JP2004287635A - Production line operation status analysis device, operation status analysis method, operation status analysis program, and operation status analysis system - Google Patents

Abstract

An object of the present invention is to analyze an operation state of a production line based on a signal indicating a state of each step without requiring a dedicated circuit or a program for each step constituting a production line.
A production line operation status analysis system includes a production line, a production facility, a data collection device for collecting data on an operation state of the production line, a data storage server, and an operation status analysis device. 60. The operation state analysis device 60 has the functions of the data acquisition unit 100 and the operation state data calculation unit 150, and inputs desired operation state data to the operation state function to calculate desired operation state data. The operating state function can be arbitrarily configured by combining a plurality of operating states with an operator. Using the operation state function, the functions of the calculation modules below the actual production state calculation module 152 are executed.
[Selection diagram] FIG.

Description

[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to an operation status analysis device for a production line, and more particularly to an operation status analysis device that analyzes the operation status of a production line including a plurality of production facilities using data collected by a data collection device.
[0002]
[Prior art]
In order to continuously perform production according to a production plan in a production line including a plurality of processes, it is important to appropriately evaluate the operation state of each process and appropriately evaluate the operation of the entire production line. As means for determining the state of each process, there is a method of recording a signal of a PLC (Programmable Logic Controller) for controlling the operation of equipment constituting each process. However, it is not possible to accurately determine the state of the equipment by simply adding a circuit that outputs a signal indicating the state of each equipment to the PLC program in advance and analyzing the recorded signals independently, so that the regularity of the state transition is used. In this case, the state estimation accuracy is increased. For example, in Patent Document 1, a personal computer (Personal Computer: PC) is connected one-to-one to a sequence controller of a facility having a plurality of states, and the operation status of the facility is corresponded to the transition information grasped by the sequence controller. It is disclosed to sample and determine transitions between the resulting states.
[0003]
[Patent Document 1]
JP-A-7-104838
[0004]
[Problems to be solved by the invention]
As described above, adding a circuit that outputs a signal indicating the state of each process to the PLC program requires setting and confirming operation of each process in the field, and also requires checking each process. Since the addresses of the internal signals are different, it is necessary to create a dedicated program for each process facility in order to determine the state, which takes time and costs.
[0005]
Even if a circuit and a program are added for each process as described above, since these are dedicated to each process, the expandability and versatility of the system are poor. For example, since it is difficult to add circuits and programs by extending to multiple processes, it is possible to further advance from the operation status of each process to the overall status of multiple related processes or the operation status of the entire production line. Difficult to grasp.
[0006]
In addition, since the circuits and programs provided in each process are not versatile, the output signals are used only for a dedicated purpose, and a plurality of signals are arbitrarily combined to express different states, etc. It is not possible to grasp the actual operation status.
[0007]
SUMMARY OF THE INVENTION An object of the present invention is to solve the problems of the prior art and eliminate the need for a dedicated circuit or program for each process constituting a production line, and to analyze the operation status based on a signal representing the state of each process. It is an object of the present invention to provide an operation status analysis device, an operation status analysis method, an operation status analysis program, and an operation status analysis system. Another object is to provide a versatile production line operation status analysis device, operation status analysis method, operation status analysis program, and operation status analysis system that can analyze the operation status by arbitrarily combining a plurality of signals. is there. Still another object is to provide a production line operation status analysis device, operation status analysis method, operation status analysis program and operation status analysis system that can analyze the operation status over a plurality of processes without requiring a special circuit or program. To provide. The invention described in the following claims is provided to achieve at least one of the above objects.
[0008]
[Means for Solving the Problems]
1. Operation status function
First, the operating state function will be described. The operation state function is a function configured by connecting a plurality of operation states by an operator. ₁ , X ₂ , X ₃ As X ₁ , X ₂ , X ₃ Are connected by operators such as AND and OR. In one example, Y ₀ = [X ₁ ORX ₂ ] ANDX ₃ And so on.
[0009]
Operating state of production equipment, X in the above example ₁ , X ₂ , X ₃ Is obtained by collecting PLC signals. In addition to the operating state, why the operating state function Y ₀ Is necessary to calculate a new state because the operating state collected from the PLC or the like cannot often sufficiently represent the operating state that is the dynamic state of the equipment.
[0010]
For example, as one example, the operating state and operating state of one cylinder, which is a work element in a production facility, will be described. Now, if one wants to grasp the operating state that the cylinder is moving forward, the PLC sends the cylinder moving instruction signal X as the operating state of the cylinder. ₂₀ Is collected, and the value is determined to be 1 (forward instruction) or 0 (no forward instruction). By the way, the cylinder advance instruction signal X ₂₀ Is 1, it is not always the case that the cylinder is moving forward. This includes, for example, the case where the cylinder has not yet started moving forward. Therefore, in order to obtain the operating state of forward running, the cylinder forward end detection signal X ₂₁ Must be checked to make sure that the value is 0 (cylinder advance end not detected).
[0011]
In this case, two operating states X ₂₀ , X ₂₁ Can be determined independently to determine whether the cylinder is moving forward. ₂₀ And (NOTX ₂₁ ) Is linked with AND, and this function is referred to as the “in progress” operating state function Z ₁ And it is sufficient. "Advancing" operating state function Z ₁ Are two operating states X ₂₀ , X ₂₁ Are linked using the operator OR and NOT. Therefore, two operating states X at every moment ₂₀ , X ₂₁ By inputting the data of (1) and (2), it is calculated whether or not the condition is satisfied (there is an advance command) and (the cylinder forward end is not detected). can do.
