Each PLC controls the equipment to be controlled according to the given order information 400. As described above, each of one or a plurality of facilities constituting the production line 100 is configured to process individual workpieces according to the order information 400.

FIG. 5 is a schematic diagram for explaining processing in each facility of the production line 100 shown in FIG. Referring to FIG. 5, workpieces are sequentially flowed from the upstream side of production line 100, and processing designated by each facility is performed. FIG. 5 shows an example in which two orders (order 1 and order 2) are sequentially processed.

As shown in FIG. 5, order information for performing processing according to order 1 and order 2 is given to equipment 1 to equipment 3, respectively. Each of the facilities 1 to 3 performs a designated process after changing the setting according to the given order information.

Regarding the facility 1, after the setting change 411 for the order 1 is executed, the process 412 of the order 1 is executed. Subsequently, after the setting change 413 for the order 2 is executed, the process 414 of the order 2 is executed. A certain amount of space may be provided between the order 1 and the order 2.

Similarly, regarding the equipment 2, after the setting change 421 for the order 1 is executed, the process 422 of the order 1 is executed. Subsequently, after the setting change 423 for the order 2 is executed, the process 424 of the order 2 is executed. Similarly, regarding the equipment 3, after the setting change 431 for the order 1 is executed, the process 432 of the order 1 is executed. Subsequently, after the setting change 433 for the order 2 is executed, the process 434 of the order 2 is executed.

As shown in FIG. 5, the timing at which a series of processing according to the same order is performed in each facility differs depending on the production line 100 and the processing capacity of each facility.

The production management server device that generates the order information in the production line 100 collects and manages information such as processing start and processing completion of each order in each facility, but the information is in units of work included in each order. Not collected and managed.

On the other hand, the management system 1 according to the present embodiment enables individual management for each workpiece included in each order even in the order management production line 100 as shown in FIG. FIG. 6 is a schematic diagram for explaining the individual management processing provided by the management system 1 according to the present embodiment.

Referring to FIG. 6, for example, by selectively extracting information on the Nth workpiece from among a plurality of workpieces included in order 1, which Nth workpiece passes through the plurality of facilities 1 to 3. It is possible to easily grasp and analyze how it was manufactured. As described above, even if the production management server device manages manufacturing only in units of orders, by using the management system 1 according to the present embodiment, manufacturing can be performed in units of workpieces included in each order. Can be managed.

FIG. 7 is a schematic diagram for explaining an overview of the individual management process in the management system 1 according to the present embodiment. Referring to FIG. 7, each of equipment 1 to equipment 5 constituting production line 100 notifies event information related to the workpiece. In the present embodiment, the “event information” includes at least one of information indicating the progress status of a process for an arbitrary work (individual) included in an arbitrary order, and information capable of predicting the progress of the process.

Specifically, event information includes that the target equipment has started processing for a work, that the target equipment has completed processing for a work, and that a work has arrived for processing. , Including discharging a certain workpiece. The event information is notified from a control device (typically PLC) for controlling each facility and a device unique to each facility.

The relay server device 200 performs processing ((1) preprocessing) for adding date and time, identification information, and the like to event information notified from each facility, and transmits the event information to the collection analysis server device 250 (see also FIG. 1).

The collection analysis server apparatus 250 performs (2) collection processing, (3) analysis processing, and (4) visualization processing on event information from each facility. In the terminal device 300, the analyzed analysis result is displayed ((5) display process). Individual management is realized by a series of these processes (see also FIG. 1). The outline of these processes will be described below.

(2) In the collection process, the collection analysis server apparatus 250 collects event information related to the process that occurs in each of one or more facilities. At this time, each event information is directly or indirectly associated with date and time information indicating the date and time of occurrence and identification information indicating the generated facility.

(3) In the analysis process, the collection / analysis server apparatus 250 analyzes the collected event information and extracts event information caused by the same work included in an arbitrary order. At this time, by referring to the order information, the order number to which the work from which the event information is extracted can be specified.

The example shown in FIG. 7 shows an example in which the processing start date and the processing completion date and time of each of the equipment 1 to the equipment 5 for the first work (work_01) included in the order number 1 are extracted.

(4) In the visualization process, the collection analysis server device 250 visually reproduces the progress of the process for a specific workpiece based on the event information extracted by (3) the analysis process. In the example shown in FIG. 7, the progress status of the process (each facility) on the production line 100 is taken on the horizontal axis, and a two-dimensional graph with the date and time when processing in each process started and completed is taken on the vertical axis is output as an analysis result. An example is shown. Such an analysis result may be provided to the terminal device 300 (see FIG. 1).

Through the processing described above, individual management of each workpiece included in each order can be realized even in a production line where production management is performed in units of orders.

<F. Details of individual management process>
Next, details of each process for realizing the individual management shown in FIG. 7 will be described.

(F1: (1) Pre-processing)
The relay server device 200 unifies the format of event information received from each facility (PLC or a device unique to each facility) as a pretreatment.

FIG. 8 is a schematic diagram for explaining preprocessing for realizing the individual management processing in the management system 1 according to the present embodiment. Referring to FIG. 8, it is assumed that event information 451, 452, 453, 454,. Each of the event information 451, 452, 453, 454,... Includes a date / time field 4501 and an event content field 4502. Every time an event occurs in any of the facilities, such event information is input to the relay server device 200.

The relay server device 200 identifies the facility that issued the event information with respect to the input event information, and adds identification information indicating the facility to the event information. More specifically, the relay server device 200 identifies the facility that issued the event from the header information (more specifically, the transmission source address) included in the packet storing the event information.

Also, the relay server device 200 determines the type of the input event information based on the character string stored in the event content field 4502, and adds the determined type to the event information. As a type to be added, “NORMAL” meaning normal is added in the case of a general event, and “WARNING” meaning warning is added in the case of an event caused by some abnormality. .

.. Are added to the event information 451, 452, 453, 454,... And transmitted to the collection analysis server apparatus 250 as event information 451A, 452A, 453A, 454A,. In the event information 451A, 452A, 453A, 454A,..., The identification information indicating the facility is stored in the transmission source field 4503, and the information indicating the type is stored in the type information field 4504.

In the relay server device 200, the processing as described above is performed as preprocessing.
In addition to the information as described above, or in place of the information as described above, other information may be added. That is, information necessary and sufficient for efficiently performing the collection process and the analysis process in the collection analysis server apparatus 250 may be added. Information that may be added to the event information includes the unique identification information of the device that issued each event information, the number assigned to the serial number between the same type of event information, and the same type of event information most recently. The elapsed time since then.

