JP4696786B2 - Production line management apparatus, production line management method, program, and computer-readable recording medium recording the program - Google Patents

Description

  The present invention relates to a production line management apparatus, a production line management method, a program, and a computer-readable recording medium on which the program is recorded, for managing the production facility in a production line having the production facility.

  In recent years, many production facilities are arranged on a production line that produces a large amount of products, and the number of workers managing these production facilities is decreasing. Under such circumstances, for example, when a malfunction occurs in a plurality of production facilities in one production line and the operation of these production facilities stops, the recovery work of the production facilities is performed in order from the production facility near the worker, or Were done in the order that they were stopped.

  However, the restoration order of such production equipment is not an order determined in consideration of the operation rate of the production line. Therefore, there arises a problem that the operating rate in the production line is greatly reduced and the loss is increased.

  Therefore, in order to solve this problem, Patent Document 1 includes a memory in which necessary information is recorded and a memory in which information from each production facility is stored, and the restoration order is determined based on the information in these memories. A configuration is disclosed in which a recovery procedure for all production facilities is performed in the shortest time. That is, this document discloses a configuration in which the operation rate of the production line (that is, the operation rate of the production facility in the production line) is maximized.

  Patent Document 2 discloses a configuration for determining the restoration order so that the operation rate of the production line is increased.

Furthermore, Patent Document 3 discloses a configuration in which priorities indicating the handling order (recovery order) are stored in advance, and only the information with the highest priority is displayed when a malfunction occurs in a plurality of production facilities. Has been. And in this document, the operation rate of the production line is improved by the above configuration.
JP 11-39006 A (publication date: February 12, 1999) JP 10-283028 A (publication date: October 23, 1998) JP 2002-229642 A (publication date: August 16, 2002)

  However, although the conventional configuration described above is intended to improve the operation rate of the production line, it is not a configuration that determines the restoration order from the viewpoint of production efficiency (that is, production volume per unit time). In other words, the conventional configuration is designed to reduce the downtime of each production facility on the production line and increase the total operation rate of each production facility on the production line. Absent.

  For this reason, in the conventional configuration, in terms of production efficiency, it is not possible to perform the recovery processing of the production equipment in an optimal recovery order, and as a result, the production amount may be greatly reduced.

  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 line management apparatus, a production line management method, a program, and a program capable of improving production efficiency in a production line. An object of the present invention is to provide a recorded computer-readable recording medium.

  In order to solve the above problems, the production line management device according to the present invention produces a buffer device for temporarily storing workpieces between a transport means for transporting workpieces to a downstream production facility and the production facility. In the production line management device that manages the production line provided for each facility, if the production facility with the smallest number of production per unit time is the bottleneck among all the production facilities, the work collected in each buffer device When the detection means for detecting the number and the plurality of production facilities are stopped due to a malfunction of the own equipment, each buffer device located between the production equipment stopped due to the malfunction of the own equipment and the bottleneck A total number calculating means for calculating the total number of workpieces collected for each production facility that is stopped based on the detection result of the detecting means immediately after the stop; Based on the calculation result of the calculation means, characterized by comprising a specifying means for specifying the production equipment in ascending order and a notification control means for notifying the notification device of the order of the production equipment specified by the specifying means. Yes.

  According to the above configuration, the number of workpieces stored in each buffer device can be detected by the detection means. In addition, when a plurality of production facilities are stopped due to a failure of the own equipment, the total number calculating means, based on the detection result of the detection means immediately after the stop, the production equipment stopped due to the trouble of the own equipment and the bottle The total number of works stored in each buffer device positioned between the neck and the neck can be calculated for each production facility that is stopped. In addition, the specifying unit can specify the production equipment in the order from the smallest total number based on the calculation result of the total number calculating unit.

  Here, when multiple production facilities are stopped, among the production facilities that are stopped due to problems with the own equipment, the production with a small number of workpieces collected in each buffer device located between the own equipment and the bottleneck When the recovery process is started from the equipment, the production loss in the production line is minimized.

  Therefore, by causing the notification control means to notify the notification device of the order specified by the specifying means, the user can know the order in which the production facilities that have been stopped should be restored.

  Therefore, the production line management device that can improve the production efficiency in the production line can be provided.

  Each production facility may include a buffer device.

  In addition, in order to solve the above-described problem, the production line management device according to the present invention is a buffer device that temporarily accumulates workpieces between a conveying unit that conveys workpieces to a downstream production facility and the production facility. In the production line management device that manages the production line provided for each production facility, out of all the production facilities, if the production facility with the smallest number of production per unit time is the bottleneck, it is stored in each buffer device When the detection means for detecting the number of workpieces and a plurality of production facilities are stopped due to a failure of the own facility, each buffer located between the production facility stopped due to the failure of the own facility and the bottleneck A total number calculating means for calculating the total number of workpieces stored in the apparatus based on the detection result of the detecting means immediately after the stop for each production facility that is stopped; Based on the calculation result of the total number calculating means, comprising: a specifying means for specifying the production facility with the smallest total number; and a notification control means for notifying the notification device of the production equipment specified by the specifying means. Yes.

  According to the above configuration, the number of workpieces stored in each buffer device can be detected by the detection means. In addition, when a plurality of production facilities are stopped due to a failure of the own equipment, the total number calculating means, based on the detection result of the detection means immediately after the stop, the production equipment stopped due to the trouble of the own equipment and the bottle The total number of works stored in each buffer device positioned between the neck and the neck can be calculated for each production facility that is stopped. In addition, the specifying unit can specify the production facility having the smallest total number based on the calculation result of the total number calculating unit.

  Here, when multiple production facilities are stopped, the number of workpieces collected in each buffer device located between the own facility and the bottleneck is small. When processing is started, the production loss in the production line is minimized.

  Therefore, by letting the notification device notify the production facility specified by the specifying means to the notification device, the user can know the production facility to be restored first.

  Therefore, the production line management device that can improve the production efficiency in the production line can be provided.

  Each production facility may include a buffer device.

  In addition, the production line management device according to the present invention, in the production line management device described above, when all of the production facilities that are stopped due to a malfunction of its own equipment is located upstream or downstream of the bottleneck The control means is characterized in that the notifying device is notified of the production facility that is closest to the bottleneck on the production line among the production facilities that are stopped.

  When all of the production facilities that are stopped due to a malfunction of the own equipment are located upstream or downstream of the bottleneck, restoration processing is started from the production facility closest to the bottleneck on the production line. The production loss on the production line is minimized by starting the process.

  Therefore, in the above case, without calculating the total number, as in the configuration of the present invention, the production that is the closest to the bottleneck on the production line among the production facilities that are stopped is simply By causing the notification control means to notify the facility to the facility, the user can know the production facility to be restored first.

  Further, the production line management device according to the present invention is the above-mentioned production line management device, in which the total number calculation means when the production facilities that are stopped due to the malfunction of the own equipment are located upstream and downstream of the bottleneck Is characterized by calculating the total number of workpieces using a predetermined numerical value instead of the number of workpieces detected by the detection means for the production facility located downstream of the bottleneck.

  When the production equipment that is stopped due to a malfunction of its own equipment is located on the upstream side and downstream side of the bottleneck, immediately after the stop, each buffer device located between the downstream production equipment and the bottleneck In some cases, the number of workpieces stored in the workpiece becomes zero.

  Therefore, based on the total number of workpieces stored in each buffer device located between the bottleneck and the production facility that is stopped due to a malfunction of its own facility, the production facility with the smallest total number is identified or the total number Even if the production equipment is specified in the order of few and the production equipment to be restored first or the order to be restored is notified, there is a possibility that the equipment or order that minimizes the production loss may not be notified.

  However, as in the present invention, for production equipment located downstream of the bottleneck, by calculating the total number of workpieces using a predetermined numerical value instead of the number of workpieces detected by the detection means. As for the downstream side, there is an effect that it is possible to increase the accuracy of notifying the equipment or the order that minimizes the production loss, rather than detecting it by the detecting means.

  As the predetermined numerical value, for example, the maximum value of the number of works that can be stored in each buffer device may be used.

  In addition, in order to solve the above-described problem, the production line management device according to the present invention is a buffer device that temporarily accumulates workpieces between a conveying unit that conveys workpieces to a downstream production facility and the production facility. In the production line management device that manages the production line provided for each production facility, the time during which the production facility is continuously stopped due to the malfunction of the own facility is defined as the stop time and the unit time of all production facilities. The bottleneck for the production facility with the smallest production number, the production number information for the production number per unit time of the bottleneck, and the maximum number of workpieces that can be stored in each buffer device Then, based on the operation status of the production line, the stop time calculation means for calculating the stop time for each production facility, the production facility stopped due to a malfunction of the own facility, and the bottom Each piece of information indicating the maximum number of each buffer device located between the neck and the maximum number acquisition means for acquiring from the storage device, and each information acquired by the maximum number acquisition means for each stop The total number of the maximum number is calculated, and the difference between the value obtained by multiplying the production number indicated by the production number information stored in the storage device by the stop time of the production facility and the calculated total number is calculated. Difference calculating means, an adding means for adding the difference calculated by the difference calculating means for each production facility for each stop, and a notification control means for notifying the notification device of the addition result by the adding means. It is characterized by.

  According to said structure, a stop time can be calculated for every production equipment based on the operation condition of a production line by a stop time calculation means. The maximum number acquisition means can acquire each piece of information indicating the maximum number of buffer devices located between the production facility stopped due to a malfunction of the own facility and the bottleneck.

  Further, the difference calculating means calculates the total number of the maximum number indicated in each piece of information acquired by the maximum number acquiring means for each stop, and the production number indicated by the production number information stored in the storage device. On the other hand, the difference between the value obtained by multiplying the stop time of the production facility and the calculated total number can be calculated. That is, the difference calculation means can calculate the production loss caused by the production facility being stopped for each production facility for each stop.

  Moreover, the said difference can be added for every production facility regarding the said each stop with an addition means. That is, the sum of the production losses can be calculated for each production facility by the adding means. Furthermore, the notification control means can notify the notification device of the addition result by the addition means.

  Therefore, the user can know for each production facility the production loss caused when the own facility stops due to a malfunction.

  Therefore, from the viewpoint of production efficiency, the user can know at least the production equipment to be preferentially maintained.

  Further, the production line management device according to the present invention is the production line management device described above, wherein when the bottleneck exists in the production line, the maximum number acquisition means is a production facility stopped due to a malfunction of its own equipment. The information indicating the maximum number of the buffer devices positioned between the bottleneck that is the farthest from the production facility on the production line among the plurality of bottlenecks is acquired from the storage device. It is characterized by that.

  When there are a plurality of bottlenecks in the production line, from the value obtained by multiplying the production number indicated by the production number information stored in the storage device by the stop time of the production facility, By subtracting the sum of the maximum number of each buffer device located between the bottleneck that is farthest from the production facility on the production line, production loss due to one stop (continuous stop) can be reduced. I want.

  Therefore, the maximum of each buffer device located between the production facility stopped due to a malfunction of its own facility and the bottleneck that is the farthest from the production facility on the production line among the plurality of bottlenecks When the maximum number acquisition unit acquires each piece of information indicating the number from the storage device, the total production loss can be calculated for each production facility.

  Further, in order to solve the above-described problem, the production line management device according to the present invention is provided with a buffer device for temporarily storing the workpiece between the production facility and the conveying means for conveying the workpiece to the downstream production facility. In the production line management device that manages the production line provided for each production facility, the time during which the production facility is continuously stopped due to a malfunction of its own facility is the stop time, and the production per unit time of all production facilities When the production facility having the smallest number is the bottleneck, and the information indicating the number of production per unit time of the bottleneck is the production number information, the detection means for detecting the number of workpieces stored in each buffer device, Based on the operation status of the production line, a stop time calculating means for calculating the stop time for each production facility, and the production facility stopped due to a malfunction of the own facility with respect to each stop. And the total number of workpieces stored in each buffer device located between the bottleneck at the time of stoppage based on the detection result of the detection means, and the production number information stored in the storage device A difference calculation means for calculating a difference between a value obtained by multiplying the production number shown by the stop time of the production facility and the calculated total number, and a difference calculated by the difference calculation means, It is characterized by comprising addition means for adding each stop for production equipment and notification control means for notifying the notification device of the addition result by the addition means.

  According to the above configuration, the number of workpieces stored in each buffer device can be detected by the detection means. Further, the stop time can be calculated for each production facility by the stop time calculation means based on the operation status of the production line. Further, the difference calculating means detects the total number of the workpieces stored in each buffer device located between the production equipment and the bottleneck, which are stopped due to a malfunction of the own equipment, at the time of the stop. A difference between a value obtained by multiplying the production quantity indicated by the production quantity information stored in the storage device by the production equipment stop time and the calculated total number based on the detection result of the means Can be calculated. That is, the difference calculation means can calculate the production loss caused by the production facility being stopped for each production facility for each stop.

  Moreover, the said difference can be added for every production facility regarding the said each stop with an addition means. That is, the sum of the production losses can be calculated for each production facility by the adding means. Furthermore, the notification control means can notify the notification device of the addition result by the addition means.

  Therefore, the user can know for each production facility the production loss caused when the own facility stops due to a malfunction.

  Therefore, from the viewpoint of production efficiency, the user can know at least the production equipment to be preferentially maintained.

  Further, the production line management device according to the present invention, in the above production line management device, when there are a plurality of bottlenecks in the production line, the difference calculation means, the production equipment stopped due to a failure of its own equipment, Of the plurality of bottlenecks, the total number of workpieces stored in each buffer device located between the bottleneck that is farthest from the production facility on the production line is calculated at the time of the stop. It is characterized by that.

  When there are a plurality of bottlenecks in the production line, from the value obtained by multiplying the production number indicated by the production number information stored in the storage device by the stop time of the production facility, By subtracting the sum of the maximum number of each buffer device located between the bottleneck that is farthest from the production facility on the production line, production loss due to one stop (continuous stop) can be reduced. I want.

  Therefore, from the value obtained by multiplying the production quantity indicated by the production quantity information stored in the storage device by the production equipment stop time, the production equipment stopped due to a malfunction of its own equipment, and the plurality of bottlenecks By subtracting the total number at the time of the stop of the workpieces stored in each buffer device located between the bottleneck that is farthest from the production equipment on the production line, There is an effect that the total sum of the production losses can be calculated for each production facility.

  Further, the production line management device according to the present invention detects the passage of the workpiece at the position where the workpiece is loaded into the buffer device and the position where the workpiece is unloaded from the buffer device in the production line management device described above. A sensor is provided for each buffer device, and the detection means detects the number of the workpieces based on a detection result by the sensor.

  According to the above configuration, each buffer device is stored in each buffer device by the pair of sensors provided at a position where the work is carried into the buffer device and a position where the work is carried out from the buffer device. There is an effect that the number of workpieces can be detected.

  Further, in the production line management device according to the present invention, in the above production line management device, when the production facility stopped due to a malfunction of its own facility is located downstream of the bottleneck, the detection means It is characterized by detecting the number of workpieces.

  When a production facility that has stopped due to a malfunction of its own facility is located downstream of the bottleneck, immediately after the stoppage, it is stored in each buffer device located between the downstream production facility and the bottleneck. There are cases when the workpiece is zero.

  Therefore, even if the total of production losses is calculated using the total number of workpieces stored in each buffer device located between the production facility that has stopped due to a malfunction of its own facility and the bottleneck, High production loss value cannot be obtained.

  However, as in the present invention, with respect to production equipment located downstream of the bottleneck, the detection means detects the number of workpieces immediately before recovery, and the detection means detects the number of workpieces when stopped. Compared to the case, there is an effect that a highly accurate production loss value can be obtained.

  The production line management device according to the present invention is the production line management device described above, wherein the notification device is a display device, and the notification control means assigns the production facility names in descending order of the value of the addition result. It is characterized by being displayed on a display device.

  According to said structure, a production equipment name can be displayed on a display apparatus by the notification control means in order with a larger value of the addition result.

  Therefore, the user can visually recognize the maintenance order of production facilities based on the viewpoint of production efficiency.

  Further, the production line management device according to the present invention includes, in the above production line management device, an association unit that associates information indicating a cause of stoppage with information indicating each stop, and the difference calculation unit includes: The difference is calculated for each type of stop cause, the adding unit adds the difference for each type of stop cause, and the notification control unit further calculates the addition result calculated for each type of stop cause Is notified to a notification device.

  According to said structure, the information which showed the cause of a stop can be linked | related with the information which shows each stop by the correlation means. Further, the difference can be calculated for each type of stop cause by the difference calculation means. Further, the difference can be calculated for each type of stop cause by the adding means.

  Therefore, the notification control means allows the notification device to notify the addition result calculated for each type of stop cause so that the user can know the total number of production losses for each type of stop cause for each production facility. It becomes possible.

The production line management method according to the present invention is a buffer device for temporarily storing a work between a transport unit for transporting a work to a downstream production facility and the production facility in order to solve the above-described problem. In the production line management method for managing the production line provided for each production facility, if the production facility with the smallest number of units produced per unit time is the bottleneck among all the production facilities, the detection means assigns each buffer device. The detection step for detecting the number of accumulated workpieces, and when a plurality of production facilities are stopped due to a failure of the own facility, the total number calculating means causes the production facility and the bottle stopped due to the failure of the own facility. Based on the detection result of the detection means immediately after the stop, the total number of workpieces stored in each buffer device positioned between the neck and the The total number calculation step of calculating for each production facility that, based on the calculation result in the total number calculation step, the identifying means, a specifying step of specifying the production facilities in order total is less, the notification control means, by the specifying step And a notification control step of notifying the notification device of the order of the specified production facilities.

  Therefore, in the production line management method of the present invention, the production efficiency in the production line can be improved as in the production line management device described above.

