WO2022195748A1 - 工程管理装置 - Google Patents
工程管理装置 Download PDFInfo
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- WO2022195748A1 WO2022195748A1 PCT/JP2021/010744 JP2021010744W WO2022195748A1 WO 2022195748 A1 WO2022195748 A1 WO 2022195748A1 JP 2021010744 W JP2021010744 W JP 2021010744W WO 2022195748 A1 WO2022195748 A1 WO 2022195748A1
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/418—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM]
- G05B19/4184—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM] characterised by fault tolerance, reliability of production system
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/418—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM]
- G05B19/41865—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM] characterised by job scheduling, process planning, material flow
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B23/00—Testing or monitoring of control systems or parts thereof
- G05B23/02—Electric testing or monitoring
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B2219/00—Program-control systems
- G05B2219/30—Nc systems
- G05B2219/31—From computer integrated manufacturing till monitoring
- G05B2219/31467—Display of operating conditions of machines, workcells, selected programs
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B2219/00—Program-control systems
- G05B2219/30—Nc systems
- G05B2219/31—From computer integrated manufacturing till monitoring
- G05B2219/31472—Graphical display of process
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B2219/00—Program-control systems
- G05B2219/30—Nc systems
- G05B2219/45—Nc applications
- G05B2219/45054—Handling, conveyor
Definitions
- the present disclosure relates to a process control device that can visually represent the production status of multiple products manufactured through multiple work processes.
- Patent Literature 1 discloses a process control apparatus that manages a plurality of work processes using a Gantt chart that visually expresses the production status. This process control device displays each of a plurality of work processes by means of a Gantt chart representing a rectangular area with the work start time as the leading edge and the work end time as the trailing edge. It makes the time visible and makes it easy to grasp the work process that is hindering productivity improvement.
- the present disclosure has been made in view of the above, and aims to obtain a process control device that can flexibly express the production status of each work process in response to a manager's request.
- the process control device of the present disclosure displays the production status of a plurality of products manufactured by a plurality of work processes, a time axis indicating the work time of each work process, A process control device that visualizes with a work process control chart composed of two coordinate systems with a process axis that shows changes in the work process, the operation data of each production facility corresponding to each work process, and the manager's
- a data input unit for inputting various acquisition information including request instruction information, a work time line showing the work time in each work process by length based on the operation data, and a transport showing the transfer time in each transport process by the slope
- the first display data which is the display data of the standard work process control chart in which the time line and the time line are arranged on the work process control chart, is output as display data for output, and the first display data is input from the data input unit.
- the production status visualized by the first display data is expressed differently from the work process control chart displayed by the first display data based on the request instruction information
- a control unit that outputs second display data which is display data of the work process control chart visualized by the expression method of the work process control chart, as display data for output; and a display unit that displays the display data for output.
- the process control device has the effect of being able to flexibly express the production status of each work process according to the manager's request.
- FIG. 1 is a diagram showing the overall configuration of a process control system including a process control device according to a first embodiment
- FIG. 1 is a diagram showing the configuration of a process control device according to a first embodiment
- FIG. 4 is a diagram showing an example of a data structure of a database included in a storage unit according to the first embodiment
- FIG. 5 is a diagram showing an example of display data of a work process control chart displayed by the process control apparatus according to the first embodiment
- FIG. FIG. 4 is a diagram showing an example of wire connection arrangement data generated by the process control device according to the first embodiment
- FIG. 4 is a diagram showing an example of first display data displayed by the process control apparatus according to the first embodiment;
- FIG. 4 is a diagram showing an example of second display data displayed by the process control apparatus according to the first embodiment;
- a diagram showing an example of display data of a work process control chart in which an identification display for assisting in grasping the production situation is added to the characteristic part of the work process control chart shown in FIG. 4 is a flow chart for explaining processing for generating first display data by the process control apparatus according to the first embodiment;
- 4 is a flow chart for explaining a process of generating second display data by the process control apparatus according to the first embodiment;
- FIG. 2 is a diagram showing an example of hardware configuration when the functions of the process control apparatus according to the first embodiment are realized using a computer system;
- FIG. 11 is a diagram showing an example of first display data displayed by the process control apparatus according to the second embodiment;
- FIG. 11 is a diagram showing an example of second display data displayed by the process control apparatus according to the second embodiment;
- FIG. 11 is a diagram showing an example of first display data displayed by the process control apparatus according to the third embodiment;
- FIG. 12 is a diagram showing an example of second display data displayed by the process control apparatus according to the third embodiment;
- FIG. 12 is a diagram showing an example of first display data generated by visualizing the production status in the case where a plurality of types of products are mixed by the process control apparatus according to the fourth embodiment in the same way as in the first embodiment;
- FIG. 12 is a diagram showing an example of operation data used by the process control device according to the fourth embodiment;
- FIG. 12 is a diagram showing an example of first display data generated by the process control apparatus according to the fifth embodiment
- FIG. 1 is a diagram showing the overall configuration of a process control system including a process control device according to Embodiment 1 of the present disclosure.
- the process control system includes a data collection device 300 , a process control device 200 and a plurality of production facilities 400 .
- a manufacturing process of one product is configured by combining a plurality of work processes, and each work process is performed by a corresponding production facility 400 .
- the data collection device 300 collects operation data from each production facility 400 that is in charge of each work process in manufacturing a product, and transmits the collected operation data to the process control device 200 .
- the operation data indicates, as an example, the work start time, which is the time when the production equipment 400 corresponding to each work process starts manufacturing each product, and the work end time, which is the time when the manufacturing is finished.
- the work start time is the time when the work is started for each product in each work process
- the "work end time” is the time when the work is finished for each product in each work process.
- the process control device 200 displays display data obtained by processing the acquired operation data according to a specific expression method.
- FIG. 2 is a diagram showing the configuration of the process control device 200 shown in FIG.
- the process control device 200 includes a control section 220 , a storage section 230 , a data input section 240 and a display section 210 .
- the data input unit 240 inputs and stores various acquired information including operation data of each production facility 400 corresponding to each work process collected by the data collection device 300, manager's request instruction information, and various setting information.
- the storage unit 230 stores various types of information necessary for visualizing the production status of products manufactured through a plurality of work processes, including various types of acquired information. For example, the storage unit 230 stores operation data and manages the operation data for each work process and each product number in a database format.
- the storage unit 230 also stores setting information including connection formats such as work time lines and delivery time lines, and information such as manager's request instruction information, which will be described later.
- the control unit 220 is a control device that performs control necessary for the process of visualizing the production status in each work process of the product.
- the control unit 220 acquires operation data from the storage unit 230, and outputs display data processed so as to visualize the production status from the acquired operation data to the display unit 210 as display data for outputting a work process control chart.
- the control unit 220 includes a connection placement unit 221 , a connection generation unit 222 , a connection adjustment unit 223 and an output unit 224 .
- the display unit 210 displays output display data of the work process control chart.
- a work process control chart is used to manage the production status of products manufactured through multiple work processes, and it visually expresses operation data so that the production status can be easily understood. Therefore, the manager can easily grasp the production situation just by looking at this work process control chart.