FIG. 8 shows a configuration example in which relatively simple contents are stored in the event contents field 4502 for convenience of explanation, but detailed information of processing results in each facility may be included. In the example illustrated in FIG. 8, the configuration in which necessary information is added as header information has been illustrated.

In addition, FIG. 8 shows an example in which the date and time is assigned in advance to each of the event information 451, 452, 453, 454,... Each controlling PLC must have a timer. In order to further simplify the device configuration, if the configuration is such that the propagation delay between each facility and the relay server device 200 can be ignored, the date / time information according to the timing at which the relay server device 200 receives the event information. May be added to the event information. By adopting such a configuration, it is not necessary to maintain a timer synchronized between facilities.

The transmission of the event information 451A, 452A, 453A, 454A,... From the relay server device 200 to the collection analysis server device 250 may be performed at an arbitrary timing. For example, real-time processing (a method for performing preprocessing immediately when event information is received and transmitting event information to the collection analysis server apparatus 250 immediately after the execution of preprocessing), sequential processing (immediately before receiving event information) When processing reaches the predetermined number of event information after the pre-processing, a method of transmitting them to the collection analysis server device 250), batch processing (collecting event information from each facility for each processing cycle, collecting For example, a method of performing preprocessing on the event information in a lump and transmitting it to the collection analysis server apparatus 250) may be employed. Further, it may be performed at different timings.

(F2: (2) Collection processing and (3) Analysis processing)
Next, (2) collection processing and (3) analysis processing performed by the collection analysis server device 250 will be described. For convenience, the description will be divided into two processes, a collection process and an analysis process. However, both processes need not be clearly divided and may be implemented as appropriate according to the situation.

FIG. 9 is a schematic diagram for explaining collection processing and analysis processing for realizing the individual management processing in the management system 1 according to the present embodiment. Referring to FIG. 9, collection analysis server apparatus 250 includes an event information storage unit 260 for collecting event information regarding processing that occurs in each of one or more facilities. In the event information storage unit 260, event information transmitted from the relay server device 200 is sequentially stored, and for each event information, work identification information for specifying which work is caused is specified. Associated. The event information storage unit 260 includes an event information field 2601 for storing event information and a work identification information field 2602 for storing work identification information. For convenience of explanation, FIG. 9 shows a simplified table structure, but the actual implementation is not limited to this, and an arbitrary data structure may be adopted.

The collection analysis server device 250 further includes a work identification module 270. The work identification module 270 executes a process for classifying the collected event information into a set of event information generated due to the same work, based on the generation source and contents of each event information. That is, the work identification module 270 determines work identification information for identifying which work is caused by each event information. Specifically, the work identification module 270 includes a plurality of rules 2711, 2721,... And corresponding counters 2712, 2722,.

A plurality of rules 2711, 2721,... Are used to determine from which equipment the input event information originates, and define characteristics unique to each equipment included in the event information. . When event information 451A, 452A, 453A, 454A,... As shown in FIG. 8 is input, the identification information stored in the transmission source field 4503 and the content stored in the event content field 4502 are as follows. It is specified. For example, the rule 2711 shown in FIG. 9 is for detecting event information of processing start of the facility 1, and includes, for example, “[From_Facility_01]” in the transmission source field 4503 and “ A condition such as “The machining cycle has started” is defined.

When the input event information matches one of the rules, the corresponding counter is incremented, and the incremented count value is associated with the input event information. For example, event information 461 (event information indicating the start of processing of the facility 1) stored in the first column in the event information storage unit 260 of FIG. 9 is associated with “0002” as work identification information, and thereafter If event information 462 (which is event information indicating the start of processing of the facility 1 as with the event information 461) is input to the event information 462, the input event information 462 follows the work that generated the event information 461. It can be judged that it was caused by another work. Therefore, work identification information “0003” different from the work associated with the work identification information “0002” is associated with the event information 462. As described above, when the collection analysis server apparatus 250 (work identification module 270) receives event information having the same contents from the same generation source a plurality of times, the collection and analysis server apparatus 250 (work identification module 270) classifies each event information as event information caused by different works.

The processing for assigning the work identification information as described above is performed, and it is specified by which work the plurality of types of event information generated at different times are generated. As described above, the collection analysis server apparatus 250 (work identification module 270) prepares a plurality of rules 2711, 2721,... According to the configuration of the production line 100 of one or a plurality of facilities in advance, and sets these rules. Apply to classify collected event information.

For convenience of explanation, FIG. 9 exemplifies a configuration in which the work identification information is incremented for each rule. However, the work identification information is not limited to such an incrementing method. Any method may be adopted as long as it is a method that can identify and identify a series of event information generated by the same work.

The above-described process for assigning workpiece identification information may be performed sequentially or batchwise. For example, the process may be performed every time event information is received, or may be started on condition that a predetermined number of event information has been accumulated.

FIG. 10 is a schematic diagram for explaining a part of the analysis process for realizing the individual management process in the management system 1 according to the present embodiment. The collection analysis server apparatus 250 generates data indicating the processing status for each work based on the event information belonging to each of the classified event information groups.

More specifically, the collection analysis server apparatus 250 groups the information stored in the event information storage unit 260 shown in FIG. 9 using the work identification information stored in the work identification information field 2602 as a key. Then, an event information set 280 for each work identification information is generated as an example of data indicating the processing status for each work as shown in FIG. In other words, the collection analysis server device 250 generates a set of event information associated with the same work identification information. By generating an event information set 280 as shown in FIG. 10 for each piece of work identification information, it is possible to specify the progress of the process for each work.

FIG. 10 illustrates a state in which the event information set 280 is grouped, but any method can be adopted as an actual implementation form. For example, event information associated with each other may be implicitly specified using some identification information given to the event information.

FIG. 11 is a schematic diagram for explaining processing for the event information set 280 for each work identification information shown in FIG. By expanding the event information set 280, for example, a tracking database 290 as shown in FIG. 11 can be generated. The tracking database 290 stores the date and time when processing is started and completed at each of the plurality of facilities installed on the production line 100 for each workpiece.

10 and 11 show an example of a simplified table structure as the tracking database 290 for convenience of explanation, but an arbitrary data structure can be adopted as an actual implementation form.

The collection analysis server device 250 identifies the order number to which the classified set belongs and the work number in the order based on the time information included in the order information 400. More specifically, the collection analysis server device 250 compares the tracking database 290 and the order information 400, so that each work of the tracking database 290 belongs to which order number, and what number work of the order number is Determine if it exists. As shown in FIG. 11, for example, the order information 400 may include the start time and completion time of each order as actual values in addition to the contents of each order. The start time and completion time are input to the production management server device automatically or manually.