  In addition, in order to solve the above-described problem, the production line management method according to the present invention is provided with a buffer device that temporarily accumulates workpieces between a conveying means that conveys workpieces to a downstream production facility and the production facility. In the production line management method for managing the production line provided for each production facility, if the production facility with the smallest number of production per unit time is the bottleneck among all the production facilities, it is stored in each buffer device by the detection means. A detection step for detecting the number of workpieces that have been stopped, and when a plurality of production facilities are stopped due to a malfunction of the own equipment, the total number calculating means causes the production equipment that has stopped due to the malfunction of the own equipment and the bottleneck. The total number of workpieces stored in each buffer device positioned between and based on the detection result of the detection means immediately after the stop A total number calculating step for each production facility, a specifying step for specifying a production facility with the smallest total number based on a calculation result in the total number calculating step, and a specifying step for specifying the production facility with the smallest total number And a notification control step for notifying the notified production facility to the notification device.

  Therefore, in the production line management method of the present invention, the production efficiency in the production line can be improved as in the production line management device described above.

  In addition, in order to solve the above-described problem, the production line management method according to the present invention is provided with a buffer device that temporarily accumulates workpieces between a conveying means that conveys workpieces to a downstream production facility and the production facility. In the production line management method for managing the production line provided for each production facility, the time during which the production facility is continuously stopped due to the malfunction of its own facility is the stop time and the production per unit time of all production facilities The production equipment with the smallest number is the bottleneck, the production number information is information indicating the production number per unit time of the bottleneck, and the maximum number of workpieces that can be stored in each buffer device is the maximum number. Then, the stop time calculation means calculates the stop time for each production facility based on the operation status of the production line, and the maximum number acquisition means. The information indicating the maximum number of each buffer device located between the production facility stopped due to a malfunction of its own equipment and the bottleneck, the maximum number acquisition step of acquiring from the storage device, the difference calculation means, With respect to each stop, the total number of the maximum number indicated in each information acquired by the maximum number acquisition means is calculated, and the stop time of the production facility with respect to the production number indicated by the production number information stored in the storage device The difference calculation step for calculating the difference between the value obtained by multiplying the total number and the calculated total number, and the addition unit adds the difference calculated by the difference calculation step for each production facility for each stop And a notification control step of notifying the notification device of the addition result of the addition step by the notification control means.

  Therefore, in the production line management method of the present invention, as in the production line management apparatus described above, the user can know at least the production equipment to be preferentially maintained from the viewpoint of production efficiency. Play.

  The production line management method according to the present invention is a buffer device for temporarily storing a work between a transport unit for transporting a work to a downstream production facility and the production facility in order to solve the above-described problem. In the production line management method for managing the production line provided for each production facility, the time during which the production facility is continuously stopped due to a malfunction of the own facility is defined as the stop time and the unit time of all production facilities. If the production equipment with the smallest number of production is the bottleneck and the information indicating the production quantity per unit time of the bottleneck is the production quantity information, the number of workpieces stored in each buffer device is detected by the detection means. A detection time step, a stop time calculation step for calculating the stop time for each production facility based on the operation status of the production line by the low time calculation means, and a difference The detection means detects the total number of workpieces stored in each buffer device located between the production equipment and the bottleneck that are stopped due to a malfunction of the own equipment at the time of the stop. While calculating based on the result, the difference between the value obtained by multiplying the production quantity indicated by the production quantity information stored in the storage device by the stop time of the production facility and the calculated total number is calculated. A difference calculating step, an adding step for adding the difference calculated by the difference calculating means for each production facility with respect to each stop by the adding means, and a notification control means for notifying the result of the addition by the adding means to the notification device And a notification control step.

  Therefore, in the production line management method of the present invention, as in the production line management apparatus described above, the user can know at least the production equipment to be preferentially maintained from the viewpoint of production efficiency. Play.

  The program according to the present embodiment is a program for causing a computer to function as each unit of the production line management apparatus.

  Therefore, there is an effect that the production line management device can be provided to the user by loading the program into the computer system.

  The recording medium according to the present embodiment is a computer-readable recording medium that records the program.

  Therefore, it is possible to provide the user with the production line management device by loading the program recorded on the recording medium into the computer system.

  As described above, the production line management device according to the present invention is the number of workpieces stored in each buffer device, assuming that the production facility with the smallest number of production per unit time is the bottleneck among all the production facilities. When a plurality of production facilities are stopped due to a malfunction of the own equipment, the detection means for detecting the problem is stored in each buffer device located between the production equipment stopped due to the malfunction of the own equipment and the bottleneck. Based on the detection result of the detection means immediately after the stop, the total number calculation means for calculating each stopped production facility, and the total number based on the calculation result of the total number calculation means It is characterized by comprising specifying means for specifying production facilities in descending order, and notification control means for notifying the notification device of the order of the production facilities specified by the specifying means. .

  Therefore, the production line management device that can improve the production efficiency in the production line can be provided.

  In addition, as described above, the production line management device according to the present invention has a work pool stored in each buffer device when a production facility having the smallest number of products per unit time is a bottleneck among all the production facilities. Each of the buffer devices located between the production facility that is stopped due to the malfunction of the own equipment and the bottleneck when the plurality of production facilities are stopped due to the malfunction of the own equipment. Based on the detection result of the detection means immediately after the stop, based on the calculation result of the total number calculation means, the total number calculation means for calculating for each production facility that is stopped, The configuration includes a specifying unit that specifies a production facility having the largest total number, and a notification control unit that notifies a notification device of the production facility specified by the specifying unit.

  Therefore, the production line management device that can improve the production efficiency in the production line can be provided.

  In addition, the production line management device according to the present invention, as described above, indicates the time during which the production facility is continuously stopped due to a failure of the own facility, and the production time per unit time among all the production facilities. The production equipment with the smallest number is the bottleneck, the production number information is information indicating the production number per unit time of the bottleneck, and the maximum number of workpieces that can be stored in each buffer device is the maximum number. Then, based on the operation status of the production line, a stop time calculating means for calculating the stop time for each production facility, and each buffer device located between the production facility stopped due to a malfunction of the own facility and the bottleneck Maximum number acquisition means for acquiring each piece of information indicating the maximum number from the storage device, and the maximum number indicated in each piece of information acquired by the maximum number acquisition means for each stop A difference calculation that calculates the total number and calculates a difference between the value obtained by multiplying the production number indicated by the production number information stored in the storage device by the stop time of the production facility and the calculated total number Means, an addition means for adding the difference calculated by the difference calculation means for each production facility for each stop, and a notification control means for notifying the notification device of the addition result by the addition means. Yes.

  Therefore, from the viewpoint of production efficiency, the user can know at least the production equipment to be preferentially maintained.

  In addition, the production line management device according to the present invention, as described above, indicates the time during which the production facility is continuously stopped due to a failure of the own facility, and the production time per unit time among all the production facilities. When the production facility having the smallest number is the bottleneck, and the information indicating the number of production per unit time of the bottleneck is the production number information, the detection means for detecting the number of workpieces stored in each buffer device, Based on the operation status of the production line, the stop time calculation means for calculating the stop time for each production facility, and each of the stops located between the production facility stopped due to a malfunction of the own facility and the bottleneck. The total number of the workpieces stored in the buffer device at the time of the stop is calculated based on the detection result of the detection means, and the production number information stored in the storage device A difference calculation means for calculating a difference between a value obtained by multiplying the production number shown by the stop time of the production facility and the calculated total number, and a difference calculated by the difference calculation means, It is characterized by comprising addition means for adding each stop for production equipment and notification control means for notifying the notification device of the addition result by the addition means.

  Therefore, from the viewpoint of production efficiency, the user can know at least the production equipment to be preferentially maintained.

[Embodiment 1]
An embodiment of the present invention will be described below with reference to FIGS. In the following description, for simplification of description, a configuration in which one production line is managed by one production line management device and one production line is in charge (managed) by one worker. explain. Moreover, in this embodiment, each production facility constituting the production line has its own facility stopped due to a failure of its own equipment with respect to the production line management device when the own facility has stopped due to its own failure. Information indicating this is transmitted in real time.

  FIG. 1 is a functional block diagram showing a configuration of a production line management apparatus (hereinafter referred to as a management apparatus) according to the present embodiment. As shown in the figure, the management device 1 includes a data input unit 11, a storage device 12, a stop information receiving unit (stop information receiving unit) 13, a stay detection unit 14, an identification information receiving unit (identification information receiving unit) 15, a loss A value calculation unit (loss value calculation unit) 16, a pattern selection unit (selection unit) 17, a notification unit (first notification unit) 18, a specification unit (specification unit) 19, a start information reception unit (start information reception unit) 20, An end information reception unit (end information reception unit) 21, a time generation unit 22, a time association unit (time association unit) 23, a recovery time calculation unit (recovery time calculation unit) 24, a setting unit (update unit) 25, and , A notification unit (second notification means) 26 is provided.

  The data input unit 11 includes a capability information association unit (capability information association unit) 31. Furthermore, the storage device 12 includes an equipment information storage unit 41 and a worker information storage unit 42. The loss value calculation unit 16 includes a first calculation unit (first calculation unit) 51, a second calculation unit (second calculation unit) 52, a third calculation unit (third calculation unit) 53, and a fourth calculation. Part (fourth computing means) 54 is provided.

  The data input unit 11 receives data from the outside and sends the received data to the storage device 12. More specifically, the data input unit 11 includes an input device such as a touch panel or a keyboard, and sends data input by the administrator of the management device 1 via the input device to the storage device 12.

  The storage device 12 receives data sent from the data input unit 11 and stores the received data in the facility information storage unit 41 or the worker information storage unit 42. Here, data stored in the facility information storage unit 41 and the worker information storage unit 42 will be described.

  As shown in FIG. 2, the facility information storage unit 41 stores the production capacity of each production facility in the production line and the margin time of each production facility in association with each production facility. Here, the production capacity is the number of workpieces that the production facility can produce per unit time. In addition, if a workpiece stays between the adjacent production equipment located on the upstream side of the own equipment and the own equipment, if the maximum number of works that can stay between the two facilities is the stayable amount, the extra time Is a value obtained by dividing the stagnation amount by the production capacity. That is, the margin time is expressed by the following formula (1).

Allowable time = amount of stagnation / production capacity (1)
In the worker information storage unit 42, as shown in FIG. 3, information on the proficiency level and the recovery time for each facility is stored in association with each worker ID. Here, the worker ID is an identifier (identification information) for identifying the worker. Further, the name of the worker may be used as the worker ID.

  The proficiency level is capability information indicating the capability of the worker regarding the production line. In the figure, the proficiency level is determined by experienced workers (skill level: 2), mid-level workers (skill level: 1), and beginners (skill level: 0) according to the length of experience in the production line. An example divided into three stages is shown. The ability information association unit 31 associates (corresponds) the proficiency level with the worker ID.

  In addition, the figure shows a case where data on the recovery time of the production facility A relating to the worker whose worker ID is 005 is not stored in the worker information storage unit 42. In such a case, since there is no recovery record, data is not input from the data input unit, or as will be described in detail later, the setting unit 25 stores the recovery time information in the worker information storage unit 42. Is not set (stored).

  Furthermore, in the same figure, the data of the recovery time of the production facility C relating to the worker whose worker ID is 002 is not numerical data but data indicated by “×” (hereinafter, “×” data). Yes. This “x” data is data indicating that the worker does not have the recovery capability of the production facility C and cannot restore the production facility. The use of this “x” data will be described later.

  The stop information receiving unit 13 receives information indicating that the own equipment has stopped from each production facility in real time for each production facility. When the stop information receiving unit 13 receives this information, the stop information receiving unit 13 sends the information to the loss value calculating unit 16 in real time. As described above, the stop information receiving unit 13 is configured to determine whether or not information indicating that the own facility has stopped from each production facility has been received and to send the received information to the loss value calculating unit 16.

  The stay detection unit 14 detects in real time for each production facility whether or not a workpiece exists between adjacent production facilities. And when it detects, the information which shows that a workpiece | work exists is sent to the loss value calculation part 16 in real time. In addition, this stay detection part 14 can be comprised by several sensors, such as a proximity sensor or a photoelectric sensor, and PLC (programmable logic controller), for example.

  The identification information receiving unit 15 receives input of information (worker ID) for identifying a worker who manages the production line. Then, the identification information receiving unit 15 sends the received worker ID to the loss value calculating unit 16 and the time association unit 23.

  Next, the loss value calculation unit 16 will be described.

  The loss value calculation unit 16 receives information sent from the stop information reception unit 13 in real time. And the loss value calculation part 16 judges the production facility which has stopped based on this information. Further, the loss value calculation unit 16 receives information sent from the stay detection unit 14 in real time. The loss value calculation unit 16 receives the information indicating that a work exists between certain production facilities from the stay detection unit 14 while the work of the stagnation amount is between the production facilities. Judged to stay. Further, the loss value calculation unit 16 receives the worker ID from the identification information reception unit 15.

  Here, calculation of the loss value in the entire production line by the loss value calculation unit 16 will be described. Here, the loss value is a value indicating a production loss that occurs in the entire production line when the production equipment of the production line is stopped due to a malfunction of the own equipment. More specifically, the loss value refers to the estimated number of workpieces that cannot be produced at one downstream production facility when the production facility stops due to a malfunction of the own facility. It is a value obtained by adding together the facilities.

  For convenience of explanation, when simply describing “loss value”, it refers to the loss value of the entire production line, and when describing “loss value for each facility”, it is a loss attributable to one production facility. Value (loss value for each production facility) shall be indicated.

  When the loss value calculation unit 16 receives information from the stop information reception unit 13 that a plurality of production facilities are stopped due to a failure of the own facility, the loss value calculation unit 16 relates to the restoration order of the production facilities stopped due to the failure of the own facility. For all recovery patterns, the production loss value on the production line when the recovery pattern is restored is calculated. The calculation of the loss value is performed every time information indicating a newly stopped production facility is received from the stop information receiving unit 13. The restoration pattern is generated by the loss value calculation unit 16.

  For example, as shown in FIG. 4, in a production line having eight production facilities A to H in this order from the upstream side, when the production facilities B and E are stopped due to a malfunction of the own facilities, there are two recovery patterns. Conceivable. That is, a recovery pattern (hereinafter referred to as a first pattern) indicated in the order of B → E and a recovery pattern (hereinafter referred to as a second pattern) indicated in the order of E → B are conceivable. If the three facilities are stopped due to a malfunction of the own facility, there are six possible recovery patterns. The loss value calculation unit 16 calculates the loss value for all such recovery patterns. Hereinafter, a specific method of calculating the loss value will be described with reference to FIG. 4 as appropriate.

  First, the loss value calculation unit 16 performs a calculation using the first calculation unit 51, the second calculation unit 52, the third calculation unit 53, and the fourth calculation unit 54 for each restoration pattern. That is, in the case shown in FIG. 4, the first pattern and the second pattern are calculated using the first to fourth calculation units (51 to 54), respectively. In addition, the calculation processes in the first to third calculation units (51 to 53) described below are performed for all production facilities that are stopped due to a failure of the own facility. That is, in the figure, it is performed with respect to both the production facilities B and E.

  In addition, in the following description from the first calculation unit 51 to the third calculation unit 53, for the sake of convenience, a description will be given of a case where the above-mentioned loss value for each facility is obtained with respect to the production facility X (X is arbitrary) that is stopped due to a malfunction of the own facility. To do. Further, a production facility in the process immediately after the production facility X is defined as a production facility X + 1. That is, based on FIG. 4, the production facility X corresponds to the production facility B and the production facility E, and the production facility X + 1 corresponds to the production facility C and the production facility F, respectively.

  Based on the received worker ID, the first calculation unit 51 reads from the worker information storage unit 42 information on recovery time (referred to as first information) related to the production facility X associated with the worker ID. Here, when there is no production facility for which restoration processing is performed first, information on the restoration time relating to the read production facility X is sent to the second calculation unit 52.

  On the other hand, when there is a production facility where the restoration process is performed first, the first calculation unit 51 associates the first information with the worker ID and each production facility where the restoration process is performed first. The recovery time information (referred to as second information) is read out, and the total recovery time indicated by each information is obtained based on both the read out information (first information and second information). Then, when there is a production facility for which the restoration process is performed first, the first calculation unit 51 sends the summation information to the second calculation unit 52.

  Specifically, in the case of the first pattern, for the production facility B, the first computation unit 51 sends only information on the recovery time (RTb) on the production facility B to the second computation unit 52. It is done. On the other hand, for the production facility E, the first computation unit 51 sends the sum information of the recovery time (RTb) for the production facility B and the recovery time (RTe) for the production facility E to the second computation unit 52. It is done.

  In the case of the second pattern, for the production facility B, the first computation unit 51 causes the second computation unit 52 to restore the recovery time (RTb) related to the production facility B and the recovery time related to the production facility E ( RTe) sum information is sent. On the other hand, regarding the production facility E, the first computation unit 51 sends information on the recovery time (RTe) regarding the production facility E to the second computation unit 52.

  The second calculation unit 52 receives information from the first calculation unit 51. Here, when the loss value calculation unit 16 receives information indicating that there is a workpiece between the production facility X and the production facility X + 1 from the stay detection unit 14, the second calculation unit 52 The following processing is performed.

  When there is no production facility to be restored first, the second calculation unit 52 reads information on the margin time related to the production facility X + 1 from the facility information storage unit 41 and the production facility X indicated in the received information. The margin time indicated in the read information is subtracted from the recovery time. On the other hand, when there is each production facility for which the restoration process is performed first, the second calculation unit 52 reads information on the margin time for the production facility X + 1 from the facility information storage unit 41 and obtains it by the first calculation unit 51. The margin time indicated in the read information is subtracted from the obtained value (that is, the total recovery time). In any case, the second calculation unit 52 sends the value obtained by subtracting the margin time to the third calculation unit 53.

