WO2023037627A1 - 管理装置および管理方法 - Google Patents
管理装置および管理方法 Download PDFInfo
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- WO2023037627A1 WO2023037627A1 PCT/JP2022/013185 JP2022013185W WO2023037627A1 WO 2023037627 A1 WO2023037627 A1 WO 2023037627A1 JP 2022013185 W JP2022013185 W JP 2022013185W WO 2023037627 A1 WO2023037627 A1 WO 2023037627A1
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- 238000000034 method Methods 0.000 claims abstract description 157
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- 238000004519 manufacturing process Methods 0.000 claims abstract description 104
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- 238000003384 imaging method Methods 0.000 claims description 8
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- 239000000047 product Substances 0.000 description 153
- 238000010586 diagram Methods 0.000 description 29
- 238000007689 inspection Methods 0.000 description 16
- 239000002699 waste material Substances 0.000 description 16
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- 238000001514 detection method Methods 0.000 description 5
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- 229910000679 solder Inorganic materials 0.000 description 5
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- 238000011144 upstream manufacturing Methods 0.000 description 2
- 230000002238 attenuated effect Effects 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 238000011143 downstream manufacturing Methods 0.000 description 1
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- 238000010438 heat treatment Methods 0.000 description 1
- 238000009434 installation Methods 0.000 description 1
- 239000013067 intermediate product Substances 0.000 description 1
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- 238000013024 troubleshooting Methods 0.000 description 1
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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], computer integrated manufacturing [CIM]
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06Q—INFORMATION AND COMMUNICATION TECHNOLOGY [ICT] SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES; SYSTEMS OR METHODS SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES, NOT OTHERWISE PROVIDED FOR
- G06Q50/00—Systems or methods specially adapted for specific business sectors, e.g. utilities or tourism
- G06Q50/04—Manufacturing
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
- Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
Definitions
- the present disclosure relates to a management device and management method.
- Patent Document 1 manages the time for each work of a plurality of processes in order to discover such waste, and one axis is time and the other axis is a plurality of processes.
- a work management system is disclosed that displays a diagram on a coordinate plane of .
- Patent Literature 1 In the technology disclosed in Patent Literature 1, in order to discover waste from the diagram, the administrator needs to grasp the state of the diagram when there is no waste as preliminary knowledge, and compare the state with the current diagram. There is Therefore, there is a problem that a person without prior knowledge cannot easily find waste.
- the present disclosure has been made in view of the above problems, and its object is to provide a management device and a management method that assist even those who do not have prior knowledge to find work waste in a production line. is.
- the management device manages the operational status of a production line including multiple processes.
- the management device includes a first acquisition unit, a collection unit, an identification unit, and a calculation unit.
- the first acquisition unit acquires event information indicating occurrence of an event in the production line.
- the collection unit collects time information indicating the processing start time and the processing end time of each of the plurality of steps for each individual product to be processed in the plurality of steps.
- the identifying unit identifies a static bottleneck process among the plurality of processes based on the time information.
- the calculation unit calculates an expected completion time of processing by the production line for each individual product based on the end time of the static bottleneck process for each individual product in the period before the occurrence of the event.
- the manager can find wasteful work on the production line by comparing the expected completion time and the actual completion time of the production line for each individual product. In other words, the manager can discover wasteful work in the production line without prior knowledge.
- the management device includes a providing unit that provides a graph in which the first axis is time and the second axis is the order of introduction of individual products.
- the graph shows the processing time period of each of the multiple processes for each individual product.
- the manager can easily grasp the processing time period of each of the multiple processes for each individual product.
- the graph further includes a line indicating the expected completion time for each individual product.
- the line indicating the estimated completion time for each individual product is almost straight. Therefore, the administrator can easily grasp the expected completion time for each individual product.
- the graph includes marks corresponding to the process in which the event occurred and to the event in the processing time period including the time at which the event occurred.
- the administrator can easily identify the cause of the large time difference between the expected completion time and the actual production line processing end time.
- the calculation unit calculates the delay time, which is the difference between the expected completion time and the processing end time of the final process among the multiple processes.
- the manager can recognize that work is wasted when the delay time is long.
- the identifying unit calculates the production time per product for each of the plurality of processes based on the time information, and determines the static bottleneck process based on the production time per product. Identify.
- static bottleneck processes can be identified by considering the production time per product.
- the management device includes a second acquisition unit that acquires a first moving image from an imaging device that includes the action range of a worker on the production line in its field of view, and a time change of the position of each individual product based on time information. and a generating unit that generates a second moving image showing The providing unit provides a screen on which the first moving image and the second moving image are displayed in synchronization.
- the administrator can easily grasp the relationship between the position of the worker and the position of the individual product by checking the first moving image and the second moving image.
- a management method for managing the operational status of a production line including multiple processes includes first to fourth steps.
- the first step is to obtain event information indicating the occurrence of an event on the production line.
- the second step is a step of collecting time information indicating the processing start time and the processing end time of each of the plurality of steps for each individual product to be processed in the plurality of steps.
- the third step is to identify a static bottleneck process among the multiple processes based on the time information.
- the fourth step is a step of calculating the expected completion time of processing by the production line for each individual product based on the end time of the static bottleneck process for each individual product in the period before the occurrence of the event.
- FIG. 3 is a diagram showing an example of a single product to be processed by the production line shown in FIG. 2;
- FIG. 3 is a schematic diagram showing the hardware configuration of a management device;
- FIG. 4 is a diagram illustrating an example of operations performed to identify static bottleneck processes; It is a figure explaining the calculation method of the completion expected time.
- FIG. 4 shows an example of the information provision screen provided by the conventional management system. It is a figure which shows an example of the information provision screen provided in this Embodiment.