[0012]
FIG. 1 is an example in which the relationship between the operating state of the cylinder and the operating state of the cylinder is represented by a ladder circuit diagram. Each operation state X ₂₀ , X ₂₁ , X ₂₂ , X ₂₃ Is indicated by a contact symbol, and the operating state function Z ₁ , Z ₂ Is indicated by a coil symbol. As shown in FIG. ₂₀ And cylinder advance end detection X ₂₁ "In progress" operating state function Z ₁ And the cylinder retraction instruction X ₂₂ And cylinder retraction end detection X ₂₃ "Retreating" operating state function Z ₂ Can be configured.
[0013]
FIG. 2 shows each operation state X. ₂₀ , X ₂₁ , X ₂₂ , X ₂₃ Is input to the operation state function in a time series, and the “in progress” operation state function Z ₁ Output data z ₁ And "retreating" operating state function Z ₂ Output data z ₂ FIG. 9 is a diagram showing an example of outputting a time chart. FIG. 2A shows an operation state of a standard cylinder, and FIG. 2A shows an example in which there is a problem in “retreating”. From these data, it is possible to extract the fact that there is a problem during “retreat” and to perform quantitative analysis such as “forward time” and “retreat time”.
[0014]
As described above, an arbitrary operating state function can be configured by combining a plurality of operating states by an operator. If a plurality of operating state data are input using the operating state function, it is not possible to grasp only the operating state data. The operating state data as a new state can be output.
[0015]
By configuring the function form of the operation state function according to the operation state analysis purpose, desired operation state data can be easily obtained. If a plurality of operation state data is input in a time series, the operation state data in a time series is output, so that more quantitative operation state data can be obtained.
[0016]
A plurality of operating states can be collected from the PLC signal of the production equipment, and the operating state function can be formed into any function form. Can be enhanced. In other words, there is no need to provide a dedicated circuit or a dedicated program for obtaining desired operating state data for each facility. Simply collecting operating state data and inputting the operating state data to the operating state function can provide a desired operating state. Data can be obtained.
[0017]
The operation state function may be a time management function in addition to the logical operation result of the digital data as described above. For example, in the case of FIG. 2, the cylinder retreat time t2 can be determined and output by a threshold function. In this example, if the threshold function is set to 2 sec <t2 <3 sec or the like, 0 can be output as the reverse time operating state data when the reverse time is not within this range.
[0018]
2. Problem solving means
The operation status analysis device according to the present invention is an operation status analysis device that analyzes the operation status of the production line based on operation status data indicating the operation status of each work element of the production line collected by the data collection device, Using a data acquisition means for acquiring a plurality of operation state data collected by the data collection device and an operation state function in which a plurality of operation states are combined by an operator, inputting a plurality of operation state data to the operation state function, Operating state data calculating means for calculating operating state data indicating the operating state of the line.
[0019]
With the above configuration, the operating state function described in “1. Operating state function” is used for calculating the operating state data. As the operation state data input to the operation state function, the operation state data of each work element of the production line is collected by the data collection device. As the operation state data of each work element of the production line, for example, a signal of a PLC provided for each process or a sensor signal can be used as it is. As described above, since the operation state function is composed of the operation state and the operator, an arbitrary function can be created by changing the type of the operation state or the type of the operator. Therefore, the operating state can be analyzed by arbitrarily combining a plurality of signals, and the versatility of the analysis system is high. Also, there is no need for a dedicated circuit or program for outputting a signal indicating the operating state.
[0020]
In addition, the operating state data calculating means inputs operating state data in a plurality of processes including the process and processes before and after the process to an operating state function in order to analyze the operating state of each process of the production line, and as operating state data. It is preferable to calculate process operation state data representing the operation state of each process.
[0021]
The plurality of operation states constituting the operation state function are not limited to only the plurality of operation states in the same process. With the above configuration, the operation state data in a plurality of steps including the step and the preceding and following steps is input to the operation state function, and the step operation state operation data of each step is calculated. The operation status function in this case is configured by combining operation statuses in a plurality of processes by an operator. Therefore, it is possible to analyze the operating state over a plurality of processes without requiring a special circuit or program.
[0022]
In addition, the operating state data calculating means may include, as the operating state of each process, an actual production state indicating actual production, an abnormal stop state indicating abnormal stop, a tool change state indicating tool change, or a quality check. Process operation in one of the following process operation states: a quality check state indicating medium, a post-process full state indicating a waste state in which the post-process work is jammed, or a pre-process empty state indicating a waste state in which there is no work in the previous process. Preferably, state data is calculated.
[0023]
Each process has a plurality of operating states. The operation state of each process can be classified into a plurality of operation states such as an actual production state, an abnormal stop state, a tool change state, a quality check state, a post-process full state, and a pre-process empty state. The operating state of each process can be quantitatively grasped by analyzing the ratio of each of these operating states to the whole. For example, it can be analyzed that a certain process has a high ratio in the actual production state and the operation status is good, and that another process has a high ratio in the abnormal stop state and is a bottleneck process.