  On the other hand, when the loss value calculation unit 16 has not received the information indicating that the workpiece exists from the stay detection unit 14, that is, when no workpiece exists, the second calculation unit 52 performs the following processing. Do.

  When there is no production facility for which recovery processing is performed first, the second calculation unit 52 uses the recovery time of the production facility X indicated in the received information for each production facility for which recovery processing is performed first. In this case, the value calculated by the first calculation unit 51 (that is, the total recovery time) is sent to the third calculation unit 53. In other words, the configuration in the case where no workpiece exists is based on the case in which the workpiece exists. In the configuration in which the workpiece exists, the margin time is set to 0 without reading the margin time from the facility information storage unit 41. Will be the same.

  Specifically, when there is a workpiece and in the case of the first pattern, the production facility B is produced from the recovery time (RTb) for the production facility B by the second arithmetic unit 52. A margin time (STc) related to the facility C is subtracted, and a value obtained by subtracting the margin time is sent to the third calculation unit 53. On the other hand, for the production equipment E, the second calculation unit 52 subtracts the margin time (STf) for the production equipment F from the sum of the restoration time (RTb) for the production equipment B and the restoration time (RTd) for the production equipment E. At the same time, a value obtained by subtracting the margin time is sent to the third arithmetic unit 53.

  Further, in the case of a workpiece and when the second pattern is used, with respect to the production facility B, the second arithmetic unit 52 restores the restoration time (RTb) for the production facility B and the restoration for the production facility E. The margin time (STc) related to the production facility C is subtracted from the sum total with the time (RTe), and a value obtained by subtracting the margin time is sent to the third calculation unit 53. On the other hand, for the production facility E, the second calculation unit 52 subtracts the margin time (STf) for the production facility F from the recovery time (RTe) for the production facility E, and the value obtained by subtracting this margin time is the third value. It is sent to the calculation unit 53.

  The third calculation unit 53 receives information from the second calculation unit 52. And the 3rd calculating part 53 reads the information of the production capacity regarding the production equipment X + 1 from the equipment information memory | storage part 41, and is set to the value (namely, the value calculated | required in the 2nd calculating part 52) shown in the said received information. Multiply the read information by the production capacity indicated. And the 3rd calculating part 53 sends the value which multiplied this production capacity to the 4th calculating part 54. FIG.

Specifically, in the case of the first pattern, regarding the production facility B, the third computation unit 53 relates to the production facility C to a value obtained by subtracting the margin time (STc) (that is, RTb−STc). The production capacity (PSc) is multiplied. Then, a value (LVb ₁ = (RTb−STc) × PSc) multiplied by the production capacity (PSc) is sent to the fourth calculation unit 54. On the other hand, for the production facility E, the third calculation unit 53 multiplies the value obtained by subtracting the margin time (STf) (that is, RTb + RTe−STf) by the production capacity (PSf) for the production facility F. Then, a value (LVe ₁ = (RTb + RTe−STf) × PSf) multiplied by the production capacity (PSf) is sent to the fourth calculation unit 54.

In the case of the second pattern, for the production facility B, the third computing unit 53 subtracts the margin time (STc) (ie, RTb + RTe−STc) to obtain the production capacity ( PSc) is multiplied. Then, a value (LVb ₂ = (RTb + RTe−STc) × PSc) multiplied by the production capacity (PSc) is sent to the fourth calculation unit 54. On the other hand, for the production facility E, the third arithmetic unit 53 multiplies the value obtained by subtracting the margin time (STf) (that is, RTb−STf) by the production capacity (PSf) related to the production facility F. Then, a value (LVe ₂ = (RTb−STf) × PSf) multiplied by the production capacity (PSf) is sent to the fourth calculation unit 54.

  The fourth calculation unit 54 receives the value obtained by the third calculation unit 53. And the 4th calculating part 54 calculates | requires the sum total of the value calculated | required in the 3rd calculating part 53 regarding all the production equipment X which has stopped by the malfunction of an own installation.

Specifically, in the case of the first pattern, the fourth computing unit 54 obtains the sum (sum) of the LVb ₁ and the LVe ₁ . In other words, the production loss value (LV ₁ ) in the production line when the first pattern is restored is as shown in the following formula (2).

LV ₁ = LVb ₁ + LVe ₁ = (RTb−STc) × PSc + (RTb + RTe−STf) × PSf) (2)
In the case of the second pattern, the fourth computing unit 54 obtains the sum (total) of the LVb ₂ and LVe ₂ . In other words, the production loss value (LV ₂ ) in the production line when the second pattern is restored is as shown in the following formula (3).

LV ₂ = LVb ₂ + LVe ₂ = (RTb + RTe−STc) × PSc + (RTb−STf) × PSf) (3)
As described above, the loss value in the production line is obtained for each restoration pattern when the production facility is restored with each restoration pattern by each computation from the first computing unit to the fourth computing unit (51 to 54). It will be.

Then, the loss value calculation unit 16 includes information on the loss values (LV ₁ and LV _{2 in} the case of FIG. 4) and information indicating which recovery pattern each loss value is based on (hereinafter, recovery pattern). (Referred to as information) is sent to the pattern selector 17. Here, the loss value information and the restoration pattern information are sent to the pattern selection unit 17 by the loss value calculation unit 16 every time the calculation processing in the fourth calculation unit 54 is performed.

  The pattern selection unit 17 receives the loss value information and the recovery pattern information from the loss value calculation unit 16. Then, the pattern selection unit 17 identifies the loss value that minimizes the value based on the received loss value information, and based on the recovery pattern information, the recovery pattern corresponding to the identified loss value Select. That is, the pattern selection unit 17 selects a restoration pattern that minimizes the loss value. Further, the pattern selection unit 17 sends information indicating the selected recovery pattern to the notification unit 18.

  The notification unit 18 can be configured by, for example, a display device having a display screen, a broadcasting device, a device that displays a warning such as a patrol light (warning display device), and / or a communication device. First, the notification unit 18 receives information indicating the restoration pattern from the pattern selection unit 17.

  Here, when the notification unit 18 is configured by a display device, the notification unit 18 performs the recovery order in the recovery pattern or the first recovery in the recovery pattern based on the information indicating the recovery pattern. The equipment is displayed on the display screen of the display device. It should be noted that whether to display the restoration order or to display the production equipment is configured so that the user of the management apparatus 1 can select in advance by an operation unit (not shown). Moreover, when the notification part 18 is comprised with a broadcasting apparatus, the notification part 18 is set as the structure which alert | reports to the operator the said restoration order or the said production equipment.

  Furthermore, when the notification part 18 is comprised with a warning display apparatus, it is set as follows. Usually, a production line is provided with a patrol light that indicates abnormality of its own equipment by lighting and rotating for each production equipment. Therefore, only the palite of the production facility is rotated at a rotational speed faster than the normal rotational speed. Thereby, it is possible to inform the worker of the production facility to be restored first.

  Further, a device that generates a warning sound as the patrol light is turned on and rotated is usually attached to the production facility. In the case of such a configuration, if the configuration is such that a warning sound is generated only for the production facility to be restored first, the worker can be notified of the production facility to be restored first.

  For example, when the notification unit 18 is configured by a communication device, the communication device transmits the restoration order or the production equipment to the portable communication terminal possessed by the worker. And it is sufficient. With this configuration, the notification unit 18 can notify the worker of the restoration order or the production facility.

  In addition, the structure of the notification part 18 is not limited above, What is necessary is just a structure which can notify an operator about the said restoration order or the said production equipment.

  Here, when there is a production facility that has already been restored, the notification to the worker by the notification unit 18 is preferably performed when the restoration process of the production facility is completed. For this purpose, the notification unit 18 may be configured to receive predetermined information from the end information reception unit 21 and perform the notification after the notification unit 18 receives the information.

  As described above, the worker identified by the worker ID received by the loss value calculation unit 16 notifies the worker of the recovery pattern with the smallest loss value on the production line when performing the recovery process. It becomes possible.

  Incidentally, as described above, the loss value calculation unit 16 receives the worker ID, and reads the recovery time information from the worker information storage unit 42 based on the worker ID. However, depending on the worker ID to be accepted, there is a case where the information on the recovery time is not stored in the facility information storage unit 41 as in the production facility A for the worker ID 005 in FIG. Therefore, in such a case, the loss value calculation unit 16 sends the received worker ID to the specifying unit 19.

  If the recovery time information is not stored, the specifying unit 19 first checks the proficiency level based on the received worker ID. When the information stored in the worker information storage unit 42 is as shown in FIG. 3, the specifying unit 19 confirms that the worker whose worker ID is 005 has a proficiency level of 1. And the specific | specification part 19 searches other worker ID matched with the information which showed that the proficiency level is 1. Further, when the other unit ID is found, the specifying unit 19 reads out information on the recovery time of the production facility A associated with the worker ID. Then, the specifying unit 19 sends the recovery time indicated in the read recovery time information to the first calculation unit 51 of the loss value calculation unit 16. Thereby, in the 1st calculating part 51, the recovery time shown by the information of the recovery time read by the specific | specification part 19 can be substituted as a recovery time at the time of calculating the said loss value. That is, in FIG. 3, the loss value is calculated using the recovery time (5.9) for the production facility A with the worker ID 003.

  For this reason, even when the recovery time is not stored as described above, the loss value calculation unit 16 can calculate the loss value. Furthermore, the loss value can be calculated using information on the recovery time regarding a worker having the same ability as the worker performing the recovery process. Therefore, even if the recovery time for the worker performing the recovery process is not stored in the storage device, a highly accurate value can be calculated for the loss value.

  In the search for the worker ID, when a plurality of worker IDs are searched, the recovery time information associated with the worker ID searched first may be used, or the search may be performed. You may use the average value of the recovery time matched with all the worker IDs made.

  The start information receiving unit 20 receives information from the worker that identifies each production facility from each other and indicates the start of a recovery process for one production facility. The start information receiving unit 20 is configured by, for example, a push-down button switch or the like provided for each production facility, and the start information receiving unit 20 receives the above information by pressing one of the button switches. recognize. In addition, when the start information receiving unit 20 receives the information, the start information receiving unit 20 sends the information to the time generation unit 22 and the loss value calculation unit 16. The start information receiving unit 20 is not limited to a button switch, and can be configured using various means such as a touch panel and a keyboard.

  The end information receiving unit 21 receives information indicating the end (completion) of the restoration process of one production facility from the worker. When the information is received, the end information receiving unit 21 sends this information to the time generation unit 22 and the notification unit 18. The end information receiving unit 21 can be configured with a button switch or the like, similar to the start information receiving unit 20.

  In addition, as described above, when the end information reception unit 21 sends the above information to the notification unit 18 and there is a production facility that has already been restored, the notification unit 18 notifies the worker of the production. This can be done when the equipment restoration process is completed.

  The time generation unit 22 receives the information described above from the start information reception unit 20 and the end information reception unit 21. Moreover, the time generation unit 22 has a clock function. Here, when receiving information from the start information receiving unit 20, the time generating unit 22 uses the received time as the recovery start time using the clock function, and sends the time information to the time association unit 23. send. On the other hand, when receiving the information from the end information receiving unit 21, the time generating unit 22 uses the clock function as the recovery end time, and sends this time information to the time association unit 23. .

  The time association unit 23 receives information on the recovery start time and information on the recovery end time from the time generation unit 22. Further, the time association unit 23 receives the worker ID from the identification information receiving unit 15. Then, the time association unit 23 sends the recovery start time information and the recovery end time information of each production facility to the recovery time calculation unit 24 in association with the worker ID.

  The recovery time calculation unit 24 calculates the time (recovery time) required for recovery for each production facility by subtracting the recovery start time from the recovery end time based on the received information on both times. Further, the recovery time calculation unit 24 sends the calculated recovery time information to the setting unit 25 in a state in which the information is associated with the worker ID and the information indicating the production facility.

  The setting unit 25 receives information about the recovery time associated with the information indicating the worker ID and the production facility from the recovery time calculation unit 24. When the information on the recovery time is not stored in the worker information storage unit 42, the setting unit 25 writes the received information in the worker information storage unit 42. On the other hand, when the recovery time information is already stored in the worker information storage unit 42, the recovery time information is updated using the received information.

  The update of the recovery time information may be configured to reflect the calculated recovery time, or the recovery time stored in the storage device may be replaced with the calculated recovery time. It may be. Here, as a configuration for reflecting the recovery time, for example, how many times the recovery time information already stored in the worker information storage unit 42 is updated is stored, and the recovery number is used to recover The structure which calculates | requires the average of time is mentioned. With such a configuration, the average of the time required for a plurality of recovery processes can be stored as the recovery time, so that the accuracy of the loss value can be improved.

  Next, a case where the loss value calculation unit 16 receives information transmitted from the start information reception unit 20 will be described. That is, a case where the restoration process is started by the worker will be described. Hereinafter, a configuration in which notification to the worker by the notification unit 18 is performed when the recovery process of the production facility is completed will be described.

  In this case, the loss value calculation unit 16 specifies the production facility where the recovery process has been started based on the information sent from the start information receiving unit 20. Then, the loss value calculation unit 16 calculates loss values for all recovery patterns related to the recovery order of the production equipment except for the production equipment for which the recovery processing has been started. In other words, the calculation is performed from the first calculation unit to the fourth calculation unit (51 to 54). Further, the loss value calculation unit 16 sends the calculated loss value to the pattern selection unit 17.

  As described above, the pattern selection unit 17 selects a recovery pattern that minimizes the loss value, and sends information indicating the selected recovery pattern to the notification unit 18. Here, the notification unit 18 determines whether information indicating the end of the recovery process described above has been received from the end information reception unit 21. And the notification part 18 performs the notification mentioned above, after receiving this information. As described above, each time a recovery process for one production facility is completed, at least a production facility to be restored next can be notified to the worker.

  By the way, for example, like the production facility C with the worker ID 002 in FIG. 3, the restoration time information is not stored as numerical data in the facility information storage unit 41 but is stored as “×” data. There may be. Here, since the “×” data is data stored when the worker cannot restore the production facility as described above, in such a case, the loss value calculation unit 16 displays the loss value. Cannot be calculated.

  Therefore, when the first calculation unit 51 of the loss value calculation unit 16 attempts to read the recovery time from the worker information storage unit 42, if the read information is “×” data, the loss value calculation is performed. The unit 16 sends predetermined information to the notification unit 26.

  When the notification unit 26 receives the predetermined information from the loss value calculation unit 16, the notification unit 26 notifies a predetermined person (hereinafter, a specific person) of information indicating that the production facility cannot be recovered. . This information notification may be wireless or wired, or may be broadcast. For example, in the case of wireless, the above information may be sent by e-mail to the specific person's portable communication terminal.

  As a result, even if a worker who cannot restore the production equipment is in charge of the production line, another person can respond and avoid the situation where the restoration work of the production equipment is not completed. it can.

  As described above, the management device 1 according to the present embodiment, when a plurality of production facilities in the production line are stopped due to a malfunction of the own facility, for each recovery pattern related to the recovery order of the production facilities, A loss value calculation unit (loss value calculation unit) 16 that calculates a production loss value in the production line when the recovery pattern is restored, and a pattern selection unit (selection unit) that selects a recovery pattern that minimizes the loss value. 17 and a notification unit (first notification means) 18 for notifying the recovery order in the selected recovery pattern.

  According to this configuration, the loss value calculation unit 16 can calculate the production loss value on the production line for each recovery pattern when the production facility stopped due to the malfunction of the own facility is recovered by each recovery pattern. it can. Further, the pattern selection unit 17 can select a recovery pattern that minimizes the production loss value. Further, the notification unit 18 can notify the recovery order in the selected recovery pattern.

  Therefore, a worker who manages the production line can know the restoration order that minimizes the loss value. Therefore, the production efficiency in the production line can be improved.

  Further, as described above, the notification unit 18 may be configured to notify the production facility to be restored first in the selected restoration pattern. By adopting such a configuration, the following effects can be obtained.

  For example, during a recovery operation of the production facility, the production facility may be newly stopped due to a malfunction of the own facility. In such a case, it can be said that it is preferable to reconsider the restoration order in terms of production efficiency for production facilities that are stopped due to a malfunction of the own facility, excluding production facilities that are performing restoration work. Therefore, the notifying unit 18 notifies the first production facility to be restored in the selected restoration pattern, so that the worker who manages the production line can select the first production facility in the restoration order in which the loss value is minimized. I can know.

  For this reason, the worker who manages the production line can know the restoration target (production facility) at which the loss value in the production line is minimized at the time of calculating the production loss value. Therefore, the production efficiency in the production line can be improved.

  Moreover, the management apparatus 1 is provided with the stop information reception part (stop information reception means) 13 which receives in real time the information which showed the production facility stopped by the malfunction of the own equipment as mentioned above, The said notification part 18 When the information indicating that the recovery process of the production facility notified by is started is received, the loss value calculating unit 16 among the production facilities indicated in the information received by the stop information receiving unit 13 is the recovery unit. The loss value is calculated for all recovery patterns related to the recovery order of the production equipment except the production equipment for which processing has been started. The pattern selection unit 17 calculates the loss value by the loss value calculation unit 16. Each time, the recovery pattern that minimizes the loss value is selected, and the notification unit 18 is configured to perform the notification every time the pattern selection unit 17 selects the recovery pattern.

  According to this configuration, the stop information receiving unit 13 can receive information indicating a production facility that is stopped due to a malfunction of the own facility in real time. In addition, the loss value calculation unit 16 calculates the loss values for all recovery patterns related to the recovery order of production facilities except production facilities for which recovery processing has been started among production facilities that have been stopped due to a failure of the own facility. It can be calculated. Furthermore, every time the loss value calculation unit 16 calculates a loss value, the pattern selection unit 17 can select a restoration pattern that minimizes the loss value. In addition, whenever the pattern selection unit 17 selects a recovery pattern, the notification unit 18 can notify the worker who manages the production line as described above.

