JP2803864B2 - Production quantity analysis system - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION [Industrial Application Field] The present invention relates to a production state quantity analysis system for predicting a production amount and a quality prediction of a production facility.

[Related Art] Conventionally, there has been proposed a production state quantity analysis system that predicts a production result by formulating the capability of a production facility in advance (also called simulation). An equation for predicting a production result used in the production state quantity analysis system is represented by the following equation.

P = f (s, c) (1) Here, P is an output state quantity, and each output element representing the production quantity and the quality of the produced product, for example, weight,
It is represented by a matrix such as the color and the number of defective products.

s is an input state quantity, which is represented by a matrix of input elements of raw materials supplied to the production equipment, for example, input elements such as weight, components, and temperature.

c is a process state quantity, which indicates a production processing state in the production process, and is represented by a matrix of each process element such as an additive and operating conditions.

 f means a function.

When the production is started, the production state quantity analysis system performs a statistical analysis using the data indicating the input state quantity described above, the process state quantity corresponding to the time when the data is input, and the data indicating the actually measured output state quantity. And the above function f
(S, c) is calculated automatically. Specifically, the function f (s, c)
Is expressed by f (s, c) = A × C + B × S (2), and the values of the constants A and B are determined.

By substituting the input state quantity and the process state quantity into the arithmetic expression thus determined, and calculating the output state quantity,
Predict output state quantities. Diagnosis processing of the cause of the abnormality is also performed using the output state quantity prediction function.

In other words, when the product obtained as a result of the production has a quality defect, the facility operator prints each element data of the input state quantity, the process state quantity and the actually measured output state quantity accumulated and stored in the production state quantity analysis system. The output and the print result are referred to, and the elements of the input state or the process state considered to be the cause of the abnormality are retrieved and extracted based on past experience.
Next, the data on the searched and extracted element is changed, and the output state quantity of the element having the abnormality is calculated by the production state quantity analysis system using the changed data. When the calculation result becomes normal, it is determined that the searched and extracted element is the cause of the abnormality.

[Problems to be solved by the invention] However, in the conventional production state quantity analysis system,
As the data of the input state quantity and the process state quantity increases, the equipment operator refers to more data when performing the abnormality diagnosis. In addition, the calculation of the output state quantity must be performed by trial and error in order to search for the element of the cause of the abnormality. As a result, the conventional system has a problem that it takes time to analyze the cause of the abnormality.

The applicant of the present application has proposed a production state quantity analysis system which shortens the analysis time of an abnormal cause by automatically extracting an input element or a process element having a high influence on a designated output element in October, 2001. Suggested on the 2nd.

However, in the above proposal, as the number of data of input elements and process elements is larger, it takes more time to create an output state formula,
There was room for improvement.

In view of the above, an object of the present invention is to provide a production state quantity analysis system that can reduce the time required to generate an output state equation.

[Means for Solving the Problems] In order to achieve such an object, the present invention provides one or more input elements indicating an input state of raw materials input to a production facility, and a production state in a production process of the production facility. Show 1
Specifying means for selecting and specifying the above-mentioned process elements and output elements indicating respective output states of a plurality of processes in the production process; and actual measurement at the production facility for all of the input elements, the process elements and the output elements Storage means for storing a value, reading means for reading the measured value of the element specified by the specifying means from the storage means, and performing statistical processing on the measured value read by the reading means to perform a state of the output element Arithmetic processing means for creating an arithmetic expression for calculating the quantity based on the state quantities of the input element and the process element.

In addition, 1 indicates the input state of raw materials to be input to the production equipment.
The input elements described above, one or more process elements indicating a production state in a production process of the production facility, and output elements indicating output states of a plurality of processes in the production process are predetermined, and the input element, the process element, and the output are determined. Storage means for storing measured values of all of the elements in the production facility, designating means for selecting and designating steps in the production process, and actual measurement of elements contained in the steps designated by the designating means Reading means for reading a value from the storage means, and an operation for performing statistical processing on the actually measured value read by the reading means to calculate the state quantity of the output element from the input element and the state quantity of the process element Arithmetic processing means for generating an expression.