More specifically, the collection analysis server apparatus 250 compares the processing start time of the facility 1 for any work included in the event information set 280 with the start time included in the order information 400, thereby obtaining a certain order. After the process is started, the work for which the process in the facility 1 is started is specified ((1) comparison and (2) order number determination in FIG. 11). In the example shown in FIG. 11, immediately after the process for the order number “A0001” is started, the process in the facility 1 for the work to which the work identification number “0002” is assigned is started. It is specified that the work “0002” is the head work of the order number “A0001”. The collection analysis server apparatus 250 associates the specified order number “A0001” with the target work and assigns work numbers in order from the first work ((3) Determination of the first work and (4) Assignment of work number in FIG. 11). . The assignment of the work number is continuously performed with reference to the order information 400 until the quantity indicated for the corresponding work number (“50” in the example shown in FIG. 11) is reached.

Through the series of processes as described above, it is possible to realize the management system 1 that can realize finer production management even at a manufacturing site where production management is performed in units of orders.

(F3: (4) Visualization processing)
Next, using the event information set 280 shown in FIG. 10 and the tracking database 290 shown in FIG. 11, etc., a process for visualizing information indicating the progress of the process for an arbitrary work (individual) included in an arbitrary order Will be described.

FIG. 12 is a schematic diagram showing an example of visualizing the analysis result provided by the management system 1 according to the present embodiment. The collection analysis server apparatus 250 visualizes the progress of processing for each workpiece processed according to the order information 400 based on the generated tracking database 290.

As an example, the collection analysis server device 250 provides a time chart 500 as shown in FIG. 12 to the terminal device 300 (see FIG. 1). In the time chart 500, the progress status of the process (each facility) in the production line 100 is set on the horizontal axis, and the date and time (or time) when the processing in each process is started and completed is set on the vertical axis. Yes. That is, the collection analysis server apparatus 250 reproduces the processing progress of each workpiece on the production line 100 on a plane defined by the axis associated with the process and the time axis. By referring to such a time chart 500, the manager of the production line 100 can grasp the progress of production based on the order in the production line 100 in more detail, and the problem part in the production line 100 (I.e., bottleneck) can be easily identified.

In the time chart 500 shown in FIG. 12, the work number 502 of each displayed work and the order number 504 to which each work belongs may be displayed together. Note that the time chart 500 shown in FIG. 12 may be displayed in real time. That is, every time event information is notified from any of the facilities, the collection process and the analysis process as shown in FIGS. 8 to 11 may be executed to update the display contents of the time chart 500 each time. By realizing such real-time display, the current situation of the production line 100 can be easily grasped.

FIG. 13 is a diagram showing an example of log information that is expanded and displayed from the time chart 500 shown in FIG. When the cursor 506 is operated in FIG. 12 and a time chart of any work is selected, event information associated with the selected work may be displayed in a list as shown in FIG. The list display shown in FIG. 13 is provided by extracting one corresponding to the selected work from among the plurality of event information sets 280 shown in FIG. That is, the collection analysis server apparatus 250 displays a list of event information classified into a set corresponding to the selected work.

12 and 13 are not limited to the visualization examples, and any display form for presenting information obtained by the collection process and the analysis process to a user such as an administrator can be employed.

(F4: Interpolation process)
In the above description, the configuration in which each of the plurality of facilities installed in the production line 100 notifies the event information of the process start and the process completion is illustrated. However, as a real problem, not all facilities can always notify event information of processing start and processing completion. In such a case, it is possible to interpolate (or estimate) the time at which the missing event information will occur using information included in the generated tracking database 290.

FIG. 14 is a schematic diagram for explaining an interpolation process for realizing the individual management process in the management system 1 according to the present embodiment. FIG. 14 shows, as an example, a tracking database 290A that is generated when the processing completion of the facility 2 is not notified as event information.

For example, the processing completion of the equipment 2 is performed after the processing of the equipment 2 is started and before the processing of the equipment 3 is started. Therefore, in the tracking database 290A, the processing start time of the equipment 2 and the processing start of the equipment 3 are started. You may make it interpolate or estimate the process completion time of the installation 2 from the time. At this time, it is preferable to interpolate the processing completion time of the equipment 2 while referring to information such as the positional relationship between the equipment 2 and the equipment 3 in the production line 100 and the conveyance speed of the conveyor 110.

(F5: Use of related information)
In order to grasp the situation in the process (each facility) in the production line 100 in more detail, the tracking database 290 shown in FIG. 11 (or the time chart 500 shown in FIG. 12) is used to progress the process of each workpiece. Corresponding related information may be associated.

FIG. 15 is a schematic diagram for explaining processing using related information in the management system 1 according to the present embodiment. Referring to FIG. 15, for example, the time chart 500 shown in FIG. 12 and the temperature performance chart 510 of the facility 1 are arranged on the same time axis. According to the time chart 500, it can be seen that the work having the work number “01” exists in the facility 1 between time t1 and time t2. Therefore, in the temperature record chart 510, the temperature record in the section from time t1 to time t2 may be stored in association with the work. By associating such various corresponding information, production management for each workpiece can be performed in more detail.

Further, in the interpolation processing shown in FIG. 14 described above, for example, even if the speed record of the corresponding section is used among the speed records of the conveyor 110 that transports the work, the arrival time of the work to a predetermined facility is estimated. Good.

(F6: processing procedure)
Next, a processing procedure for realizing the individual management processing described above will be described. FIG. 16 is a flowchart showing a processing procedure related to the individual management processing in the management system 1 according to the present embodiment. Each step shown in FIG. 16 is typically realized by a processor executing a processing program in each of the relay server device 200 and the collection analysis server device 250.

Referring to FIG. 16, relay server device 200 determines whether event information has been received from a PLC that controls any of the facilities or a device specific to any of the facilities (step S <b> 100). If no event information has been received (NO in step S100), the processes in and after step S100 are repeated.

On the other hand, if any event information has been received (YES in step S100), the relay server device 200 adds necessary information to the received event information and transmits it to the collection analysis server device 250 (step S102). That is, the relay server device 200 performs preprocessing on the received event information. And the process after step S100 is repeated.

The collection analysis server device 250 determines whether event information has been received from the relay server device 200 (step S200). If no event information has been received (NO in step S200), the processes in and after step S200 are repeated.

On the other hand, if any event information has been received (YES in step S200), collection / analysis server apparatus 250 stores the received event information (step S202), and based on the source of the stored event information and its contents. The work identification information is determined, and the determined work identification information is associated with the event information (step S204).