  Therefore, a worker or the like knows in real time the restoration order that minimizes the loss value or the restoration target (production facility) that has the smallest loss value on the production line when the production loss value is calculated. Can do.

  In addition, as described above, the management apparatus 1 includes an end information receiving unit (end information receiving unit) 21 that receives end information indicating that the recovery process for one production facility has ended, and the pattern selection unit 17 has a recovery pattern. The notification by the notification unit 18 that is performed every time is selected is also performed after the end information reception unit 21 receives the end information.

  According to this configuration, the end information receiving unit 21 can receive end information indicating that the production facility restoration process for one production facility has ended. As a result, the management apparatus can know that the restoration processing has been completed for one production facility that has been the restoration target.

  By the way, in a configuration in which information indicating a production facility that has been stopped due to a malfunction of its own facility is received in real time, another production facility is automatically As a result, the stop information receiving unit 13 may receive information indicating the newly stopped production facility. Further, there may be a case where notification is performed a plurality of times while a recovery process is being performed on a certain production facility.

  Under such circumstances, when the above-described notification is newly made by the notification unit 18 while the worker or the like is performing the recovery process on the certain production facility, the worker or the like is notified. There is a risk of being swung around. For this reason, it is not so preferable from the point of efficiency of recovery processing.

  However, in the above configuration, the notification by the notification unit 18 that is performed every time the pattern selection unit 17 selects the restoration pattern is performed after the end information reception unit 21 receives the end information. This is performed after the restoration process is completed for one production facility that has been a restoration target. Therefore, efficient recovery processing can be performed, and production efficiency can be improved.

  In addition, as described above, the management device 1 includes an identification information receiving unit (identification information receiving unit) 15 that receives a worker ID (identification information) that identifies a worker who manages a production line, and each of the production facilities. The storage device 12 stores information indicating production capacity, information indicating margin time, and information indicating recovery time associated with each worker ID. The loss value calculation unit 16 includes the storage device 12. From which the information indicating the production capacity, the information indicating the surplus time, and the recovery time information associated with the received worker ID are read out, and the loss value is calculated using these information It is.

  According to this configuration, the identification information receiving unit 15 can receive a worker ID that identifies a worker who manages the production facility. Thereby, in the management apparatus 1, it can be judged which worker is managing the production line. In addition, the storage device 12 stores information indicating the production capacity, information indicating margin time, and information indicating recovery time associated with each worker ID stored in the storage device 12 in each production facility. Is remembered. That is, regarding the recovery time, the recovery time of each worker is stored for each production facility.

  Further, the loss value calculation unit 16 stores the information indicating the production capacity, the information indicating the surplus time, and the information indicating the recovery time associated with each piece of identification information stored in the storage device 12 in each production facility. And the loss value is calculated. Here, regarding the recovery time, since the recovery time associated with the received worker ID is used, the loss value can be calculated using the recovery time corresponding to the worker.

  Therefore, it is possible to calculate the loss value in consideration of the worker's recovery processing capability for each production facility. Therefore, it is possible to appropriately calculate the production loss value in the production line when the restoration is performed with each restoration pattern.

  In addition, as described above, the management apparatus 1 receives the start information reception unit (start information reception unit) 20 that receives start information indicating that the production facility recovery process for one production facility has been started, and the start information. When the received time is the recovery start time, and the time when the end information is received is the recovery end time, the time correspondence attaching unit receives the recovery start time and the recovery end time of each production facility in association with the worker ID. (Time correlating means) 23, a recovery time calculating section (recovery time calculating means) 24 for calculating the time required for recovery from the received both times, and the time required for the recovery are stored in the storage device 12. It is a structure provided with the setting part (update means) 25 which updates the memorize | stored information of the recovery time matched with the said worker ID.

  According to this configuration, the start information accepting unit 20 can accept start information indicating that the restoration process for one production facility has been started. Thereby, the management apparatus 1 can know that the recovery process was started regarding one production facility which was the recovery target.

  Further, the time correlating unit 23 can accept the recovery start time and the recovery end time of each production facility in association with the worker ID. Further, the recovery time calculation unit 24 can calculate the time required for recovery from both times. Thereby, it is possible to calculate the time required for recovery by the worker for each production facility. In addition, the setting unit 25 can update the recovery time information associated with the worker ID stored in the storage device 12 using the time required for the recovery. Therefore, the accuracy of the recovery time used for calculating the loss value can be increased.

  Further, as described above, the management device 1 stores the received worker ID, and the worker identified by the worker ID is stored in the stored worker ID. A capability information association unit (capability information association means) 31 for associating capability information indicating the capability of the job, and a work having the same capability as the worker identified by the received worker ID based on the capability information A specifying unit (specifying means) 19 for specifying a worker ID indicating a worker, the storage device 12 is information on recovery time associated with the received worker ID, and the loss value When information on the recovery time of the production facility used for calculation is not stored, the loss value calculation unit 16 is a recovery time associated with the identified worker ID and is used for calculating the loss value. Same as production equipment Recovery time of production facilities, are also configured to substitute a recovery time in calculating the loss value.

  According to this configuration, the ability information association unit 31 can associate the ability information indicating the ability of the worker identified by the worker ID with the worker ID stored in the storage device 12. Further, the identification unit 19 can identify a worker ID indicating a worker having the same ability as the worker identified by the received worker ID based on the capability information.

  Here, when the storage device 12 does not store the recovery time information associated with the received worker ID and the production facility recovery time information used for the calculation of the loss value. In this state, the loss value cannot be calculated.

  However, in the above configuration, the loss value calculation unit 16 is a recovery time associated with the specified worker ID and the recovery time of the same production equipment as the production equipment used for the calculation of the loss value. Is substituted for the recovery time when calculating the loss value. For this reason, the loss value can be calculated. Furthermore, the loss value can be calculated using information on the recovery time regarding a worker having the same ability as the worker performing the recovery process.

  Therefore, even if the recovery time for the worker performing the recovery process is not stored in the storage device 12, it is possible to calculate a highly accurate value for the loss value.

  In addition, as described above, the storage device 12 is the recovery time information associated with the predetermined identification information, and the production facility is used as the recovery time information of the predetermined production facility. Information indicating that recovery is not possible is stored, and when calculating the loss value, when information on the recovery time of the predetermined production facility is required, a predetermined notification is sent to a predetermined worker. It can be said that it is the structure provided with the notification part (2nd notification means) 26 to perform.

  By the way, the production line may have production facilities that cannot be restored by inexperienced workers. Under such circumstances, in the above configuration, the notifying unit 26 needs the information on the recovery time of the unrecoverable production facility associated with the identification information indicating the worker or the like to calculate the loss value. In this case, a predetermined notification can be given to a predetermined worker.

  Therefore, another worker can respond, and the situation where the restoration work of the production facility is not completed can be avoided.

  Next, the processing flow in the management apparatus 1 will be described with reference to FIGS. 5 shows the processing from step 1 (S1) to step 12 (S12), and FIG. 6 shows the processing after step 12.

  First, the identification information receiving unit 15 receives an input of a worker ID (S1). After S1, the stop information receiving unit 13 determines whether or not information (hereinafter referred to as stop information) indicating that the own equipment has stopped due to a failure of the own equipment has been received from each production facility (S2). If it is determined in S2 that the stop information has not been received, the process returns to S2. On the other hand, if it is determined in S2 that the stop information has been received, the stop information receiving unit 13 determines whether the stop information has been received from a plurality of production facilities (S3).

  In S3, when it is determined that the stop information has been received from a plurality of production facilities, the loss value calculation unit 16 generates all the recovery patterns related to the recovery order of the production facilities that are stopped due to the malfunction of the own facility ( S4). On the other hand, if it is determined in S3 that the stop information is not received from a plurality of production facilities, the process returns to S3 again.

  After S4, the first computing unit 51 is associated with the worker ID, and information on recovery time (first information, or first information and second information) regarding the plurality of production facilities (each production facility). ) Is read from the worker information storage unit 42 (S5).

  After S5, the stagnation detection unit 14 causes stagnation between each production facility (that is, the production facility X) and the production facility (that is, the production facility X + 1) in the next process of this production facility. It is determined whether or not (S6). In S6, when it is determined that the stagnation has occurred, the second calculation unit 52 reads information on the margin time for the production facility X + 1 from the facility information storage unit 41 (S7). On the other hand, if it is determined in S6 that no retention has occurred, the margin time is not read and the margin time is set to 0 (S8). And after S7 or S8, the 3rd calculating part 53 reads the information of the production capacity regarding the production equipment X + 1 from the equipment information storage part 41 (S9).

  After S9, the loss value calculation unit 16 designates one restoration pattern from the restoration patterns not yet designated among all restoration patterns (S10). And after S10, as above-mentioned regarding the said specified recovery pattern by each calculating part (51-54) of the loss value calculation part 16, as mentioned above, the recovery time of the said production equipment X, and the production regarding the production equipment X + 1. Using the capacity and the spare time, the loss value when the production facility is restored with the restoration pattern is obtained (S11).

  After S11, the loss value calculation unit 16 determines whether or not loss values have been calculated for all recovery patterns (S12). In S12, when the loss value is not calculated for all the recovery patterns, the process returns to S10 again. On the other hand, when the loss values have been calculated for all the recovery patterns in S12, the pattern selection unit 17 selects the recovery pattern having the minimum value among the calculated loss values (S13). ).

  After S13, the notification unit 18 notifies the recovery order in the selected recovery pattern (or the production equipment to be recovered first in the selected recovery pattern) (S14). After S14, the start information receiving unit 20 determines whether information that identifies each production facility from each other and indicates the start of the recovery process of the production facility (hereinafter referred to as start information) is received. (S15).

  In S15, when the start information is not received, the stop information receiving unit 13 determines whether stop information is newly received from each production facility (S16). If it is determined in S16 that new stop information has been received, the process returns to S4 again. On the other hand, if it is not determined in S16 that new stop information has been received, or if the start information is received in S15, the end information receiving unit indicates the end of the restoration process for one production facility. It is determined whether or not information (hereinafter referred to as end information) has been accepted (S17).

  If the end information is not accepted in S17, the process returns to S16 again. On the other hand, in S17, when the end information is received, the time association unit 23 generates the recovery start time information and the recovery end time information generated by the time generation unit 22 respectively. And associated with the worker ID (S18). Further, after S18, the recovery time calculation unit 24 calculates the recovery time for each production facility by subtracting the recovery start time from the recovery end time (S19).

  After S19, the setting unit 25 determines whether or not the recovery time information is already stored in the worker information storage unit 42 (S20). In S20, if the recovery time information is already stored, the setting unit 25 updates the recovery time information using the calculated recovery time information (S21). On the other hand, if the recovery time information is not yet stored, the setting unit 25 writes the calculated recovery time information in the worker information storage unit 42 (S22).

  After S21 or S22, the stop information receiving unit 13 determines whether stop information is newly received from each production facility (S23). If it is determined in S23 that the stop information has been newly received, the process returns to S4 again. On the other hand, if it is not determined in S23 that the stop information has been newly received, the process ends.

  By the way, in the said embodiment, the structure which manages one production line with one management apparatus, and was in charge of (managing) one production line was demonstrated. However, the present invention is not limited to this, and the present invention can also be applied to a configuration in which a plurality of production lines are managed by a single management apparatus, and a plurality of production lines are handled by one worker. Hereinafter, this configuration will be described.

  In this case, the loss value calculation unit 16 is configured to calculate the loss value for each production line when a plurality of production facilities in the plurality of production lines are stopped due to a malfunction of the own equipment. In other words, the loss value calculation unit 16 causes the production loss in each production line to be restored by each restoration pattern for all restoration patterns related to the restoration order of the production equipment that has been stopped due to a malfunction of its own equipment. A value is calculated for each production line. Thereby, the loss value of each restoration pattern in each production line is calculated for each production line.

  Furthermore, the pattern selection unit 17 is configured to select a recovery pattern that minimizes the loss value in all production lines. That is, a recovery pattern related to recovery of one production line that has the smallest loss value between different production lines is selected.

  By configuring the management device 1 in such a configuration, even if there are a plurality of production lines, the worker who manages the production line has a recovery order in which the loss value is minimized, or the loss value is Know the first production facility in the minimal recovery order.

  By the way, when different products are manufactured in each production line and multiple production lines are stopped, the profit margin or selling price of the product differs depending on the product being manufactured. It can be said that priority should be given to restoring the production line.

  In such a case, the loss value calculation unit 16 sets the recovery time related to the production facility stopped due to the malfunction of the own facility, the production capacity related to the production facility in the process immediately after the production facility stopped due to the malfunction of the own facility, and It is preferable that the loss value is calculated by multiplying a value calculated based on the margin time for the production facility by a value that increases in accordance with the importance of each production line. Specifically, it is preferable to multiply the calculation result in the fourth calculation unit 54 by a value that increases according to the importance of each production line. The value that increases according to the importance may be stored in the storage device 12 in advance, and the fourth calculation unit 54 may sequentially read from the storage device 12.

  As described above, it is possible to calculate the loss value in consideration of the type of product manufactured on the production line.

  As described above, the production line management apparatus according to the present embodiment, as described above, when a plurality of production facilities in the production line are stopped due to a malfunction of the own facility, for all recovery patterns related to the recovery order of the production facilities, Loss value calculation means for calculating a production loss value in the production line when the recovery pattern is restored, selection means for selecting a recovery pattern that minimizes the loss value, and recovery order in the selected recovery pattern It is characterized by comprising first notification means for notifying.

  According to the above configuration, the loss value calculation means can calculate the production loss value in the production line for each recovery pattern when the production facility stopped due to a malfunction of the own facility is recovered by each recovery pattern. it can.

  Further, the selection means can select a recovery pattern that minimizes the production loss value. Furthermore, the first notification means can notify the restoration order in the selected restoration pattern.

  Therefore, a worker who manages the production line can know the restoration order that minimizes the loss value.

  Therefore, it is possible to provide a production line management device that can improve production efficiency in the production line.

  As described above, the production line management apparatus according to the present embodiment, as described above, when a plurality of production facilities in the production line are stopped due to a malfunction of the own facility, for all recovery patterns related to the recovery order of the production facilities, Loss value calculation means for calculating a production loss value in the production line when restored by each recovery pattern, selection means for selecting a recovery pattern that minimizes the loss value, and first in the selected recovery pattern And a first notification means for notifying the production facility to be restored.

  According to the above configuration, the loss value calculation means can calculate the production loss value in the production line for each recovery pattern when the production facility stopped due to a malfunction of the own facility is recovered by each recovery pattern. it can.

  Further, the selection means can select a recovery pattern that minimizes the production loss value.

  By the way, during the recovery of the production equipment, the production equipment may be newly stopped due to a malfunction of the own equipment. In such a case, it can be said that it is preferable to reconsider the restoration order in terms of production efficiency for production facilities that are stopped due to a malfunction of the own facility, excluding production facilities that are performing restoration work.

  Therefore, by notifying the first production facility to be restored first in the selected restoration pattern by the first notifying means, the worker who manages the production line, etc. can obtain the first production facility in the restoration order in which the loss value is minimized. Can know.

  For this reason, the worker who manages the production line can know the restoration target (production facility) at which the loss value in the production line is minimized at the time of calculating the production loss value.

  Therefore, it is possible to provide a production line management device that can improve production efficiency in the production line.

  Further, the production line management device according to the present embodiment, in the production line management device described above, includes stop information receiving means for receiving in real time information indicating a production facility that has stopped due to a problem with its own facility, When the information indicating that the recovery process of the production facility notified by the first notification unit is started is received, the loss value calculating unit is the production facility indicated in the information received by the stop information receiving unit. The loss value is calculated for all recovery patterns related to the recovery order of the production equipment except the production equipment for which the recovery processing has been started, and the selection means is configured such that the loss value calculation means calculates the loss value. Each time the calculation is performed, the restoration pattern that minimizes the loss value is selected, and the first notification unit performs the notification every time the selection unit selects the restoration pattern. It is characterized by performing.

  According to said structure, the information which showed the production equipment stopped by the malfunction of the own equipment can be received in real time by a stop information reception means.

  In addition, the loss value calculation means calculates the loss values for all recovery patterns related to the recovery order of production equipment, except production equipment that has started recovery processing, among production equipment that has been stopped due to a malfunction of its own equipment. it can.

  Furthermore, every time the loss value calculation unit calculates the loss value, the selection unit can select a recovery pattern that minimizes the loss value. Further, the above-mentioned notification can be made to the worker who manages the production line by the first notification unit every time the selection unit selects a recovery pattern.

  Therefore, a worker or the like knows in real time the restoration order that minimizes the loss value or the restoration target (production facility) that has the smallest loss value on the production line when the production loss value is calculated. There is an effect that can be.

  Further, the production line management device according to the present embodiment includes an end information receiving unit that receives end information indicating that the recovery process for one production facility has ended in the production line management device, and the selection unit includes: The notification by the first notification means performed every time the restoration pattern is selected is performed after the end information receiving means receives the end information.

  According to said structure, the completion information which shows that the restoration process of the production equipment regarding one production equipment was complete | finished by the completion information reception means can be received. As a result, the production line management apparatus can know that the restoration process has been completed for one production facility that has been the restoration target.

  By the way, in a configuration in which information indicating a production facility that has been stopped due to a malfunction of its own facility is received in real time, another production facility is automatically There is a case where it stops due to a malfunction of the equipment, and as a result, the stop information receiving means receives information indicating the newly stopped production equipment. Further, there may be a case where notification is performed a plurality of times while a recovery process is being performed on a certain production facility.

  Under such circumstances, when the above notification is newly made by the first notification means while the worker etc. is performing the recovery process for the certain production facility, the worker is notified. There is a risk of being swayed by information. For this reason, it is not so preferable from the point of efficiency of recovery processing.

