JP2019016134A - Production support system and production support method - Google Patents

Abstract

To provide a production support system that performs production support to reduce a decrease in production efficiency when a plurality of process stops occur in a production line.SOLUTION: The production support system includes: stop cause stop status acquisition means; stop cause stop history storage means; and stop corresponding priority determination means. The stop cause stop status acquisition means monitors a process of a production line and acquires a stop cause and a stop status. The stop cause stop history storage means stores a cause of the stop and a history of the stop status. Also, it holds an estimated suspension time for each stop cause calculated from the stop history. According to the above configuration, even when there is a plurality of troubles with different stop times in the same process, it is possible to calculate an accurate estimated suspension time. When stops occur in a plurality of processes, the stop corresponding priority determination means determines a priority order of work corresponding to each stop based on the estimated suspension time of each process.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a production support system and a production support method.

  In the production of industrial products at present, a line production system is often employed in which products are conveyed by a conveyor and the like, and facilities and workers perform assembly operations on the products, and sequentially process the products. In such a line production system, a tact time is assigned in each process, and each facility or worker is required to finish the work within the assigned tact time. By the way, in the line production method, a specific process may be stopped due to troubles such as running out of parts, and production may be stopped. In such a case, it is common to call a trouble handling worker, perform a recovery work, and return to the production state again.

  When a plurality of troubles occur simultaneously in such a production method, the time until the line is restored varies depending on the order in which the troubles are dealt with. In other words, it is important to determine the priority of correspondence so that it can be recovered quickly. For this reason, work priority determination methods that shorten the time to production recovery are being studied.

  For example, Patent Document 1 discloses a method for scoring items such as progress rate and model priority for equipment abnormality, and setting a high priority for equipment with a large total score. Further, Patent Document 2 discloses a method of calculating a stop expected time for each process having an abnormality based on past results and assigning a high priority to a process having a long stop expected time. In addition, the priority order of support may be determined so that the restoration work end time of each process is as much as possible. Patent Document 3 discloses a method for determining the priority order based on the cycle time of the apparatus and the number of buffers waiting for processing. According to this method, the priority of correspondence is determined in the order in which the timing at which the processing of the next device becomes impossible comes earlier because the supply of the product from the defective device is interrupted. Thereby, the time which a process stops in the next process of a malfunction apparatus as the whole line can be shortened.

JP 2006-39650 A Japanese Patent No. 6020176 Japanese Patent No. 5963697

  However, each of the above techniques has problems. In the technique of Patent Document 1, the priority of correspondence is determined based on the priority of equipment and work-in-progress products, and the type of abnormality is not considered. For example, in a component mounting facility on a surface mounting line, the stop time is greatly different between a stop due to a component shortage and a stop due to a component suction error even in the same process. That is, the stop time may vary greatly depending on the cause of the stop. However, in the technique of Patent Document 1, since the priority order is determined regardless of the type of abnormality, there is a case where priority is given to work that contributes little to speeding up the recovery of the entire line. As a result, the reduction in production efficiency of the entire production line has become large.

  In the technique of Patent Document 2, the expected stop time is calculated based on the past average stop time for each process. For this reason, when there are a plurality of types of abnormalities in the same process and the respective stop times are different, a stop expected time far from the actual stop time may be calculated. As a result, the reduction in production efficiency of the entire production line has become large.

  In the technique of Patent Document 3, the time required for recovery of the process in which an abnormality has occurred is calculated based only on the level of proficiency of the worker. When there was a mode, it was difficult to give priority in accordance with reality. As a result, the reduction in production efficiency of the entire production line has become large.

  The present invention has been made in view of the above-described problems, and an object of the present invention is to provide a production support system that performs production support that reduces a decrease in production efficiency when a stop of a plurality of processes occurs in a production line. It is said.

  In order to solve the above-described problems, the production support system of the present invention includes a stop cause stop status acquisition unit, a stop cause stop history storage unit, and a stop correspondence priority order determination unit. The stop cause stop status acquisition means monitors the production line process and acquires the stop cause and the stop status. The stop cause stop history storage means stores a history of a stop cause and a stop state. In addition, the estimated stop time for each cause of stop calculated from the stop history is held. According to the above configuration, even when there are a plurality of troubles with different stop times in the same process, it is possible to calculate an accurate stop expected time. The stop priority order determining unit determines the priority order of work corresponding to each stop based on the expected stop time of each process when a stop occurs in a plurality of processes.