Subsequently, the collection analysis server device 250 determines whether or not a condition for proceeding with the analysis process is satisfied (step S206). When the analysis process is executed every time the event information is received, a condition of whether or not new event information is received can be used as a condition for proceeding with the analysis process. Alternatively, when the analysis process proceeds after a predetermined number of event information has been collected, the condition for proceeding with the analysis process may be a condition as to whether or not a predetermined number of unprocessed event information has been collected. it can. That is, the execution frequency of the analysis process can be adjusted by appropriately setting the conditions for proceeding with the analysis process.

If the conditions for proceeding with the analysis process are not satisfied (NO in step S206), the process proceeds to step S212.

If the conditions for advancing the analysis process are satisfied (YES in step S206), the collection analysis server device 250 extracts event information to which the same work identification information is assigned, and sets an event information set (see FIG. 10) is generated or updated (step S208). Then, the collection analysis server device 250 expands the event information set 280 and generates or updates the tracking database (see FIG. 11) (step S210).

Further, the collection / analysis server apparatus 250 determines whether an analysis result request is received from any of the terminal apparatuses 300 (step S212). If no analysis result request has been received from any terminal device 300 (NO in step S212), the processing in step S200 and subsequent steps is repeated.

If an analysis result request has been received from any of the terminal devices 300 (YES in step S212), the collection analysis server device 250 visualizes the analysis result based on the tracking database generated in step S210, and requests the request source. To the terminal device 300 (step S214). The visualized analysis result provided in step S214 may be updated each time. And the process after step S200 is repeated.

<G. Field information collection processing>
In the above description, individual management based on “event information” including at least one of information indicating the progress status of a process for an arbitrary work (individual) included in an arbitrary order and information on which the progress of the process can be estimated. The process has been described. In the management system 1 according to the present embodiment, it is possible to collect information other than event information from a PLC arranged in each facility or a device unique to each facility. In the following, a description will be given of a form in which information (hereinafter also referred to as “field information”) acquired or managed by a PLC or a device unique to each facility is collected and used for various analysis processes.

(G1: PLC configuration example)
In the present embodiment, “field information” means a general term for information directly or indirectly related to processing of a work in each facility, and may include “event information”. “Field information” includes, for example, detection results (input signals) of arbitrary sensors arranged in each facility, output commands (output signals) to arbitrary actuators, status of arbitrary devices, user operation history, etc. Can be included. Management system 1 according to the present embodiment collects field information acquired by one or more facilities.

FIG. 17 is a schematic diagram illustrating an example of a hardware configuration of a PLC related to collection of field information used in the management system 1 according to the present embodiment. Referring to FIG. 17, for example, the PLC 111 that controls the facility 1 includes one or more functional units 130 connected in parallel to the arithmetic unit 120, and one or more connected via the field bus 150. A remote IO device 121 may be included. The remote IO device 121 includes a communication unit 140 and one or a plurality of functional units 130.

Each of the functional units 130 typically has a function such as DI that receives a digital signal or AI that receives an analog signal, and collects field information from the equipment to be controlled. For example, the functional unit 130 is connected to a displacement sensor that measures the position / height of the workpiece, a photoelectric sensor that detects the arrival of the workpiece, and the like. Field information collected by the functional unit 130 of the remote IO device 121 is transmitted to the arithmetic unit 120 periodically or in an event manner via the field bus 150.

In response to a command from the arithmetic unit 120, the remote IO device 121 receives the type information of the connected functional unit 130 itself, the type information of the sensor connected to the functional unit 130, the current set value of the sensor, the sensor The self-diagnosis information and measurement data (for example, the received light amount of the photoelectric sensor) and the current setting values (range width, threshold value, etc.) of the functional unit 130 can be sent to the arithmetic unit 120.

A similar configuration may be adopted for the PLC 112 that controls the facility 2 and other PLCs not shown. However, it is not necessary to provide a remote IO device for every PLC, and remote IO devices are arranged according to the number and type of field information to be collected.

The field information collected by the functional unit 130 connected to the PLC (main unit) and the functional unit 130 connected to the remote IO device is similar to the event information described above via the local network 116 via the relay server device 200 ( (See FIG. 1). The field information may be periodically transmitted from the PLC to the relay server device 200, or may be transmitted to the relay server device 200 in response to an event from the relay server device 200.

Alternatively, the field information for a predetermined period may be temporarily stored in the PLC and then transmitted together, or may be transmitted every time the field information is collected. Alternatively, when field information is transmitted in an event manner, only field information designated by the relay server device 200 may be selectively transmitted.

(G2: Data collection process)
Field information collected by the PLC or a device unique to each facility is collected by the collection analysis server device 250 via the relay server device 200. Hereinafter, data collection processing in the collection analysis server apparatus 250 will be described.

The collection analysis server device 250 sequentially stores each value of the field information in association with the collection time. FIG. 18 is a schematic diagram showing an example of field information collected in the management system according to the present embodiment. Referring to FIG. 18, for example, the field information database 700 collected by the collection analysis server device 250 is associated with the collected time separately from the tag name 710 given to each field information. Are sequentially stored. Note that the field information sampling cycle (collection cycle) is not necessarily the same depending on the type of field information, the type of sensor, the performance of the PLC, and the like. Therefore, the field information database 700 may have a period during which field information cannot be collected. Even in such a case, various analysis processes as described later can be executed. Note that a series of field information may be formed by interpolating using the field information before and after the period in which the field information is missing.

Field information 701 (tag: 001-0001) stored in the field information database 700 corresponds to, for example, a detection result of a photoelectric sensor that detects the arrival of a workpiece, and indicates “ON” when a workpiece is detected. In this situation, “OFF” is indicated.

Field information 702 and 703 (tags: 001-0002 and 001-0003) stored in the field information database 700 correspond to, for example, a detection result of a displacement sensor that detects the size of a work, and the work to be detected is When entering the detection field, the detection result (analog value) is output.

(G3: association process)
The collection analysis server apparatus 250 collects a field information database 700 as shown in FIG. 18 and executes an analysis process. As an example of this analysis processing, the collection analysis server device 250 executes processing for associating the collected field information with the corresponding work.

FIG. 19 is a schematic diagram for explaining an example of association processing for field information in the management system according to the present embodiment. Referring to FIG. 19, collection / analysis server apparatus 250 executes a process of associating field information included in field information database 700 with a corresponding work, using the result of the individual management process executed first or in parallel. . In the example shown in FIG. 19, it is assumed that each field information included in the field information database 700 is from the facility 1. By applying the processing start date and time of processing completion for each piece of work as shown in FIG. 11 described above to such field information, as shown in FIG. Alternatively, it is possible to specify which range of a plurality of field information is caused by a specific work. In the example shown in FIG. 11, in the individual management process that the process in the facility 1 for the work with the work identification number “0002” of the order number “A0001” has been started from “2015/09/01 09:00:00” Based on the result, a process of associating field information after “2015/09/01 09: 0: 15” with the work is executed. For other works and other equipment, field information associated with each work is specified by the same procedure as shown in FIG.