- FIG. 10 is a diagram showing an example of a selection screen for a playback time zone;
- FIG. 10 is a diagram showing another example of the information providing screen provided in the present embodiment;
- FIG. 10 is a diagram showing still another example of the information providing screen provided in the present embodiment;
- FIG. 1 is a diagram illustrating an example of a system to which a management device according to an embodiment is applied; As shown in FIG. 1, the system 1 includes a management device 100, a production line 200, a host system 300, a camera 400 that is an imaging device, a terminal 500, and a time synchronization server 600. A system 1 is provided at a production site such as a factory.
- the production line 200 includes a plurality of processes 210 that sequentially process the single product 2 and one or more transport devices 230 that transport the single product 2 between adjacent processes 210 .
- the single product 2 is an individual product and includes an intermediate product.
- the host system 300 has a database 310 in which information on the production line 200 is accumulated.
- the information accumulated in the database 310 is acquired from an input device, facilities of a plurality of processes 210 included in the production line 200, and a control device (for example, a programmable logic controller (PLC)) (not shown) that controls the facilities. .
- PLC programmable logic controller
- Information accumulated in the database 310 includes event information indicating occurrence of an event in the production line 200 .
- An event is an element in which the four points (4M) of Man, Machine, Material, and Method change. , troubleshooting of equipment, change of material or material manufacturer, change of manufacturing method, change of inspection method, etc.
- the event information indicates the type of event, the process in which the event occurred, the time when the event occurred, the start time and end time of the event, and the like.
- the event information indicates the occurrence time of an event that ends in a short time, such as a change of materials, and indicates the start time and completion time of the event, for an event that takes a long time, such as equipment repair.
- the information accumulated in the database 310 may include production record information.
- the production record information indicates the product type, lot number, input start time and input completion time of each lot, production quantity, input man-hours, throughput, and the like.
- the camera 400 is installed so as to include the action range of the worker on the production line 200 in its field of view, and images the field of view.
- the captured moving image is used to confirm the worker's flow line.
- the system 1 may include multiple cameras 400 .
- the management device 100 manages the operational status of the production line 200.
- the terminal 500 is, for example, a general-purpose computer device (laptop PC, tablet, smart phone, etc.), and is communicably connected to the management device 100 .
- the management device 100 provides the terminal 500 with information indicating the operation status of the production line 200 in response to a request from the terminal 500 .
- the time synchronization server 600 is placed on the Internet and manages absolute time.
- the management device 100 executes a management method including steps S1 to S4.
- step S ⁇ b>1 the management device 100 acquires (reads) event information indicating the occurrence of an event in the production line 200 from the database 310 of the host system 300 .
- step S2 the management device 100 collects time information indicating the processing start time and processing end time of each of the plurality of steps 210 for each individual product 2 to be processed in the plurality of steps 210.
- the management device 100 sends from each process 210 a signal indicating that the single product 2 has been carried in (hereinafter referred to as a "carrying-in signal”) and a signal indicating that the single product 2 has been carried out (hereinafter referred to as a "carrying-out signal"). (referred to as a "signal”) and
- the management device 100 acquires the time when the carry-in signal is received from the time synchronization server 600 as the processing start time.
- the management device 100 acquires the time when the unloading signal is received from the time synchronization server 600 as the processing end time.
- the management device 100 manages the time information indicating the processing start time and the processing end time thus acquired.
- steps S1 and S2 are not particularly limited.
- the management device 100 may execute step S1 each time an event occurs, or may execute step S1 at regular intervals (for example, one day). In this case, step S1 is executed after step S2.
- step S1 the management device 100 acquires event information regarding events that have occurred within a certain period of time.
- step S3 the management device 100 identifies the static bottleneck process among the multiple processes 210 based on the time information.
- a static bottleneck process is a process that controls the production efficiency of the production line 200 .
- a static bottleneck process is a process that constantly has the greatest impact on the pitch time of the entire production line 200 during regular process progress.
- the pitch time also called tact time, is the maximum value of the cycle time of each process.
- the cycle time is the work cycle time from the completion of the work for the single product 2 to the completion of the work for the next single product 2 .
- the process with the maximum cycle time is identified as the static bottleneck process.
- the static bottleneck process the process that minimizes the number of product units 2 output per unit time is specified.
- the bottleneck process also includes a dynamic bottleneck process.
- a dynamic bottleneck process is a process in which the processing capacity is attenuated due to the occurrence of an unexpected event, temporarily affecting the pitch time of the entire production line 200 .
- static bottleneck processes are identified instead of dynamic bottleneck processes.
- step S4 the management device 100 calculates the expected completion time of the processing by the production line 200 for each individual product 2 based on the end time of the static bottleneck process for each individual product 2 in the period before the occurrence of the event. calculate.
- the expected completion time is the time at which processing by the production line 200 will be completed assuming that no event occurs. Therefore, the manager can find wasteful work in the production line 200 by comparing the expected completion time and the actual completion time of the processing by the production line 200 for each individual product 2 . In other words, the manager can find waste in the work on the production line 200 without having prior knowledge of the state of the diagram when there is no waste.
- the production line 200 included in the system 1 is not limited to the line including the three processes 210 shown in FIG. 1, and can take various forms.
- FIG. 2 is a diagram showing an example of a production line applied to the system of this embodiment.
- FIG. 2 shows a production line 200A for surface mounting (SMT: Surface Mount Technology).
- FIG. 3 is a diagram showing an example of a single product to be processed by the production line shown in FIG.
- the single product 2 has a PCB board 5 and is also called an "Individual Piece".
- the electronic circuit 6 is mounted on the PCB board 5 by processing the single product 2 by the production line 200A.
- a two-dimensional code 3 indicating an individual ID for identifying a single product 2 is printed in advance on the PCB board 5 .
- the two-dimensional code 3 is printed at multiple locations, but the two-dimensional code 3 may be printed at only one location.
- a code reader which will be described later, may be installed at a position where one of the two two-dimensional codes 3 can be read. Therefore, the flexibility of the installation position of the code reader is increased.
- the production line 200A includes six processes 210a-210f.
- the product unit 2 is conveyed in order of steps 210a to 210f.