[0024]
With the above-described configuration, for at least one of the plurality of process operation states, the operation state data in a plurality of steps including the step and the preceding and following steps is input to the operation state function and calculated. All of the plurality of process operation states may be calculated by an operation state function. By using the operation status function, the process operation status can be calculated only by inputting the operation status data of a plurality of processes including the process concerned and the process before and after, and dedicated to each process for outputting a signal indicating the operation status of the process. There is no need for a specific circuit or program or a special circuit or program that spans the process.
[0025]
Further, the operating state data calculating means may include a plurality of operation state data including the work presence / absence state data in the process, the work presence / absence state data in a process before the process, and the work presence / absence state data in a process after the process. It is preferable to calculate process operation data representing the actual production state of each process based on the process operation data.
[0026]
It is not sufficient to judge the actual production state only by grasping the state in which the work exists in the process. This is because even if there is a work in the process, even if the work is waiting for a full work in the post-process without receiving the actual work such as machining or assembly, This is because the case where the workpiece is made to wait in the previous process is not included. With the above configuration, the actual production state of the process is calculated based on the operation state data of the presence or absence of the work in the process and the processes before and after the process. Therefore, the actual production state data that is correctly obtained by the analysis over a plurality of processes can be calculated without using a special circuit or program.
[0027]
In addition, the operating state data calculating means may determine the full state of the post-process of each step based on a plurality of operation state data including the data indicating whether the work is completed in the relevant step and the data indicating whether the work is present in a subsequent step of the relevant step. It is preferable to calculate the process operation data to be represented.
[0028]
Regarding the full state of the post-process, it is not sufficient to judge that there is no use in the post-process just by grasping the state where the work exists in the post-process of the relevant process. This is because, even if there is a work in the post-process, no wasted time is provided if the process has not yet completed the actual work. With the above configuration, the post-process full state is calculated based on the operation state data in the process and the post-process. Therefore, the post-process full state data correctly obtained by the analysis over a plurality of processes can be calculated without using a special circuit or program.
[0029]
The operating state data calculating means may include a step of representing an empty state of the preceding process of each process based on a plurality of operating state data including the workpiece presence / absence status data in the process and the workpiece presence / absence status data in the preceding process of the process. It is preferable to calculate operation data.
[0030]
Regarding the empty state of the previous process, it is not sufficient to judge that there is no use in the previous process just by grasping the state where there is no work in the previous process of the relevant process. This is because, even if there is no work in the previous process, no wasted time if there is a work in the process. With the above configuration, the previous process empty state is calculated based on the operation state data of the presence or absence of the work in the relevant process and the previous process. Therefore, it is possible to calculate the pre-process empty state data correctly obtained by the analysis over a plurality of processes without using a special circuit or program.
[0031]
Further, the data acquisition unit acquires the operation state data according to the time series, and the operation data calculation unit calculates the operation state data according to the time series based on the acquired operation state data according to the time series. It is preferable to analyze the change over time in the operating state. By analyzing the change over time, the operating state data can be grasped more quantitatively. In addition, time-series analysis of the operating state can be performed without requiring a dedicated circuit and program.
[0032]
Further, an operation status analysis method according to the present invention is an operation status analysis method for analyzing the operation status of a production line based on operation status data indicating the operation status of each work element of a production line collected by a data collection device. Inputting a plurality of operation state data to the operation state function using a data acquisition step of acquiring a plurality of operation state data collected by the data collection device and an operation state function in which the plurality of operation states are combined by an operator; Operating state data calculating step of calculating operating state data representing the operating state of the production line.
[0033]
The operating condition analysis program according to the present invention is an operating condition analyzing program for analyzing the operating condition of a production line based on operating condition data indicating the operating condition of each work element of a production line collected by a data collecting device. The operation status analysis device uses a data acquisition processing procedure for acquiring a plurality of operation status data collected by the data collection device, and an operation status function in which a plurality of operation statuses are combined by an operator, and generates a plurality of operation status data. Is input to the operating state function, and an operating state data calculating process for calculating operating state data representing the operating state of the production line is executed.
[0034]
Further, the operation status analysis system according to the present invention is provided for each process of the production line, a plurality of data collection devices that collect and output operation state data representing the operation state of each work element constituting the production line, A data storage server that receives and outputs data output from each data collection device, and obtains a plurality of operation state data from the data storage server, and uses an operation state function in which a plurality of operation states are combined by an operator, An operation status analysis device that calculates operation status data representing the operation status of the production line by inputting a plurality of acquired operation status data to the operation status function.
[0035]
With the above configuration, the operation state data of each work element constituting the production line is collected by a data collection device provided in each step. The data collection device collects, as operation state data of each work element, for example, data of a plurality of control elements for controlling the operation of production equipment constituting each process, data of signals of various sensors, and the like. Then, the data collected by the data collection device is stored by the data storage server. Therefore, since the operation state data arranged in each process unit is stored by the data storage server, the load on the data storage server is reduced. For example, in each process, every time the processing on the work is completed, the operation state data can be sent to the data storage server in a lump, and data storage with good division can be performed with a small load. Further, even if the configuration of the production line changes, it is divided in process units, so that the data collection system can have flexibility.