- the work process control chart will be described later in detail.
- FIG. 3 is a diagram showing the data structure of the database that the storage unit 230 has.
- FIG. 3 shows, as an example, a data structure in which operation data is stored in a database format in the case of repeatedly producing a plurality of products in which workpieces are manufactured through a plurality of work processes as shown in FIG.
- the database of the storage unit 230 has a configuration in which work start times and work end times at which work is performed in each work process are stored in association with each work associated with each product number.
- "Product number" is a unique number assigned to each product manufactured in a factory.
- the operation data of the product related to the product number "SN0001" indicates that manufacturing in work process 1 started at time “08:00:00” and finished at time “08:10:00", then work process 2 Production in operation 3 starts at time “08:15:00” and ends at time “08:20:00", then production in operation step 3 starts at time “08:25:00” and finishes at time " 08:35:00”, and then production in operation step 4 started at time 08:40:00 and finished at time 08:50:00.
- the product number is a number assigned to each product that is actually produced, but the same number may be assigned to each group of products.
- FIG. 5 shows an example of the display data of the work process control chart displayed by the process control device 200.
- FIG. FIG. 5 shows the operation data shown in FIG. 3 as a work process control chart displayed on the display unit.
- the work process control chart is composed of two coordinate systems: a time axis in units of time and a process axis in units of work processes.
- the work process control chart consists of two coordinate systems: the time axis that shows the work time of each work process, and the process axis that shows changes in the work process in which manufacturing is performed. are arranged at the corresponding coordinate positions and connected, for each of a plurality of products, the work time in each work process, the transport time in each transport process, and the production waiting time in each work process can be visualized visually.
- the production waiting time includes the setup time.
- work process 1 is the most upstream work process, and downstream work processes are shown as proceeding to the right.
- Time axes t1, t2, t3, and t4 are the time axis for work process 1, the time axis for work process 2, the time axis for work process 3, and the time axis for work process 4, respectively.
- the vertical axis of the work process control chart is the time axis
- the horizontal axis is the process axis.
- the time axis and the process axis may be reversed.
- the line segment that connects the coordinates corresponding to the work start time and work end time in each work process indicates the work time in each work process, and is hereinafter referred to as the work time line.
- the coordinate point corresponding to the work start time may be referred to as the "start point of the work time line”
- the coordinate point corresponding to the work end time may be referred to as the "end point of the work time line”. be.
- the longer the work time line the longer the work time required for the work process.
- the transport time required to transport the workpiece from the first work process among the plurality of work processes to the work process subsequent to the first work process (hereinafter referred to as "second work process”) is , corresponds to the slope of a line segment connecting the end point of the work time line of the first work process and the start point of the work time line of the second work process (hereinafter referred to as "transportation time line").
- transport time line For example, in the transfer time line 1a shown in FIG. 5, the transfer of the first workpiece starts from work process 1 at "08:10:00" and ends at work process 2 at "08:15:00". indicates that The greater the slope of the transfer time line, the longer the transfer time between the first work process and the second work process.
- the production waiting time in each work process is the end point of the work time line related to the first product among the multiple products on the time axis of the same work process and the product following the first product (hereinafter referred to as “ (hereinafter referred to as “second product”) and the starting point of the work time line (hereinafter referred to as "work time line interval”).
- work time line intervals 1T, 2T, 3T, and 4T shown in FIG. The wider the work time line interval, the longer the production waiting time.
- the process control device 200 can identify the following three causes based on the characteristics of the length of the work time line, the interval of the work time line, or the inclination of the transfer time line. can assist in identification.
- FIG. 5 shows a case in which the work time line intervals 1T, 2T, 3T, and 4T in the work process 2 are all wider than the predetermined time. In such a case, there is a possibility that wasteful adjustment time other than the predetermined time occurs during the production waiting time of the work process 2 due to the lack of production capacity of the production equipment corresponding to the work processes before and after the work process 2.
- the production capacity of the production equipment in work process 1 is insufficient, the work time in work process 1 will be longer for all products, and as a result, the work start time in the next work process 2 will be delayed. As a result, the work time line intervals 1T, 2T, 3T, and 4T become wider than the predetermined time. Therefore, in a certain work process, when all the work time line intervals are wider than necessary, in the work process before and after the work process, the production capacity of the corresponding production equipment is insufficient for the production plan. suggests that it is possible.
- the second product (product number SN0002) work (hereinafter referred to as the "second work") has completed the work in work process 3 and is being transported to work process 4.
- the work can be transported from the work process 3 in the work process 4 immediately after a predetermined time interval required for setup, etc. Since it is possible to start work on the second work that has arrived, the slope of the transfer time line becomes the same as the slope of the transfer time line 1c of the first work that was normally transferred.
- the slope of the transfer time line 3b for the work of the third product (product number SN0003) (hereinafter referred to as the "third work") is greater than the slope of the transfer time line 3b, but this is the work Due to the fact that the work time for the third work in process 3 was longer than planned, the work start time for the work of the fourth product (product number SN0004) (hereinafter referred to as the "fourth work”) in work process 3 was originally because it was later than planned. In such a case, although the slope of the transfer time line 4b in FIG. 5 increases, the work time line interval on the work process 3 does not become wider than necessary.
- the work time line interval between a work time line m2 and a work time line n2 following the work time line m2 is longer than necessary. and the slope of the transport time line connecting to the starting point of the work time line n2 is greater than the slope of the other transport time lines between the first work process and the second work process, between the work processes This suggests that there may have been transport troubles.
- connection placement unit 221 places a first mark ( ⁇ ) representing the work start time and a second mark ( ⁇ ) representing the work end time at corresponding coordinate positions on the work process control chart. do.
- a specific process performed by the connection placement unit 221 will be described.
- the wire placement unit 221 acquires operation data for each product number from the database of the storage unit 230 . Then, from the acquired operation data for each product number, the work start time and work end time of each work process, and the number of work processes, which is the number of work processes required to manufacture one product, are extracted.
- the connection arrangement unit 221 determines the time axis and the coordinates of the work process control chart. Calculate each scale of the process axis. In this case, since the scale of the process axis corresponds to the interval of the time axis, it may hereinafter be referred to as the interval of the time axis.
- the connection arrangement unit 221 displays the work process control chart in the display area designated for the work process control chart. Based on the extracted maximum work end time, the number of work processes, and the display area for displaying the work process control chart, the scale of the time axis and the interval of the time axis are calculated so as to fit. Intervals on the time axis are calculated so as to be equal intervals.
- the wire placement unit 221 stores the calculated scale of the time axis and the interval of the time axis in the storage unit 230 as setting information of the coordinate system of the work process control chart. In this manner, the connection placement unit 221 generates a work process control chart coordinate system that fits in the display area designated for the work process control chart.
- connection placement unit 221 puts a first mark ( ⁇ ) and a second mark ( ⁇ ).
- the wire connection arrangement unit 221 places the first mark ( ⁇ ) and the second mark ( ⁇ ) are displayed to generate connection layout data.