- steps 210a to 210f will be referred to as “step 210” unless the steps 210a to 210f are specifically distinguished.
- Each step 210 processes the single product 2 conveyed from the upstream side, and outputs the processed single product 2 to the downstream side.
- Equipment 220 is installed in each process 210 .
- the first step 210a is the printing step.
- a printer 220a is installed as equipment 220 in step 210a.
- the printer 220a receives the single product 2 from the loader 220g and applies cream solder to the PCB board 5. As shown in FIG.
- the single product 2 that has undergone the process of step 210a is transported to step 210b by the transport device 230a.
- the second step 210b is the print inspection step.
- a print inspection machine 220b is installed as equipment 220 in step 210b.
- the print inspection machine 220b inspects whether or not the shape of the cream solder is within a reference range based on an image obtained by imaging the PCB board 5 coated with cream solder, for example.
- the single product 2 that has undergone the process of step 210b is transported to step 210c by the transport device 230b.
- the third step 210c is the mounting step.
- a mounter 220c is installed as equipment 220 in step 210c.
- the mounter 220 c mounts electronic components on predetermined positions on the PCB board 5 .
- the single product 2 that has undergone the process of step 210c is transferred to step 210d by the transfer device 230c.
- the fourth process 210d is a mounting inspection process.
- a mounting inspection machine 220d is installed as equipment 220 in step 210d.
- the mounting inspection machine 220d inspects whether or not the position of the electronic component is within the reference range based on an image obtained by imaging the PCB board 5 on which the electronic component is mounted, for example.
- the single product 2 that has undergone the process of step 210d is transported to step 210e by the transport device 230d.
- a fifth step 210e is a reflow step.
- a reflow furnace 220e is installed as equipment 220 in step 210e.
- the reflow furnace 220e melts the cream solder by heating the PCB board 5 and solders the electronic components.
- the single product 2 that has undergone the process of step 210e is transported to step 210f by the transport device 230e.
- the sixth step 210f is a reflow inspection step.
- a reflow inspection machine 220f is installed as equipment 220 in the process 210f.
- the reflow inspection machine 220f inspects the presence or absence of soldering defects, for example, based on an image obtained by imaging the PCB board 5 to which electronic components are soldered.
- the single product 2 that has undergone the process of step 210f is transferred to the unloader 220h by the transfer device 230f.
- the unloader 220h unloads the single product 2 produced by the production line 200A to the outside.
- Each of the facilities 220 (printer 220a, print inspection machine 220b, mounting machine 220c, mounting inspection machine 220d, reflow furnace 220e, and reflow inspection machine 220f) installed in processes 210a to 210f has code readers 240, 242. .
- code readers 240, 242. In FIG. 2, only the code readers of the printing machine 220a installed in the process 210a are marked with the codes "240" and "242".
- the code reader 240 is placed near the entrance of the facility 220, reads the two-dimensional code 3 of the single product 2 put into the facility 220, and outputs a carry-in signal including the read individual ID.
- the carry-in signal is output to the management device 100 .
- the code reader 242 is placed near the exit of the facility 220, reads the two-dimensional code 3 of the single product 2 discharged from the facility 220, and outputs a carry-out signal including the read individual ID.
- the unloading signal is output to the management device 100 .
- FIG. 4 is a schematic diagram showing the hardware configuration of the management device.
- Management device 100 typically has a structure that conforms to a general-purpose computer architecture.
- the management device 100 includes a processor 101, a memory 102, a storage 103, and a communication interface 104.
- the processor 101 is composed of a CPU (Central Processing Unit), an MPU (Micro Processing Unit), and the like.
- the memory 102 is composed of, for example, a volatile storage device such as a DRAM (Dynamic Random Access Memory) or an SRAM (Static Random Access Memory).
- the storage 103 is configured by, for example, a non-volatile storage device such as an SSD (Solid State Drive) or HDD (Hard Disk Drive).
- the storage 103 stores a management program 110 for managing the operational status of the production line 200 .
- the communication interface 104 exchanges data with external devices (for example, equipment 220 of each process 210, host system 300, camera 400).
- FIG. 5 is a schematic diagram showing the functional configuration of the management device.
- the management device 100 includes a first acquisition unit 11, a collection unit 12, a second acquisition unit 13, a storage unit 14, an identification unit 15, a calculation unit 16, a work position detection A section 17 , a second moving image generation section 18 , and an information provision section 19 are provided.
- Storage unit 14 is implemented by memory 102 and storage 103 shown in FIG.
- First acquisition unit 11 , collection unit 12 and second acquisition unit 13 are implemented by communication interface 104 and processor 101 executing management program 110 .
- the identifying unit 15 , the calculating unit 16 , the work position detecting unit 17 , the second moving image generating unit 18 , and the information providing unit 19 are realized by the processor 101 executing the management program 110 .
- the first acquisition unit 11 acquires event information 21 indicating occurrence of an event in the production line 200 from the host system 300 . Furthermore, the first acquisition unit 11 also acquires the production record information 20 from the host system 300 . The first acquisition unit 11 stores the acquired production record information 20 and event information 21 in the storage unit 14 . The first acquisition unit 11 may acquire new production record information 20 and event information 21 from the host system 300 each time new production record information 20 and event information 21 are accumulated in the host system 300 . Alternatively, the first acquisition unit 11 may acquire from the host system 300 the production record information 20 and the event information 21 accumulated during the certain period of time (for example, one day) at regular intervals.
- the collection unit 12 collects time information 22 indicating the processing start time and processing end time of each of the plurality of steps 210 for each individual product 2 to be processed in the plurality of steps 210 .
- the collection unit 12 receives the carry-in signal and the carry-out signal from the facility 220 installed in each process 210 .
- the collection unit 12 acquires the time when the carry-in signal is received from the time synchronization server 600 as the processing start time.
- the collection unit 12 acquires from the time synchronization server 600 the time when the unloading signal is received as the processing end time.