[Operation] In the present invention, an arithmetic expression (output) representing an output state of an output element by selectively using an arbitrary step or any one of an input, a step, and an output element among all the steps in a production facility. State expression). Therefore, as compared with the related art, the time required to create the above-mentioned arithmetic expression can be shortened with a reduction in the number of handling data and the number of steps for creating the arithmetic expression.

[Example] Hereinafter, an example of the present invention will be described in detail with reference to the drawings.

 FIG. 1 shows a basic configuration of an embodiment of the present invention.

In FIG. 1, reference numeral 100 denotes one or more input elements indicating an input state of raw materials input to a production facility, one or more process elements indicating a production state in a production process of the production facility, and a plurality of steps in the production process. Is an specifying element for selecting and specifying an output element indicating each output state.

Reference numeral 200 denotes storage means for storing actual measured values of the input element, the process element, and the output element in the production facility.

Reference numeral 300 denotes reading means for reading the measured value of the element specified by the specifying means from the storage means, and performs statistical processing on the actually measured value read by the reading means to determine the state quantity of the output element by the input element and the input element. It is an arithmetic processing means for creating an arithmetic expression for calculating from the state quantity of the process element.

The designation means 100 also designates a process,
The reading means also reads the measured values of the elements included in the designated process.

 FIG. 2 shows a specific circuit configuration of the embodiment of the present invention.

In FIG. 2, a computer 1, a disk storage device 2,
A keyboard input device 3, a display device 4, a printing device 5, and an input / output interface 6 are connected to a common bus 7.

The computer 1 controls the operation of the entire production state quantity analysis system, and also performs output state quantity prediction processing and abnormality diagnosis processing according to the present invention. The computer 1 operates as reading means and arithmetic processing means.

The disk storage device 2 stores, as storage means, data indicating actual measured input state quantities, process state quantities, and output state quantities input from the production equipment 20 via the keyboard input device 3 and / or the input / output interface 6 for each element item. To the disk. Further, the keyboard input device 3 operates as an instruction unit.

The display device 4 is used when displaying the prediction result of the output state quantity and the abnormality diagnosis result calculated by the computer 1. The printing device 5 is used to print out data such as input state quantities, process state quantities, and measured output state quantities stored in the disk storage device 2.

FIG. 3 shows an address configuration of a data storage area of each state quantity of the disk of the disk storage device 2.

The memory address is configured to store input data at each data input time, and a data storage area is determined for each element.

FIG. 4 shows the address configuration of the storage area of the prediction data of the output state quantity of the disk of the disk storage device 2.

The storage area is defined such that the memory address stores the time information when the data of the input state quantity is input and the predicted data of the output state quantity when the raw material input at that time is output as a product in association with each other. Have been.

Next, the output state quantity Y (t) of the present invention is converted to the process state quantity X.
(T) and an arithmetic expression calculated from the input state quantity U (t) will be described.

That is, the output state quantity Y (t) is obtained by the following equation.

Y (t) = AX (t) + BU (t) (2) In the above _{formula, y 1 (t) ~y n} (t) is the output state quantity Y
These are the level values of 1 to n (positive integer) elements (output elements) constituting (t), and represent the actual measured values of the output elements for the raw material input at time t.

x ₁ (t) to x _m (t) are level values indicating the states of _{1 to m} (positive integer) elements (process elements) constituting the process state quantity X (t), and are input at time t. Represents the state of the process element added to the raw material.

u ₁ (t) to u _l (t) are levels indicating the states of 1 to 1 (positive integer) elements (input elements) of the raw material input at time t constituting the process state quantity U (t). Value.

A and B are constants determined from measured output state quantities.
Constant A is represented by the matrix of each count a ₁₁ ~a _nm prescribed in combination with n output element and the m process elements. The constant B is represented by a matrix of counts b _{11 to} b _nl determined by a combination of n output elements and 1 input elements.

In this embodiment, as shown in FIG. 5, input elements, process elements, and output elements are classified for each process position, and the corresponding process numbers are assigned in advance.