  An advantage of the present invention is that it is possible to provide a production support system that performs production support that reduces a decrease in production efficiency when a plurality of processes are stopped in a production line.

It is a block diagram which shows 1st Embodiment. It is a block diagram which shows 2nd Embodiment. It is a block diagram which shows the detail of the process monitoring part of 2nd Embodiment. It is a table | surface which shows an example of the data which the stop cause stop log | history DB of 2nd Embodiment hold | maintains. It is a block diagram which shows the detail of the corresponding | compatible priority order setting part of 2nd Embodiment. It is a block diagram which shows the detail of the work progress acquisition part of 2nd Embodiment. It is a flowchart which shows the priority determination operation | movement of 2nd Embodiment. It is a flowchart which shows instruction | indication operation | movement to the operator of 2nd Embodiment. It is a schematic diagram which shows an example of the work navigation of 3rd Embodiment.

  Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. However, the preferred embodiments described below are technically preferable for carrying out the present invention, but the scope of the invention is not limited to the following. In addition, the same number is attached | subjected to the same component of each drawing, and description may be abbreviate | omitted.

(First embodiment)
FIG. 1 is a block diagram illustrating a production support system according to the first embodiment. The production support system includes a stop cause stop status acquisition unit 1, a stop cause stop history storage unit 2, and a stop response priority order determination unit 3.

  The stop cause stop status acquisition means 1 monitors the process of the production line and, if there is a stop, acquires the stop cause and the stop status. Here, it is assumed that the production line includes a plurality of steps (step 1, step 2,..., Step n). Here, the cause of the stop is a cause of the stop of the process, and can also be referred to as a trouble mode. Such a trouble mode can be transmitted to the stop cause / stop state acquisition means 1 by, for example, an error message from the facility or an input from the operator. Similarly, the stop status can be transmitted to the stop cause stop status acquisition means 1 by inputting data (log data) for notifying operation / stop of the facility or an operation / stop signal from the operator.

  The stop cause stop history storage unit 2 receives the stop status for each stop cause from the stop cause stop status acquisition unit 1 and stores the history as a stop cause stop history. The stop cause stop history storage unit 2 also holds the expected stop time for each stop cause calculated from the stop history. The expected stop time is calculated from the past stop time results for each cause of the stop. For this reason, even when there is a stop cause (trouble mode) with different stop times in the same process, it is possible to calculate the expected stop time according to reality.

  The stop priority order determination unit 3 determines the priority order corresponding to each stop (trouble) when a stop occurs in a plurality of steps. The stop correspondence priority order determination unit 3 accesses the stop cause stop history storage unit 2 and acquires the expected stop time in the same trouble as the stop cause of the currently stopped process. Then, based on the expected stop time of each process that is currently stopped, the priority for executing the work corresponding to the recovery of the stop is determined so that the production efficiency of the entire production line is increased.

  As described above, according to the present embodiment, the priority order corresponding to the trouble can be determined based on the expected stoppage time that matches the reality. For this reason, the reduction in production efficiency due to the stop of the process can be reduced.

(Second Embodiment)
FIG. 2 is a block diagram illustrating a production support system according to the second embodiment. The production support system includes a process monitoring server 100, a stop cause stop history DB 200, and a stop correspondence management server 300. Here, DB is a database.

  The process monitoring server 100 includes a process monitoring unit 110 that monitors each process of the production line. Each process monitoring unit 110 monitors the assigned process. Here, a process 1 monitoring unit 110-1, a process 2 monitoring unit 110-2, ..., and a process n monitoring unit 110-n that monitor process 1 are provided.

  Details of one process monitoring unit 110 are shown in FIG. The process monitoring unit 110 includes an equipment operation log acquisition unit 111, an in-process status acquisition unit 112, a process progress acquisition unit 113, a stop cause acquisition unit 114, a stop time measurement timer 115, and a data transmission unit 116. ing.

  The facility operation log acquisition unit 111 acquires operation data of facilities used in the process.

  The in-process status acquisition unit 112 acquires the in-process status of the process to be monitored. Here, the work-in-progress status indicates how many products are in the buffer when the process has a buffer waiting before processing.

