JP4279639B2 - Production management apparatus and production management method - Google Patents

Description

  The present invention relates to a production management apparatus and a production management method for resetting a production schedule when a failure occurs in a production line for steel products.

  When an equipment failure occurs in a steel product production line, in the conventional technology, many measures as described below have to be performed based on the judgment of the worker of the production line.

  When an equipment failure occurs in the production line, the production line must first be stopped, the cause of the failure must be investigated, and the failure point must be recovered early. On the other hand, if the operation is continued even if the equipment in which the equipment failure has occurred is suspended, the operation is continued with the equipment suspended until the equipment is restored (hereinafter referred to as this operation state). Is called “provisional operation”).

  However, when the temporary operation is performed, not all the production lines are completely operated, so that there are operational restrictions such as the type and size of the product being limited. Therefore, the worker had to reorganize the production schedule by moving the product that cannot be manufactured by the temporary operation later or by transferring to a different product that can be manufactured.

  In the temporary operation, a process for reassembling the production schedule is generated in this way, and in some cases, many workers need to be involved in this process. For example, the primary contact to the personnel required to stop or cope with the operation is the person in charge of the operation. It is determined whether the operation can be continued with some facilities suspended, and the operational restrictions of temporary operation with some facilities suspended are the operation engineer, manufacturing schedule based on operational restrictions due to temporary operation It is the person in charge of production management who reorganizes.

In this way, many people are involved in the event of a failure, so if there is a failure in the middle of the night or on a holiday, you will be in contact with each other, hold a meeting, etc. It took a lot of time to call urgently and start temporary operation. Therefore, until the temporary operation started, the operation was stopped and the productivity deteriorated.
JP-A-5-342222 JP 2000-172308 A

  The problem to be solved is the human work load that is required until the temporary operation starts when a failure occurs. When a failure occurs, the production schedule is reset according to the state of the equipment failure. An object of the present invention is to provide a production management device and a production management method.

  In order to achieve the above object, the production management device according to claim 1 is a production management device for managing the production schedule of steel products, and when an abnormality occurs in the devices constituting the production line. Fault signal to be generated, failure data recording a case relating to the abnormality of the device corresponding to the abnormality signal, provisional operation method data recording a control method of the device corresponding to a case relating to the abnormality of each device, and individual Storage means for storing temporary operation restriction condition data recording restriction conditions for performing temporary operation of the apparatus corresponding to the case relating to the abnormality of the apparatus, and when the abnormality signal is input, the failure data is referred to Thus, a failure case determination unit that identifies a device in which a failure or abnormality has occurred, specifies the content of the abnormality that has occurred, and a content of the abnormality identified by the failure case determination unit. The temporary operation method determining means for acquiring the control method of the individual device at the time of temporary operation from the temporary operation method data, and the constraint condition when performing the temporary operation according to the control method of the individual device. Provisional operation schedule determination means for determining the production schedule at the time of provisional operation based on the provisional operation restriction condition determination means acquired from the condition data, the production schedule for normal operation, the control method of individual devices, and the restriction conditions Means.

  In the present invention, “abnormality” includes “failure” of the apparatus.

  The production management device according to claim 2 is the production management device according to claim 1, wherein the storage means has a period for performing temporary operation of the device corresponding to a case relating to an abnormality of each device. The recorded temporary operation period data is stored, the temporary operation method determining means obtains a period of temporary operation from the temporary operation period data, and the temporary operation schedule determining means is a production schedule for normal operation And a manufacturing schedule for a period in which the temporary operation is performed is determined based on the control method of each device and the constraint conditions.

  The production management method according to claim 3 is a production management method of a management device that manages a production schedule of steel products, and an abnormality signal that is generated when an abnormality occurs in an apparatus constituting a production line is input. A failure case determination step for identifying a device in which a failure or abnormality has occurred with reference to failure data recording a case relating to the abnormality of the device corresponding to the abnormality signal, and identifying the content of the abnormality that has occurred And a temporary operation method in which the control method of each device at the time of temporary operation is recorded based on the contents of the abnormality specified in the failure case determination step, and the control method of the device corresponding to the case regarding the abnormality of each device is recorded. Temporary operation method determination process acquired from data, and the corresponding device corresponding to the cases related to the abnormalities of individual devices, the constraint conditions when performing temporary operation according to the control method of each device Based on the provisional operation restriction condition determination process acquired from the provisional operation restriction condition data that records the restriction conditions for provisional operation, the production schedule for normal operation, the control method and restriction conditions of each device And a temporary operation schedule determination step for determining a production schedule at the time of temporary operation.