(G4: Display processing)
The range of field information associated with each work is specified by the association process described above. The identified field information is preferably displayed in a more user-friendly manner.

FIG. 20 is a schematic diagram showing an example of field information display processing in the management system according to the present embodiment. In FIG. 20A, the progress status of the process (each facility) in the production line 100 is set on the horizontal axis, and the date and time (or time) at which the processing in each process is started and completed is set on the vertical axis. An example of a time chart 500 is shown. On the time chart 500 shown in FIG. 20A, the user operates the cursor 506 to show a section indicating processing at the target equipment of any work (in the example shown in FIG. 20A, “work — 02”). When “is processed in the facility 1) is selected, a time chart 520 of field information acquired in the selected section is displayed as shown in FIG. That is, the collection analysis server apparatus 250 displays the associated field information in response to the selection of the workpiece in the visualization process.

In the time chart 520, the collected one or more field information is displayed in a manner that can be compared on the time axis in common. Note that the display mode is not limited to that shown in FIG. 20B, and a plurality of field information may be displayed in an overlapping manner.

In the time chart 520, a tag name 522 given to displayed field information and incidental information 524 such as a preset sensor name may be displayed in addition to the time waveform of the corresponding field information. .

As illustrated in FIG. 20, by adopting the switching associated with the macro behavior and the micro behavior of each workpiece, the manager of the production line 100 and the like can make progress in manufacturing based on the order in the production line 100. The situation can be grasped in more detail, and a problem part (that is, a bottleneck) in the production line 100 can be examined in detail.

(G5: Trend monitoring process)
The range of field information associated with each work is specified by the association process described above. As a result, for example, changes in local field information that occur within a predetermined period from the start of processing for each workpiece can be collected for each workpiece. For example, by comparing field information collected from a device that operates only for a few seconds from the start of processing at a certain facility over a plurality of workpieces, the deterioration tendency of the facility can be predicted.

FIG. 21 is a schematic diagram for explaining an example of a trend monitoring process using field information in the management system according to the present embodiment. In FIG. 21, for example, the adsorption pressure (average value during operation) of an apparatus that adsorbs a workpiece in a certain facility is displayed in the order of processed workpieces. That is, the work number is set on the horizontal axis, and the adsorption pressure is set on the vertical axis.

21. It is possible to calculate the deterioration tendency characteristic for the adsorption pressure from the plot value of the adsorption pressure for each workpiece as shown in FIG. Based on the calculated deterioration tendency characteristics, it is possible to estimate the number of workpieces until reaching a predetermined deterioration level (such as a calibration value and a damage value). That is, it is possible to estimate the number of workpieces that can be processed before some maintenance work is required. It should be noted that the caption value indicates a first stage level in which the apparatus or process corresponding to the acquired field information shows a tendency to deteriorate. When this condition value is reached, an immediate response is not always necessary, This means that monitoring or repair / replacement in the near future is necessary. The damage value indicates a second stage level indicating that the device or process corresponding to the acquired field information is deteriorated, and when the damage value is reached, the device or process needs to be repaired or replaced. Means.

As described above, the collection analysis server apparatus 250 may implement a monitoring function for monitoring a tendency that may occur in the facility by comparing field information associated with a plurality of works in the predetermined facility. . By implementing such a function, various measures can be taken before equipment failure occurs, and the probability of equipment failure that occurs unexpectedly can be reduced.

It should be noted that not only the trend monitoring function but also a function of monitoring and notifying that a predetermined deterioration level has been reached may be implemented.

<H. KPI calculation processing>
As described above, the management system 1 according to the present embodiment enables individual management for each work included in each order even in the production line 100 for order management. By such individual management, KPI (Key Performance Indicators) can be accurately calculated. The KPI calculation process will be described below.

The management system 1 according to the present embodiment can calculate KPIs defined in ISO (International Organization for Standardization) -22400. In ISO-22400, 34 types of indicators are defined as KPI, and the management system 1 can calculate any of the indicators, but in the following description, the following 5 types of indicators used for production management in the production line Will be described.

(1) Allocation ratio
The degree of load is an index for measuring whether the equipment is properly placed and performing efficient production within a minimum amount of time, and the actual operation time of the equipment relative to the actual order execution time (AOET) It means the ratio of (AUBT: Actual unit busy time).

Degree of load = actual device operating time / actual order execution time (2) Production rate (Throughput rate)
The production amount is an index for measuring the amount of capacity that the device can produce per hour, and means the number of facilities produced with respect to the actual order execution time.

Production volume = number of production / actual order execution time (3) Quality ratio (or quality ratio)
The quality rate is an index for measuring the performance of whether the device is producing a good product, and means the non-defective product output of the equipment.

Quality rate = number of non-defective products / number of products produced (4) Scrap ratio
The discard rate is an index for measuring the performance of whether the device is producing a good product, and means the amount of defective products produced by the equipment.

Waste rate = number of defective products / number of productions (5) Rework ratio
The repair rate is an index for measuring the amount of loss due to the addition of post-operation even if the product can finally be recovered to a non-defective product, and means the number of repairs to the number of facilities produced.

Repair rate = Number of repairs / Production number In addition to the KPI defined in ISO-22400, a scrap ratio after rework may be calculated with respect to the production number of equipment. The discard rate with respect to the number of facilities produced is an index for measuring the loss amount of a production line that has failed in production.

Disposal rate with respect to the number of production of equipment = number of discarded after rework / number of production Hereinafter, the calculation procedure of each index will be described with reference to the drawings. FIG. 22 is a schematic diagram for explaining KPI calculation processing in the management system 1 according to the present embodiment. The production line 100 shown in FIG. 22 is provided with equipment 1 to equipment 4 for executing various processing processes for workpieces. After the processing processes in these equipment 1 to equipment 4, inspection by an automatic inspection device and person in charge A visual inspection shall be performed.

(H1: Load degree calculation procedure)
The calculation of the degree of load requires an actual order execution time and an actual operation time of the apparatus.

Since the actual execution time means the time required for production according to a certain order, for example, processing for all workpieces according to the order from the time when processing on the production line 100 for the first workpiece is started according to the certain order. It can be regarded as a period until the time when is completed. In other words, the collection analysis server apparatus 250 has an actual operating time (AUBT) of equipment corresponding to the time when processing is actually performed on each work in each of one or a plurality of equipment based on the collected event information. Is calculated.