  The process progress acquisition unit 113 acquires the process progress of the process of the target process. Here, the process progress is the progress of the process performed in the process, and represents, for example, how much the process has progressed with respect to a preset cycle time. In this case, the remaining time is obtained by subtracting the progress from the cycle time.

  The stop cause acquisition unit 114 acquires the stop cause when a stop (trouble) occurs in the process. Here, the cause of the stop is a cause of the stop of the process, and can also be referred to as a trouble mode. As an example, taking a component mounting facility on the surface mounting line as an example, stops due to out of components, stops due to component adsorption mistakes, stops due to board transfer errors, stops due to human body entering the prohibited entry area and operating safety sensors, etc. Is mentioned. These stop modes are various, and the stop time varies greatly depending on the mode. In the above example, for example, in the case of out of parts, it takes a time in minutes to supply a new part. However, when the safety sensor is activated, the sensor is only reset, and can be recovered in a few seconds. As described above, there can be many causes for stopping the process. On the other hand, if the cause is the same, it is also true that the recovery process is completed in the same amount of time. This is the basis for accumulating data for each cause of stoppage. In the following description, “stop” and “trouble” are used interchangeably unless otherwise specified.

  The stop time measurement timer 115 measures the time from when the stop occurs until the recovery work is completed and the operation is restarted.

  The data transmission unit 116 transmits the data obtained in 111 to 115 to the stop cause stop history DB 200 and the stop correspondence management server 300.

  The stop cause stop history DB 200 records data transmitted from the process monitoring server 100 as a stop cause stop history. The reason why the stop history is not simply called the stop history but is called the stop cause stop history is to record the stop history separately for each cause of stop. The stop cause stop history DB 200 also calculates and holds the expected stop time for each stop cause using the stop history.

  FIG. 4 shows an example of data held in the stop cause stop history DB 200. The data is aggregated for each cause of stop, and the number of stops and the cumulative stop time are recorded. The cumulative stop time represents the cumulative stop time from when the process is stopped due to the stop cause until the process is recovered. For example, in the process 1 of the product A, there are five stops due to the cause 1-1, and the accumulated time is 2500 seconds. Assuming that the expected stop time is calculated as an average stop time, the expected stop time of cause 1-1 is 500 seconds. On the other hand, even in the same process 1, in the case of a stop due to cause 1-3, the expected stop time is 20 seconds. As shown in this example, according to the present embodiment, it is possible to grasp an accurate stop expected time corresponding to the cause of the stop. On the other hand, in the method of uniformly handling the process stop time regardless of the trouble mode as in the technique of Patent Document 2, there is a possibility of calculating the expected stop time deviating from the reality, and the accuracy is low.

  Next, returning to FIG. 2, the stop correspondence management server 300 will be described. The expected stop time acquisition unit 310 acquires the expected stop time corresponding to the cause of the stop of the currently stopped process received from the process monitoring server 100 from the stop cause stop history DB 200.

  The response priority setting unit 320 sets the priority for the corresponding trouble so that the decrease in production efficiency of the entire production line is reduced based on the expected stop time of each process when a plurality of processes are stopped. To do. Details of the response priority setting unit 320 will be described later.

  The worker management unit 330 acquires and manages the status of the worker who is in charge of troubleshooting. The situation of the worker includes, for example, the current position and the work currently being performed.

  The instruction creating unit 340 creates an instruction for the worker based on the correspondence priority order and the worker's situation. This instruction is transmitted to terminals 400-1, 400-2, 400-3,. The terminal 400 is, for example, a mobile terminal held by an operator, but may be a stationary terminal.

  FIG. 5 is a block diagram showing details of the correspondence priority order setting unit 320. The response priority setting unit 320 includes a stop cause acquisition unit 321, a stop expected time acquisition unit 322, a work progress acquisition unit 323, a priority calculation unit 324, and a sort unit 325. The response priority setting unit 320 calculates the priority based on the expected stop time and the work progress in the trouble of the stopped process, and the sorting unit 325 sorts the priority in descending order of priority, Set the priority of the trouble that the worker will handle. Here, the work progress acquisition unit 323 may include a cycle time storage unit 3231, a processing time measurement unit 3232, and a remaining time calculation unit 3233, for example, as illustrated in FIG. 6. The cycle time storage unit 3231 stores a cycle time predetermined for each process. The processing time measurement unit 3232 measures an elapsed time after starting the processing in the process. The remaining time calculation unit 3233 calculates the remaining time of the process by subtracting this elapsed time from the cycle time.