- connection arrangement unit 221 when generating connection arrangement data from the operation data shown in FIG. 3, the connection arrangement unit 221 performs the following processing.
- the wire placement unit 221 acquires the work start time “08:00:00” and the work end time “08:10:00” in the work process 1 for the product related to the product number “SN0001”.
- the connection placement unit 221 acquires the work start time “08:15:00” and the work end time “08:20:00” in the work process 2 for the product related to the product number “SN0001”.
- the connection placement unit 221 acquires the work start time “08:25:00” and the work end time “08:35:00” in the work process 3 for the product related to the product number “SN0001”.
- the connection placement unit 221 acquires the work start time "08:40:00” and the work end time "08:50:00” in the work process 4 for the product related to the product number "SN0001".
- connection placement unit 221 manages the work process based on the work start time "08:00:00" and the work end time "08:10:00” in the work process 1 of the product related to the product number "SN0001".
- a first mark ( ⁇ ) and a second mark ( ⁇ ) are placed at corresponding coordinate positions on the figure.
- the connection arrangement unit 221 determines the work process control chart based on the work start time "08:15:00” and the work end time "08:20:00” in the work process 2 of the product related to the product number "SN0001". Place a first mark ( ⁇ ) and a second mark ( ⁇ ) at the corresponding coordinate positions above.
- connection arrangement unit 221 determines the work process control chart based on the work start time "08:25:00” and the work end time “08:35:00” in the work process 3 of the product related to the product number "SN0001". Place a first mark ( ⁇ ) and a second mark ( ⁇ ) at the corresponding coordinate positions above.
- the wire connection arrangement unit 221 determines the work process control chart based on the work start time "08:40:00” and the work end time "08:50:00” in the work process 4 of the product related to the product number "SN0001”. Place a first mark ( ⁇ ) and a second mark ( ⁇ ) at the corresponding coordinate positions above.
- the connection generation unit 222 selects the first mark ( ⁇ ) and the second mark ( ⁇ ) placed on the work process control chart that correspond to the same product number and the same work process.
- the work time line is generated by connecting the first mark ( ⁇ ) and the second mark ( ⁇ ). That is, the connection generation unit 222 arranges the first work process and the second work process of the plurality of work processes on the respective time axes for each of the plurality of products based on the connection arrangement data, A work time line is generated by connecting the first mark ( ⁇ ) and the second mark ( ⁇ ) for one product.
- connection generation unit 222 selects the second mark ( ⁇ ) and the second mark ( ⁇ ) placed on the work process control chart for one product in the first work process.
- a transfer time line is generated by connecting the mark ( ⁇ ) and the first mark ( ⁇ ) in the second work process. Processing by the connection generation unit 222 will be described with reference to FIG.
- FIG. 7 is a diagram for explaining processing by the connection generation unit 222. As shown in FIG. FIG. 7 is a diagram in which a work time line and a transportation time line are generated from the wire connection arrangement data shown in FIG.
- connection generation unit 222 connects the first mark ( ⁇ ) and the second mark ( ⁇ ) in the work process 1 for the product related to the product number “SN0001”, and creates the work time line 11 in the work process 1. Generate. Similarly, the connection generation unit connects the first mark ( ⁇ ) and the second mark ( ⁇ ) in the remaining work processes for the product related to the product number "SN0001", and sets work time lines 12 to 14. Generate. At this time, the connection generation unit 222 generates the work time line according to the format of the work time line set in advance by the data input unit 240 and stored in the storage unit 230 .
- the work time line As the format of the work time line, it is possible to set the color of the connection, the type of connection, the thickness of the connection, the type of the first mark of the connection, the type of the second mark of the connection, etc.
- the work time line is generated as a solid line.
- connection generation unit 222 connects the second mark ( ⁇ ) of the work time line 11 and the first mark ( ⁇ ) of the work time line 12 for the product related to the product number "SN0001".
- a transport time line 1a is generated.
- the connection generation unit will also divide the second mark ( ⁇ ) of the work time line and the first mark ( ⁇ ) of the work time line between the remaining work processes. are connected to generate the transport time lines 1b and 1c.
- the connection generator generates the transport time line according to the format of the transport time line set in advance by the data input unit 240 and stored in the storage unit 230 .
- the transport time line it is possible to set the color of the connection, the type of connection, the thickness of the connection, the type of the first mark of the connection, the type of the second mark of the connection, etc.
- the example in FIG. the transportation time line is generated by a dashed-dotted line.
- the connection generation unit 222 repeats such processing for other product numbers, and generates display data (hereinafter referred to as “first display data”) for a work process control chart that serves as a reference as shown in FIG. do. That is, the first display data is display data before adjusting the expression method of the work process control chart. For example, if the display data of the work process control chart that serves as a reference for ease of use is generated to match the display area of the entire screen, then that is the first display data, or half of the screen from the beginning. If the display data of the work process control chart that serves as a reference is generated so as to be easy to use according to the display area of , it will be the first display data. In FIG. 7, a line segment including the first mark ( ⁇ ) and the second mark ( ⁇ ) is the working time line.
- the connection generation unit 222 stores the generated first display data in the storage unit 230 .
- Second display data is generated from one display data. That is, when the manager's request instruction information for the first display data is input from the data input unit 240, the connection adjustment unit 223 converts the production status visualized by the first display data into the request instruction information.
- second display data which is the display data of the work process control chart visualized in a work process control chart representation method different from the representation method of the work process control chart displayed by the first display data. .
- both the first display data and the second display data are the display data of the work process control chart that visualizes the same production situation, but the second display data is the work displayed by the first display data. It is the display data of the work process control chart after adjusting the representation method of the process control chart.
- the display unit 210 has a sufficient display area, the display area in which the work process control chart can be displayed is limited, and the display size of the work process control chart may be limited.
- the first display data is first created in accordance with the display area of the entire screen, and later it is desired to simultaneously display other information on the same screen.
- the work process control chart is displayed in the display area of half of the screen, and other information is displayed in the other half of the display area. will be limited.
- the work process control chart when compressing and displaying the work process control chart displayed by the first display data as shown in FIG. 7 so as to fit in such a limited display area, the If the scale of the work process control chart is simply changed according to the display size of the limited display area and the display data of the work process control chart is generated and displayed, the work process control chart may not be easy to see and display. be.
- the work process control chart displayed by the first display data is simply displayed by changing the scale according to the display size of the limited display area, the work displayed by the first display data If the process control chart is compressed in the direction of the time axis, the work time line may also be compressed in the direction of the time axis and collapsed, making it difficult to see. unfavorable above.
- FIGS. 7 and 8 even when displaying a work process control chart in which the work process control chart displayed by the first display data is compressed in the direction of the time axis, a representation method is used so that the work time line is not collapsed.
- FIG. 8 is a diagram for explaining processing by the connection adjustment unit 223.
- the expression method is adjusted so that the work time line is not collapsed.