  However, in the configuration of the present invention, since the notification by the first notification unit performed every time the selection unit selects the recovery pattern is performed after the end information reception unit receives the end information, the notification by the first notification unit is This is performed after the restoration process is completed for one production facility that has been a restoration target.

  Therefore, it is possible to perform an efficient recovery process, and it is possible to improve the production efficiency.

  In addition, the production line management device according to the present embodiment produces a recovery time and a number of workpieces that each production facility can produce per unit time in the above production line management device. When the capacity and the time from when the production facility of the previous process stops due to a malfunction of the facility until the own facility stops due to the work not flowing due to the stop, the loss value calculation The means calculates the loss value based on a recovery time relating to a production facility stopped due to a malfunction of the own facility, a production capacity relating to a production facility in a process subsequent to the production facility, and a margin time relating to the production facility. It is characterized by that.

  The production loss in the production line is generally obtained as the sum of losses caused by production facilities stopped due to malfunctions.

  In addition, if one production facility stops due to a malfunction of its own facility, it affects the production in the production facility (the production facility immediately after) immediately after the production facility. This effect also depends on the recovery time. Further, if the margin time is longer than the recovery time, the production in the immediately following production facility is not affected, but if it is short, the production in the immediately following production facility is affected. The production efficiency of the production line is also related to the production capacity of the production facility immediately after the above.

  Therefore, the loss value is calculated based on the recovery time related to the production facility stopped due to the malfunction of the own facility, and the production capacity and margin time related to the production facility in the next process after the production facility stopped due to the malfunction of the own facility. It is possible to calculate.

  Further, in the production line management device according to the present embodiment, in the production line management device, the loss value calculation means relates to each production facility stopped due to a malfunction of the own facility, First calculation means for obtaining the sum of the recovery times of the respective production facilities that are subjected to the recovery process, and when there is no production facility that is first subjected to the recovery process for each of the production facilities, the recovery time of the production equipment From this, if there is a production facility that is first subjected to the recovery process while subtracting the margin time for the production facility of the next step, the production of the next step is calculated from the value obtained by the first calculation means. A second computing means for subtracting a margin time for equipment, a third computing means for multiplying a value obtained by the second computing means for the production equipment, and a production capacity for the production equipment in the next process; of It is characterized in that it comprises a fourth arithmetic means for obtaining the sum of the values obtained by the third arithmetic means of all production equipment was stopped by condition.

  According to the above configuration, first, with respect to each production facility stopped due to a malfunction of the own facility, the sum of the recovery time of the production facility and the recovery time of each production facility where the recovery process is performed first is performed by the first calculation means. Is required. In addition, when there is no production facility for which the recovery process is performed first for each production facility, the second calculation means subtracts the spare time for the production facility in the next process from the recovery time of the production facility. On the other hand, when there is a production facility where the restoration process is performed first, a margin time related to the production facility of the next process is subtracted from the value obtained by the first calculation means. Further, the third calculation means can multiply the value obtained by the second calculation means for each production facility by the production capacity related to the production equipment in the next process.

  As described above, the production loss value generated in each production facility can be obtained.

  Furthermore, the sum total of the value calculated | required by the said 3rd calculating means is calculated | required by the 4th calculating means regarding all the production facilities stopped by the malfunction of the own equipment.

  Therefore, the production loss value in the entire production line can be obtained.

  The production line management device according to the present embodiment includes an identification information receiving unit that receives identification information for identifying a worker who manages the production line, and a production capacity in each of the production facilities. Information indicating margin time, information indicating the recovery time, and information indicating the recovery time associated with each piece of identification information, and the loss value calculating means is configured to produce the production capacity from the storage device. , Information indicating margin time, and recovery time information associated with the received identification information, and the loss value is calculated using these information.

  According to said structure, the identification information which identifies the worker who manages production equipment can be received by the identification information reception means. As a result, the production line management device can determine which worker is managing the production line.

  Further, the storage device stores information indicating production capacity, information indicating margin time, and information indicating recovery time associated with each piece of identification information stored in the storage device. ing. That is, regarding the recovery time, the recovery time of each worker is stored for each production facility.

  Further, the loss value calculation means reads the information indicating the production capacity, the information indicating the surplus time, and the information indicating the recovery time associated with each identification information stored in the storage device. Then, the loss value is calculated. Here, regarding the recovery time, since the recovery time associated with the received identification information is used, the loss value can be calculated using the recovery time according to the worker.

  Therefore, it is possible to calculate the loss value in consideration of the worker's recovery processing capability for each production facility. Therefore, there is an effect that it is possible to appropriately calculate the production loss value in the production line when the restoration is performed with each restoration pattern.

  Further, the production line management device according to the present invention is the above-mentioned start information receiving means for receiving start information indicating that the production facility recovery processing related to one production facility is started in the production line management device. Is a recovery start time, and a time at which the end information is received is a recovery end time, a time association means for receiving the recovery start time and the recovery end time of each production facility in association with the identification information Recovery time calculating means for calculating the time required for recovery from both received times, and the recovery time associated with the identification information stored in the storage device using the time required for the recovery And updating means for updating the information.

  According to said structure, the start information which shows that the recovery process regarding one production facility was started can be received by the start information reception means. As a result, the production line management apparatus can know that the restoration process has been started for one production facility that has been the subject of restoration.

  Further, the time correlating means can accept the recovery start time and the recovery end time of each production facility in association with the identification information. Furthermore, the recovery time calculation means can calculate the time required for recovery from both times. Thereby, it is possible to calculate the time required for recovery by the worker for each production facility.

  Further, the update means can update the recovery time information associated with the identification information stored in the storage device using the time required for the recovery.

  Therefore, there is an effect that it is possible to improve the accuracy of the recovery time used for calculating the loss value.

  Regarding the update of the recovery time, it may be configured to reflect the calculated time required for the recovery, or the recovery time stored in the storage device may be required for the calculated recovery. The configuration may be replaced by time.

  Further, in the production line management device according to the present embodiment, in the production line management device, the storage device stores the received identification information, and the stored identification information is stored in the storage identification information. , Ability information correspondence means for associating ability information indicating the ability of the worker identified by the identification information, and having an ability equivalent to the worker identified by the received identification information based on the ability information Specifying means for identifying identification information indicating a worker, the storage device is information on recovery time associated with the received identification information, and the production equipment used for calculating the loss value When the recovery time information is not stored, the loss value calculation means is a recovery time associated with the identified identification information, and the production facility used for calculating the loss value The recovery time of the same production facilities, is characterized by substituting the recovery time in calculating the loss value.

  According to said structure, the capability information corresponding | compatible means can match the capability information which showed the capability of the worker identified by this identification information with the identification information memorize | stored in the said memory | storage device. Further, the identification means can identify identification information indicating a worker having the same ability as the worker identified by the received identification information based on the capability information.

  Here, if the storage device is information on the recovery time associated with the received identification information and the information on the recovery time of the production facility used for calculating the loss value is not stored, In this state, the loss value cannot be calculated.

  However, in the configuration of the present invention, the loss value calculating means is a recovery time associated with the identified identification information and the recovery time of the same production equipment as the production equipment used for calculating the loss value. , It is used as a recovery time when calculating the loss value. For this reason, the loss value can be calculated.

  Furthermore, the loss value can be calculated using information on the recovery time regarding a worker having the same ability as the worker performing the recovery process.

  Therefore, even if the recovery time for the worker performing the recovery process is not stored in the storage device, it is possible to calculate a highly accurate value for the loss value.

  Further, in the production line management device according to the present embodiment, in the production line management device described above, the storage device is information on a recovery time associated with predetermined identification information, and a predetermined production facility. As information on the recovery time, information indicating that the production facility cannot be recovered is stored, and when calculating the loss value, information on the recovery time of the predetermined production facility is required. It is characterized by comprising a second notification means for giving a predetermined notification to the worker.

  The production line may have production facilities that cannot be restored by inexperienced workers. Under such circumstances, according to the above-described configuration, the second notification means uses the information on the recovery time of the unrecoverable production equipment associated with the identification information indicating the worker or the like to calculate the loss value. When necessary, a predetermined notification can be given to a predetermined worker.

  Therefore, another worker can respond, and there is an effect that it is possible to avoid a situation where the restoration work of the production facility is not completed.

  Further, the production line management device according to the present embodiment is the production line management device described above, wherein the loss value calculation means is configured when a plurality of production facilities in a plurality of production lines are stopped due to a malfunction of the own equipment. Is for calculating the loss value for each production line, and the selection means selects a recovery pattern that minimizes the loss value in all production lines.

  According to the above configuration, the loss value is calculated for each production line by the loss value calculation means when a plurality of production facilities in the plurality of production lines are stopped due to a malfunction of the own equipment. In other words, with the loss value calculation means, in each production line, all the recovery patterns related to the recovery order of the production equipment that has been stopped due to a malfunction of its own equipment, the production loss value in the production line when it is restored with each recovery pattern Is calculated for each production line.

  In addition, the selection unit selects a recovery pattern that minimizes the loss value in all production lines. That is, a recovery pattern related to recovery of one production line that has the smallest loss value between different production lines is selected.

  Therefore, even if there are multiple production lines, the worker who manages the production line must select the first production facility in the restoration order that minimizes the loss value or the restoration order that minimizes the loss value. I can know.

  In addition, the production line management device according to the present embodiment produces a recovery time and a number of workpieces that each production facility can produce per unit time in the above production line management device. When the capacity and the time from when the production facility of the previous process stops due to a malfunction of the facility until the own facility stops due to the work not flowing due to the stop, the loss value calculation The means includes a value calculated based on a recovery time relating to a production facility stopped due to a malfunction of the own facility, a production capacity relating to a production facility in a process subsequent to the production facility, and a margin time relating to the production facility. The loss value is calculated by multiplying a value that increases in accordance with the importance of the line.

  The production loss in the production line is generally obtained as the sum of losses caused by production facilities stopped due to malfunctions.

  In addition, if one production facility stops due to a malfunction of its own facility, it affects the production in the production facility (the production facility immediately after) immediately after the production facility. This effect also depends on the recovery time. Further, if the margin time is longer than the recovery time, the production in the immediately following production facility is not affected, but if it is short, the production in the immediately following production facility is affected. The production efficiency of the production line is also related to the production capacity of the production facility immediately after the above.

  Therefore, based on at least the recovery time related to the production facility stopped due to the malfunction of the own equipment, and the production capacity and margin time related to the production equipment of the next process after the production facility stopped due to the malfunction of the own equipment, The loss value can be calculated.

  By the way, when different products are manufactured in each production line and multiple production lines are stopped, the profit margin or selling price of the product differs depending on the product being manufactured. It can be said that priority should be given to restoring the production line.

  Therefore, by calculating the loss value by multiplying the value calculated based on the recovery time, production capacity, and margin time by the value that increases according to the importance of each production line, the product manufactured on the production line There is an effect that it is possible to calculate a loss value in consideration of the type.

  As described above, the production line management method according to the present embodiment, as described above, when a plurality of production facilities in the production line are stopped due to a malfunction of the own facility, for all recovery patterns related to the recovery order of the production facilities, Loss value calculation step for calculating a production loss value in the production line when recovery is performed with each recovery pattern, a selection step for selecting a recovery pattern that minimizes the loss value, and a recovery order in the selected recovery pattern And a notification step for notifying the above.

  According to the above method, the loss value calculation step can calculate the production loss value on the production line for each recovery pattern when the production facility stopped due to the malfunction of the own facility is recovered by each recovery pattern. it can.

  Further, the selection step can select a recovery pattern that minimizes the production loss value. Furthermore, the notification step can notify the recovery order in the selected recovery pattern.

  Therefore, a worker who manages the production line can know the restoration order that minimizes the loss value.

  Therefore, the production line management method that can improve the production efficiency in the production line can be provided.

  As described above, the production line management method according to the present embodiment, as described above, when a plurality of production facilities in the production line are stopped due to a malfunction of the own facility, for all recovery patterns related to the recovery order of the production facilities, A loss value calculating step for calculating a loss value of production in the production line at the time of recovery by each recovery pattern, a selection step for selecting a recovery pattern that minimizes the loss value, and first in the selected recovery pattern And a notification step for notifying the production facility to be restored.

  According to the above method, the loss value calculation step can calculate the production loss value on the production line for each recovery pattern when the production facility stopped due to the malfunction of the own facility is recovered by each recovery pattern. it can.

  Further, the selection step can select a recovery pattern that minimizes the production loss value.

  By the way, during the recovery of the production equipment, the production equipment may be newly stopped due to a malfunction of the own equipment. In such a case, it can be said that it is preferable to reconsider the restoration order in terms of production efficiency for production facilities that are stopped due to a malfunction of the own facility, excluding production facilities that are performing restoration work.

  Therefore, by notifying the production facility to be restored first in the selected restoration pattern in the notification step, the worker who manages the production line knows the first production facility in the restoration order in which the loss value is minimized. be able to.

  For this reason, the worker who manages the production line can know the restoration target (production facility) at which the loss value in the production line is minimized at the time of calculating the production loss value.

  Therefore, the production line management method that can improve the production efficiency in the production line can be provided.

  The program according to the present embodiment is a program for causing a computer to function as each unit of the production line management apparatus.

  Therefore, there is an effect that the production line management device can be provided to the user by loading the program into the computer system.

  The recording medium according to the present embodiment is a computer-readable recording medium that records the program.

  Therefore, it is possible to provide the user with the production line management device by loading the program recorded on the recording medium into the computer system.

[Embodiment 2]
Another embodiment of the present invention will be described below with reference to FIGS.

  FIG. 7 is a diagram showing a schematic configuration of the production line management apparatus according to the present embodiment. As shown in the figure, the production line management device 100 includes sensors 110a, 110b, 110c, PLCs (programmable logic controllers) 111a, 111b, 111c, PLCs 112a, 112b, 112c, an operation status management device 116, and a video camera 113. , A video cutting device 114 and a server device 115 are provided. Further, as shown in the figure, the operation status management device 116 includes a stop cause classification device (classification information generation device) 120, an input device 121, a display device 122, an information processing device 123, an output device 124, and a maintenance order determination device. 125 is provided.

  Each sensor (110a, 110b, 110c...) Performs sampling at the same cycle and at the same time.

  Here, it is assumed that the production line managed by the production line management apparatus 100 includes a plurality of production facilities (in the figure, only some production facilities (M1, M2, M3) are illustrated). In this embodiment, it is assumed that one worker is responsible for a plurality of production facilities.

  Furthermore, the production line is provided with a belt conveyor (only a part of the belt conveyors (C1, C2, C3) is shown in the figure) between the production facilities. And by this belt conveyor, a workpiece | work is conveyed to the production facility of the following process (downstream). In addition, between the belt conveyor and the production equipment downstream of the belt conveyor, a buffer unit for temporarily storing workpieces (in the figure, only some buffer units (B1, B2, B3) are shown) (buffer device) Is provided.

  Note that the maximum number (hereinafter, also referred to as the maximum number) that can be stored in each buffer unit is set in advance for each buffer. In each buffer unit, the workpiece is sent from the buffer unit to the production facility in the order in which the workpiece enters the buffer unit. That is, in each buffer unit, first-in first-out is performed for the work.

  In addition, although an example in which the buffer unit Bi is provided separately from the production facility Mi will be described, the present invention is not limited to this, and the production facility Mi may have a configuration including the buffer unit Bi.

  In addition, each production facility is assumed to have a stop button for stopping the operation of its own device. Further, each production facility (M1, M2, M3) sends a signal indicating whether or not the stop button is depressed (that is, the stop state) to each PLC (112a, 112b, and 112c). Output. That is, each production facility outputs a signal indicating whether or not its own production facility has been stopped. Moreover, the said signal is output in the state synchronized with the output from each sensor (110a-110c). That is, the signal is output at the same cycle and the same time as the output of each sensor.

  The sensor 110a is disposed between the production facility M1 and a production facility (not shown) on the upstream side of the production facility M1. The sensor 110a detects whether a workpiece exists at a predetermined position on the production line at a predetermined cycle (sampling cycle). The sensor 110a sequentially outputs a signal indicating the presence / absence of a work to the PLC 111a.

  The PLC 111a sequentially receives the output from the sensor 110a. Then, the PLC 111a associates the received output with date / time information indicating the date / time. Then, the PLC 111a sequentially sends the associated information (hereinafter, first correspondence information) to the stop cause classification device 120 in the operation status management device 116. Here, when receiving a signal indicating that there is a workpiece, the PLC 111a sends, for example, first correspondence information as illustrated in FIG. 8 to the stop cause classification device 120. On the other hand, when receiving a signal indicating that there is no work, the PLC 111a sends, for example, first correspondence information as shown in FIG.

  In FIG. 8, data “output 1” indicating that there is a work is associated with the date and time information. In FIG. 9, data “output 0” indicating that there is no work is associated with the date and time information.

  The sensor 110b is disposed between the production facility M1 and the production facility M2. The sensor 110b detects whether or not a work exists at a predetermined position on the production line at a predetermined cycle. The sensor 110b sequentially outputs a signal indicating the presence / absence of a workpiece to the PLC 111b.

  The PLC 111b sequentially receives the output from the sensor 110b. Then, the PLC 111b associates the received output with date / time information indicating the date / time. Then, the PLC 111b sequentially sends the associated information (hereinafter, second association information) to the stop cause classification device 120 in the operation status management device 116. The second association information sent by the PLC 11b is information in the same format as the first association information sent by the PLC 111a.

  The sensor 110c is disposed between the production facility M2 and a production facility (not shown) on the downstream side of the production facility M2. The sensor 110c detects at a predetermined cycle whether or not a workpiece is present at a predetermined position on the production line. Then, the sensor 110c sequentially outputs a signal indicating the presence / absence of a work to the PLC 111c.