[0036]
BEST MODE FOR CARRYING OUT THE INVENTION
Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. In the following, a part production line for producing engine parts for vehicles will be described as an example. However, as long as the production line is a production line including a plurality of production facilities or processes, a production line other than the engine part production line is used. There may be. For example, a production line for parts other than engine parts, an assembly line, an inspection line, and the like may be used, and the invention is not limited to a production line for vehicles.
[0037]
FIG. 3 is a block diagram illustrating a configuration of the operation status analysis system 10 of the production line. The operation status analysis system 10 is connected to each of the production facilities 20 constituting the production line, an abnormality display device 22 for displaying an abnormal state of each production facility 20, and each of the production facilities 20 and the abnormality display device 22, respectively. It includes a data collection device 30 that collects data on the operation state, a data storage server 50 connected to each data collection device 30 via a network 40, and an operation status analysis device 60 also connected to the network 40.
[0038]
Each production facility 20 is composed of various processing machines for completing engine parts, such as a machining center, a lathe, a drill, and other assembling machines for attaching accessory parts, an inspection machine, a work transport mechanism, and the like. Together constitute an engine parts production line.
[0039]
Each production facility 20 includes a plurality of work elements for performing a target work, the operation of the work elements is controlled by a plurality of control elements, and the position and the like are detected by a plurality of sensors. For example, in the case of sequentially moving a workpiece using a plurality of cylinder heads, each cylinder head is a work element, and a hydraulic actuator for driving each cylinder head or a relay for turning on / off the operation of a motor is controlled. A sensor corresponds to an element, such as a limit switch for detecting the position of each cylinder head. Sequence control is performed by the plurality of relays so that each production facility 20 performs a predetermined operation.
[0040]
Each production facility is provided with a PLC 24 for performing sequence control by digital signals. The data of each ON / OFF signal in the PLC 24 is output to the data collection device 30 via the communication line 26 as digital data representing an operation state of a control element that controls the operation of the production facility 20. In addition, various sensors output analog signals representing the operation states of the working elements of the production equipment to the data collection device 30 via an analog signal output interface (not shown) and the communication line 28.
[0041]
The operation state data representing these operation states corresponds to the operation state of each of a plurality of work elements in one production facility 20, and also, for example, the timing at which the work is carried into the production facility, the position, or the state of the work from the production facility. Such as the operation timing of the production equipment, such as the timing and position at which the equipment is carried out, is expressed as one work element. Further, when it is more convenient to form a single process by using a plurality of production facilities, a process including a plurality of facilities itself may be expressed as one work element so as to express its operation state.
[0042]
The abnormality display device 22 is a device that displays the current status of each process at a glance so that, for example, lamps corresponding to each process are two-dimensionally arranged, and the lamps are changed in color according to the content of the abnormality. A so-called "andon" that lights up can be used. For example, when a process is abnormally stopped, "red" is lit, and when it is necessary to replace tools or parts, etc., "yellow" is lit and forecasted. When the vehicle is stopped, a display such as lighting “blue” can be performed.
[0043]
The lighting of the abnormality display device 22 is controlled by the PLC 24 provided in the abnormality display device 22. Operating state data from each production facility 20 is input to the PLC 24 provided in the abnormality display device 22 via a signal line (not shown). From the PLC 24 provided in the abnormality display device 22, an ON / OFF signal for a work element of the abnormality display device 22, for example, each lamp, is output to the data collection device 30 as operation state data.
[0044]
The data collection device 30 is provided for each process, and is a device that collects operation state data of a work element in each process, and can be configured by a general PC. As described above, the data collection device 30 is also connected and provided for the abnormality display device 22. When one process is composed of one production facility, one data collection device 30 is connected to each production facility, and as described above, a single process is performed by a plurality of production facilities. When convenient, one data collection device 30 is connected to the process.
[0045]
The data collection device 30 communicates with the corresponding PLC 24 and the analog output interface via the communication lines 26 and 28, collects necessary operation state data, and transfers the collected data to itself to thereby collect data. Perform collection. Data collection is performed by executing a data collection program in accordance with the contents registered in a data collection setting file that specifies the type of data to be collected and a collection condition setting file that specifies the period of collection.
[0046]
The data collection device 30 is a device that transfers the collected operation status data to the data storage server 50 via the network 40 at a predetermined timing, for example, at a certain number of samples or at a timing when an arbitrary operation is completed. It can be constituted by a general personal computer or the like. As the predetermined timing, the data collected from the production device 20 may be, for example, each time the processing on the workpiece is completed. The data collected from the abnormality display device 22 may be transferred at a timing such as when the operation of the production line is completed or when the production lot is switched. Data transfer is performed by executing the program according to an appropriate file transfer protocol (for example, using File Transfer Protocol: FTP). In order to store the untransferred data, the data collection device 30 is provided with a storage device.
[0047]
The data storage server 50 is a server that communicates with each data collection device 30 via the network 40, and collects and accumulates operation state data and the like from each data collection device 30. Data transfer between each data collection device 30 is performed by executing a file transfer program as described above. The classification and accumulation of the received data are performed by executing a data server program in accordance with a server setting file that defines the data classification.
[0048]
The operation status analysis device 60 is a device that acquires necessary data from the data storage server 50, processes the data, and analyzes the operation status of the production line, and can be configured by a general computer. Specifically, the user specifies a desired analysis menu or setting item, obtains necessary operation state data from the data storage server 50, executes a process corresponding to the specified analysis menu, and performs production. It has the function of quantitatively analyzing and outputting the operation status of the line. Software can be used to perform a process corresponding to an analysis menu or the like on data, and a predetermined process can be performed by executing a corresponding analysis program. Part of the processing can be executed by hardware.