- the collection unit 12 generates time information 22 indicating the processing start time and the processing end time for each individual product 2 for each process 210 and stores the generated time information 22 in the storage unit 14 . In this manner, the collection unit 12 collects the time information 22 for each individual product 2 for each process 210 .
- the time information 22 is information that associates a process ID that identifies the process 210 in which the equipment 220 is installed, an individual ID that identifies the individual product 2, a processing start time, and a processing end time.
- the collection unit 12 causes the time information 22 to include a process ID that identifies the process 210 including the equipment 220 that is the source of the carry-in signal and the carry-out signal.
- the collection unit 12 causes the time information 22 to include an individual ID (individual ID corresponding to the two-dimensional code 3 of the individual product 2) read from the carry-in signal and the carry-out signal.
- the second acquisition unit 13 acquires first moving image data (hereinafter simply referred to as "first moving image") 24 from the camera 400.
- the first moving image 24 is obtained by imaging with the camera 400 .
- the field of view of camera 400 includes the range of motion of workers on production line 200 . Therefore, the first moving image 24 shows a worker working on the production line 200 .
- the second acquiring unit 13 acquires the first moving image 24 in units of a predetermined period of time at predetermined time intervals (for example, in units of one minute).
- the second acquisition unit 13 stores the acquired first moving image 24 in the storage unit 14 .
- the first moving image 24 is stored in the storage unit 14 in association with the camera ID that identifies the camera 400 that captured the image.
- the identifying unit 15 identifies the static bottleneck process among the multiple processes 210 based on the time information 22 stored in the storage unit 14 .
- the identification unit 15 performs an operation for identifying a static bottleneck process.
- FIG. 6 is a diagram illustrating an example of computations performed to identify static bottleneck processes.
- the specifying unit 15 calculates the standard time of the process 210 based on the time information 22 acquired from the equipment 220 of each process 210 .
- the specifying unit 15 extracts the time information 22 including the process ID corresponding to the process 210 from the time information 22 stored in the storage unit 14 for each of the multiple processes 210 .
- the specifying unit 15 calculates the processing time from the processing start time to the processing end time for each of the extracted time information 22 .
- the identifying unit 15 creates a histogram of the calculated processing times, as shown in FIG. 6, and determines the median value as the standard time.
- the standard time is also called RPT (Raw Process Time) and corresponds to the standard processing time in step 210 .
- the identification unit 15 calculates the production time per product for each of the multiple processes 210 . Specifically, the specifying unit 15 stores in advance the number N of products that can be processed simultaneously for each process 210 . The specifying unit 15 calculates the time obtained by dividing the standard time by N as the production time per product.
- the identification unit 15 stores "p" as the number of products that can be processed at the same time for the process 210 in which p units of equipment 220 capable of processing only one single product 2 are installed.
- the specifying unit 15 stores "q" as the number of products that can be processed simultaneously for the process 210 in which only one facility 220 (for example, the reflow furnace 220e) capable of accommodating q pieces of individual products 2 at the same time is installed. are doing.
- the identifying unit 15 identifies the process with the longest production time per product as the static bottleneck process.
- the static bottleneck process may change for each product type or lot. Therefore, the specifying unit 15 may read out the introduction start time and the introduction completion time of each product type or each lot from the production record information 20 . Then, the identification unit 15 identifies the static bottleneck process in each product type or each lot based on the time information 22 including the individual IDs of the individual products 2 that have been loaded from the loading start time to the loading completion time. may
- the calculation unit 16 calculates the expected completion time of processing by the production line 200 for each individual product 2 based on the processing end time of the static bottleneck process for each individual product 2 in the period before the occurrence of the event. In the production line 200, processing is performed on a lot-by-lot basis. Therefore, the calculation unit 16 calculates the expected completion time for each individual product 2 for each lot.
- FIG. 7 is a diagram explaining a method of calculating the expected completion time.
- FIG. 7 shows an example where production line 200 includes three processes 210x, 210y, and 210z, with process 210y being the static bottleneck process.
- FIG. 7 shows a graph 30 in which the horizontal axis is the time and the vertical axis is the order in which the individual products 2 are introduced.
- a graph 30 shows processing time periods 31x, 31y, and 31z of steps 210x, 210y, and 210z for each single product 2, respectively.
- processing time zones 31 x, 31 y, and 31 z are defined by time information 22 .
- the calculator 16 identifies a period T before the occurrence time (or start time) of the first event indicated by the event information 21 .
- the calculation unit 16 calculates the number of individual products 2 for which the step 210y is completed per unit time in the period T (hereinafter referred to as "ideal processing speed"). Specifically, the calculation unit 16 obtains the approximate straight line 32 for the point 33 corresponding to the processing end time of the step 210y for each individual product 2 in the period T.
- FIG. The ideal processing speed corresponds to the slope of the approximate straight line 32 .
- the calculation unit 16 obtains a line 35 that passes through a point 34 corresponding to the processing end time of the final step 210 for the first single product 2 and that is parallel to the approximate straight line 32 .
- the calculation unit 16 calculates the delay time, which is the difference between the expected completion time and the processing end time of the final step 210 among the plurality of steps.
- Information indicating the standard time of each step 210 calculated by the identifying unit 15 and information indicating the expected completion time and delay time calculated by the calculating unit 16 are stored in the storage unit 14 as calculation result information 23.
- the work position detection unit 17 detects the worker's position (hereinafter referred to as "work position") for each time based on the first moving image 24. For example, the work position detection unit 17 uses a known object recognition technique to detect the area in which the worker appears in each frame of the first moving image 24 . The work position detection unit 17 determines, for example, the center of the circumscribed rectangle of the detected area as the work position. The work position detection unit 17 generates work position information 25 that associates the time of each frame with the work position detected from the frame, and stores the generated work position information 25 in the storage unit 14 .
- the second moving image generation unit 18 Based on the time information 22, the second moving image generation unit 18 generates a second moving image showing the temporal change of the position of each individual product 2 (hereinafter referred to as "product position").