In the example shown in FIG. 22, for example, the time when the first workpiece according to a certain order passes through the entrance of the facility 1 is set as the starting point of the actual order execution time (“order start” in FIG. 22), and the last time according to the order. The time at which the workpiece has passed through the discharge port of the equipment 4 can be set as the end point of the actual order execution time (“order completed” in FIG. 22).

Since the management system 1 according to this embodiment performs solid management for each workpiece, the processing time for each workpiece in each device can be calculated as the actual operating time of the device.

FIG. 23 is a schematic diagram for explaining a method of calculating the actual operating time of the device in the management system 1 according to the present embodiment.

Referring to FIG. 23A, when the target apparatus can process only one work at a time (that is, a plurality of works cannot be processed simultaneously), the period from the process start time to the process end time for each work Can be regarded as the actual operation time (AUBT_n) for the workpiece. Therefore, the actual operating time of each device can be calculated as the sum of the actual operating times for each workpiece (ie, ΣAUBT_n).

As described above, the collection analysis server apparatus 250 integrates the period from the start of processing at the target facility to the completion of processing for each of one or more workpieces processed according to the same order information 400. From this, the actual operating time of the equipment corresponding to the time when the processing was actually performed is calculated.

On the other hand, referring to FIG. 23B, for an apparatus capable of processing a plurality of workpieces at the same time, if the actual operation time for each workpiece is simply summed, an incorrect value corresponding to the overlap period is calculated. End up. Therefore, the actual operation time of each device may be calculated as a value obtained by subtracting the sum of overlapping periods (ie, Σ overlapping period) from the sum of actual operating times for each workpiece (ie, ΣAUBT_n).

The actual operation time of the actual device excludes the time when the device is on standby or stopped for some reason (waiting for material supply, setup change, dealing with some trouble, etc.). Usually, if the tracking database 290 as shown in FIG. 11 can be generated, such a stop time is naturally excluded, so there is no need to take special consideration. However, if the device stops for some reason between the start and completion of the processing of any workpiece, the stop period is not recorded in the tracking database 290, so the PLC that controls the device Based on the information from the system, the information from the production management server device, the difference between the processing start time and the processing completion time, etc., the standby or stop time is calculated and corrected using the calculated time. Also good.

Since the actual order execution time and the actual operation time of the apparatus can be calculated by the above procedure, the degree of load can be calculated from these values. That is, the collection analysis server device 250 is defined as a KPI based on the time required for processing according to the order information 400 and the actual operation time of the equipment corresponding to the time when processing is actually performed for each workpiece. Determine the load level.

The actual operation time of the apparatus can be calculated for each apparatus arranged on the production line 100 or can be calculated for the entire production line 100. That is, by using the management system 1 according to the present embodiment, it is possible to calculate both the degree of load for each apparatus arranged in the production line 100 and the degree of load for the entire production line 100, and the management Depending on the needs of the person, the alternative or both may be calculated and presented.

(H2: Production volume)
The calculation of the production amount requires the actual order execution time and the number of productions. Since the method of calculating the actual order execution time has been described above, description thereof will not be repeated here.

The production number can be defined from a plurality of viewpoints. However, in the production line 100 shown in FIG. 22, the number of workpieces that have been processed in the facilities 1 to 4 is calculated as the number of production (prior to inspection) (PQ). : Products Quantity) That is, for a certain order, the total number of workpieces discharged from the equipment 4 can be calculated as the production number.

Since the actual order execution time and the number of productions can be calculated by the above procedure, the production volume can be calculated from these values.

(H3: Quality rate / good product rate)
The number of production and the number of non-defective products are required for the calculation of the quality rate / non-defective product rate. Since the method for calculating the number of production has been described above, description thereof will not be repeated here.

The number of non-defective products can be defined from a plurality of viewpoints. However, in the production line 100 shown in FIG. 22, the number of workpieces judged as “non-defective” by the automatic inspection device (after inspection, reworked) It is the number of good products (GQ) before. That is, for a certain order, out of the workpieces discharged from the equipment 4, the total number determined as non-defective by the automatic inspection apparatus can be calculated as the number of non-defective products.

Since the number of productions and the number of non-defective products can be calculated by the above procedure, the quality rate / non-defective product rate can be calculated from these values.

(H4: discard rate / defective product rate)
To calculate the discard rate / defective product rate, the number of productions and the number of defective products are required. Since the method for calculating the number of production has been described above, description thereof will not be repeated here.

The number of defective products can be defined from a plurality of viewpoints. However, in the production line 100 shown in FIG. 22, the number of workpieces determined as “defective products” by the automatic inspection device (after inspection, The number of defective products (SQ: Scrap Quantity) before rework. That is, it is possible to calculate, as the number of defective products, the total number of workpieces discharged from the equipment 4 that are determined to be defective by the automatic inspection device for a certain order.

Since the number of productions and the number of defective products can be calculated by the above procedure, the discard rate / defective product rate can be calculated from these values.

(H5: Rework rate)
To calculate the rework rate, the number of productions and the number of rework are required. Since the method for calculating the number of production has been described above, description thereof will not be repeated here.

The number of repairs can be defined from a plurality of viewpoints. However, in the production line 100 shown in FIG. 22, the result of the visual inspection by the person in charge among the works determined as “defective” by the automatic inspection apparatus. The number of workpieces that have been reworked after being determined to be minor defects is taken as the rework quantity (RQ). That is, for a certain order, the number of reworked workpieces among the workpieces determined to be defective by the automatic inspection apparatus can be calculated as the number of rework.

The number of productions and the number of repairs can be calculated by the above procedure, and the repair rate can be calculated from these values.

(H6: Waste rate relative to the number of facilities produced)
The calculation of the discard rate relative to the number of facilities produced requires the number of production and the number of discarded after rework. Since the method for calculating the number of production has been described above, description thereof will not be repeated here.

The number of discarded items after rework can be defined from a plurality of points of view. However, in the production line 100 shown in FIG. As a result, although it was determined that it was a minor defect and it was repaired, the defect could not be resolved, and the number of workpieces that were finally discarded was reworked to be the number of discarded items. That is, for a certain order, the number of workpieces that have been reworked among the workpieces that have been determined to be defective by the automatic inspection apparatus, but could not be made nondefective can be calculated as the number of discarded items after reworking. .

According to the above procedure, the number of productions and the number of scraps after reworking can be calculated. From these values, the discard rate relative to the number of productions of equipment can be calculated.

<I. Comparison between production lines>
In the above description, the individual management method for each workpiece included in each order and the method for calculating the KPI are described for one production line. However, the management system 1 manages a plurality of production lines. May be. In particular, KPI is an index calculated in accordance with international standards, and is a problem for each production line by comparing between production lines and between factories (manufacturing bases) including one or more production lines. Pursuing points can be facilitated.