[0049]
The operation status analysis device 60 includes a CPU 70, a communication control unit 72 that communicates with the data storage server 50 via the network 40, an input unit 74 such as a keyboard for a user to specify an analysis menu or a setting item, and an analysis. An output unit 76 such as a display for displaying the operation status of the production line and an external storage device 78 such as a hard disk for storing a file 80 of the operation status function are connected to each other by an internal bus.
[0050]
The data acquisition unit 100 in the CPU 70 has a function of requesting the data storage server 50 to transfer necessary data via the communication control unit 72 and acquiring the data. The required data differs depending on the type of analysis menu specified by the user.
[0051]
The operation state data calculation unit 150 has a function of acquiring necessary operation state data from the data storage server 50 and calculating operation state data using an operation state function. The actual production state calculation module 152 and the actuator state calculation module 166 in the operation state data calculation unit 150 have a function of calculating respective operation state data in accordance with the type of analysis menu specified by the user. The operation status function corresponding to the type of the analysis menu designated by the user is read from the file 80 in the external storage device 78. The details of the calculation of the operating state data will be described with reference to FIG.
[0052]
The actual production state calculation module 152 is a function of an operation state analysis process that is executed when the user specifies the “calculation of actual production state” menu and specifies the process. Specifically, it has a function of acquiring operation status data of the process and the processes before and after the process, and calculating, as the operation status of the process, operation status data indicating whether or not actual production is being performed.
[0053]
FIG. 4 shows an operation state function Y that outputs an operation state during actual production. ₁ , Using the same symbols as those shown in FIG. ₁ No work in front process X ₂ , The process completion X ₃ , Post-process full work X ₄ , X during continuous operation ₅ It shows the relationship with. As shown in FIG. 4, the respective operation states are linked by AND, OR, and NOT, and the states of (there is a work in the previous process) and (the work in the previous process) and the state of (the work has not been completed) and (the work is not a full work in the post process). )) And an operating state function Y representing the state of (during continuous operation) ₁ Can be used to calculate during actual production.
[0054]
In other words, the “in actual production” is an operation state in which actual work is being performed without waste, so that (during continuous operation) is not sufficient, and (actual process work is present) and (pre-process work is present) and It is necessary that there be no waste in relation to the process or that (the process is not completed) and (the post-process is not full work) and there is no waste in relation to the post-process. To grasp the operating state during actual production, it is necessary to monitor five operating state data. ₁ Is used, five operation state data are collected in time series, and these are collected into an operation state function Y ₁ , The operating state data during actual production can be output in chronological order. FIG. 5 shows each operation state X in the time series. ₁ , X ₂ , X ₃ , X ₄ , X ₅ Data and the operating state function Y during actual production ₁ Here is an example of output data.
[0055]
The abnormally stopped state calculation module 154 is a function of an operating state analysis process that is executed when the user specifies a menu of “abnormally stopped state calculation” and specifies the process. Specifically, it has a function of acquiring a plurality of operation state data of the process and calculating operation state data indicating whether or not the process is abnormally stopped as the operation state of the process.
[0056]
FIG. 6 shows an operation state function Y for outputting an operation state during abnormal stop. ₂ And X as the operating state during continuous operation. ₅ , Abnormal signal X ₆ Is expressed in the same notation as in FIG. As shown in FIG. 6, by linking the operation states with AND, it is possible to calculate the state of (not continuous operation) and the state of (abnormal) as abnormal stop.
[0057]
That is, the abnormal stop is an operation state in which the process is stopped due to an abnormality, and therefore, the operation state in which an abnormal signal is output is not sufficient, and the operation state in which the process is stopped is not sufficient. . Therefore, the operation state function Y which connects the two operation states by AND (not in continuous operation) and represents (abnormal) ₂ And collects two operation state data in a time series, and collects these data into an operation state function Y ₂ To output the operating state data during abnormal stop in a time series.
[0058]
The tool change state calculation module 156 is a function of an operation state analysis process that is executed when the user designates a “tool change state calculation” menu and specifies the process. Specifically, it has a function of acquiring a plurality of pieces of operation state data of the process and calculating operation state data indicating whether or not a tool is being changed as the operation state of the step.
[0059]
FIG. 7 shows an operation state function Y for outputting an operation state during tool change. ₃ And tool change forecast X as each operation state ₇ , Individual exchange signal X ₈ Is expressed in the same notation as in FIG. As shown in FIG. 7, by linking the respective operation states by AND, it is possible to calculate that the state of (there is a tool change forecast) and the state of (individually changing) are being changed.
[0060]
That is, during the tool change, the tool change forecast is issued, and the operation state is such that the operator or the like is actually performing the tool change. Therefore, the operation state in which the tool change forecast is issued is not sufficient. Therefore, an operation state function Y representing two operation states linked by AND (with tool change forecast) and (individual change) ₃ And collects two operation state data in a time series, and collects these data into an operation state function Y ₃ To output the operating state data during tool change in chronological order.
[0061]
The quality check state calculation module 158 is a function of an operation state analysis process that is executed when the user specifies the menu of “quality check state calculation” and specifies the process. Specifically, it has a function of acquiring a plurality of operation state data of the process and calculating operation state data indicating whether or not a quality check is being performed as the operation state of the process.