- the second moving image is, for example, an animation in which marks corresponding to individual products 2 (hereinafter referred to as “product marks”) are superimposed on a model image of the production line 200 .
- the second moving image generator 18 extracts the time information 22 for each process 210 for each individual product 2 .
- the second moving image generator 18 determines the product position at the process start time as the entrance position of the process 210 and the product position at the process end time as the exit of the process 210 .
- the second moving image generator 18 determines the product position at each time from the process start time to the process end time, assuming that the process 210 moves at a constant speed from the entrance to the exit.
- the second moving image generation unit 18 assumes that each product unit 2 moves at a constant speed from the exit of the upstream process 210 of the two adjacent processes 210 to the entrance of the downstream process 210.
- the product position at each time from the processing end time of the process 210 on the downstream side to the processing start time of the process 210 on the downstream side is determined.
- the second moving image generation unit 18 generates the second moving image by superimposing the product mark on the position corresponding to the product position at that time on the model image of the production line 200 for each time frame of the second moving image.
- the second moving image generation unit 18 generates a second moving image 26 for each predetermined time (for example, every minute).
- the information providing unit 19 provides various types of information. Specifically, the information providing unit 19 provides the terminal 500 with an information providing screen generated from the information stored in the storage unit 14 in response to a request from the terminal 500 .
- the information providing screen includes, for example, the standard time and the expected completion time indicated by the calculation result information 23, the delay time that is the difference between the expected completion time and the actual processing end time of the final step 210, the first moving image 24, the second 2 moving image 26, the flow line of the worker generated from the work position information 25, and the like.
- FIG. 8 is a diagram showing an example of an information providing screen provided by a conventional management system.
- FIG. 8 shows an information providing screen 940 including a diagram with time on the horizontal axis and a plurality of processes on the vertical axis.
- Informational screen 940 shows a diagram corresponding to production line 200 including three processes. That is, the diagram shows a processing time slot 941 for the first step, a processing time slot 942 for the second step, and a processing time slot 942 for the third step. With such a diagram, it is difficult to indicate the expected completion time of the production line 200 for each individual product 2 when no event has occurred.
- the expected completion time is indicated in the diagram, it is conceivable to attach a plurality of dots corresponding to the expected completion times of the plurality of individual products 2 to the row corresponding to the final process. In this case, it is difficult for the administrator to grasp the correspondence relationship between each of the plurality of points and the plurality of single product units 2 that have been introduced. As a result, it becomes difficult for administrators to discover waste.
- a line 945 indicates the processing end time for each process of each individual product 2 . Waste on the production line is due to events that have occurred in the past. Therefore, the administrator follows the line 945 to identify the cause of waste. However, the line 945 will be drawn by the number of product units 2 . Therefore, it becomes difficult to identify a target line 945 from many lines 945 and trace the identified line 945 . As a result, it becomes difficult to identify the cause of waste. In particular, when multiple events occur, it becomes even more difficult to identify the cause of the waste.
- the administrator can easily identify the cause of waste by using the management device 100 according to the present embodiment.
- FIG. 9 is a diagram showing an example of an information providing screen provided in this embodiment.
- FIG. 9 shows an information providing screen 40 including a graph 30 in which the first axis (horizontal axis) is the time and the second axis (vertical axis) is the order of introduction of the individual products 2 .
- the graph 30 shows processing time periods 41h to 41k from the processing start time to the processing end time of the four processes for each single product 2.
- the information provision screen 40 shown in FIG. 9 is displayed for the target lot.
- the information providing unit 19 Based on the event information 21, the information providing unit 19 identifies the process in which each event occurred and the time of occurrence or end of each event (hereinafter referred to as "event time"). The information providing unit 19 determines a processing time period that corresponds to the identified process and includes the identified event time. The information providing unit 19 displays a mark 42 (including marks 42 a and 42 b ) indicating occurrence of an event in the determined processing time period in the graph 30 of the information providing screen 40 . That is, the graph 30 includes a mark 42 corresponding to the process in which the event occurred and to the event in the processing time period including the time at which the event occurred.
- the information providing unit 19 includes in the graph 30 of the information providing screen 40 a straight line 44 that connects the points 43 corresponding to the estimated completion times of the individual products 2 . That is, the graph 30 includes a straight line 44 indicating the expected completion time for each individual product 2 . Furthermore, the information providing unit 19 includes a line 46 that connects the points 45 corresponding to the processing end time of the final process of each individual product 2 in the graph 30 . The information providing unit 19 includes in the graph 30 an arrow 47 indicating the delay time, which is the difference between the expected completion time and the processing end time of the final process, for the individual product 2 that was put in last in the target lot.
- the manager can grasp the delay time in the target lot. Further, by confirming the time difference between the straight line 44 and the line 46, the administrator can easily grasp which single product 2 out of the multiple single products 2 included in the target lot has been wasted in processing. .
- the administrator confirms that the time difference between the straight line 44 and the line 46 is large for the single product 2 corresponding to the processing time zone including the mark 42a, compared to the single product 2 put in immediately before. As a result, the administrator can guess that the cause of the time difference 48a is the event corresponding to the mark 42a.
- the administrator can confirm that the time between the straight line 44 and the line 46 matches the time difference 48a for the single product 2 that was introduced after the single product 2 corresponding to the mark 42a. As a result, the administrator can understand that the influence of the event corresponding to the mark 42a is maintained even in the single product 2 processed after the occurrence of the event.
- the administrator confirms that the time difference between the straight line 44 and the line 46 is large for the single product 2 corresponding to the processing time zone including the mark 42b, compared to the single product 2 put in immediately before. As a result, the administrator can guess that the cause of the time difference 48b is the event corresponding to the mark 42b.
- the administrator can confirm that the time between the straight line 44 and the line 46 matches the time difference 48b for the single product 2 that was introduced after the single product 2 corresponding to the mark 42b. As a result, the administrator can understand that the influence of the event corresponding to the mark 42b is maintained even in the single product 2 processed after the occurrence of the event.