FIG. 24 is a schematic diagram showing a configuration example of the management system 1A according to the present embodiment. Referring to FIG. 24, in management system 1A, collection analysis server apparatus 250 is associated with a plurality of production lines 100A to 100C, and collects and analyzes event information from each of the plurality of production lines 100A to 100C. The analysis result for each production line is provided to the terminal device 300.

Necessary information is added to the event information from the PLC in charge of the relay server apparatuses 200A to 200C arranged in the production lines 100A to 100C, respectively, and transmitted to the collection analysis server apparatus 250.

The collection analysis server device 250 may generate analysis results for each of the production lines 100A to 100C and provide them to the terminal device 300 in a comparable manner.

Note that the plurality of production lines 100A to 100C shown in FIG. 24 may be arranged in the same factory, or may be arranged in a plurality of different production bases. In addition, since necessary information is exchanged via a network, a plurality of manufacturing bases may straddle a plurality of countries and regions.

Furthermore, a combination of data anonymization methods may be used to compare KPIs between production lines and factories owned by different companies and organizations.

<J. User interface>
Next, an example of an analysis result user interface provided to the terminal device 300 by the collection analysis server device 250 will be described. The user interface exemplified below is applicable when managing a single production line as shown in FIG. 1 and also when managing a plurality of production lines as shown in FIG.

25 to 28 are diagrams showing examples of user interface screens provided by the management system 1 according to the present embodiment. As an example, the management system 1 according to the present embodiment provides user interface screens 600A to 600C as shown in FIGS. 25 to 28 to the terminal device 300 and the like. The user interface screens 600A to 600C may be configured so that the display can be freely switched by selecting tabs 601 to 603 at the bottom of the screen.

Referring to FIG. 25, a user interface screen 600A displayed by selecting a tab 601 displays KPIs at each of the production sites (or production lines or factories) to be managed. The user interface screens 600A to 600C show an example in which the factory A and the factory B are management targets.

More specifically, the user interface screen 600A includes a KPI display area 611 for displaying each KPI for factory A using a pie chart and numerical values, and a KPI for each factory B using a pie chart and numerical values. And a KPI display area 612 to be displayed.

As the KPI, the above-mentioned five indicators are displayed in a manner that can be compared between the A factory and the B factory. As shown in FIG. 25, by comparing each index of KPI between manufacturing bases, the administrator can easily specify the manufacturing bases and devices that should be the target of equipment improvement. As supplementary information, the positions of factory A and factory B are marked in the map screen 608.

As described above, the collection analysis server apparatus 250 has a display function for displaying a plurality of indexes defined by KPI. In this display function, typically, a plurality of indicators are displayed side by side or superimposed. In addition, this display function can display indexes defined by KPI calculated for each of a plurality of production lines side by side or superimposed.

Referring to FIG. 26, the user interface screen 600B displayed by selecting the tab 602 displays the details of the KPI in the selected manufacturing base among the manufacturing bases to be managed. More specifically, on the user interface screen 600B, the current value of each index of KPI (or a value calculated for any period) is displayed as in the KPI display area 611 of FIG. A trend value (past performance value) 621 of each index is displayed in a graph. In this graph display, a common time axis is set, and temporal changes of each index of KPI can be compared with each other.

The user interface screen 600B includes a check box group 605 for selecting a manufacturing base, and can also display KPI indexes for one or a plurality of manufacturing bases selected by the user side by side.

As shown in FIG. 27, when a plurality of check boxes are selected in the check box group 605 included in the user interface screen 600B, it is possible to display the KPI indexes for a plurality of manufacturing bases in an overlapping manner. ing. More specifically, for each manufacturing base, the trend value (past performance value) 621 of each index of KPI is displayed as a graph on the same coordinate for each index. In this graph display, a common time axis is set, and the temporal change of each index of KPI can be compared between manufacturing bases.

Also, in the KPI display area 611, the current values (or values calculated for any period) of each indicator of KPI are displayed side by side so that they can be compared between manufacturing bases. It is preferable that the value of each index of KPI displayed in the KPI display area 611 is a value calculated or acquired at substantially the same timing.

Referring to FIG. 28, the user interface screen 600C displayed by selecting the tab 603 provides information for supporting the cause analysis in the case where some trouble occurs. Specifically, the user interface screen 600C includes a check box group 630 for designating various conditions, and event information that matches the condition selected by the user from the check box group 630 is displayed in a list in the log display area 640. The

The administrator can identify the reason why the target malfunction has occurred by referring to the event information listed in the log display area 640.

By providing the user interface screens 600A to 600C as described above to the administrator, etc., it is possible to grasp in real time what is happening at the manufacturing site, and other using KPI, which is a common index. By comparing productivity with other manufacturing bases, it is possible to efficiently plan future capital investment.

<K. Summary>
The following summarizes some aspects that can be included in the present invention.

(1) Individual management When production management is performed in units called “orders” in which a predetermined number of works of the same type are grouped together, even if some trouble occurs in a certain order unit, It is not possible to easily grasp which one of the plurality of contained workpieces has a defect.

Therefore, there is a demand for a management system capable of realizing finer production management even at a manufacturing site where production management is performed in units of orders.

In response to such a request, a management system associated with a production line including one or more facilities is provided. In this management system, each of one or a plurality of facilities is configured to process individual workpieces according to order information including designation of the type of manufacturing object and designation of the number of manufacturing objects. This management system collects event information related to processing that occurs in each of one or a plurality of facilities, and event information collected by the collection function based on the source and contents of each event information. Function for classifying into a set of event information caused by the generation, generation function for generating data indicating the processing status of each work based on event information belonging to each of the sets classified by the classification function, and generation And a visualization function for visualizing the progress of processing for each workpiece processed according to the order information based on the data generated by the function.

採用 By adopting the above management system, production management in work units included in order units can be facilitated.

(2) KPI calculation Conventionally, various methods and indicators for evaluating the productivity of a production line have been proposed, but they are often unique to a production line or a company, and relative to other production lines. It is not easy to perform a general evaluation, for example, an evaluation that productivity is high or low for other production lines. Therefore, it has never been possible to compare the productivity of similar production lines between different companies. Therefore, a management system that can objectively evaluate and manage each manufacturing site is desired.