  The PLC 111c sequentially receives the output from the sensor 110b. Then, the PLC 111c associates the received output with date / time information indicating the date / time. Then, the PLC 111c sequentially sends the associated information (hereinafter referred to as third correspondence information) to the stop cause classification device 120 in the operation status management device 116. The third correspondence information sent by the PLC 111c is information in the same format as the first and second correspondence information sent by the PLCs 111a and 111b.

  The PLC 112a sequentially receives signals indicating whether or not the production facility M1 has been stopped from the production facility M1. Then, the PLC 112a associates the received signal with date / time information indicating the date / time. Then, this associated information (hereinafter referred to as fourth correspondence information) is sent to the stop cause classification device 120 in the operation status management device 116. Here, when a signal indicating that the operation has been stopped is received, for example, fourth correspondence information as shown in FIG. 10 is sent. On the other hand, when a signal not indicating that the operation has been stopped is received, for example, fourth correspondence information as shown in FIG. 11 is sent.

  In FIG. 10, data “output 1” indicating that the operation of the production facility is stopped is associated with the date / time information. In FIG. 11, data “output 0” indicating that the operation of the production facility is not stopped is associated with the date and time information.

  The PLC 112b sequentially receives a signal indicating whether or not the production facility M2 has been stopped from the production facility M2. Then, the PLC 112b associates the received signal with date / time information indicating the date / time. Then, this associated information (hereinafter referred to as fifth correspondence information) is sent to the stop cause classification device 120 in the operation status management device 116. Note that the fifth correspondence information sent by the PLC 112b is information in the same format as the fourth correspondence information sent by the PLC 112a.

  The PLC 112c sequentially receives a signal indicating whether or not the production facility M3 has been stopped from the production facility M3. Then, the PLC 112c associates the received signal with date / time information indicating the date / time. Then, this associated information (hereinafter referred to as sixth correspondence information) is sent to the stop cause classification device 120 in the operation status management device 116. The third correspondence information sent by the PLC 112c is information in the same format as the fourth and fifth correspondence information sent by the PLCs 112a and 112b.

  The video camera 113 captures a video (moving image) in the vicinity of the production facility on the production line. Further, the video camera 113 sequentially associates the video with date / time information indicating the date / time. Then, the video camera 113 sends the video associated with the date / time information to the video cutting device 114.

  The video cutting device 114 receives the video from the video camera. Then, when receiving a predetermined instruction from the operation status management device 116, the video cutout device 114 cuts out a predetermined video from the received video and sends the cut out video to the operation status management device 116.

  The server device 115 stores identification information for identifying each worker in association with information indicating a production facility handled by each worker. In addition, the server device 115 stores the assigned time information indicating the assigned time of each worker in association with the identification information of each worker.

  Next, each part (120-124) of the operation status management apparatus 116 will be described.

  First, the stop cause classification device 120 will be described. FIG. 12 is a block diagram showing the configuration of the stop cause classification device 120. As shown in the figure, the stop cause classification device 120 includes a data writing / reading unit (130 to 132), a data storage unit (133 to 135), a state detecting unit 136, and an equipment state specifying unit 137. .

  The data writing / reading unit 130 receives the first to third association information for each PLC from the PLC (111a, 111b, 111c). Then, the data writing / reading unit 130 sequentially writes the received association information in the data storage unit 133.

  FIG. 13 is a diagram showing a series of first association information (first association information group) stored in the data storage unit 133. FIG. 14 is a diagram showing a series of second correspondence information (second correspondence information group) stored in the data storage unit 133. 13 and 14 show a case where the sampling period of the sensors 110a and 110b is 1 second. The sampling cycle needs to be at least equal to or shorter than the takt time of the production facility having the shortest takt time in consideration of the takt time (processing time of one workpiece) of each production facility.

  The third association information is also stored in the data storage unit 133 sequentially. As a result, the data storage unit 133 stores a series of third association information (third association information group) in the same format as the first and second association information.

  The data writing / reading unit 131 receives the fourth to sixth association information for each PLC from the PLC (112a, 112b, 112c). Then, the data writing / reading unit 131 sequentially writes the received association information in the data storage unit 134. FIG. 15 is a diagram showing a series of fourth association information stored in the data storage unit 134. Also, the fifth and sixth association information is also stored in the data storage unit 134 in the same format as the fourth association information.

  The state detection unit 136 detects whether or not a workpiece is passing at the point where each sensor (110a to 110c) is installed, for each output time of the signals of the sensors (110a to 110c). And the state detection part 136 attaches | subjects the flag according to a detection result to each corresponding information. Furthermore, the state detection unit 136 sends a series of correspondence information (each correspondence information group) to which the flag is attached to the equipment state identification unit 137.

  Hereinafter, the detection method will be specifically described with reference to an example in which the state detection unit 136 detects whether or not the workpiece has passed the point where the sensor 110a is installed and attaches the flag.

  First, the state detection unit 136 acquires a series of first association information that is data related to the sensor 110 a from the data storage unit 133 via the data writing / reading unit 130. Thereafter, the state detection unit 136 determines whether there is a change in the output during the period based on each output during the predetermined period. If it has changed, a flag of “pass” is attached to the first association information indicating the first time of the period. On the other hand, if it has not changed, a flag of “stop” is attached to the first association information indicating the first time. Here, the description will be made with reference to FIGS. 13 and 16 as follows.

  First, the state detection unit 136 acquires first association information after 11:25:34 as shown in FIG. Then, based on each output (four outputs) in the period from 11:25:34 to 11:25:37, it is determined whether or not there is a change in the output in the period. In this case, since the output changes during the period, the flag “pass” is attached to the first correspondence information indicating 11:25:34 (first time of the period).

  Next, the time of the period is shifted by 1 second, and it is determined whether or not there is a change in output in this period (that is, a period from 11:25:35 to 11:25:38). A flag corresponding to the determination result is attached to the first correspondence information indicating 35 minutes. In this case, a flag “pass” is attached.

  Thereafter, the same processing as described above is performed by sequentially shifting the time of the period one second later. Here, for example, since there is no change in output in the period from 11:25:42 to 11:25:45, the first correspondence information indicating 11:25:42 is referred to as “stop”. Add a flag.

  In addition, the state detection unit 36 sets the output value of the first association information to which the flag “pass” is attached and the output value is “0”. Change from “0” to “1”. The reason for making such a change is that it is not necessary to distinguish between “output 0 pass” and “output 1 pass”.

  Through the above processing, a first association information group with the above flag attached as shown in FIG. 16 can be obtained. Moreover, the 2nd and 3rd corresponding | compatible information group to which the said flag was attached | subjected by the same process can be obtained. FIG. 17 shows a second association information group with the flag.

  In the above description, the period is set to 4 seconds (that is, four pieces of data are used) in assigning the flag, but the present invention is not limited to this. However, considering that the line speed is determined by the production equipment having the maximum tact time in the production line, it is preferable to set the period to the maximum tact time.

  In addition, the state detection unit 136 acquires each series of association information (association information group) that is data on each production facility (M1 to M3) from the data storage unit 134 via the data writing / reading unit 131. To do. Then, this associated information group (fourth to sixth associated information groups) is sent to the equipment state specifying unit 137.

  The equipment state specifying unit 137 receives from the state detection unit 136 a series of each piece of associated information (each associated information group) to which the flag is attached. Hereinafter, the association information group to which the flag is attached is referred to as a flag assignment information group (specifically, a first flag assignment information group, a second flag assignment information group, and a third flag assignment information group). Each piece of information constituting the flag assignment information group (that is, the association information with a flag attached) is referred to as flag assignment information.

  The equipment state specifying unit 37 includes a flag assignment information group generated based on the output of a sensor installed between the production equipment and the production equipment one upstream side of the production equipment, the production equipment, and the production equipment Based on a flag addition information group generated based on the output of a sensor installed between one downstream production facility, the operation status of the production facility is specified for each production facility and for each time. And the equipment state specific | specification part 137 is the information which showed the operation condition of the production equipment identified for every time (specifically, the operation information which showed operation of a production equipment, or the stop information which showed the stop of this equipment) Is stored in the data storage unit 135 via the data writing / reading unit 132.

  Here, a specific method of specifying the operation status of the production facility will be specifically described below. Here, the description will be given taking as an example the specification of the operation status of the production facility M1. However, the production facility M2 and the production facility M3 are the same as the production facility M1.

  The equipment state specifying unit 137 deletes the information regarding the “output” and the “value” of the output in the correspondence information of the fourth correspondence information group received from the state detection unit 136 and newly adds the information to the correspondence information. Appropriate information is added. Specifically, when the output value is “1”, new information “stop by worker” is added. Note that the association information to which the information “stop by worker” is added (hereinafter referred to as worker stop (forced stop) information) corresponds to stop information indicating the stop of the equipment.

  On the other hand, when the output value is “0”, the following processing is performed. The equipment state identification unit 137 adds the following new information to the fourth correspondence information for the time based on the first flag assignment information for a certain time and the second flag assignment information for the time. Append.

  First, when the equipment state identifying unit 137 determines that the first flag assignment information includes information “output 1 passage” and the second flag assignment information includes information “output 1 passage” Then, the equipment state specifying unit 137 determines that the production equipment M1 is operating as shown in FIG. 18 (corresponding to pattern 1 in FIG. 18). And the equipment state specific | specification part 137 adds the information of "operation" as new information, as shown, for example in FIG. The association information to which the information “operation” is added corresponds to operation information indicating the operation of the facility.

  In addition, when the equipment state specifying unit 37 determines that the first flag assignment information includes information “output 1 pass” and the second flag assignment information includes information “output 1 stop” Then, the equipment state specifying unit 137 determines that the production equipment M1 is operating as shown in FIG. 18 (corresponding to the pattern 2 in FIG. 18). And the equipment state specific | specification part 137 adds the information of "operation" as new information.

  In addition, when the equipment state specifying unit 137 determines that the first flag assignment information includes information “output 1 passing” and the second flag assignment information includes information “output 0 stop” Then, the equipment state specifying unit 137 determines that the production equipment M1 is operating as shown in FIG. 18 (corresponding to the pattern 3 in FIG. 18). And the equipment state specific | specification part 137 adds the information of "operation" as new information.

  In addition, when the equipment state specifying unit 137 determines that the first flag assignment information includes the information “output 1 stop” and the second flag assignment information includes the information “output 1 pass” As shown in FIG. 18, the equipment state specifying unit 137 determines that the production equipment M1 is stopped due to a trouble (corresponding to the pattern 4 in FIG. 18). And the equipment state specific | specification part 137 adds the information "trouble stop" as new information, as shown, for example in FIG. Note that the association information to which the information “trouble stop” is added (hereinafter, trouble stop information) corresponds to the stop information indicating the stop of the equipment.

  In addition, when the equipment state identification unit 137 determines that the first flag assignment information includes information “output 1 stop” and the second flag assignment information includes information “output 1 stop” As shown in FIG. 18, the equipment state specifying unit 37 determines that the production equipment M1 is stopped due to waiting for the work to be taken out (corresponding to the pattern 5 in FIG. 18). And the equipment state specific | specification part 137 adds the information "carry-out waiting stop" as new information, as shown, for example in FIG. Note that the association information to which the information “carrying out waiting stop” is added (hereinafter referred to as carrying out waiting stop information) corresponds to the stop information indicating the stop of the equipment.

  In addition, when the equipment state identification unit 137 determines that the first flag assignment information includes information “output 1 stop” and the second flag assignment information includes information “output 0 stop” As shown in FIG. 13, the equipment state specifying unit 137 determines that the production equipment M1 is stopped due to a trouble (corresponding to the pattern 6 in the figure). And the equipment state specific | specification part 37 adds the information of "trouble stop" as new information.

  In addition, when the equipment state specifying unit 137 determines that the first flag provision information includes information “output 0 stop” and the second flag provision information includes information “output 1 pass” As shown in FIG. 18, the equipment state specifying unit 137 determines that the production equipment M1 is stopped due to waiting for the work to be carried in (corresponding to the pattern 7 in the figure). And the equipment state specific | specification part 137 adds the information of "carrying-in waiting stop" as new information. Note that the association information to which the information “carrying-in standby stop” is added (hereinafter referred to as “carrying-in waiting stop information”) corresponds to stop information indicating the stop of the equipment.

  In addition, when the equipment state specifying unit 137 determines that the first flag assignment information includes information “output 0 stop” and the second flag assignment information includes information “output 1 stop” As shown in FIG. 18, the equipment state specifying unit 137 determines that the production equipment M1 is stopped due to waiting for the workpiece to be loaded (corresponding to the pattern 8 in FIG. 18). And the equipment state specific | specification part 137 adds the information of "carrying-in waiting stop" as new information.

  In addition, when the equipment state specifying unit 137 determines that the first flag assignment information includes information “output 0 stop” and the second flag assignment information includes information “output 0 stop” Then, as shown in FIG. 18, the equipment state specifying unit 137 determines that the production equipment M1 is stopped due to waiting for workpieces to be loaded (corresponding to the pattern 9 in FIG. 18). And the equipment state specific | specification part 37 adds the information of "carrying-in waiting stop" as new information.

  Further, when the data writing / reading unit 132 receives a predetermined instruction from the information processing device 123, the data writing / reading unit 132 reads the information (operation information and stop information) stored in the data storage unit 135 and uses the read information as information. The data is sent to the processing device 123.

  Here, the processing flow in the stop cause classification device 120 will be described with reference to FIG.

  First, the data writing / reading unit 130 and the data writing / reading unit 131 receive the correspondence information from each PLC for each PLC, and the received correspondence information is sequentially sent to each data storage unit (33). Write to (34) (S31). After S31, the state detection unit 136 reads the association information from the data storage unit 133 (S32). After S32, the state detection unit 136 detects whether or not the workpiece has passed through the place where each sensor is installed at each time (S33).

  In S33, when it is detected that the workpiece has passed at a certain time, the state detection unit 136 is information obtained through the PLCs 111a to 111c and includes date and time information indicating this time. A flag “pass” is attached to the association information (S34). On the other hand, if it is not detected in S33 that the workpiece has passed at a certain time, the state detection unit 136 is information obtained through the PLCs 11a to 11c and indicates this time. A flag “stop” is attached to the association information including the date and time information (S35).

  After S34 and S35, the state detection unit 136 determines whether or not all the association information read from the data storage unit 133 has been flagged (S36).

  If it is determined in S36 that no flag is attached to all the association information, the process returns to S33 again. On the other hand, if it is determined in S36 that all the association information is flagged, the equipment state specifying unit 37 is obtained based on the output of the sensor on the upstream side of the production equipment. Correspondence information with a flag attached (flag assignment information), correspondence information with the flag obtained based on the output of a sensor on the downstream side of the production equipment, and the production equipment From the output of the provided PLC (that is, PLC 112a, PLC 112b, or PLC 112c), the operating status of the production facility is specified (S37).

  After S37, the equipment state specifying unit 137 stores, in the data storage unit 135, information (operation information / stop information) indicating the operation status identified for each time via the data writing / reading unit 132. (S38). Thus, a series of processing ends.

  The input device 121 receives input of information by a worker and a production line manager. The input device 121 is composed of, for example, a keyboard and a touch panel. Information input by the worker includes stop cause information indicating the cause of the stoppage of the production equipment, action content information indicating the action details of the production equipment, identification information indicating the worker identification information, and display contents on the display device 122. The instruction information to instruct | indicate is mentioned. Further, as information input by the administrator, search information for performing data search can be cited.

  The display device 122 receives information (drawing data described later) sent from the information processing device 123. Then, the display device 122 displays an image based on the received information on a display screen (not shown) of the display device 122.

  Here, the information processing apparatus 123 will be described. As illustrated in FIG. 22, the information processing apparatus 123 includes an operation status acquisition unit 140, a data association unit 141, a video data acquisition unit 142, an ID information reception unit 143, a charge information acquisition unit 144, a display control unit 145, and a stop cause reception. Unit 146, treatment content reception unit 147, determination unit 148, warning sound generation unit 149, data transmission unit 150, and storage device 151. The storage device 151 includes a memory 151a and a memory 151b.

  The operation status acquisition unit 140 sends the predetermined instruction described above to the data writing / reading unit 132 of the stop cause classification device 120. Then, the operation status acquisition unit 140 receives information (operation status information) indicating the operation status of the production facility at each time, which is stored in the data storage unit 135 of the stop cause classification device 120. That is, the operation status acquisition unit 140, for example, as shown in FIGS. 19, 20, and 23, operation information indicating the operation of the production facility and stop information indicating the stop of the facility (worker stop information Trouble stop information / unloading stop information / loading stop information) is sequentially acquired for each production facility. Further, the operation status acquisition unit 140 sends the acquired information to the data association unit 141.

  The data association unit 141 receives the operation status information from the operation status acquisition unit 140 for each production facility. Then, the data association unit 141 sends the time information included in the stop information to the video data acquisition unit 142.

  The video data acquisition unit 142 receives the time information from the data association unit 141. Then, video information for a certain period of time including the time before and after the time indicated by the time information is acquired from the video cutting device 114. Thereafter, the video data acquisition unit 142 sends the acquired video information to the data association unit 141.

  The data association unit 141 associates each piece of stop information with video information of a time corresponding to each piece of stop information, and stores the associated information in the memory 151a. For example, a nonvolatile RAM (Random Access Memory) can be used as the memory 151a.

  The ID information receiving unit 143 receives ID information that is input via the input device 121 and identifies a worker. Then, the ID information reception unit 143 sends this ID information to the responsible information acquisition unit 144.

  Here, the operator operates the input device 121 when inputting ID information. In this case, for example, the display control unit 145 may create drawing data for displaying a login screen as shown in FIG. 24 and display the login screen on the display screen of the display device 122. Then, by selecting an icon indicating OK on the login screen, the ID information receiving unit 143 may transmit the ID information to the responsible information acquiring unit 144.