[0062]
In a production line, a process may be stopped in order to perform a quality check on whether a work is processed or assembled according to production specifications. For example, when a sampling quality check is performed for one workpiece per 100 pieces, a quality check forecast is issued at the same time as the sampling is performed, and in accordance with the forecast, an operator or the like goes to the process where the forecast is issued. Then, the process is suspended and the quality of the work is checked. Therefore, whether or not the process is under quality check is one of the operation status data indicating the operation status of the process.
[0063]
FIG. 8 shows an operation state function Y for outputting an operation state during quality check. ₄ And the quality check forecast X as each operation state ₉ , Individual check signal X ₁₀ Is expressed in the same notation as in FIG. As shown in FIG. 8, by linking the respective operation states by AND, it is possible to calculate that the state of (with quality check forecast) and the state of (individual check) is under quality check.
[0064]
That is, the quality check is being performed, which means that the quality check forecast is issued and the operation state in which the worker or the like is actually performing the quality check is not sufficient in the operation state in which the quality check forecast is issued. Therefore, an operation state function Y representing two operation states linked by AND (with quality check forecast) and (individual check) ₄ And collects two operation state data in a time series, and collects these data into an operation state function Y ₄ To output the operating state data during the quality check in time series.
[0065]
The post-process full state calculation module 160 is a function of an operating state analysis process that is executed when the user specifies the menu of “post-process full state calculation” and specifies the process. Specifically, the operation status data of the relevant process and the post-process is acquired, and the operation status data indicating whether the post-process is full or not is determined as an operation status in which the process is wasted because the work is clogged in the post-process. Has the function of calculating
[0066]
FIG. 9 shows an operation state function Y that outputs the operation state of the post-process full state. ₅ And the post-process full work X ₄ , The process completion X ₃ Is expressed in the same notation as in FIG. As shown in FIG. 9, the respective operation states are linked by AND, and the state of (post-process full work) and (the relevant process is completed) can be calculated as the post-process full state.
[0067]
That is, the post-process full state is an operation state in which the actual work of the process is completed and the work is clogged in the post-process, but the process is wasted even though the work is to be carried out to the post-process. Therefore, it is not enough for the post-process to be performed only by the full work, and it is not sufficient to complete the actual work of the process. Therefore, an operation state function Y that connects two operation states with AND (post-process full work) and (completes the process) ₅ And collects two operation state data in a time series, and collects these data into an operation state function Y ₅ , And the operation status data of the full post-process can be output in chronological order.
[0068]
The pre-process empty state calculation module 162 is a function of an operation state analysis process that is executed when the user specifies the “pre-process empty state calculation” menu and specifies the process. Specifically, the operation status data of the process and the previous process is acquired, and the operation status data indicating whether or not the previous process is empty is calculated as an operation status in which the process is wasted because no work comes from the previous process. It has a function to do.
[0069]
FIG. 10 shows an operation state function Y that outputs the operation state of the empty state of the previous process. ₆ , And each operation state, there is no process work X ₁ No work in front process X ₂ Is expressed in the same notation as in FIG. As shown in FIG. 10, each operation state is linked by AND, and the state of (there is no process work) and the state of (there is no work in the previous process) can be calculated as the empty state in the previous process.
[0070]
That is, the empty state in the previous process is an operation state in which the process is wasted because the work does not come from the previous process. Therefore, it is not sufficient that there is no work in the previous process, and there is no work in the process. Is not enough. Therefore, an operating state function Y representing two operating states connected by AND (without the process work concerned) and (without the preceding process work) ₆ And collects two operation state data in a time series, and collects these data into an operation state function Y ₆ To output the operation state data of the empty space in the previous process in chronological order.
[0071]
As described above, the operation status of each process includes an operation status such as a status where the process is stopped due to abnormal stop or the like and a waste status such as a full status of the post-process, in addition to the status of actual production. In order to ascertain the operation status of each process as a whole, it is preferable to ascertain the ratio of the time occupied by the plurality of operation states and the change in the time series. In each process, a so-called output rate is used as a value indicating a time ratio of each operation state in a certain period. This volume rate can also be calculated by using the operation status function.
[0072]
FIG. 11 is a bar graph of the operation time obtained by accumulating the time of each operation state of the process. Here, the yield rate represents the ratio of each operation state when the total operation time is 1, particularly the ratio of the actual operation time for producing non-defective products. In addition, as shown in FIG. 11, it is possible to calculate the yield rate and analyze the operating state during the entire operation time. For example, the load time and the ratio that gives the work load to the process, the actual production time and the ratio of actually producing parts during the load time, the actual working time and the actual production time that produce a good product in the actual production time The ratio and the like can be obtained.
[0073]
In FIG. 11, the difference between the total operation time and the load time is the dead time in which no load is applied to the process, and the time y in the post-process full state is shown. ₅ And the time y in which the previous process is empty ₆ It is. Therefore, these are operated by the functions of the post-process full state calculation module 160 and the pre-process empty state calculation module 162, respectively. ₅ = 1 time y ₅ And the operating state function Y ₆ = 1 time y ₆ Can be sought.