- FIG. 10 is an example of a work process control chart displayed by second display data generated by This shows a case where the length of each work time line on the work process control chart displayed by the first display data is compressed in the direction of the time axis without being changed.
- connection adjustment unit 223 calculates an inclination angle for inclining the work time line based on the compression ratio in the direction of the time axis. Each work time line is tilted according to the obtained tilt angle and rearranged on the work process control chart.
- the request instruction information to the purport of "change the work process control chart displayed by the first display data to a work process control chart compressed to 1/2 in the time axis direction". is entered by the administrator from the data entry unit.
- the request instruction information is input in a sentence format, but the instruction method of the request instruction information is an example and is not limited to this.
- connection adjustment unit 223 analyzes the content of the request instruction information, and adjusts the expression method based on the analysis result. Specifically, first, the connection adjustment unit 223 calculates the inclination angle of the work time line based on the analysis result of the request instruction information.
- the inclination angle ⁇ of the work time line can be calculated by the following equation (1).
- the connection adjustment unit 223 compresses the coordinate system of the work process control chart displayed by the first display data by half in the time axis direction, and reduces the work displayed by the second display data. Generate a coordinate system for process control charts.
- connection adjustment unit 223 adjusts the position of the second mark ( ⁇ ) on the work time line with the middle point of each work time line on the work process control chart displayed by the first display data as the fulcrum.
- each work time line is tilted with the same length so that it faces the process axis direction by the calculated tilt angle of 60 degrees.
- the work time line on the work process control chart displayed by the first display data is tilted in the direction of the process axis while maintaining the same length according to the compression rate, and this work time line is referred to as an "inclined work time line".
- connection adjustment unit 223 reads the setting information of the scale of the time axis from the storage unit 230, and the scale of the time axis of the work process control chart displayed by the first display data is displayed by the second display data. Compress the time axis by changing to the scale of the time axis of the work process control chart.
- connection adjusting unit 223 determines that the position of the first mark of each inclined work time line corresponds to each inclined work time line on the scale of the time axis of the work process control chart displayed by the second display data.
- Each inclined work time line is translated in the direction of the time axis so that it coincides with each work start time.
- connection adjustment unit 223 adjusts the connection relationship between each work time line of the work process control chart displayed by the first display data and each transfer time line in accordance with each inclined work time line after the parallel movement. Each transport time line is rewired so as to maintain the second display data. As a result, second display data as shown in FIG. 8 can be obtained.
- the connection adjustment unit 223 stores the generated second display data in the storage unit 230 .
- the output unit 224 outputs the first display data to the display unit 210 as display data for outputting the work process control chart until the request instruction information for the first display data is input from the data input unit.
- the second display data is output to the display unit 210 as output display data for the work process control chart.
- the first display data and the second display data may be collectively referred to as "work process control chart display data".
- the feature quantity of the characteristic portion that serves as a judgment index for the quality of the production situation such as the length of the work time line, the interval of the work time line, or the inclination of the transport time line, on the work process control chart is managed.
- the cause of hindering productivity improvement can be specified by confirming by the person, but by setting the allowable value in advance for each feature value in the process control device, the output unit , From the work process control chart displayed by the display data of the work process control chart, extract the feature amount of the characteristic part that is the judgment index of the production situation, and if the feature amount of the characteristic part exceeds the allowable value,
- the display data of the work process control chart in which an identification indication for assisting the grasp of the production status is added to the characteristic portion, may be output as the output display data of the work process control chart.
- the output unit Add an indicator to indicate that it is wider than allowed. For example, there is a method of displaying a mark (x) at each work time line interval on the time axis of the work process, but it is sufficient if all the work time line intervals are wider than the allowable value.
- the identification display method is not limited to this method.
- the manager may be concerned that the production capacity of the production equipment related to the work process before and after the work process to which the identification mark is attached is insufficient. I know there is.
- an allowable value for the inclination of the transfer time line is set for each work process, and if there is a transfer time line with an inclination equal to or greater than the allowable value, the output unit detects that there is a transfer trouble between processes on the transfer time line.
- Add identification to indicate what might be happening. For example, there is a method of displaying the transport time line in a different color from the transport time line in which transport troubles do not occur. It suffices to indicate that there is an object, and the identification display method is not limited to this method.
- a permissible value for the length of the work time line is set for each work process, and if there is a work time line with a length greater than the permissible value, the output unit detects that a production trouble has occurred in that work process.
- FIG. 9 is a diagram showing an example of display data of a work process control chart in which an identification display that assists in grasping the production status is added to the characteristic part of the work process control chart shown in FIG.
- a mark (x) is added to the corresponding work time line interval as an example of identification display indicating that all the work time line intervals are wider than the allowable value.
- a mark ( ⁇ ) is added on the corresponding transport time line.
- a mark ( ⁇ ) is added on the corresponding work time line.
- the output unit 224 automatically adds an identification display to the characteristic portion on the work process control chart according to the judgment criteria, so that the manager can It eliminates the need to find the characteristic part by oneself, and can easily identify the cause that hinders productivity improvement. That is, the output unit 224 extracts the feature amount of the feature portion that serves as a judgment index for the quality of the production situation from the work process control chart displayed by the first display data or the second display data, and extracts the feature amount for each feature amount.
- FIG. 10 is a flowchart for explaining the process of generating the first display data.
- the connection placement unit 221 acquires operation data from the storage unit 230 (step 1). Specifically, the wire placement unit 221 acquires the operation data for each product number from the database of the storage unit 230, and extracts the work start time and work end time for each work process and the number of work processes.
- the wire placement unit 221 displays the first display data in the display area designated for the first display data.
- a coordinate system of the work process control chart displayed by the first display data is generated so as to fit within the display area specified for the display data of (step 2).
- connection placement unit 221 puts a first mark ( ⁇ ) and a second mark ( ⁇ ) is placed (step3).
- the connection generation unit 222 selects the first mark ( ⁇ ) and the second mark ( ⁇ ) placed on the work process control chart that correspond to the same product number and the same work process. ( ⁇ ) and the second mark ( ⁇ ) are connected to generate a working time line (step 4).
- connection generation unit 222 selects the second mark of the work time line related to the first work process, out of the first mark ( ⁇ ) and the second mark ( ⁇ ) placed on the work process control chart.
- a transfer time line is generated by connecting the mark ( ⁇ ) and the first mark ( ⁇ ) of the work time line related to the second work process (step 5). Note that the order of step 4 and step 5 may be reversed, or they may be performed in parallel.
- the output unit outputs the first display data generated by the processing up to step 5 to the display unit 210 as the output display data for the work process control chart (step 6).
- FIG. 11 is a flowchart for explaining the process of generating the second display data.
- request instruction information for the first display data is input by the administrator from the data input unit 240 (step 7).
- the connection adjustment unit 223 generates a coordinate system for the work process control chart displayed by the second display data (step 8).
- the connection adjustment unit 223 analyzes the content of the request instruction information (step 9).
- the connection adjustment unit 223 adjusts the expression method according to the request instruction on the first display data based on the analysis result of the content of the request instruction information, and converts the second display data. Generate (step10).