  The assigned information acquisition unit 144 receives the ID information from the ID information reception unit 143. Further, the person-in-charge acquisition unit 144 receives information indicating the production facility handled by the worker identified by the ID information based on the received identification information from the server device 115, and the worker's charge time information. To get. Then, the charge information acquisition unit 144 sends the acquired information indicating the production facility and the charge time information to the display control unit 145.

  Here, when a predetermined instruction related to data input by an operator is input to the display control unit 45 via the input device 121, the display control unit 145 is indicated in the information indicating the production facility from the memory 151a. The associated information about the production facility and the time indicated in the assigned time information is read out. Then, the display control unit 145 creates drawing data for data input based on the read information. Further, the display control unit 145 sends the created drawing data to the display device 122. In this case, for example, a screen (input screen) as shown in FIG. 25 is displayed on the display screen of the display device 122 as an input reception screen. In this figure, the worker specified by the ID information is in charge of at least the production facilities M1 to M3, and a display relating to a part of the assigned time zone (time T1 to time T2) is made. Yes.

  When the display control unit 145 receives a screen scroll instruction from a worker or the like, the display control unit 145 causes the display screen of the display device 122 to display a screen that is scrolled up and down and left and right. As a result, the other equipment handled by the worker and the operating status after T2 can be displayed on the display screen.

  The creation of each drawing data constituting the drawing data for data input will be described below.

  First, for each production facility, the display control unit 145 creates drawing data related to a rectangular wave that distinguishes each information so as to be visible along a time series based on operation information and stop information. Explaining based on this figure, the display control unit 145 plots dots at the position where the vertical axis is in the HIGH state for the time included in the operation information, and the vertical axis is the position at the LOW state for the time included in the stop information. In addition to plotting the dots, the drawing data for drawing the plotted dots by line segments along the time series is created. In addition, the display control unit 145 also creates drawing data indicating a time axis representing time at regular intervals.

  The display control unit 145 also has a comment box (CB1 in the figure) for inputting the cause of the stoppage of the production facility, and a comment comment box for inputting the content of treatment performed on the production facility regarding the stoppage due to the stop cause Drawing data for displaying (CB2 in the figure) on the display device 122 is created. Here, the display control unit 145 creates drawing data so that both comment boxes are arranged at positions corresponding to the drawing indicating the stop. In the following description, a comment box for inputting a stop cause is referred to as a stop cause box, and a comment comment box for inputting treatment details is referred to as a treatment content box.

  Furthermore, the display control unit 145 responds to the position corresponding to the drawing indicating each stop according to the type of stop information (that is, worker stop information, trouble stop information, carry-out wait stop information, and carry-in wait stop information). Further, drawing data for displaying an identifier (for example, a graphic) is created. In the figure, when a figure is used as an identifier, and in the case of worker stop information, trouble stop information, carry-out waiting stop information, and carry-in wait stop information, a diamond-shaped figure (◆), A display example showing a star-shaped figure (★), a downward triangle figure (▼), and an upward triangle figure (▲) is shown. The shape of each stop information figure may be any shape as long as it can be distinguished from each other.

  In addition, the display control unit 145 draws each click so that the clickable icon (ICON1 in the figure) associated with the video information at the time of the stop is arranged at a position corresponding to the drawing indicating the stop. Create data. When the display control unit 145 detects that the icon is clicked by an input from the input device 121 (or the display device 122 when the display device 122 is a touch panel type), the display control unit 145 displays the icon on the display screen of the display device 122. The video information of the predetermined time related to the stop associated with the icon is displayed as a moving image. The display position or size of the video information on the display screen is not particularly limited.

  Further, the display control unit 145 arranges a clickable icon (ICON2 in the figure) for calling a setting screen for changing the contents shown on the input screen at a predetermined position on the input screen. Create drawing data. Here, when the display control unit 145 detects that the icon has been clicked by an input from the input device 121 or the like, the display control unit 145 switches the display content of the display screen of the display device 122 to the setting screen. Here, the setting screen is, for example, a screen for changing the assigned time zone (time zone indicated from the work start time to the work end time) or the like. An example of the setting screen will be described later.

  As will be described in detail later, the display control unit 145 has a clickable icon (ICON 3 in the figure) for storing information input to the information processing device 123 arranged at a predetermined position on the input screen. As shown, drawing data is created. Here, when information indicating that the icon has been clicked is input from the input device 121 or the like to the information processing device 123, the same information as the information temporarily stored in the memory 151a is sent to the memory 151b. Information is stored in the memory 151b. For example, a hard disk drive can be used as the memory 151b.

  Hereinafter, a clickable icon for calling the setting screen is referred to as a setting icon, and a clickable icon for saving information input to the information processing apparatus 123 is referred to as a save icon.

  Next, processing of information input by a worker will be described.

  The stop cause acceptance unit 146 accepts the input of the stop cause information indicating the cause of the stop of the production facility input via the input device 121 for each stop of the production facility. Then, the stop cause reception unit 146 sends the received stop cause information to the data association unit 141.

  The data association unit 141 receives stop cause information for each stop of each production facility from the stop cause receiving unit 146. Here, the data association unit 141 converts the stop cause information into the associated information stored in the memory 151a for each stop (that is, each stop information and video information of the time corresponding to each stop information). Associated information). When this association is completed, the data association unit 141 sends information (first end information) indicating that the association is completed to the display control unit 145.

  When the display control unit 145 receives the first end information from the data association unit 141, the display control unit 145 creates drawing data for displaying the stop cause information corresponding to each stop in the frame of each stop cause box on the display screen. . The drawing data is sent to the display device 122, and display based on the drawing data is performed on the display screen.

  The treatment content accepting unit 147 accepts input of treatment content information indicating the treatment content for the stop, which is input via the input device 121, for each stop of each production facility. Then, the treatment content reception unit 147 sends the received treatment content information to the data association unit 141.

  The data association unit 141 receives treatment content information for each stop of each production facility from the treatment content reception unit 147. Here, the data association unit 141 converts the treatment content information into the associated information stored in the memory 151a for each stop (that is, each stop information and video information of a time corresponding to each stop information). , Information associated with each stop cause information). When this association ends, the data association unit 141 sends information (second end information) indicating that the association is completed to the display control unit 145.

  When the display control unit 145 receives the second end information from the data association unit 141, the display control unit 145 creates drawing data for displaying the treatment content information corresponding to each stop within the frame of each treatment content box on the display screen. . The drawing data is sent to the display device 122, and display based on the drawing data is performed on the display screen.

  Here, FIG. 26 shows an input screen after the stop cause information and the treatment content information are input.

  Note that when the save cause information and / or action content information is temporarily stored in the memory 151a and the operator clicks the save icon on the display screen, all the information temporarily stored in the memory 151a is stored in the memory 151a. 151b is stored.

  The determination unit 148 determines whether or not stop cause information is input in the storage area of the memory 151b set for the stop cause information input to the stop cause box. Furthermore, the determination unit 148 determines whether or not the treatment content information is input in the storage area of the memory 151b set for the treatment content information input in the treatment content box with respect to all the treatment content boxes. .

  When the determination unit 148 determines that all the stop cause information and the treatment content information have not been input, the determination unit 148 sends predetermined information to the display control unit 145 and the warning sound generation unit 149. send.

  When the display control unit 145 receives the predetermined information from the determination unit 148, the display control unit 145 creates drawing data for displaying a warning on the display screen of the display device 122. In this case, a display indicating a warning is made on the display screen of the display device 122 based on the drawing data.

  The warning sound generation unit 149 includes an amplifier and a speaker, and generates a warning sound when receiving the predetermined information from the determination unit 148.

  Here, when the input of all the stop cause information and the treatment content information is completed and the save icon is clicked, a series of input processes for the information processing apparatus 123 regarding the worker specified by the ID information is completed. Become. Such processing is performed for each worker.

  When receiving a predetermined instruction from the input device 121, the data transmission unit 150 reads information stored in the device from the memory 151 b and sends the information to the output device 124. When the output device 124 receives the above information from the data transmission unit 150, the output device 124 prints it out in a list format.

  Next, the maintenance order determination device 125 provided in the operation status management device 116 will be described. As shown in FIG. 27, the maintenance order determination device 125 includes a storage unit 161, a stop time calculation unit (stop time calculation unit) 162, a storage unit 163, a loss number calculation unit 164, an operation rate calculation unit 165, and a display control unit. (Notification control means) 166 is provided.

  In the storage unit 161, it is possible to store in advance a production capacity of a production facility (the number of products produced per unit time) and a buffer unit between the production facility and one upstream of the production facility. The maximum value (maximum number) of workpieces is stored in association with each production facility. For example, the storage unit 161 stores a table as shown in FIG. In addition, the information indicating the production number per unit time of the production equipment that is the bottleneck is hereinafter referred to as production number information. The bottleneck will be described later.

  The stop time calculation unit 162 first acquires trouble stop information and worker stop information among the stop information described above for each production facility from the memory 151 a of the storage device 151 in the information processing device 123. And the stop time calculation part 162 calculates the time when the production equipment was stopped by the trouble, and the time when the production equipment was stopped by the worker, for each production equipment, based on the acquired information. Furthermore, the stop time calculation unit 162 calculates the total time (hereinafter referred to as stop time Ta) of the time when the production facility is stopped due to a trouble and the time when the production facility is stopped by the worker. At this time, the stop time calculating unit 162 stores the information indicating the calculated stop time Ta in the storage unit 163 in association with information indicating the start time of each stop (first stop start time information). .

  Further, the information indicating the time when the production facility is stopped due to the trouble and the information indicating the time when the production facility is stopped by the worker are lost by the stop time calculating unit 162 in real time. Sent to.

  Further, for each production facility, the stop time calculation unit 162 includes a time when the production facility is stopped due to a trouble, a time when the production facility is stopped by a worker, a time when the production facility is stopped due to waiting for loading, and a waiting time for unloading. To calculate the total time (hereinafter referred to as stop time Tb) with the time when the production facility is stopped. At this time, the stop time calculation unit 162 acquires the above-described stop information (here, trouble stop information, worker stop information, carry-in wait stop information, carry-out wait stop information) for each production facility from the memory 51a. And the stop time calculation part 162 calculates the stop time Tb of a production facility for every production facility based on this acquired stop information. At this time, the stop time calculation unit 162 stores the information indicating the calculated stop time Tb in association with information indicating the start time of each stop (second stop start time information), similarly to Ta. Stored in the unit 163.

  For Ta and Tb, values within a predetermined time (for example, the latest 24 hours) may be acquired. Further, the value itself of the predetermined time and the start time (or end time) of the predetermined time may be configured to be set by the user via the input device 121, for example.

  As described above, the stop time calculation unit 162 determines the stop time (that is, the time during which the production equipment is continuously stopped due to the malfunction of the own equipment) for each production equipment based on at least the operation status of the production line. calculate.

  The loss number calculation unit 164 calculates the production loss caused by the stop of the production facility (that is, the number of workpieces that could have been produced (processed) if there was no stop (hereinafter referred to as loss number)) for each production facility. . In this calculation, information stored in the storage unit 161 and information stored in the storage unit 163 are used. Then, the loss count calculation unit 164 stores the calculated loss count in the storage unit 163 for each production facility.

  More specifically, as shown in FIG. 27, the loss number calculation unit 164 includes a maximum number acquisition unit (maximum number acquisition unit) 164a, a difference calculation unit (difference calculation unit) 164b, and an addition unit (addition unit) 164c. Yes.

  The maximum number acquisition unit 164a acquires, from the storage device, each piece of information indicating the maximum number of each buffer unit Bi located between the production facility stopped due to a malfunction of its own facility and the bottleneck.

  The difference calculation unit 164b calculates the total number of the maximum number indicated in each piece of information acquired by the maximum number acquisition unit 164a for each stop, and for the production number indicated by the production number information stored in the storage device 161. Then, the difference between the value obtained by multiplying the stop time of the production facility and the calculated total number is calculated.

  The adding unit 164c adds the difference calculated by the difference calculating unit 164b for each production facility with respect to each stop.

  Then, the loss number calculation unit 164 stores the addition result by the addition unit 164c in the storage unit 163 as the loss number.

  Hereinafter, the calculation of the number of losses will be described with a specific example. Here, as shown in FIG. 29, a production line including production facilities M1, M2,..., M7 from the upstream side will be described as an example. In the figure, X is the starting point of the production line and Y is the ending point of the production line. That is, the workpiece input from X is carried out to Y as a product via each production facility M1 to M7. The travel time from the production facility M7 to Y is set to 0 for convenience of explanation.

  Moreover, let the belt conveyors which convey a workpiece | work to production equipment M1-M7 be belt conveyors C1-C7, respectively. Furthermore, each buffer part between the belt conveyor Ci and the production facility Mi is defined as a buffer part Bi (where 1 ≦ i ≦ 7 and an integer). Hereinafter, the production capacity of the production facility Mi (here, the production amount per second (number of processed pieces)) is Vi. Further, the time required for transport by the belt conveyor Ci (transport time) is ti (seconds). In addition, the maximum value of the number of workpieces that can be stored in the buffer unit Bi is defined as bi. Further, the processing time at each production facility Mi is set to 0 seconds for convenience of explanation.

  In addition, there are usually production facilities that become bottlenecks in the production line. A bottleneck is a production facility with the smallest number of products per unit time among all production facilities. In the example of the production line in the figure, it is assumed that the production facility M4 is a bottleneck. Regarding the bottleneck specification, the loss number calculation unit 164 reads the table (see FIG. 28) stored in the storage unit 161, and the production facility having the smallest maximum number may be specified as the bottleneck. Moreover, it is good also as a structure which this apparatus recognizes a bottleneck when a user inputs the production equipment which is a bottleneck to a production line management apparatus.

  Here, the number of losses when the bottleneck (production equipment M4) is stopped for T seconds will be described with reference to FIGS. 30 (a) and 30 (b).

  First, the number of workpieces staying immediately before the production facility M4 stops (the total of the number of workpieces on the belt conveyor and the number of workpieces stored in the buffer unit) will be described.

  In this case, as shown in FIG. 30A, the number of workpieces staying between X and the production facility M1 (hereinafter referred to as X-M1 retention number) immediately before the stop of the production facility M4 is V4 × t1 + b1. Further, the number of workpieces staying between the production equipment M1 and the production equipment M2 immediately before the stop (hereinafter referred to as M1-M2 staying number) is V4 × t2 + b2. Further, the number of workpieces staying between the production equipment M2 and the production equipment M3 (hereinafter referred to as M2-M3 staying number) immediately before the stop is V4 × t3 + b3. Further, the number of workpieces staying between the production equipment M3 and the production equipment M4 immediately before the stop (hereinafter referred to as M3-M4 staying number) is V4 × t4 + b4.

  On the other hand, the number of workpieces staying between the production equipment M4 and the production equipment M5 immediately before the stop (hereinafter referred to as M4-M5 staying number) is V4 × t5. Such a staying number is because the work does not stay in the buffer part B5 on the downstream side of the bottleneck. For the same reason, the number of workpieces staying between the production equipment M5 and the production equipment M6 immediately before the stop (hereinafter referred to as M5-M6 staying number) is V4 × t6. In addition, the number of workpieces staying between the production equipment M6 and the production equipment M7 immediately before the stop (hereinafter referred to as M6-M7 staying number) is V4 × t7.

  Next, the number of staying workpieces after the production facility M4 is stopped will be described.

  In this case, as shown in FIG. 30 (a), the X-M1 staying number, the M1-M2 staying number, the M2-M3 staying number, and the M3-M4 staying number after the production facility M4 is stopped are respectively the above production. This is the same value as the number of stays immediately before the facility M4 stops. On the other hand, the M4-M5 staying number, the M5-M6 staying number, and the M6-M7 staying number are 0. This is because downstream of the production facility M4 that is a bottleneck, production is performed as long as the workpiece is supplied even after the production facility M4 is stopped. That is, the product continues to be carried out to Y until t5 + t6 + t7 seconds elapse after the production facility M4 is stopped.

  On the other hand, when the production facility M4 resumes operation after T seconds (assuming t5 + t6 + t7 <T) after the production facility M4 stops, the product is carried out to Y as shown in FIG. 30 (b). It is after T + t5 + t6 + t7 seconds have elapsed since the facility M4 was stopped.

  Therefore, the loss number L when the production facility M4 is stopped for T seconds is V4 × T as shown by the following equation (4).

L = V4 × {(T + t5 + t6 + t7) − (t5 + t6 + t7)} = V4 × T (4)
As described above, when the production equipment M4 that is a bottleneck is continuously stopped for T seconds, a production loss is generated by the number obtained by multiplying the bottleneck production capacity by the stop time (T).

  Next, the number of losses when the production facility M2, which is the upstream production facility of the bottleneck (production facility M4), is stopped for T seconds will be described with reference to FIGS. 31 (a) and 31 (b).

  First, the number of staying workpieces immediately before the production facility M2 stops will be described.

  In this case, as shown in FIG. 31 (a), the X-M1 staying number, the M1-M2 staying number, the M2-M3 staying number, the M3-M4 staying number, the M4-M5 staying number immediately before the stop of the production facility M2, The M5-M6 staying number and the M6-M7 staying number are the same as in the case shown in FIG. That is, the number of stays described above is the same value as when the production facility M4 is assumed to have stopped.

  Next, the number of staying workpieces after the production facility M2 is stopped will be described.

  In this case, the number of stays X-M1 and the number of stays M1-M2 after the production facility M2 is stopped are the same as the number of stays immediately before the stop of the production facility M2. On the other hand, the M2-M3 stay number, the M3-M4 stay number, the M4-M5 stay number, the M5-M6 stay number, and the M6-M7 stay number are 0. This is because downstream of the production facility M2, production is performed as long as workpieces are supplied even after the production facility M2 is stopped.