  Next, the response priority setting method of the stop response management server 300 will be described. The response priority order sets the priority order for the recovery response work so as to reduce the reduction in production efficiency of the production line. Therefore, the goal is to reduce the overall output of the production line as much as possible. Therefore, for example, the priority is calculated according to the following principle, and the higher the number, the higher the priority. The stopped process is referred to as a self process, the previous process is referred to as a pre-process, and the subsequent process is referred to as a next process. As a general rule, 1) The higher the number of devices waiting for in-process processing, the higher the priority. 2) The higher the priority is, the longer the stay time of the own process is. 3) The higher the priority is, the shorter the time until the next process process accepts the next product.

  The contribution of 1) is a = (number of buffers * cycle time of own process−current processing remaining time of previous process). Since the in-process does not increase while the previous process is processing, the remaining processing time of the previous process is reduced. The contribution of 2) is b = (remaining time of current process + estimated stop time). The contribution of 3) is set as c = (− current processing remaining time of the next step). This is negative in the sense that the next product cannot be accepted while the next process is currently processing, so there is a delay.

  Next, the operation of the stop response management server 300 from when trouble occurs in a plurality of processes until the priority order of response is set will be described. FIG. 7 is a flowchart showing this operation. First, a trouble occurrence notification for a plurality of processes is received from the process monitoring server 100 (S1). At the same time, the cause of occurrence of each trouble is acquired (S2). Next, for each trouble, an expected stop time corresponding to the cause of occurrence is acquired (S3). Next, the in-process status of each target process is acquired from the process monitoring server 100 (S4). Next, the cycle time and remaining time of each target process, its previous process and the next process are acquired (S5). Next, using the acquired in-process status of each target process, each cycle time and remaining time, and the expected stop time corresponding to the cause of the stop, the priority of the response to each process in which a trouble has occurred is calculated (S6). ). Correspondence priorities are determined in descending order of priority (S7).

  Next, a method for navigating a response instruction to an operator who handles a trouble using the determined priority order will be described. FIG. 8 is a flowchart illustrating an example of an operation in which the stop response management server 300 notifies the worker of a response instruction. The response instruction can be notified, for example, by transmitting a trouble response instruction to the terminal 400.

  The trouble handling work instruction transmission is repeatedly performed in descending order of priority by the loop processing of S101 to S109 until all the handling work is completed. First, the operator management unit 330 is referenced to search for a free worker (S102). If there is a free worker (S102_Yes), the worker is instructed to deal with the trouble with the highest priority at that time (S103). When the worker completes the treatment, the treatment completion notification transmitted by the worker or the treatment target equipment is received (S104). Here, the time from the occurrence of the stop of the process to the completion of the treatment is recorded as the stop time (S105). This result is accumulated in the stop cause stop history DB 200 in association with the stop cause and the stop time. This completes the treatment for one trouble and returns to the next priority treatment instruction operation.

  On the other hand, when a free worker is not found in S102 (S102_No), a search is made as to whether there is a worker who is currently performing a treatment with a lower priority than the target treatment (S106). If a corresponding worker is found here (S106_Yes), the current treatment is interrupted and a treatment for the target trouble is instructed (S107). After that, it returns to the loop after S104.

  On the other hand, when there is no worker engaged in the treatment having a lower priority than the target treatment (S106_No), the process waits for a predetermined time (S108) and returns to S102. As described above, it is possible to efficiently instruct the operator to deal with troubles with high priority.

(Third embodiment)
In this embodiment, a specific example of setting the priority order described in the second embodiment and an instruction to the worker will be described. FIG. 9 is a schematic diagram showing this specific example.

  The production line has seven steps from step 1 to step 7. The cycle time of each step is Step 1:30 s, Step 2: 40 s, Step 3: 90 s, Step 4: 90 s, Step 5: 20 s, Step 6:30 s, Step 7:30 s.

  Here, it is assumed that trouble occurs in the steps 3 and 7. The cycle time, remaining time, and the number of buffers in step 3 and steps 2 and 4 before and after step 7, and step 7 and previous step 6 are as follows. In addition, as a method for the process monitoring server to detect the occurrence of a trouble, a method for detecting a stop from the facility operation log, a method for an operator who notices the occurrence of the trouble to press the switch, or the like can be used.