- the output unit 224 outputs the second display data to the display unit 210 as display data for outputting the work process control chart (step 11).
- the process control apparatus 200 maintains each work time line with the same length even when it is desired to compress the work process control chart displayed by the first display data in the direction of the time axis.
- tilting it is possible to generate and display the second display data in which the work process control chart displayed by the first display data is compressed in the direction of the time axis without collapsing each work time line. Therefore, by checking the work process control chart displayed by the second display data, the manager can grasp the production status without impairing the visibility.
- the manager by displaying the work time line and the transportation time line in different formats, and by adding an identification display to the characteristic part of the work process control chart, it is possible to prevent the manager from grasping the production situation and improving productivity. can assist in identifying the cause of the failure.
- FIG. 12 is a diagram showing an example of hardware configuration when the functions of the process control apparatus 200 according to the first embodiment are realized using a computer system.
- the process control apparatus 200 includes a processor 901 that executes various processes, a memory 902 that is an internal memory, an external storage device 903 that stores various information, an input interface 904 that inputs various information, and displays various information. and a display 905 .
- the processor 901 is a CPU (Central Processing Unit).
- the processor 901 may be a processing device, an arithmetic device, a microprocessor, a microcomputer, or a DSP (Digital Signal Processor).
- Each function of control unit 220 is implemented by processor 901, software, firmware, or a combination of software and firmware.
- Software or firmware is written as a program and stored in the external storage device 903 .
- the processor 901 reads software or firmware stored in the external storage device 903 into the memory 902 and executes it.
- the memory 902 is a non-volatile or volatile semiconductor memory such as RAM (Random Access Memory), ROM (Read Only Memory), flash memory, EPROM (Erasable Programmable Read Only Memory) or EEPROM (registered trademark) (Electrically Erasable Memory). Programmable Read Only Memory).
- the external storage device 903 is a HDD (Hard Disk Drive) or SSD (Solid State Drive). The functions of the storage unit 230 are implemented using the external storage device 903 .
- the input interface 904 is responsible for inputting information from the data collection device 300 and the administrator.
- the input interface 904 also includes input devices such as a keyboard, mouse, or touch panel.
- the functionality of data input section 240 is realized through the use of input interface 904 .
- the functions of the display unit 210 are implemented using the display 905 .
- Embodiment 2 even if the manufacturing process includes parallel processes in which the same work content is performed in parallel, the representation method of the work process control chart can be adjusted to make it easier for the manager to recognize the production status. A process control device will be described.
- the configuration of the process control apparatus according to the second embodiment is also the same as the configuration of the process control apparatus 200 according to the first embodiment, so description thereof will be omitted.
- the production capacity of a single production facility is insufficient in a certain work process, the production capacity may be covered by performing the same work content in parallel with multiple production facilities.
- FIG. 13 a case will be described in which the same work content is performed in the production equipment 2a and the production equipment 2b in parallel in the work process 2.
- FIG. 14 is a work process control chart displayed by the first display data generated separately as the work process 2b.
- the time axes t2a and t2b are the time axis of the work process 2a and the time axis of the work process 2b, respectively.
- work process 2 is divided into work process 2a and work process 2b instead of showing work process 2 as one work process if the production capacity of a single production facility is not insufficient. Therefore, when the manager looks at the work process control chart and grasps the production status, the work process 2a and the work process 2b visually look like separate and unrelated processes. This prevents the operator from grasping the production status by treating the work process 2a and the work process 2b as one process unit as the work process 2. ⁇
- the data input unit 240 is used by the manager to, for example, ⁇ change the work process control chart displayed by the first display data relating to the manufacturing process including the parallel process to an easy-to-read work process control chart.
- the connection adjustment unit 223 analyzes the contents of the request instruction information, and makes it easier to see the work process control chart displayed by the first display data regarding the manufacturing process including the parallel process.
- the expression method adjustment processing is performed to generate the second display data.
- the connection adjustment unit 223 generates second display data by narrowing the interval of the time axis of the parallel processes of the work process control chart displayed by the first display data. Processing performed by the connection adjustment unit 223 in this case will be described.
- the administrator inputs the compression rate of the interval of the time axis of the parallel processes from the data input unit 240 and sets it in the storage unit 230 in advance.
- the connection adjustment unit 223 analyzes the content of the request instruction information and adjusts the expression method based on the analysis result. As in this case, when request instruction information is input from the data input section to request a change to a work process control chart that is easier to see, which is displayed by the first display data, the following processing is performed. conduct.
- connection adjustment unit 223 reads out the setting information of the scale of the process axis of the work process control chart displayed by the first display data from the storage unit 230 and the compression rate of the interval of the time axis of the parallel processes. Multiply the scale of the process axis of the work process control chart displayed by the display data of, that is, the interval of the time axis of the work process control chart displayed by the first display data by the compression ratio of the time axis interval of the parallel process to calculate the interval of the time axis for the parallel process.
- connection adjustment unit 223 changes the scale of the process axis of the work process control chart displayed by the first display data to the interval of the time axis for the parallel process only for the section corresponding to the parallel process, A process axis of the work process control chart displayed by the second display data is generated by compressing only the section corresponding to the parallel process on the process axis.
- the connection adjustment unit 223 adjusts each work time line on the work process control chart displayed by the first display data according to the scale of the process axis of the work process control chart displayed by the second display data. is translated in the direction of the process axis. For example, in the case of FIG. 14, work time lines 63, 72 and 73 are translated.
- connection adjustment unit 223 adjusts the connection relationship between each work time line on the work process control chart displayed by the first display data and each transportation time line in accordance with each work time line after the parallel movement. Each transport time line is rewired so as to maintain the second display data.
- the connection adjustment unit 223 stores the generated second display data in the storage unit 230 .
- the interval of the time axis for parallel processes can be freely set according to the preferences of the manager so that the work process control chart is easy to see. For example, if you want to display the time axis of the parallel process of the work process control chart displayed by the first display data together, set the compression rate of the interval of the time axis of the parallel process to 0. , the time axes overlap and appear to be displayed on one time axis.
- FIG. 15 shows the work process control chart displayed by the first display data shown in FIG. It is an example of the work process control chart displayed by the second display data made easy to see.
- a work process control chart displayed by the second display data shown in FIG. is a work process control chart in which the intervals of the time axis t2b are narrowed.
- the transfer time line 6b between work process 2a and work process 3 and the transfer time line 7a between work process 1 and work process 2b are Compared to the gradients of the transfer time lines 6a and 7b between other work processes, the gradient appeared to be gentle, but the work process management displayed by the second display data as shown in FIG.
- the slopes of the transfer time line 6b' between the work processes 2a and 3 and the transfer time line 7a' between the work process 1 and the work process 2b are different from the transfer time lines 6a and 7a' between the other work processes. Since the slope is equivalent to that of 7b, an appropriate analysis can be performed when the manager identifies the cause of the production trouble from the characteristics of the work process control chart.