These pieces of information are tabulated and stored in the disk storage device 2.
Is stored in a disk in the, and is used for creating the output state formula together with flag information described later.

The above-mentioned arithmetic expression is an expression that uses all the elements related to the production equipment. However, if all these elements are used, it takes a long time to create the elements. Are selectively specified to generate output state expressions for these specified elements and / or steps.

Hereinafter, the procedure for generating the output state formula according to the present invention will be described with reference to the flowcharts of FIGS. 7 to 9.

(I) Creation of an output state equation by designating an element The computer 1 executes the control procedure shown in FIG. This control procedure includes an input process for designating an element and / or a process (step S100), a process for creating an output state equation (step S200), and an analysis (prediction) process for an output state quantity using the created output state equation (step S300).
It is composed of

FIG. 8 shows a detailed control procedure of the input processing in step S100 of FIG.

In FIG. 8, the flag information is initialized. As shown in FIG. 5, the flag information is provided for each element. When flag information is on (bit “1”), it indicates that there is a designation, and when flag information is off (bit “0”), there is no designation. Is shown. The flag information is given as an initial value.

Subsequently, the production state quantity analysis diagram shown in FIG.
(Step S101 → S102). The production state quantity analysis diagram shows the names and numbers of the production processes, the names and numbers of the input, process, and output elements in each process, and the connection of each process.

When the user designates and inputs an element number in the display screen using the cursor keys of the keyboard input device 3 using the cursor, the computer 1 identifies the element specified by the user based on the position of the cursor. Subsequently, the flag information corresponding to the designated element is turned on (steps S103 → S104 → S1)
04-1).

Hereinafter, the same procedure is repeated, the flag information of the designated element is turned on, and the control procedure is terminated by a user's input termination instruction.

Next, the creation process of the output state formula in step S200 in FIG. 7 will be described with reference to FIG.

In FIG. 9, a flag information table (see FIG. 5)
The first flag information is read from, and the presence or absence of designation is confirmed (step S201 → S202 → S203). By this confirmation, the number of elements specified for each element is counted. By this counting, p input elements, q process elements, and r output elements are obtained.

Next, each state quantity in the output state equation (5) is set based on this number information. More specifically, matrix variables representing input state quantities, process state quantities, and output state quantities are set. Subsequently, matrix variables a (1,1) to a (r, q) representing the coefficient A and matrix variables b (1,1) to b (r, p) representing the coefficient B in the output state formula are set.

Hereinafter, the values of the coefficients A and B are obtained by the regression analysis method using the actually measured values of the designated elements (steps S207 and S20).
8).

When the production state quantity is predicted at the time T, the values of a ₁₁ and b ₁₁ calculated by the above equation (5) and the measured values of the input elements and the process elements obtained corresponding to the time T are substituted. Thus, the predicted value of the output element is calculated. Further, when the value of the process element has not been obtained, the predicted value of the output element is calculated by substituting the value to be set.

(Ii) Creation of output state equation by designating process In the display state of the production state quantity analysis diagram in FIG. 6, when a process is selected and designated, the computer 1 turns on all flag information of elements of the designated process. (Steps S102 → S103 → S103-1 in FIG. 8).

Hereinafter, based on the flag information, an output state formula is created in the same procedure as in the element specification.

By using the output state formula created in this way, prediction and analysis of the output state of an arbitrary process and the output state of the final process are executed in step S300 in FIG.

As described above, in the present embodiment, the input element, the process element, and the output element are selectively designated, and an output state expression of only the designated element is created.

In the regression analysis method, since the matrix A is expanded to calculate the coefficients A and B, the creation time of the output state equation is proportional to about the square of the number of elements. For this reason, compared with the conventional example in which all the elements must be used, in this embodiment, since the process and the elements are selected, the time required to create the output state equation can be greatly reduced.

In addition, after analyzing the production state quantities using all the elements, elements and processes that do not affect the output state quantities can be omitted from the analysis processing, contributing to shortening the analysis processing time. Can be.