  The production management method according to claim 4 is the production management method according to claim 3, wherein the temporary operation method determining step performs provisional operation of the device corresponding to a case relating to an abnormality of each device. The period for performing the temporary operation is acquired from the temporary operation period data in which the period to be performed is recorded. The production schedule for the period of temporary operation is determined.

  According to the present invention, when an abnormality occurs, the manufacturing schedule is reset according to the situation, so that the human work load can be reduced, and the provisional operation can be started quickly. The fall of property can be prevented.

  First, a production line to which the production management apparatus 1 of the present invention is applied will be described. FIG. 9 shows a schematic diagram of the production line.

  The hot metal sent from the blast furnace is put into the converter. In the converter, the amount of carbon contained in the hot metal is adjusted, and a special alloy is added to roughly adjust the components. The production unit in this converter is called charge, and the component adjusted in the converter is called molten steel.

  Move the molten steel to the ladle, move the ladle to a predetermined place, and then perform secondary refining. In secondary refining, the components of the molten steel are finely adjusted. The molten steel that has undergone secondary refining is transferred to continuous casting. In continuous casting, molten steel is taken out from the bottom of the ladle and cooled with water to continuously produce slabs.

  The manufactured slab is stored in a slab yard, and then charged into a heating furnace called a tunnel furnace. After the temperature rises, the slab is hot rolled by a hot rolling mill to become a coil. The coil is stored in a coil yard.

  Each production device constituting such a production line is notified of malfunctions or abnormalities in equipment, such as a sensor for detecting and notifying malfunctions or abnormalities, or an abnormal alarm device for notifying occurrence of abnormalities when operated by an operator. Equipment (not shown) is provided.

  When a failure or abnormality occurs, an abnormality signal is sent from the equipment provided in each production apparatus to the production management apparatus 1 of the present invention, and the production management apparatus 1 receives the abnormality signal. Then, generation of temporary operation schedule data (temporary schedule data 21) is started.

  By adding information identifying the device to the abnormal signal, by making the abnormal signal into a specific signal pattern for each device, or by preparing an input port for receiving the abnormal signal for each device, It is possible to specify which production device has an abnormality.

  Moreover, in embodiment shown below, in order to demonstrate clearly, it demonstrates taking the case where a failure and abnormality generate | occur | produce in the apparatus which comprises a hot rolling line (consisting of seven rolling stands).

  Next, an embodiment of the present invention will be described with reference to FIGS.

  As shown in FIG. 1, the production management apparatus 1 in this embodiment includes a failure case determination unit 2, a temporary operation method determination unit 3, a temporary operation constraint condition determination unit 4, and a temporary operation schedule determination unit 5. Data 11, provisional operation method data 12, provisional operation period data 13, provisional operation restriction condition data 14, operation restriction condition data 15, facility capacity data 16, and schedule data 17 are stored in a storage device or auxiliary storage device (not shown). Yes.

  When a failure signal is input, the failure case determination unit 2 refers to the failure data 11, identifies a production facility in which a failure or abnormality has occurred, and has a function of identifying the content of the failure that has occurred and the state of the failure. Have.

  In addition, the temporary operation method determination unit 3 determines the control method and temporary operation of each production apparatus during the temporary operation until the recovery based on the contents of the abnormality specified by the failure case determination unit 2 and the state of the failure. It has a function of determining the period to be performed.

  In addition, the temporary operation constraint condition determination unit 4 has a function of acquiring a constraint condition when performing a temporary operation according to the control method of each production apparatus.

  Moreover, the temporary operation schedule determination part 5 has a function which determines the manufacturing schedule at the time of temporary operation based on the production schedule at the time of performing normal operation, and the constraint conditions at the time of performing temporary operation.