- Embodiment 3 even in the same work process, when there is subtle variation in the time required for production, so-called cycle time, the representation method of the work process control chart is adjusted so that the manager can easily recognize the variation in cycle time.
- a process control device that can be used will be described.
- the configuration of the process control apparatus according to the third embodiment is also the same as the configuration of the process control apparatus 200 according to the first embodiment, so the description is omitted.
- FIG. 16 is an example of a work process control chart displayed by the first display data generated by the same method as in the first embodiment for a manufacturing process composed of three work processes.
- FIG. 16 shows an example of a case where the cycle time of work process 1 has slight variations.
- the process control apparatus 200 according to the third embodiment adjusts the expression method of the work process control chart displayed by the first display data so that the variations in the cycle time can be easily grasped visually. display the second display data.
- request instruction information is input from the data input section to the effect of "change to a work process control chart that makes it easier to see variations in the cycle time of work process 1."
- the connection adjustment unit 223 analyzes the request instruction information and performs the following processing.
- connection adjustment unit 223 determines that the position of the first mark on the work time line 91 in work process 1 of product number SN0002 matches the position of the first mark on work time line 81 in work process 1 of product number SN0001.
- the work time line 91 in the work process 1 of the product number SN0002 is translated in the direction of the time axis so as to do.
- the connection adjustment unit 223 also adjusts the work time lines 92 and 93 of the other work processes of the product number SN0002 by the time obtained by translating the work time line 91 of the work process 1 of the product number SN0002 in the direction of the time axis. is translated in the direction of the time axis.
- the wire connection adjustment unit 223 also adjusts the transport time lines 9a and 9b of the product number 2 by the amount of time obtained by translating the work time line 91 in the work process 1 of the product number SN0002 in the time axis direction. direction.
- the connection adjusting unit 223 similarly processes the remaining product numbers. As a result, the connection adjusting section 223 generates the second display data shown in FIG.
- each work time line and each transfer time line are moved in parallel so as to match the position of the first mark of the work time line 81 in work process 1 of product number SN0001.
- Each work time line and each transfer time line may be translated so as to match the position of the first mark of the work time line in work process 1 of the product number.
- connection adjustment unit 223 requests a change to a work process control chart that makes it easier to see variations in the cycle time of a specific work process among the work processes of the work process control chart displayed by the first display data.
- the request instruction information is input, first, among the work time lines and the transfer time lines on the work process control chart displayed by the first display data, the specific work process specified by the request instruction information
- Each work time line in a specific work process designated by the request instruction information is translated in the direction of the time axis so that the positions of the first marks of each work time line match.
- each work time line in the specific work process specified by the request instruction information is related to each work time line in the specific work process specified by the request instruction information by the same amount of time obtained by translating each work time line in the specific work process specified by the request instruction information in the direction of the time axis.
- each other work time line and each transportation time line are translated in the direction of the time axis to generate second display data. That is, in the specific work process specified by the request instruction information, each work time line translated in the direction of the time axis, each other work time line related to the same product number, and each transportation time line are requested.
- Second display data is generated by translating each work time line in the specific work process specified by the instruction information in the direction of the time axis by the same amount of time as the time line is translated in the direction of the time axis.
- connection adjustment unit 223 performs each work in a specific work process specified by the request instruction information.
- Each connection line group on the work process control chart displayed by the first display data is translated in the direction of the time axis so that the positions of the first marks on the time line match, and the second display data In other words, it generates
- the process control apparatus 200 superimposes and displays a plurality of groups of connection lines so that the positions of the first marks of the work time lines of the designated work processes match. Since variations in the cycle time can be made visible visually, the administrator can easily grasp the variations.
- Embodiment 4 a process control apparatus capable of visualizing the production status for each product type when multiple types of products are mixed and produced will be described.
- the configuration of the process control apparatus according to the fourth embodiment is also the same as the configuration of the process control apparatus 200 according to the first embodiment, so description thereof will be omitted.
- FIG. 18 shows an example of a work process control chart based on the first display data generated by visualizing the production situation when multiple types of products are mixed in the same way as in the first embodiment.
- the connection groups with product numbers SN0001 and SN0002 show the production status when products of product type A were produced
- the connection groups with product numbers SN0003 and SN0004 show the production status when products of product type B were produced.
- the connection group with the product number SN0005 shows the production status when the product of the product type C is produced.
- FIG. 19 shows an example of operation data used by the process control device 200 according to the fourth embodiment.
- Product type information is added to the operation data shown in FIG. 19 for each product number.
- the connection generation unit 222 when product type information is added to each of a plurality of products, the connection generation unit 222 generates the work time line and the transportation time line by selecting the product type The format of the working time line and the format of the transportation time line are changed based on the information, and first display data is generated according to the changed format of the working time line and the format of the transportation time line. That is, based on the product type information, the connection generation unit 222 generates work time lines that are set in advance so that work time lines corresponding to the same type and work time lines corresponding to different types have different formats.
- connection generation unit 222 changes the format of the preset transport time lines so that the transport time lines corresponding to the same type and the transport time lines corresponding to different types have different formats. Then, the connection generation unit 222 generates the first display data according to the changed working time line format and transport time line format.
- FIG. 20 shows a work process control chart displayed by the first display data generated by the connection generation unit 222 through such processing.
- the format of the first mark of the work time line is changed from ⁇ to ⁇ , and the transportation time line is one point.
- the format is changed from dashed lines to dotted lines.
- the format of the first mark of the working time line is changed from ⁇ to ⁇ , and the format of the transportation time line is changed from the one-dot chain line to the solid line.
- the work process control chart displayed by the first display data shown in FIG. 20 is an example, and for example, the color scheme of the work time line and the transportation time line may be changed.
- the second display data can be generated from the first display data by a method similar to that described in the above embodiments.
- Embodiment 5 the process control apparatus that displays the work process control chart that visualizes the results of the production status performed in the past has been described.
- a process control apparatus capable of predicting and displaying a visualized work process control chart of the production status after the time when the operation data is acquired from each production facility will be described.
- the process control apparatus according to the fifth embodiment acquires operation data from each production equipment for the production status of the plurality of products when all the products manufactured in each work process are of the same type. Visualize it with a work process control chart, including after the time you set it. The description of the same parts as in the first embodiment will be omitted, and the parts different from the first embodiment will be described.
- FIG. 21 is a diagram showing the configuration of a process control device 200A according to the fifth embodiment.
- the configuration of the process control apparatus 200A according to the fifth embodiment is the same as the configuration of the process control apparatus 200 according to the first embodiment, and the predicted value of the operation data after the time when the operation data is acquired from each production facility (hereinafter referred to as "predicted operation data”) is added.
- the predicted operation data creation unit 225 stores the data in the storage unit 230. Analyze the work time and production waiting time in each work process from the stored operation data, and predict operation based on the analyzed work time, production waiting time, and the number of units in the pre-instructed production plan in each work process Create data.