 The following example can be considered in addition to the present embodiment.

(1) In this embodiment, the creation of the production state quantity on the premise that the first step and the input element of that step are specified has been described. The value of the output element immediately before the head of the performed process or element may be automatically set by the computer 1 as the value of the input element. Further, the value of the input element of the designated first step may be input from the keyboard input device 3 as needed.

(2) In the present embodiment, only the automatic creation processing of the output state equation has been described. However, the analysis processing function of the production state quantity analysis system is used to analyze the cause of the abnormality by the output state equation created in the embodiment. Needless to say, it may be performed.

(3) In the present embodiment, an example in which the step designation and the element selection designation are separately performed has been described, but the step selection designation and the element selection designation may be used in combination. Further, in selecting and selecting a process, a process may be selected by specifying a range of the first and last processes.

Furthermore, when there are a large number of elements, unnecessary elements or steps may be specified to specify the elements used in the output state formula.

In this case, an on value is given to the flag information, and the element specified by the user is turned off.

[Effects of the Invention] As described above, according to the present invention, an output is performed by selectively using an arbitrary one of all the processes in a production facility or any one of input, process, and output elements. An arithmetic expression (output state expression) representing the output state of the element is created. Therefore, as compared with the related art, the time required to create the above-mentioned arithmetic expression can be shortened with a reduction in the number of handling data and the number of steps for creating the arithmetic expression. In addition, by inputting post-processes and changing process conditions for abnormal products detected in the middle of the production process, it is possible to easily execute a prediction process as to whether or not the quality can be modified. Can be

[Brief description of the drawings]

FIG. 1 is a block diagram showing a basic configuration of an embodiment of the present invention, FIG. 2 is a block diagram showing a specific circuit configuration of the embodiment of the present invention, and FIGS. FIG. 6 is an explanatory view showing a display example of the embodiment of the present invention, and FIGS. 7 to 9 are flowcharts showing control procedures executed by the computer 1 of the embodiment of the present invention. is there. DESCRIPTION OF SYMBOLS 1 ... Computer, 2 ... Disk storage device, 3 ... Keyboard input device, 4 ... Display device, 5 ... Printing device, 6 ... Input / output interface, 10 ... Production state quantity analysis system, 20 ... Production equipment.

Continuation of the front page (72) Inventor Kazuki Baba 1-3-1 Yoko, Kawasaki-ku, Kawasaki-shi, Kanagawa Prefecture Asahi Engineering Co., Ltd. (56) References JP-A-62-268260 (JP, A) JP-A-3 -121755 (JP, A) JP-A-63-312050 (JP, A) (58) Fields investigated (Int. Cl. ⁶ , DB name) B23Q 41/00-41/08 G06F 17/60, 19/00 G05B 23/02

Claims (2)

(57) [Claims] At least one input element indicating an input state of a raw material input to a production facility, at least one process element indicating a production state in a production process of the production facility, and each output of a plurality of processes in the production process. Specifying means for selecting and specifying an output element indicating a state; storage means for storing actual measured values of the input element, the process element, and the output element in the production facility; and elements specified by the specifying means Reading means for reading the measured value of the data from the storage means; and performing statistical processing on the measured value read by the reading means to calculate the state quantity of the output element by the state quantity of the input element and the process element. A production state quantity analysis system, comprising: an arithmetic processing unit that creates an arithmetic expression. 2. One or more input elements indicating an input state of raw materials to be input to a production facility, one or more process elements indicating a production state in a production process of the production facility, and respective outputs of a plurality of steps in the production process. An output element indicating a state is predetermined,
Storage means for storing measured values of all of the input elements, process elements and output elements in the production facility, designating means for selecting and designating a process in the production process, and a process designated by the designating means Reading means for reading the measured values of the elements contained in the storage means from the storage means; and performing statistical processing on the measured values read by the reading means to obtain the state quantities of the output elements of the input elements and the process elements. A production state quantity analysis system, comprising: an arithmetic processing unit that creates an operation expression for calculating the state quantity.