- the administrator can identify the two events corresponding to the marks 42a and 42b as the cause of the delay time indicated by the arrow 47.
- the information providing screen 40 shown in FIG. 9 accepts an operation for instructing video playback. For example, when the mark 42 is clicked, the information providing unit 19 provides a selection screen for the playback time zone.
- FIG. 10 is a diagram showing an example of a playback time zone selection screen.
- the selection screen 70 includes an input field 71 for designating the production line 200 , input fields 72 and 73 for selecting the video time period, and an input field 74 for selecting the camera 400 .
- the administrator inputs necessary items in the input fields 71 to 74 according to the production line 200, the time zone and the camera 400 for which he/she wants to check the moving image.
- the selection screen 70 includes radio buttons 75a to 75c and a play button 76.
- the radio button 75a is selected when the first moving image 24 is desired to be reproduced.
- the radio button 75b is selected when the first moving image 24 and the second moving image 26 are desired to be reproduced.
- the radio button 75c is selected when the worker's flow line is desired to be displayed.
- the information providing unit 19 provides an information providing screen according to the selection of the radio buttons 75a to 75c in response to the reproduction button 76 being clicked.
- the information providing unit 19 creates a moving image for playback in response to clicking the playback button 76 .
- the information providing unit 19 stores one or more first moving images 24 corresponding to the camera ID of the camera 400 input in the input field 74 and included in the playback time period input in the input fields 72 and 73.
- the one or more first moving images 24 are read out from the unit 14 and connected.
- the information providing unit 19 reads one or more second moving images 26 included in the reproduction time period from the storage unit 14 and connects the one or more second moving images 26 .
- FIG. 11 is a diagram showing another example of the information providing screen provided in this embodiment.
- FIG. 10 shows an information providing screen 50 provided when the play button 76 is clicked while the radio button 75b is selected on the selection screen 70 shown in FIG.
- the information provision screen 50 includes areas 51 and 52, a play button 53, a scroll bar 54, a speed change button 56, and a download button 57.
- the information provision unit 19 synchronizes the first video 24 and the second video 26 and displays them on the information provision screen 50 in response to the playback button 53 being clicked. Specifically, the first moving image 24 is displayed in the area 51 and the second moving image 26 is displayed in the area 52 .
- a worker 58 is shown in the first moving image 24 .
- the second moving image 26 also includes product marks 59 at the positions of the individual products 2 .
- the product mark 59 is displayed at the position of the single product 2 housed in the equipment 220 . Therefore, by checking the areas 51 and 52, the manager can easily grasp the relationship between the position of the worker 58 and the position of each individual product 2 at each time.
- the display form of the product mark 59 is preferably different for each lot of the single product 2. This allows the administrator to grasp the lot change.
- the product mark 59b indicates the product position of the lot that is input next to the lot of the single product 2 corresponding to the product mark 59a.
- the administrator when the administrator identifies the event that causes the delay time on the information providing screen 40 shown in FIG. 9, the administrator confirms the first moving image 24 and the second moving image 26 in the time period including the occurrence time of the event. As a result, the manager can confirm whether or not the work situation was appropriate when the event occurred.
- the manager determines that the video of the worker with short delay time is ideal work and Videos may be used to educate workers with long lag times.
- An appropriate relationship between the position of the product unit 2 and the position of the worker can be grasped by checking the video of the worker whose delay time is short. A worker with a long delay time can learn an appropriate position for himself according to the position of the single product 2 based on this relationship.
- the manager can grasp the relationship between the worker's work position and the product position due to lot changes.
- the manager can use the information providing screen 50 shown in FIG. 10 for education of work at the time of lot change.
- a worker who takes a long time to change a lot can check the videos of other workers to find the appropriate position of the product in the lot before the change, the product position in the lot after the change, and the worker's position. It can understand the relationship and learn its own appropriate position according to the product position of each lot.
- the information providing unit 19 changes the frames displayed in the areas 51 and 52 according to the operation of the scroll bar 54 on the cursor 54a.
- the information providing section 19 changes the playback speed according to the operation of the speed change button 56 . Accordingly, by appropriately operating the scroll bar 54 and the speed change button 56, the administrator can check the details of the first moving image 24 and the second moving image 26 for a desired time period.
- the information providing unit 19 saves the files indicating the first moving image 24 and the second moving image 26 to be reproduced in the specified folder of the terminal 500 .
- the administrator can confirm the first moving image 24 and the second moving image 26 using the files saved (downloaded) in the designated folder of the terminal 500 without accessing the management device 100 .
- the files downloaded to the terminal 500 include a video in which one or more first videos 24 included in the playback time period are linked, and a video in which one or more second videos 26 included in the playback time zone are linked. indicate.
- FIG. 12 is a diagram showing still another example of the information providing screen provided in this embodiment.
- the information providing screen 60 shown in FIG. 12 includes a table 61 showing changes in monthly production numbers for each product type.
- the manager identifies the product whose monthly production quantity is less than the planned quantity, and confirms the information provision screen 40 shown in FIG. 9 for the identified product.
- the administrator may check the effect of education using the information providing screen 50 shown in FIG. 11 on the information providing screen 60 shown in FIG.
- the information providing unit 19 may provide the terminal 500 with an information providing screen showing the standard time of each step 210.
- code readers 240 and 242 are installed in the equipment installed in step 210 .
- the code readers 240 and 242 may also be installed on the conveying device 230 between the adjacent processes 210 to manage the period during which the single product 2 is conveyed by the conveying device 230 .
- the specifying unit 15 calculates the production time per product by dividing the standard time by the number of products N that can be processed simultaneously.
- the method of calculating the production time per product is not limited to this.
- a process with a large variation in the histogram shown in FIG. 6 can be a static bottleneck process. Therefore, the production time per product may be calculated in consideration of the histogram variations. For example, the sum of the standard time and the time that is a predetermined coefficient times the standard deviation of the histogram is calculated, and the production time per product is calculated by dividing the sum by the number of products N that can be processed simultaneously. good.