In response to such a request, a management system associated with a production line including one or more facilities is provided. In this management system, each of one or a plurality of facilities is configured to process individual workpieces according to order information including designation of the type of manufacturing object and designation of the number of manufacturing objects. This management system actually collects event information generated in each of one or a plurality of facilities and actually works for each work in each of the one or a plurality of facilities based on the event information collected by the collecting means. The load ratio (Allocation ratio) defined as KPI (Key Performance Indicators) based on the calculation function that calculates the time when the process was executed, the time required for the process according to the order information, and the time calculated by the calculation means And a determination function for determining.

By adopting the management system described above, each manufacturing site can be objectively evaluated and managed using KPI, which is an index calculated according to international standards.

(3) Comparison between production bases / comparison between production lines / comparison between factories Conventionally, various improvement activities have been carried out at production sites. In carrying out such improvement activities, if there is any information that can be used as a comparative reference, it will help determine which equipment is beneficial for improvement. However, no such system has ever existed. For this reason, improvement activities were often performed based on the experience of skilled workers.

In response to such a request, a management system associated with a plurality of production lines including one or a plurality of facilities is provided. The management system collects event information generated in each of the plurality of production lines, and an index (typically, each of the plurality of production lines based on the event information collected by the collection function. A calculation function for calculating (index defined as KPI) and a display function for displaying the calculated indexes for each of the plurality of production lines side by side.

(4) Application of collection processing and analysis processing In the above description, a case where production management is performed for each workpiece included in each order at a manufacturing site where production management is performed in units of orders has been illustrated. Even at a manufacturing site, the above-described collection processing and analysis processing can be applied. In other words, in the management system according to the present embodiment, individual event management is possible if event information that can identify the source and contents of the management system can be collected. Even if the information specifying the workpiece in the order is included, the above-described processing can be performed.

Other aspects of the present invention can be easily understood by those skilled in the art with consideration of the entire specification of the present application.

By adopting the management system described above, information for supporting improvement activities can be provided.
The embodiment disclosed this time should be considered as illustrative in all points and not restrictive. The scope of the present invention is defined by the terms of the claims, rather than the description above, and is intended to include any modifications within the scope and meaning equivalent to the terms of the claims.

1, 1A management system, 101-105 equipment, 111-115 PLC, 100, 100A, 100C production line, 110 conveyor, 116 local network, 120 arithmetic unit, 122, 202 processor, 124, 134 bus controller, 126, 204 memory , 128 communication interface, 130 functional unit, 132 IO module, 136,224 internal bus, 140 communication unit, 150 fieldbus, 200, 200A, 200C relay server device, 206 global communication interface, 208 local communication interface, 210 hard disk drive, 214 processing program, 216 optical drive, 220 input unit, 222 output unit, 250 collection analysis service Server device, 260 event information storage unit 270 work identification module, 280 event information set, 290,290A tracking database, 300 terminal, 400 order information, 2711,2721 rule, 2712,2722 counter.

Claims (15)

1. A management system associated with a production line including one or a plurality of facilities, wherein each of the one or more facilities is an individual workpiece according to order information including designation of a type of production object and designation of the number of production objects. Is configured to handle
   Collection means for collecting event information relating to processing occurring in each of the one or more facilities;
   Classifying means for classifying the event information collected by the collecting means into a set of event information caused by the same work based on the source and content of each event information;
   Generating means for generating data indicating the processing status of each work based on event information belonging to each of the sets classified by the classification means;
   A management system comprising: visualization means for visualizing the progress of processing for each workpiece processed according to the order information based on data generated by the generation means.
2. The management system according to claim 1, wherein the classification unit classifies the collected event information according to a configuration of the one or more facilities in the production line.
3. The management system according to claim 1, wherein when the event information having the same content is received a plurality of times from the same source, the classification means classifies each event information into event information caused by different works.
4. 4. The visualization unit according to claim 1, wherein the visualization unit reproduces the processing progress of each workpiece on the production line on a plane defined by an axis associated with a process and a time axis. The management system described.
5. The management system according to any one of claims 1 to 3, wherein the visualization means displays a list of event information classified into a set corresponding to the selected work.
6. 4. The method according to claim 1, wherein the generation unit specifies an order number to which the set classified by the classification unit belongs and a work number in the order based on time information included in the order information. Management system described in the section.
7. The collection means further collects field information acquired by the one or more facilities,
   The management system according to any one of claims 1 to 3, wherein the generation unit executes a process of associating the collected field information with a corresponding work.
8. The management system according to claim 7, wherein the visualization means displays associated field information in response to a work selection.
9. The management system according to claim 7, further comprising monitoring means for monitoring a tendency that can occur in the facility by comparing field information respectively associated with a plurality of works in the predetermined facility.
10. A management method in a production line including one or a plurality of facilities, wherein each of the one or more facilities processes individual workpieces according to order information including designation of a type of a production object and designation of the number of production objects. Is configured to
    Collecting event information relating to processing occurring in each of the one or more facilities;
    Classifying the event information collected in the collecting step into a set of event information caused by the same work based on the source and content of each event information;
    Generating data indicating a processing status for each work based on event information belonging to each of the sets classified in the classifying step;
    And a step of visualizing the progress of processing for each workpiece processed according to the order information based on the data generated in the generating step.
11. A management system associated with a production line including one or a plurality of facilities, wherein each of the one or more facilities is an individual workpiece according to order information including designation of a type of production object and designation of the number of production objects. Is configured to handle
    Collection means for collecting event information generated in each of the one or more facilities;
    Based on the event information collected by the collecting means, calculating means for calculating the time that each of the one or more facilities is actually processed for each work;
    A management system comprising: a determination unit that determines a load degree (Allocation ratio) defined as KPI (Key Performance Indicators) based on a time required for processing according to the order information and a time calculated by the calculation unit .
12. The calculation means actually performs processing for each of one or a plurality of workpieces processed in accordance with the same order information from an integrated value of a period from the start of processing at the target facility to the completion of the processing. The management system according to claim 11, wherein the calculated time is calculated.
13. The determination means determines another index defined as KPI in addition to the load degree,
    The management system according to claim 11, further comprising a display unit that displays a plurality of indexes determined by the determination unit side by side or superimposed.
14. The management system is associated with a plurality of the production lines,
    The management system according to claim 13, wherein the display unit displays the indicators calculated for each of the plurality of production lines side by side or superimposed.
15. A management method in a production line including one or a plurality of facilities, wherein each of the one or more facilities processes individual workpieces according to order information including designation of a type of a production object and designation of the number of production objects. Is configured to
    Collecting event information occurring at each of the one or more facilities;
    Based on the event information collected in the collecting step, calculating a time at which processing is actually performed for each work in each of the one or more facilities;
    And determining a load ratio (Allocation ratio) defined as KPI (Key Performance Indicators) based on the time required for the processing according to the order information and the time calculated in the calculating step. .

Images