  The failure data 11 is data in which cases related to failures and abnormalities in each production device corresponding to the abnormality signal are recorded. The failure data 11 for the hot rolling line constitutes a hot rolling line as shown in FIG. The first rolling stand, the second rolling stand, etc. An abnormal signal emitted from the seventh rolling stand and an abnormal case corresponding to the abnormal signal are recorded in the item of abnormal contents.

  For example, the failure data 11 shown in FIG. 2 indicates that the hydraulic device of the first rolling stand has failed when an abnormal signal is issued from the abnormal input 1 of the first rolling stand, and at the same time, the abnormal input 2 When the abnormal signal is issued, the electric device of the first rolling stand has also failed, indicating that the first rolling stand has failed.

  Moreover, the temporary operation method data 12 is data in which a control method of each production apparatus corresponding to a case relating to a failure or abnormality of each production apparatus is recorded, and the temporary operation method data 12 for the hot rolling line is shown in FIG. Thus, according to the example which generate | occur | produced, operation | movement of each hydraulic device from a 1st rolling stand to a 7th rolling stand and each electrically-driven apparatus is recorded.

  For example, the temporary operation method data 12 in FIG. 3 indicates that when the hydraulic device of the first rolling stand fails, the electric device of the first rolling stand is controlled to open the roll gap and rotate the roll. Yes.

  In addition, as shown in FIG. 4, the temporary operation period data 13 includes items of abnormal contents and temporary operation periods. Recorded data.

  The temporary operation constraint data 14 is data that records the constraint conditions for performing the temporary operation of each production device corresponding to a case related to a failure or abnormality of each production device, and the temporary operation constraint data for the hot rolling line. As shown in FIG. 5, the condition data 14 records the steel type, coil thickness, coil width, and coil length of the coil manufactured in the hot rolling line.

  For example, the temporary operation constraint data 14 in FIG. 5 indicates that when the hydraulic device of the first rolling stand fails, the coil having a coil thickness of 2.0 mm or less is not manufactured, and the entire first rolling stand is In the case of failure, it indicates that the manufacture of a coil of steel grade β is not performed, and that a coil having a coil thickness of 2.0 mm or less and a coil having a coil width of 1650 mm or less are not manufactured.

  The operation constraint condition data 15 is data in which operation constraints are recorded for each production line. The operation restriction condition data 15 for the hot rolling line records the rolling order restriction, for example, the coffin schedule. The coffin schedule indicates a rolling order, and is usually rolled in order from a wide coil to a narrow coil. The rolling order is also limited by the hardness, steel type, and thickness of the coil (from a thick coil to a thin coil).

  The equipment capacity data 16 is data in which man-hours required in each process of the converter, secondary refining, continuous casting, heating, and rolling are recorded. The man-hour mentioned here is a unit processing time required for manufacturing in each process, for example, a time required to heat one slab or a time required to roll one slab. . The number of man-hours varies depending on the steel type of the coil and the size of the slab even in the same process.

  The schedule data 17 is data that records a production schedule when each production line operates normally, and the schedule data 17 for the hot rolling line includes a production number, a production date, and a start, as shown in FIG. The data includes items of time, order steel type, manufacturing coil thickness, manufacturing coil width, manufacturing coil length, and manufacturing coil weight.

  Next, operation | movement of the production management apparatus 1 is demonstrated using the flowchart of FIG.

  The hot rolling mill of the hot rolling line is composed of a plurality of rolling stands (seven rolling stands in FIG. 9). Each of the rolling stands is provided with upper and lower rolls, and the distance between the upper and lower rolls is controlled by two devices, an electric device and a hydraulic device. Make it thick. Now, assume that the hydraulic device of the first rolling stand has failed and an abnormal signal is issued to the production management device 1.

  Upon receiving the abnormal signal (step S01), the failure case determination unit 2 of the production management device 1 specifies the device that issued the abnormal signal, and then specifies the abnormal content generated with reference to the failure data 11 (step S01). S02). When the received abnormality signal is from the abnormality input 1, the failure case determination unit 2 acquires the abnormality content “failure of the first rolling stand hydraulic device”, and the occurrence of the abnormality and “failure of the first rolling stand hydraulic device” Is generated and notified to the provisional operation method determination unit 3. At this time, the failure case determination unit 2 may refer to the failure data 11 after a predetermined time has elapsed since the first abnormal signal was received.