- the predicted operation data creation unit 225 first obtains an analysis value of the working time in each work process and an analysis value of the production waiting time from the operation data acquired from each production facility so far. Calculate The analysis value of work time and the analysis value of production waiting time are, for example, a population of multiple work time data and multiple production waiting time data extracted from the operation data acquired from each production facility so far. From the distribution state, it is also possible to calculate the analysis value of the work time and the analysis value of the production waiting time.
- the predicted operation data creation unit 225 acquires operation data from each production equipment based on the analyzed value of the working time and the analyzed value of the production waiting time in each work process, and the number of units in the production plan instructed in advance.
- a predicted work start time and a predicted work end time are calculated for each work process after that time to create predicted operation data. Specifically, by sequentially accumulating the analysis values of working time and production waiting time for each work process on the operation data acquired from each production equipment so far, the number of units in the production plan is accumulated.
- Predicted operation data is created by calculating the predicted value of the work start time and the predicted value of the work end time in each work process after the time when the operation data is acquired from the equipment.
- the predicted operation data creation unit 225 analyzes the tendency of work time and production waiting time in each work process from the operation data acquired from each production equipment so far, and finds the tendency of work time and production waiting time to be delayed. If it is found, add the delay time as a correction value when calculating the predicted value of the work start time and the predicted value of the work end time in each work process after the time when the operation data was acquired from each production equipment , the predicted operation data may be created.
- the predicted operation data creating unit 225 stores the predicted operation data in the storage unit 230 .
- the wire connection placement unit 221 receives each production up to the present. Connection arrangement data is generated based on operation data obtained by adding predicted operation data to operation data acquired from equipment. After that, the first display data or the second display data is generated by a method similar to that of the first embodiment.
- the connection generation unit 222 performs the work before and after the time desired by the administrator, such as the current time when the operation data is acquired from each production facility or the scheduled time. By changing the formats of the time line and the transportation time line, the production status may be displayed so that the manager can easily grasp it.
- FIG. 22 shows an example of a work process control chart displayed by the first display data generated by the process control device 200A through such processing. From the work process control chart shown in FIG. 22, the manager can predict how many products will be produced by the appointed time, or the scheduled end time when the number of production plans instructed in advance will be completed.
- the process control device 200A in this embodiment can predict and display the production status after the current time based on the operation data acquired from each production facility up to now. , it is possible to determine the necessity of overtime work or holiday work at an early stage.
- the configuration shown in the above embodiment shows an example of the content of the present disclosure, and can be combined with another known technology, and the configuration can be changed without departing from the gist of the present disclosure. It is also possible to omit or change a part.
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Abstract
Description
図1は、本開示の実施形態1における工程管理装置を含む工程管理システムの全体構成を示した図である。工程管理システムは、データ収集装置300と、工程管理装置200と、複数の生産設備400と、を備える。一つの製品の製造工程は、複数の作業工程を組合せて構成されており、各作業工程は、それぞれ対応する生産設備400が担っている。データ収集装置300は、製品の製造において、各作業工程を担う各生産設備400から稼働データを収集し、収集した稼働データを工程管理装置200に送信する。稼働データは、本実施の形態では、一例として各作業工程において対応する生産設備400が製品毎に製造を開始した時刻である作業開始時刻、及び製造を終了した時刻である作業終了時刻を示すが、これに限らず、生産管理に利用可能なデータであれば良い。すなわち、「作業開始時刻」は、各作業工程において製品毎に作業が開始された時刻であり、また、「作業終了時刻」は、各作業工程において製品毎に作業が終了した時刻である。工程管理装置200は、取得した稼働データを、特定の表現方法に従って加工した表示データを表示する。
ある作業工程において、作業時間線間隔が全て必要以上に広くなっている場合は、当該作業工程の前後の作業工程において、対応する生産設備の生産能力が生産計画に対して不足している可能性を示唆している。