[0074]
The difference between the load time and the actual production time is the time during which the process is stopped, and the time y during the abnormal stop state. ₂ , Tool change time y ₃ , Quality check status time y ₄ In addition, the time y during which the change ₇ Is included. Time y during which changeover is stopped ₇ Other than the above, the operation state function Y ₂ = 1, Y ₃ = 1, Y ₄ = 1 time y ₂ , Y ₃ , Y ₄ And the time y during which the change is stopped ₇ For example, manual input data from the input unit 74 can be used.
[0075]
Here, the change stop state is one of the operating states, and is a state in which the process is stopped in order to change the work content of the process. For example, in the process, when processing parts of the engine A in the morning and processing parts of the engine B in the afternoon, a jig for holding the work, a tool for processing the work, or a hub or the like in which these are integrated. This is the time required to change the setup from engine A parts to engine B parts. Normally, the changeover operation is often performed with the power supply of the process turned off for safety. Therefore, the operation of the PLC also temporarily stops, and the collection of the operation state data also temporarily stops. Therefore, the work time data in the stoppage state of the shift stop can be manually input as the time data of the stop state in the stoppage from the input unit 74, and can be used for calculating the output rate. Of course, it is assumed that the power of the process is not turned off even during the change work, and a change stop switch etc. is provided for each process, and this change stop switch is operated during the change work, and the change stop signal is output. It can also be sent to the operation status analyzer via PLC. Then, the operation state function indicating the shift stop state is converted into the shift stop signal and the continuous operation signal X. ₅ And the like.
[0076]
The difference between the actual production time and the actual working time is the time for producing defective products. That is, the actual production time y ₁ Is the actual working time y that produced a good product ₁₁ And the time of production of defective products y ₁₂ And y ₁ = Y ₁₁ + Y ₁₂ It is. The determination of a good product or a defective product is performed in an inspection process, and y is determined in a predetermined period. ₁₁ / Y ₁ × 100% is separately calculated as a so-called orthogonality ratio. Therefore, the traverse rate data is manually input from the input unit 74, and y ₁₁ = Y ₁ × (direct rate) × 100% and actual working time y ₁₁ Etc. can be calculated and used for the yield rate calculation.
[0077]
As described above, by inputting the change stop state data and the traverse rate data from the input unit 74, the ratio of each operating state to the total operating time in each process, that is, the yield rate, is calculated using the operating state function. can do. The output rate calculation module 164 is a function of an operating state analysis process that is executed when the user specifies a menu of “output rate calculation” and specifies the process. Specifically, the operation state data in a plurality of steps including the step and the steps before and after the step, the step change stop state time data and the orthogonality data of the step in a predetermined period are obtained, and It has the function of calculating the time of the operating state and calculating the ratio between them.
[0078]
In the example of FIG. 11, it can be understood that the ratio of the actual production state is less than 50%, and the other operation states of the stopped state or the waste state occur at substantially the same rate. Note that, as described above, in the yield calculation module, the actual working time y shown in FIG. ₁₁ , Actual production time y ₁ , Load time (y ₁ + Y ₂ + Y ₃ + Y ₄ + Y ₇ ), Or the ratio of these times to the total operating time can also be calculated.
[0079]
FIG. 12 shows the operation state of the process in a time series. That is, the change of the operation state of the process every moment is represented by time on the horizontal axis. The analysis of the overall operation status in the time series of such a process can also be added to the analysis menu.
[0080]
The actuator state calculation module 166 is a function of an operation state analysis process that is executed when the user specifies a menu of “actuator state calculation” and specifies a specific actuator of a target process. Specifically, it has a function of acquiring time-series operation state data of a target actuator and calculating operation state data of the actuator.
[0081]
For example, FIG. 2 described above shows a forward operating state and a backward operating state of a cylinder as an actuator. As described above, the forward operation state of the cylinder is represented by an operation state function Z representing (forward instruction is present) and (cylinder forward end is not detected). ₁ Similarly, the cylinder retreat operating state is represented by an operating state function Z representing (with a retraction instruction) and (no cylinder retraction end detected). ₂ Can be calculated using The operating state of an actuator other than the cylinder, for example, a screwing head can be calculated in the same manner. In this way, the operating state data of a specific actuator can be calculated using the operating state function.
[0082]
【The invention's effect】
According to the production line operation status analysis apparatus, operation status analysis method, operation status analysis program, and operation status analysis system of the present invention, each process constituting the production line does not require a dedicated circuit or program, and each process The operation status can be analyzed based on the signal indicating the status of the operation. ADVANTAGE OF THE INVENTION According to the operation condition analysis apparatus of a production line, the operation condition analysis method, the operation condition analysis program, and the operation condition analysis system which concern on this invention, an operation condition can be analyzed using the operation condition function which arbitrarily combines several operation condition signals. . According to the operation condition analysis device, operation condition analysis method, operation condition analysis program, and operation condition analysis system of the production line according to the present invention, the operation condition is analyzed over a plurality of processes without requiring a special circuit or program. it can.
[Brief description of the drawings]
FIG. 1 is a diagram illustrating an operation state function according to the present invention.
FIG. 2 is a diagram illustrating an example of outputting an operation state as a time chart using the operation state function according to the present invention.
FIG. 3 is a block diagram showing a configuration of an operation status analysis system of a production line in the embodiment according to the present invention.
FIG. 4 shows an operation state function Y for outputting an operation state during actual production in the embodiment according to the present invention. ₁ FIG.