  When the provisional operation method determination unit 3 receives the abnormality content code, the provisional operation method data 12 refers to the provisional operation method data 12 and acquires the control method of each production apparatus corresponding to the generated abnormality content (step S03). If it is an abnormal content “failure of the first rolling stand hydraulic device”, the temporary operation method determination unit 3 acquires a control method called “roll rotation” of the electric device of the first rolling stand from the temporary operation method data 12.

  Next, the temporary operation method determination unit 3 refers to the temporary operation period data 13 and acquires a period during which the temporary operation corresponding to the generated abnormal content is performed (step S04). Since the “first rolling stand hydraulic device failure” occurred, the temporary operation method determination unit 3 acquires “12 hours” as the period for performing the temporary operation. The period for which the temporary operation is performed may be set to a period that the operator is expected according to the actual situation. The temporary operation method determination unit 3 generates a temporary operation code including a code indicating a device to be controlled and a control method, and a code indicating a period for performing the temporary operation, and notifies the temporary operation constraint condition determination unit 4 together with the abnormal content code. .

  When the temporary operation constraint condition determination unit 4 receives the abnormality content code and the temporary operation code, the temporary operation constraint condition determination unit 4 refers to the temporary operation constraint condition data 14 and acquires the constraint condition when performing the temporary operation according to the control method of each production apparatus. (Step S05). For example, if the number of operable rolling stands decreases, the minimum sheet thickness that can be rolled must be made larger than usual. Since the “first rolling stand hydraulic device failure” occurred, the provisional operation constraint condition determination unit 4 acquires “coil thickness 2.0 mm” as a constraint condition and generates a condition code indicating this constraint condition. The abnormal content code and the temporary operation code are supplied to the temporary operation schedule determination unit 5. This “coil thickness of 2.0 mm” indicates that “rolling with a hot coil thickness of 2.0 mm or less is not performed”.

  When the provisional operation schedule determination unit 5 receives the abnormality content code, the provisional operation code, and the condition code, first, the provisional operation schedule determination unit 5 refers to the schedule data 17 to obtain a normal production schedule (step S06). Next, the temporary operation schedule determination unit 5 changes the manufacturing schedule according to the constraint condition indicated by the condition code. Since the constraint condition here is “coil thickness 2.0 mm”, coils thinner than 2.0 mm are excluded from the manufacturing schedule.

  Next, the temporary operation schedule determination unit 5 refers to the operation constraint condition data 15 and the facility capacity data 16 to determine whether there is any coil whose manufacturing schedule does not match the conditions for normal operation due to the change. Coils that do not meet the operating conditions are excluded from the manufacturing schedule.

  Next, the temporary operation schedule determination unit 5 adjusts the time length of the manufacturing schedule at the time of temporary operation based on the temporary operation code. For example, if “12 hours” is recorded in the temporary operation code as the period of temporary operation, it indicates that normal operation is possible after 12 hours. Since a production schedule is not required, a production schedule having a time length exceeding the period of temporary operation is not set.

  In this way, the temporary operation schedule determination unit 5 sets the production schedule at the time of temporary operation, generates temporary schedule data 21 in which the production schedule at the time of temporary operation is recorded (step S07), and outputs it. Each production apparatus is controlled on the basis of the outputted temporary schedule data 21, and temporary operation is performed.

  In addition, since the coil manufactured in the temporary manufacturing schedule must be excluded from the normal manufacturing schedule, the temporary operation schedule determination unit 5 changes the schedule data 17 after generating the temporary schedule data 21. FIG. 8 shows provisional schedule data 21 output by the provisional operation schedule determination unit 5.

  In addition, when the abnormality is resolved and normal operation is possible, the product recorded in the temporary schedule data 21 is recorded in the manufacturing performance as a coil that must be remanufactured and is reflected in the manufacturing schedule again. .

  In addition, the abnormal example of the hot rolling line shown in this embodiment is a mere example, and is not limited to this. For example, in the case of a hydraulic apparatus, the abnormal situation may be classified in more detail, such as “hydraulic abnormality rise” and “hydraulic abnormality drop”. In addition, the temporary operation method of the hydraulic device and the electric device, and the constraint conditions of the coil to be manufactured are merely examples, and it is natural that the operation method and the constraint conditions of each production device can be determined by dividing the abnormal situation in detail. Come different.