- a management device (100) comprising a calculation unit (16) for calculating time.
- (Configuration 2) A providing unit (19) for providing a graph (30) having a first axis of time and a second axis of the order of introduction of the product unit (2), The management device (100) according to configuration 1, wherein the graph (30) indicates processing time periods (41h to 41k) of each of the plurality of steps (210) for each of the individual products (2).
- Composition 3 The management device (100) according to configuration 2, wherein the graph (30) further includes a line (44) indicating the expected completion time for each product (2).
- the graph (30) includes a mark (42) corresponding to the process in which the event occurred and the event in the processing time zone (41h to 41k) including the time at which the event occurred. 4.
- the management device (100) according to 2 or 3.
- composition 5 The management device according to any one of configurations 1 to 4, wherein the calculation unit (16) calculates a delay time that is a difference between the expected completion time and the processing end time of the final step among the plurality of steps. (100).
- composition 6 The specifying unit (15) calculating the production time per product for each of the plurality of processes based on the time information; 6.
- Composition 7 a second acquisition unit (13) that acquires a first moving image (24) from an imaging device (400) that includes in its field of view the action range of a worker on the production line (200); a generating unit (18) that generates a second moving image (26) showing a temporal change in the position of each individual product (2) based on the time information (22);
- the management device (100) according to Configuration 2, wherein the providing unit (19) provides a screen on which the first moving image (24) and the second moving image (26) are displayed in synchronization.
- a management method for managing the operation status of a production line (200) including a plurality of processes, obtaining event information indicating occurrence of an event in the production line (200); a step of collecting time information indicating the processing start time and processing end time of each of the plurality of steps (210) for each individual product (2) to be processed in the plurality of steps (210); identifying a static bottleneck process among the plurality of processes (210) based on the time information; Based on the end time of the static bottleneck process for each individual product (2) in the period before the occurrence of the event, calculate the expected completion time of processing by the production line (200) for each individual product.
- a management method comprising:
Abstract
Description
本実施の形態に係る管理装置が適用されるシステムの概略について説明する。図1は、実施の形態に係る管理装置が適用されるシステムの一例を示す図である。図1に示されるように、システム1は、管理装置100と、生産ライン200と、上位システム300と、撮像装置であるカメラ400と、端末500と、時刻同期サーバ600と、を備える。システム1は、工場等の生産現場に設けられる。
<生産ラインの例>
システム1に含まれる生産ライン200は、図1に示される3つの工程210を含むラインに限定されず、様々な形態を取りうる。
図4は、管理装置のハードウェア構成を示す模式図である。管理装置100は、典型的には、汎用的なコンピュータアーキテクチャに従う構造を有する。
図5は、管理装置の機能構成を示す模式図である。図5に示されるように、管理装置100は、第1取得部11と、収集部12と、第2取得部13と、記憶部14と、特定部15と、算出部16と、作業位置検出部17と、第2動画生成部18と、情報提供部19と、を備える。記憶部14は、図4に示すメモリ102およびストレージ103によって実現される。第1取得部11、収集部12および第2取得部13は、通信インターフェイス104と管理プログラム110を実行するプロセッサ101とによって実現される。特定部15、算出部16、作業位置検出部17、第2動画生成部18、および情報提供部19は、管理プログラム110を実行するプロセッサ101によって実現される。
図8は、従来の管理システムによって提供される情報提供画面の一例を示す図である。図8には、横軸を時刻、縦軸を複数の工程とするダイヤグラムを含む情報提供画面940が示される。情報提供画面940は、3つの工程を含む生産ライン200に対応するダイヤグラムを示す。すなわち、ダイヤグラムは、1番目の工程の処理時間帯941、2番目の工程の処理時間帯942、3番目の工程の処理時間帯942を示す。このようなダイヤグラムでは、イベントが発生していないときの、各製品単体2の生産ライン200の完了予想時刻を示すことが難しくなる。仮にダイヤグラムにおいて完了予想時刻を示す場合、最終工程に対応する行に複数の製品単体2の完了予想時刻にそれぞれ対応する複数の点を付すことが考えられる。この場合、管理者は、複数の点の各々と投入された複数の製品単体2との対応関係を把握することが難しい。その結果、管理者は、無駄を発見することが難しくなる。