  Step 3: Cycle time: 90 seconds, expected stop time due to the cause: 30 seconds, expected remaining time: 40 seconds, number of buffers: 1 sheet. Step 2: cycle time: 40 seconds, expected remaining time: 10 seconds. Step 4: Cycle time: 90 seconds, expected remaining time: 20 seconds, number of buffers: 0 sheets.

  Step 7: cycle time: 30 seconds, expected stop time due to the cause: 20 seconds, expected remaining time: 5 seconds. Step 6: cycle time: 30 seconds, expected remaining time: 15 seconds. Number of buffers: 0, no next process.

Using the above values, the priority of trouble handling in each of steps 3 and 7 is calculated as follows.
Process 3: Priority = (1 * 90-10) + (30 + 40)-(20) = 130
Step 7: Priority = (− 15) + (20 + 5) − (0) = 10
In addition, it is assumed that three workers, worker 1, worker 2, and worker 3, are assigned to the production line, and each worker is performing the following work. Worker 1: Work with priority 20, Worker 2: Empty, Worker 3: Work with priority 50

  Based on the above priority and the situation of the worker, first, an instruction is sent to the terminal of the worker 2 to carry out the troubleshooting in step 3. On the other hand, since the worker 1 is working with the priority 20 and the worker 3 is working with the priority 50, the trouble of the step 7 with the priority 10 lower than that is not supported by any worker. In this case, when the high priority treatment is completed, the response to the step 7 is instructed.

  The present invention has been described above using the above-described embodiment as an exemplary example. However, the present invention is not limited to the above embodiment. That is, the present invention can apply various modes that can be understood by those skilled in the art within the scope of the present invention.

DESCRIPTION OF SYMBOLS 1 Stop cause stop condition acquisition means 2 Stop cause stop history memory | storage means 3 Stop corresponding | compatible priority determination means 100 Process monitoring server 110 Process monitoring part 200 Stop cause stop history DB
300 stop management server 310 stop expected time acquisition unit 320 response priority setting unit 330 worker management unit 340 instruction creation unit 400 terminal

Claims (10)

Monitoring a production line having a plurality of processes, and when the process is stopped, a stop cause stop status acquisition means for acquiring a stop cause and a stop status;
A stop cause stop history storage means for storing a history of the stop cause and the stop status as a stop cause stop history;
Stop correspondence priority order determining means for determining a priority order for performing the stop correspondence of the process based on the cause of the stop, the stop condition, and the stop cause stop history when a plurality of the processes are stopped. Production support system characterized by The stop cause stop history storage means is
The production support system according to claim 1, wherein a stop history including a stop time is held for each stop cause. The stop cause stop history storage means is
The production support system according to claim 2, wherein a stop expected time corresponding to the cause of the stop calculated based on the stop time and the stop history is held. The said stop corresponding | compatible priority determination means calculates the priority which performs stop stop of the said process based on the said stop estimated time, and determines the said priority based on the said priority. Production support system. The stop cause stop status acquisition means is
Monitor the progress of the process and the progress of the process,
The stop correspondence priority order determining means calculates a priority for performing stop correspondence of the process based on the in-process status and the progress status of the process, and determines the priority order based on the priority. The production support system according to claim 4. 6. The production support system according to claim 4, wherein the stop correspondence priority order determination unit notifies an operator who executes the stop correspondence based on the priority to a stop correspondence instruction of the process. . The stop correspondence priority determination means holds the priority of the work that the worker is currently executing,
The production support system according to claim 6, wherein the stop correspondence instruction for the process is notified to the worker based on a comparison result between the priority and a priority for performing the stop correspondence of the process. Monitor production lines with multiple processes,
When the process stops, obtain the cause of the stop and the stop status,
Store the history of the stop cause and the stop status as a stop cause stop history,
When a plurality of the processes are stopped, a priority order for performing the stop response of the processes is determined based on the stop cause, the stop status, and the stop cause stop history. The production support method according to claim 8, wherein a stop history including a stop time is held in association with the cause of the stop. Monitoring a production line having multiple processes;
When the process stops, obtaining a stop cause and a stop state;
Storing the history of the stop cause and the stop status as a stop cause stop history;
A step of determining a priority order for performing stop of the process based on the stop cause, the stop state, and the stop cause stop history when a plurality of the processes are stopped. Support program.

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