  Further, in this embodiment, the manufacturing schedule at the time of temporary operation of the hot rolling line is set due to the abnormality that has occurred in the hot rolling line, but actually, the manufacturing schedule at the time of temporary operation of other processes is also the same. The provisional schedule data 21 is generated.

  Moreover, the program describing the processing performed by the failure case determination unit 2, the temporary operation method determination unit 3, the temporary operation constraint condition determination unit 4, and the temporary operation schedule determination unit 5 shown in FIG. The production management apparatus 1 may be realized by executing it.

It is a figure which shows the function structure of a production management apparatus. It is a figure which shows failure data. It is a figure which shows provisional operation method data. It is a figure which shows provisional operation period data. It is a figure which shows provisional operation restriction condition data. It is a figure which shows schedule data. It is a flowchart which shows the process sequence of a production management apparatus. It is a figure which shows provisional schedule data. It is a schematic diagram of the manufacturing line to which this invention is applied.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Production management apparatus 2 Failure example determination part 3 Temporary operation method determination part 4 Temporary operation restriction condition determination part 5 Temporary operation schedule determination part 11 Failure data 12 Temporary operation method data 13 Temporary operation period data 14 Temporary operation restriction condition data 15 Operation restriction Condition data 16 Equipment capacity data 17 Schedule data 21 Temporary schedule data

Claims (4)

A production management device for managing the production schedule of steel products,
Fault data that is generated when an abnormality occurs in a device constituting the production line, and failure data that records a case related to the abnormality of the device corresponding to the abnormality signal;
Temporary operation method data recording the control method of the device corresponding to the case regarding the abnormality of each device,
Temporary operation constraint data that records the constraint conditions for performing the temporary operation of the device corresponding to the case relating to the abnormality of each device;
Storage means for storing
When an abnormality signal is input, referring to the failure data, a failure occurrence determination unit that identifies a device in which a failure or abnormality has occurred, and identifies the content of the abnormality that has occurred,
Based on the contents of the abnormality specified by the failure case determination means, the temporary operation method determination means for acquiring the control method of each device at the time of temporary operation from the temporary operation method data;
Temporary operation constraint condition determining means for acquiring the constraint condition when performing temporary operation according to the control method of each device from the temporary operation constraint condition data,
Temporary operation schedule determination means for determining a production schedule at the time of temporary operation, based on the production schedule when normally operating, the control method of individual devices, and the constraint conditions;
A production management device comprising: The storage means stores temporary operation period data in which a period of temporary operation of the device corresponding to a case regarding an abnormality of each device is recorded,
The temporary operation method determining means acquires a period for performing the temporary operation from the temporary operation period data,
The temporary operation schedule determination means determines a production schedule for a period of temporary operation based on a production schedule for normal operation, a control method of individual devices, and constraint conditions. The production management apparatus according to 1. A production management method for a management device for managing a production schedule of steel products,
When an abnormal signal that is generated when an abnormality occurs in a device that constitutes a production line, a failure or an abnormality occurs with reference to failure data that records cases related to the abnormality of the device that correspond to the abnormal signal. A failure case determination process for identifying the device and identifying the content of the abnormality that has occurred,
Based on the contents of the abnormality specified in the failure case determination process, the control method of each device at the time of temporary operation is determined based on the temporary operation method data recording the control method of the device corresponding to the case regarding the abnormality of each device. A provisional operation method determination step to be acquired;
Acquire constraint conditions for temporary operation according to the control method of each device from temporary operation constraint data that records the constraint conditions for the temporary operation of the device corresponding to the cases related to individual device abnormalities A provisional operation constraint condition determination process,
Temporary operation schedule determination step for determining the production schedule at the time of temporary operation based on the production schedule when normally operating, the control method of individual devices, and the constraint conditions;
A production management method comprising: The provisional operation method determination step acquires a period for performing provisional operation from provisional operation period data recording a period for performing provisional operation of the apparatus corresponding to an example related to the abnormality of each apparatus,
The temporary operation schedule determination step determines a production schedule for a period of temporary operation based on a production schedule at the time of normal operation, a control method of individual devices, and constraint conditions. 3. The production management method according to 3.

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