同一作業工程間内にある複数の搬送時間線のうち、ある製品に関する搬送時間線の傾きが、他の製品に関する搬送時間線の傾きより大きい場合は、作業工程間の搬送トラブルが発生している可能性を示唆している。
同一作業工程の時間軸上において、ある製品に関する作業時間線が、他の製品に関する作業時間線より長い場合は、当該作業工程において、当該製品に対する作業を行ったときに生産トラブルが発生していた可能性を示唆している。
θ=arccosX ・・・(1)
次に、結線配置部221は、step1で抽出した情報に基づいて、第一の表示データ用に指定された表示エリアに第一の表示データを表示した際に、第一の表示データが第一の表示データ用に指定された表示エリアに収まるように第一の表示データによって表示される作業工程管理図の座標系を生成する(step2)。
次に、出力部は、step5までの処理によって生成された第一の表示データを作業工程管理図の出力用表示データとして表示部210へ出力する(step6)。
実施の形態2では、製造工程に同一作業内容を並列に行う並列工程を含んでいる場合でも、作業工程管理図の表現方法を調整して、管理者が生産状況を認識しやすくすることができる工程管理装置について説明する。実施の形態2にかかる工程管理装置の構成も、実施の形態1の工程管理装置200の構成と同様のため、説明を省略する。
実施の形態3では、同一作業工程でも生産に掛かる時間、いわゆるサイクルタイムの微妙なバラツキがある場合に、作業工程管理図の表現方法を調整して、管理者がサイクルタイムのバラツキを認識しやすくすることができる工程管理装置について説明する。実施の形態3にかかる工程管理装置の構成も、実施の形態1の工程管理装置200の構成と同様のため、説明を省略する。
実施の形態4では、複数種類の製品を混在して生産するような場合、製品の種類ごとに生産状況を可視化することができる工程管理装置について説明する。実施の形態4にかかる工程管理装置の構成も、実施の形態1の工程管理装置200の構成と同様のため、説明を省略する。
実施の形態1~4では、過去に行われた生産状況の実績を可視化した作業工程管理図を表示する工程管理装置について説明したが、実施の形態5では、全て同一種別の製品を各作業工程で繰り返して製造する場合に、各生産設備から稼働データを取得した時刻以降の生産状況を予測して可視化した作業工程管理図を表示することができる工程管理装置について説明する。すなわち、実施の形態5に係る工程管理装置は、各作業工程で製造される複数の製品が全て同一種別の製品の場合において、当該複数の製品の生産状況を、各生産設備から稼働データを取得した時刻以降も含めて、作業工程管理図で視覚化する。実施の形態1と同じ部分については説明を省略し、実施の形態1と異なる部分について説明する。
Claims (9)
- 複数の作業工程により製造される複数の製品の生産状況を、各作業工程の作業時間を示す時間軸と、作業工程の変化を示す工程軸との2つの座標系で構成された作業工程管理図で視覚化する工程管理装置であって、
前記各作業工程に対応する各生産設備の稼働データ、及び管理者の要求指示情報を含む、各種取得情報を入力するデータ入力部と、
前記稼働データに基づいて、長さによって前記各作業工程における作業時間を示す作業時間線と、傾きによって各搬送工程における搬送時間を示す搬送時間線とを、前記作業工程管理図上に配置した、基準となる作業工程管理図の表示データである第一の表示データを出力用表示データとして出力し、前記データ入力部から、前記第一の表示データに対する前記要求指示情報が入力された場合、前記第一の表示データによって視覚化された生産状況を、前記要求指示情報に基づいて、前記第一の表示データによって表示される作業工程管理図の表現方法とは異なる作業工程管理図の表現方法で視覚化した作業工程管理図の表示データである第二の表示データを前記出力用表示データとして出力する制御部と、
前記出力用表示データを表示する表示部と、
を備えたことを特徴とする工程管理装置。 - 前記制御部は、
前記稼働データから、前記各作業工程において製品毎に作業が開始された時刻である作業開始時刻及び作業が終了した時刻である作業終了時刻を抽出し、前記作業工程管理図上の対応する座標位置に、前記各作業工程での前記作業開始時刻を表す第一の印と前記作業終了時刻を表す第二の印を配置した表示データである結線配置データを生成する結線配置部と、
前記結線配置データに基づいて、前記複数の製品それぞれについて、前記複数の作業工程のうちの第一の作業工程と当該第一の作業工程に後続する第二の作業工程のそれぞれの時間軸上に配置された、一の製品についての前記第一の印と前記第二の印とを結線して前記作業時間線を生成し、前記一の製品についての、前記第一の作業工程での前記第二の印と、前記第二の作業工程での前記第一の印とを結線して前記搬送時間線を生成して、前記第一の表示データを生成する結線生成部と、
前記データ入力部から、前記第一の表示データに対する前記要求指示情報が入力された場合、前記第一の表示データによって表示される作業工程管理図の表現方法を、前記要求指示情報に応じて調整して、前記第二の表示データを生成する結線調整部と、
前記データ入力部から、前記第一の表示データに対する前記要求指示情報が入力されるまでは、前記第一の表示データを前記出力用表示データとして出力し、前記データ入力部から、前記第一の表示データに対する前記要求指示情報が入力された場合、前記第二の表示データを前記出力用表示データとして出力する出力部と、
を備えたことを特徴とする請求項1に記載の工程管理装置。 - 前記出力部は、
前記第一の表示データ、又は前記第二の表示データによって表示される作業工程管理図から、生産状況の良否の判断指標となる特徴部分の特徴量を抽出し、前記特徴量毎に予め定められた許容値に基づいて、前記第一の表示データ、又は前記第二の表示データによって表示される作業工程管理図上の前記特徴部分に生産状況の把握を補助する識別表示を付加した作業工程管理図の表示データを前記出力用表示データとして出力する
ことを特徴とする請求項2に記載の工程管理装置。 - 前記結線調整部は、
前記データ入力部から、前記第一の表示データによって表示される作業工程管理図を時間軸方向に指定された圧縮率で圧縮した作業工程管理図への変更を要求する要求指示情報が入力された場合、前記第一の表示データによって表示される作業工程管理図の座標系を時間軸方向に前記圧縮率で圧縮して、前記第二の表示データによって表示される作業工程管理図の座標系を生成し、前記第一の表示データによって表示される作業工程管理図上の各作業時間線を、前記圧縮率に合わせて、同じ長さのまま工程軸方向に傾けた各傾斜作業時間線を生成し、前記各傾斜作業時間線の前記第一の印の位置が、前記第二の表示データによって表示される作業工程管理図の座標系の時間軸の目盛りで、前記各傾斜作業時間線に対応する各作業開始時刻となるように、前記各傾斜作業時間線を時間軸方向に平行移動させ、平行移動後の前記各傾斜作業時間線に合わせて、前記第一の表示データによって表示される作業工程管理図上の各作業時間線と各搬送時間線との接続関係を維持するように、各搬送時間線を再結線して、前記第二の表示データを生成する、
ことを特徴とする請求項2又は3に記載の工程管理装置。 - 前記結線調整部は、
前記複数の作業工程に、同一作業内容を並列に行う並列工程を含んでいて、前記データ入力部から、前記第一の表示データによって表示される作業工程管理図を見やすくした作業工程管理図への変更を要求する要求指示情報が入力された場合、前記第一の表示データによって表示される作業工程管理図の工程軸を、前記並列工程に対応する区間のみ圧縮して、前記第二の表示データによって表示される作業工程管理図の座標系を生成し、当該座標系に合わせて、前記第一の表示データによって表示される作業工程管理図上の各作業時間線を当該座標系の工程軸方向に平行移動させた後、当該各作業時間線に合わせて、前記第一の表示データによって表示される作業工程管理図上の各作業時間線と各搬送時間線との接続関係を維持するように、各搬送時間線を再結線して、前記第二の表示データを生成する、
ことを特徴とする請求項2又は3に記載の工程管理装置。 - 前記結線調整部は、
前記データ入力部から、前記第一の表示データによって表示される作業工程管理図の作業工程のうち、特定の作業工程のサイクルタイムのバラツキを見やすくした作業工程管理図への変更を要求する要求指示情報が入力された場合、前記第一の表示データによって表示される作業工程管理図上の各作業時間線と各搬送時間線のうち、前記特定の作業工程における各作業時間線の前記第一の印の位置が一致するように、前記特定の作業工程における各作業時間線を時間軸方向に平行移動させ、前記特定の作業工程における各作業時間線を時間軸方向に平行移動させた同じ時間分だけ、前記特定の作業工程における各作業時間線と関連する、他の各作業時間線、及び各搬送時間線を、時間軸方向に平行移動させて、前記第二の表示データを生成する、
ことを特徴とする請求項2又は3に記載の工程管理装置。 - 前記結線生成部は、
予め設定された前記作業時間線の書式、及び前記搬送時間線の書式に従って、前記作業時間線、及び前記搬送時間線を生成することを特徴とする請求項2から6のいずれか一つに記載の工程管理装置。 - 前記結線生成部は、
前記稼働データにおいて、前記複数の製品に対して、それぞれ製品の種別情報が付加されている場合、前記作業時間線、及び前記搬送時間線を生成する際に、前記製品の種別情報に基づいて前記作業時間線の書式、及び前記搬送時間線の書式を変更し、変更された前記作業時間線の書式、及び前記搬送時間線の書式に従って、前記第一の表示データを生成する、
ことを特徴とする請求項7に記載の工程管理装置。 - 前記複数の製品が全て同一種別の製品の場合、
前記稼働データから、各作業工程における作業時間、及び生産待ち時間を分析して各作業工程の作業時間の分析値、及び各作業工程の生産待ち時間の分析値を算出し、前記各作業工程の作業時間の分析値、前記各作業工程の生産待ち時間の分析値、及び予め指示された生産計画の台数に基づいて、前記稼働データを取得した時刻以降の稼働データの予測値である予測稼働データを作成する予測稼働データ作成部と、
を更に備え、
前記データ入力部から、前記稼働データを取得した時刻以降の生産状況を予測して可視化した作業工程管理図を要求する要求指示情報が入力された場合、
前記結線配置部は、
前記稼働データに前記予測稼働データを付加した稼働データに基づいて、前記結線配置データを生成する、
ことを特徴とする請求項2から7のいずれか一つに記載の工程管理装置。
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