FIG. 5 is a diagram showing an example of time-series data of each operation state and data of a calculated actual production operation state in the embodiment according to the present invention.
FIG. 6 is a diagram illustrating an operation state function Y for outputting an operation state during abnormal stop in the embodiment according to the present invention. ₂ FIG.
FIG. 7 shows an operation state function Y for outputting an operation state during tool change in the embodiment according to the present invention. ₃ FIG.
FIG. 8 is a diagram illustrating an operation state function Y that outputs an operation state during quality check in the embodiment according to the present invention. ₄ FIG.
FIG. 9 is a diagram illustrating an operation state function Y that outputs an operation state of a post-process full state in the embodiment according to the present invention. ₅ FIG.
FIG. 10 is a diagram illustrating an operation state function Y that outputs an operation state of a pre-process empty state in the embodiment according to the present invention. ₆ FIG.
FIG. 11 is a diagram showing a yield rate as an overall operation state of a process using operation state data calculated using an operation state function in the embodiment according to the present invention.
FIG. 12 is a diagram showing, in the embodiment according to the present invention, operating states of processes in a time series using operating state data calculated using an operating state function.
[Explanation of symbols]
10 operation status analysis system, 20 production equipment, 22 abnormality display device, 30 data collection device, 50 data storage server, 60 operation status analysis device, 70 CPU, 78 external storage device, 80 operation status function file, 100 data acquisition unit, 150 operation state data calculation unit, 152 actual production state calculation module, 154 abnormal stop state calculation module, 156 tool change state calculation module, 158 quality check state calculation module, 160 post-process full state calculation module, 162 pre-process empty state Calculation module, 164 Output rate calculation module, 166 Actuator state calculation module.

Claims (10)

An operation status analysis device that analyzes the operation status of the production line based on operation status data representing the operation status of each work element of the production line collected by the data collection device,
Data acquisition means for acquiring a plurality of operation state data collected by the data collection device,
An operating state data calculating unit that uses an operating state function in which a plurality of operating states are combined by an operator, inputs a plurality of operating state data to the operating state function, and calculates operating state data representing the operating state of the production line,
An operation status analysis device, comprising: The operation status analysis device according to claim 1,
The operating state data calculating means inputs operating state data in a plurality of processes including the process and the processes before and after the process to an operating state function in order to analyze the operating state of each process of the production line, and as operating state data, An operation status analysis apparatus for calculating process operation status data representing an operation status of a process. The operation status analysis device according to claim 2,
The operating state data calculating means, as the operating state of each process, the actual production state indicating the actual production, the abnormal stop state indicating the abnormal stop, the tool change state indicating the tool change, or the quality check Process operation state data for any one of the following process operation states: a quality check state, a full state in the post-process indicating a waste state in which the post-process work is clogged, or an empty state in the previous process indicating a waste state in which no work is present in the previous process An operating condition analysis apparatus characterized by calculating the following. The operation status analysis device according to claim 3,
The operating state data calculating means includes:
Work presence / absence state data in the process,
Work presence / absence state data in the process before the process,
Work presence / absence state data in the post-process of the process,
An operation status analysis apparatus which calculates process operation data representing an actual production state of each process based on a plurality of operation state data including: The operation status analysis device according to claim 3,
The operating state data calculating means includes:
Work completion status data in the process,
Work presence / absence state data in the post-process of the process,
An operation status analysis apparatus that calculates process operation data representing a post-process full state of each process based on a plurality of operation state data including: The operation status analysis device according to claim 3,
The operating state data calculating means includes:
Work presence / absence state data in the process,
Work presence / absence state data in the process before the process,
An operation status analysis apparatus, which calculates process operation data indicating an empty state of a previous process of each process based on a plurality of operation state data including: The operation status analysis device according to claim 1,
The data acquisition means acquires operation state data according to a time series,
The operation data analysis means calculates the operation data according to the time series based on the acquired operation data according to the time series, and analyzes the change with time of the operation state. An operation status analysis method for analyzing an operation status of a production line based on operation status data representing an operation status of each work element of a production line collected by a data collection device,
A data acquisition step of acquiring a plurality of operation state data collected by the data collection device,
An operating state data calculating step of inputting a plurality of operating state data to the operating state function using an operating state function in which a plurality of operating states are combined by an operator, and calculating operating state data representing the operating state of the production line,
An operation status analysis method, comprising: An operation status analysis program for analyzing the operation status of the production line based on operation status data representing the operation status of each work element of the production line collected by the data collection device,
The operation status analyzer
A data acquisition processing procedure for acquiring a plurality of operation state data collected by the data collection device,
An operating state data calculation processing procedure for inputting a plurality of operating state data to the operating state function and calculating operating state data representing the operating state of the production line, using an operating state function in which a plurality of operating states are combined by an operator,
An operation status analysis program characterized by causing a computer to execute. A plurality of data collection devices that are provided for each process of the production line and collect and output operation state data representing the operation state of each work element constituting the production line;
A data storage server for receiving and storing data output from each data collection device;
By acquiring a plurality of operation state data from the data storage server, using an operation state function obtained by combining a plurality of operation states with an operator, and inputting the acquired plurality of operation state data to the operation state function, the production line An operation state analysis device that calculates operation state data representing the operation state;
An operation status analysis system characterized by including:

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