上記の説明では、工程210に設置される設備にコードリーダ240,242が設置される。これに加えて、隣り合う工程210間の搬送装置230にもコードリーダ240,242が設置され、製品単体2が搬送装置230で搬送されている期間が管理されてもよい。
以上のように、本実施の形態は以下のような開示を含む。
複数の工程(210)を含む生産ライン(200)の稼働状況を管理する管理装置(100)であって、
前記生産ライン(200)におけるイベントの発生を示すイベント情報(21)を取得する第1取得部(11)と、
前記複数の工程(210)の処理対象となる製品単体(2)ごとに、前記複数の工程(210)の各々の処理開始時刻および処理終了時刻を示す時刻情報(22)を収集する収集部(12)と、
前記時刻情報(22)に基づいて、前記複数の工程(210)のうちの静的ボトルネック工程を特定する特定部(15)と、
前記イベントの発生前の期間における、前記製品単体(2)ごとの前記静的ボトルネック工程の終了時刻に基づいて、前記製品単体(2)ごとに、前記生産ライン(200)による処理の完了予想時刻を算出する算出部(16)と、を備える管理装置(100)。
第1軸を時刻とし、第2軸を前記製品単体(2)の投入の順番とするグラフ(30)を提供する提供部(19)を備え、
前記グラフ(30)は、前記製品単体(2)ごとに、前記複数の工程(210)の各々の処理時間帯(41h~41k)を示す、構成1に記載の管理装置(100)。
前記グラフ(30)は、さらに、前記製品単体(2)ごとの前記完了予想時刻を示す線(44)を含む、構成2に記載の管理装置(100)。
前記グラフ(30)は、前記イベントの発生した工程に対応し、かつ、前記イベントの発生した時刻を含む前記処理時間帯(41h~41k)に前記イベントに対応するマーク(42)を含む、構成2または3に記載の管理装置(100)。
前記算出部(16)は、前記完了予想時刻と前記複数の工程のうちの最終工程の前記処理終了時刻との差である遅れ時間を算出する、構成1から4のいずれかに記載の管理装置(100)。
前記特定部(15)は、
前記時刻情報に基づいて、前記複数の工程の各々について、製品1個当たりの生産時間を算出し、
前記製品1個当たりの生産時間に基づいて、前記静的ボトルネック工程を特定する、構成1から5のいずれかに記載の管理装置(100)。
前記生産ライン(200)の作業者の行動範囲を視野に含む撮像装置(400)から第1動画(24)を取得する第2取得部(13)と、
前記時刻情報(22)に基づいて、前記製品単体(2)ごとの位置の時間変化を示す第2動画(26)を生成する生成部(18)と、をさらに備え、
前記提供部(19)は、前記第1動画(24)と前記第2動画(26)とが同期して表示される画面を提供する、構成2に記載の管理装置(100)。
複数の工程を含む生産ライン(200)の稼働状況を管理する管理方法であって、
前記生産ライン(200)におけるイベントの発生を示すイベント情報を取得するステップと、
前記複数の工程(210)の処理対象となる製品単体(2)ごとに、前記複数の工程(210)の各々の処理開始時刻および処理終了時刻を示す時刻情報を収集するステップと、
前記時刻情報に基づいて、前記複数の工程(210)のうちの静的ボトルネック工程を特定するステップと、
前記イベントの発生前の期間における、前記製品単体(2)ごとの前記静的ボトルネック工程の終了時刻に基づいて、前記製品単体ごとに、前記生産ライン(200)による処理の完了予想時刻を算出するステップと、を備える管理方法。
Claims (8)
- 複数の工程を含む生産ラインの稼働状況を管理する管理装置であって、
前記生産ラインにおけるイベントの発生を示すイベント情報を取得する第1取得部と、
前記複数の工程の処理対象となる製品単体ごとに、前記複数の工程の各々の処理開始時刻および処理終了時刻を示す時刻情報を収集する収集部と、
前記時刻情報に基づいて、前記複数の工程のうちの静的ボトルネック工程を特定する特定部と、
前記イベントの発生前の期間における、前記製品単体ごとの前記静的ボトルネック工程の終了時刻に基づいて、前記製品単体ごとに、前記生産ラインによる処理の完了予想時刻を算出する算出部と、を備える管理装置。 - 第1軸を時刻とし、第2軸を前記製品単体の投入の順番とするグラフを提供する提供部を備え、
前記グラフは、前記製品単体ごとに、前記複数の工程の各々の処理時間帯を示す、請求項1に記載の管理装置。 - 前記グラフは、さらに、前記製品単体ごとの前記完了予想時刻を示す線を含む、請求項2に記載の管理装置。
- 前記グラフは、前記イベントの発生した工程に対応し、かつ、前記イベントの発生した時刻を含む前記処理時間帯に前記イベントに対応するマークを含む、請求項2または3に記載の管理装置。
- 前記算出部は、前記完了予想時刻と前記複数の工程のうちの最終工程の前記処理終了時刻との差である遅れ時間を算出する、請求項1から4のいずれか1項に記載の管理装置。
- 前記特定部は、
前記時刻情報に基づいて、前記複数の工程の各々について、製品1個当たりの生産時間を算出し、
前記製品1個当たりの生産時間に基づいて、前記静的ボトルネック工程を特定する、請求項1から5のいずれか1項に記載の管理装置。 - 前記生産ラインの作業者の行動範囲を視野に含む撮像装置から第1動画を取得する第2取得部と、
前記時刻情報に基づいて、前記製品単体ごとの位置の時間変化を示す第2動画を生成する生成部と、をさらに備え、
前記提供部は、前記第1動画と前記第2動画とが同期して表示される画面を提供する、請求項2に記載の管理装置。 - 複数の工程を含む生産ラインの稼働状況を管理する管理方法であって、
前記生産ラインにおけるイベントの発生を示すイベント情報を取得するステップと、
前記複数の工程の処理対象となる製品単体ごとに、前記複数の工程の各々の処理開始時刻および処理終了時刻を示す時刻情報を収集するステップと、
前記時刻情報に基づいて、前記複数の工程のうちの静的ボトルネック工程を特定するステップと、
前記イベントの発生前の期間における、前記製品単体ごとの前記静的ボトルネック工程の終了時刻に基づいて、前記製品単体ごとに、前記生産ラインによる処理の完了予想時刻を算出するステップと、を備える管理方法。
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CN109034671A (zh) * | 2018-09-06 | 2018-12-18 | 深圳百胜扬工业电子商务平台发展有限公司 | 工厂产线目标产品生产时长确定方法及装置 |
CN110298578B (zh) * | 2019-06-24 | 2022-11-29 | 电子科技大学 | 一种混流生产线动态瓶颈预测方法 |
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2022
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Patent Citations (4)
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JP2010040007A (ja) | 2008-08-08 | 2010-02-18 | Hitachi Ltd | 作業管理システムおよび作業管理方法 |
JP2012208900A (ja) * | 2011-03-30 | 2012-10-25 | Mitsubishi Heavy Ind Ltd | 進捗表示装置、進捗表示方法および進捗表示プログラム |
JP2020027446A (ja) * | 2018-08-10 | 2020-02-20 | 川崎重工業株式会社 | 検証管理システム、検証管理方法及びプログラム |
JP2020106958A (ja) * | 2018-12-26 | 2020-07-09 | 株式会社日立製作所 | 生産計画立案支援装置及び方法 |
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TW202312048A (zh) | 2023-03-16 |
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