  By the way, since the production facility M4 downstream of the production facility M2 is a bottleneck, immediately after the production facility M2 is stopped, b3 workpieces are collected in the buffer unit B3 and b4 workpieces are accumulated in the buffer unit B4. ing. Therefore, in the production line, after the production facility M2 is stopped, the product continues to be carried out to Y until t3 + t4 + t5 + t6 + t7 + (b3 + b4) / V4 seconds elapses.

  On the other hand, if the production facility M2 resumes operation after T seconds (t3 + t4 + t5 + t6 + t7 + (b3 + b4) / V4 <T) after the production facility M2 stops, the product is carried out to Y as shown in FIG. 31 (b). As shown in the figure, it is after T + t3 + t4 + t5 + t6 + t7 seconds have elapsed since the production facility M2 was stopped.

  Therefore, the loss number L when the production facility M2 is stopped for T seconds is V4 × T− (b3 + b4) as shown in the following formula (5).

L = V4 × {(T + t3 + t4 + t5 + t6 + t7) − (t3 + t4 + t5 + t6 + t7 + b3 / V4 + b4 / V4)} = V4 × T− (b3 + b4) (5)
As described above, when the production equipment upstream of the bottleneck is stopped continuously for T seconds, the number of bottleneck production capacity multiplied by the stop time (T) is used to determine whether the production facility between the bottleneck and the bottleneck A production loss is caused by the number obtained by subtracting the number of workpieces accumulated in the buffer section.

  Next, the number of losses when the production facility M6, which is the production facility downstream of the bottleneck (production facility M4), is stopped for T seconds will be described with reference to FIGS. 32 (a) and 32 (b).

  First, the number of staying workpieces immediately before the production facility M6 stops will be described.

  In this case, as shown in FIG. 32 (a), X-M1 staying number, M1-M2 staying number, M2-M3 staying number, M3-M4 staying number, M4-M5 staying number immediately before the stop of the production facility M6, The M5-M6 staying number and the M6-M7 staying number are the same as in the case shown in FIG. That is, the number of stays described above is the same value as when the production facility M4 is assumed to have stopped.

  Next, the number of staying workpieces after the production facility M6 is stopped will be described.

  In this case, the X-M1 staying number, the M1-M2 staying number, the M2-M3 staying number, and the M3-M4 staying number after the production facility M6 is stopped are respectively the staying number immediately before the production facility M6 is stopped. It becomes the same value. On the other hand, the M4-M5 staying number and the M5-M6 staying number are V4 × t5 + b5 and V4 × t6 + b6, respectively. That is, workpieces are stored in the buffer unit B5 and the buffer unit B6 up to the upper limit quantity. This is because the workpiece is sent from X even when the production facility M6 is stopped. Further, the M6-M7 staying number is zero. This is because downstream of the production facility M6, production is performed as long as the workpiece is supplied even after the production facility M6 is stopped. That is, the product continues to be carried out to Y until t7 seconds elapse after the production facility M6 stops.

  On the other hand, when the production facility M6 resumes operation after T seconds (assuming t7 <T) after the production facility M6 stops, the product is carried out to Y as shown in FIG. 32 (b). It is after T + t7 seconds have elapsed since the facility M6 was stopped.

  Therefore, the loss number L when the production facility M6 is stopped for T seconds is V4 × T− (b5 + b6) as shown in the following formula (6).

L = V4 * T-{(V4 * t5 + b5-V4 * t5) + (V4 * t6 + b6-V4 * t6)} = V4 * T- (b5 + b6) (6)
In this way, when the production facility M6 is stopped, the number of losses is reduced by b5 + b6 compared to when the bottleneck (production facility M4) is stopped. This is due to the following reason.

  First, due to the stop of the production equipment M6, the work is collected in the buffer B5 and the buffer B6, which are not collected until the production equipment M6 is stopped. Then, as the operation of the production facility M6 resumes, the collected workpieces are sequentially processed. Here, since the bottleneck is upstream of the production facility M6, the number of workpieces stored in the buffer units B5 and B6 decreases sequentially and becomes zero after a certain period of time. As a result, the number of losses is reduced by the number of workpieces stored in the buffer unit B5 and the buffer unit B6 by stopping the production facility M6 (see FIG. 32B).

  As described above, when the production facility downstream of the bottleneck is continuously stopped for T seconds, the number of bottleneck production capacities multiplied by the stop time (T) is used to determine the distance between the bottleneck and the stopped production facility. A production loss is caused by the number obtained by subtracting the number of workpieces accumulated in the buffer section.

Next, based on the above consideration, a generalized formula for the number of losses is shown. In the following, a production facility that has stopped is denoted by Mj (where j is a natural number), and a production facility that is a bottleneck is denoted by Mbn (where bn is a natural number). Further, with generalization, i is a natural number here. Further, the production capacity of the bottleneck is Vbn. Note that the number of losses shown in the equations (7) to (10) is the number of losses caused by one stop (continuous stop).
When j = bn L = Vbn × T (7)
・ If j <bn

・ If j> bn

  However, in the equations (8) and (9), when the value of L is negative, L = 0 is set. As described above, when the value of L becomes negative, the production facility is stopped for a relatively short time, and the work stored in the buffer section downstream of the production facility is stored. The case where Y is made to carry out a product without delay by processing is mentioned.

  Here, the calculations in the above equations (7) to (9) are performed by the difference calculation unit 164b. That is, Vbn × T in the above formulas (7) to (9) corresponds to a value obtained by multiplying the production number indicated by the production quantity information by the stop time of the production facility, and is represented by Σ. The term corresponds to the total number of maximum numbers indicated in each piece of information acquired by the maximum number acquisition unit 164a.

  The addition unit 164c adds the difference calculated by the difference calculation unit 164b (that is, the value obtained by any one of the equations (7) to (10)) for each production facility for each stop. That is, the total number of losses is obtained for each production facility that has stopped due to a malfunction of its own device.

  It should be noted that the calculation of the total sum of the number of losses may be configured to obtain the total sum within the predetermined time described above (for example, the latest 24 hours).

  Next, the operation rate calculation unit 165 will be described. The operation rate calculation unit 165 calculates the actual operation rate W1 and the mere operation rate W2 of each production facility within the predetermined time described above.

  Specifically, the operation rate calculation unit 165 first acquires information indicating the stop time Ta and information indicating the stop time Tb from the storage unit 163. And the operation rate calculation part 165 calculates the actual operation rate W1 shown by the following formula | equation (10) using the acquired stop time Ta. Furthermore, the operating rate calculation unit 165 calculates an operating rate W2 represented by the following formula (11) using the acquired stop time Tb. In Expressions (10) and (11), the operating time of the production facility (that is, the predetermined time) is Tz.

W1 = (Tz−Ta) / Tz × 100 (10)
W2 = (Tz−Tb) / Tz × 100 (11)
Then, the operation rate calculation unit 165 stores the calculated actual operation rate W1 and operation rate W2 in the storage unit 163 for each production facility.

  Next, the display control unit 166 will be described.

  Based on the information stored in the storage unit 163, the display control unit 166 displays, for each production facility, the loss number calculated by the loss number calculation unit 164, the stop time Ta, the actual operation rate W1, and the operation rate W2. 122 is displayed. For example, the display control unit 166 displays the table shown in FIG. 33 on the display device. In this case, as shown in the figure, the display control unit 166 displays the production facility name, the stop time, the actual operation rate W1, and the operation rate W2 related to the production facility in descending order of the number of losses.

  In the example of the figure, as can be seen from the columns of the production facility M4 and the production facility M1, the production facility M4 whose stop time Ta is shorter than the production facility M1 has a larger number of losses. Thus, normally, the magnitude of the stop time Ta is not necessarily proportional to the magnitude of the number of losses.

  Furthermore, when the operation status management device 116 receives a predetermined instruction from the user via the input device 121, the display control unit 166 categorizes the production facilities as shown in FIG. Arranged in this order, the display device 122 displays a figure in which the ratio obtained by dividing the cumulative sum by the total number of losses in all production facilities is displayed as a percentage. That is, so-called Pareto display is performed.

  When the operation status management apparatus 116 receives an instruction to select a production facility from the user via the input device 121, the display control unit 166, as shown in FIG. 35, selects the selected production facility (in the figure, the production facility M4). ), The cause of the stop described above, the number of losses and the stop time caused by the stop cause are displayed on the display device 122 for each stop cause.

  Further, when the operation status management device 116 receives a predetermined instruction from the user via the input device 121, the display control unit 166 categorizes by stop cause and increases the appearance frequency (loss number) as shown in FIG. Arranged in this order, the display device 122 displays a figure in which the ratio obtained by dividing the cumulative sum by the total number of losses in all production facilities is displayed as a percentage.

  As described above, the production line management apparatus 100 stops due to a malfunction of its own equipment and the stop time calculating unit (stop time calculating means) 162 that calculates the above stop time for each production facility based on the operation status of the production line. The maximum number acquisition unit (maximum number acquisition means) 164a that acquires the information indicating the maximum number of each buffer unit located between the production facility and the bottleneck from the storage device 161, The total number of the maximum number indicated in each piece of information acquired by the number acquisition unit 164a is calculated and obtained by multiplying the production number indicated by the production number information stored in the storage device 161 by the stop time of the production facility. The difference calculation unit (difference calculation unit) 164b that calculates the difference between the calculated value and the total number calculated above, and the difference calculated by the difference calculation unit 164b are used for each stop. An addition unit (addition unit) 164c for each production facility and a display control unit (notification control unit) 166 for displaying (notifying) the addition result by the addition unit 164c on the display device (notification device) 122 are provided. .

  According to this configuration, the stop time calculation unit 162 can calculate the stop time for each production facility based on the operation status of the production line. In addition, the maximum number acquisition unit 164a can acquire each piece of information indicating the maximum number of buffer units located between the production facility and the bottleneck that are stopped due to a failure of the own facility. Further, the difference calculation unit 164b calculates the total number of the maximum number indicated in each piece of information acquired by the maximum number acquisition unit 164a for each stop, and the production indicated by the production number information stored in the storage device 161. It is possible to calculate a difference between a value obtained by multiplying the number by the stop time of the production facility and the calculated total number. That is, the difference calculation unit 164b can calculate, for each production facility, the production loss caused by the production facility being stopped for each stop.

  Moreover, the said difference can be added for every production facility regarding the said each stop by the addition part 164c. That is, the sum of the production losses can be calculated for each production facility by the adding unit 164c. Furthermore, the display control unit 166 can cause the display device 122 to display the addition result by the addition unit 164c.

  Therefore, the user can know for each production facility the production loss caused when the own facility stops due to a malfunction. Therefore, the user can know at least the production equipment to be preferentially maintained from the viewpoint of production efficiency.

  By the way, in the above, the example using a table as shown in FIG. 28 was given and demonstrated. However, the present invention is not limited to this.

  For example, as shown in FIG. 37, first, the sensor 110a is installed at the entrance of the buffer unit B1 (that is, the end point side of the belt conveyor C1). The sensor 110b is installed at the entrance of the buffer unit B2, and the sensor 110c is installed at the entrance of the buffer unit B3. With respect to the other buffer units, sensors are installed at the same positions.

  In addition to the sensors described above, sensors 117a, 117b, 117c,... Are newly provided on the production line. More specifically, the sensor 117a is installed at the outlet of the buffer unit B1 (that is, near the production facility M1). Further, the sensor 117b is installed at the outlet of the buffer unit B2, and the sensor 117c is installed at the outlet of the buffer unit B3. Regarding the other buffer units, sensors are installed at the same position (exit of each buffer unit).

  That is, the sensor 110a is installed at the entrance of the buffer unit B1, and the sensor 117a is installed at the exit of the buffer unit B1. A sensor 110b is installed at the entrance of the buffer unit B2, and a sensor 117b is installed at the exit of the buffer unit B2. Further, a sensor 110c is installed at the entrance of the buffer unit B3, and a sensor 117c is installed at the exit of the buffer unit B3.

  Here, the sensors 117a, 117b, 117c,... Perform sampling in the same manner as the sensors 110a, 110b, 110c,. The sensors 117a, 117b, 117c,... Send the sampling results to the PLCs 111a, 111b, 111c,.

  Further, as shown in FIG. 38, the stop cause classification apparatus 120 is provided with a buffer unit number calculation unit (detection means) 138 and a storage unit 139.

  Then, the buffer unit number calculation unit 138 calculates the number of workpieces accumulated in each buffer unit Bi from the detection results of the sensors 110a, 110b, 110c... And the detection results of the sensors 117a, 117b, 117c. For example, as shown in FIG. 39A, the buffer unit number calculating unit 138 stores the number of workpieces that have passed the sensor 110a in the storage unit 139 in association with the time information. Further, as shown in FIG. 39B, the buffer unit number calculating unit 138 stores the number of workpieces that have passed through the sensor 117a in the storage unit 139 in association with the time information.

  Further, as shown in FIG. 39 (c), the buffer unit number calculating unit 138 determines from the number of workpieces that have passed the sensor 110a up to a certain time to one second before the certain time (one sampling period before). Is subtracted from the number of workpieces that have passed the sensor 117a. Further, the buffer unit number calculating unit 138 stores the number of workpieces after the subtraction in the storage unit 139 in association with the certain time.

  As described above, the number of workpieces accumulated in the buffer unit B1 at each time is calculated and stored. Similarly, for the other buffer units B2, B3,..., The number of works stored in the buffer unit Bi at each time is calculated by the buffer unit number calculating unit 138, and the calculated value is stored in the storage unit 139. Stored in

  In addition, in the case of a configuration that newly uses the sensors 17a as described above, the configuration of the difference calculation unit 164b is configured so that each buffer located between the production facility stopped due to a malfunction of the own facility and the bottleneck with respect to each stop. The total number of workpieces stored in the section at the time of the stop is calculated based on the detection result of the buffer section number calculating section 138, and the production number indicated by the production number information stored in the storage device 161 is calculated. What is necessary is just to set it as the structure which calculates the difference of the value obtained by multiplying the stop time of a production facility, and the said calculated total.

  In the case of the above-described configuration, the maintenance order determination device 125 includes information on the number of workpieces stored in the storage unit 139 (number information at a time immediately before the production facility stops, at a time after a certain time has elapsed since the stop. By referring to the number information, etc., the above-described table becomes unnecessary.

  As described above, in the case of the above configuration, the production line management device is based on the buffer unit number calculation unit (detection means) 138 that detects the number of workpieces stored in each buffer device, and the operation status of the production line. , A stop time calculation unit (stop time calculation means) 162 for calculating the stop time for each production facility, and each buffer unit located between the production facility and the bottleneck that has stopped due to a malfunction of the own facility with respect to each stop. The total number of the workpieces stored in the above-described stop state is calculated based on the detection result of the buffer unit number calculating unit 138, and the production is indicated with respect to the production number indicated by the production number information stored in the storage device 161. A difference calculation unit (difference calculation unit) 164b that calculates a difference between a value obtained by multiplying the equipment stop time and the total number calculated above, and a difference calculation unit 164b An addition unit (adding unit) 164c that adds the difference thus produced for each production facility with respect to each stop, and a display control unit (notification control unit) that displays an addition result by the addition unit 164c on the display device (notification device) 122 166.

  According to the above configuration, the number of workpieces stored in each buffer device can be detected by the buffer number calculation unit 138. Further, the stop time calculation unit 162 can calculate the stop time for each production facility based on the operation status of the production line. Further, the difference calculation unit 164b, for each stop, determines the total number of workpieces stored in each buffer unit located between the production facility stopped due to a malfunction of the own facility and the bottleneck at the time of the stop. Calculated based on the detection result of the number calculation unit 138, the value obtained by multiplying the production number indicated by the production number information stored in the storage device 161 by the stop time of the production facility, and the above calculation The difference from the total number can be calculated. That is, the difference calculation unit 164b can calculate, for each production facility, the production loss caused by the production facility being stopped for each stop.

  Moreover, the said difference can be added for every production facility regarding the said each stop by the addition part 164c. That is, the sum of the production losses can be calculated for each production facility by the adding unit 164c. Furthermore, the display control unit 166 can cause the display device 122 to display the addition result by the addition unit 164c.

  Therefore, the user can know for each production facility the production loss caused when the own facility stops due to a malfunction. Therefore, the user can know at least the production equipment to be preferentially maintained from the viewpoint of production efficiency.

  By the way, in the above, the case where one bottleneck exists in the production line was described as an example. Hereinafter, a case where two bottlenecks exist in the production line will be described. In the following description, as shown in FIG. 40, it is assumed that the production facility M3 and the production facility M5 are bottlenecks in the production line including the production facilities M1, M2,. In the following description, it is assumed that the production line includes the sensors 117a, 117b, 117c,.

  Furthermore, hereinafter, the number of workpieces stored in the buffer unit Bi, which is detected by the combination of the sensors described above, is assumed to be qi. Further, the production capacity of the production facility M3 and the production facility M5 which are bottlenecks is described as Vbn.

  Here, the number of losses when the production facility M5, which is one of the bottlenecks, has stopped for T seconds will be described with reference to FIG.

  First, the number of staying workpieces immediately before the production facility M6 stops will be described.

  In this case, as shown in FIG. 41, the X-M1 staying number, the M1-M2 staying number, and the M2-M3 staying number immediately before the stop of the production facility M5 are Vbn × t1 + q1, Vbn × t2 + q2, and Vbn, respectively. Xt3 + q3. Note that the values of q1, q2, and q3 are the same values as b1, b2, and b3, respectively. On the other hand, the M3-M4 staying number, the M4-M5 staying number, the M5-M6 staying number, and the M6-M7 staying number immediately before the stop of the production facility M5 are Vbn × t4, Vbn × t5, and Vbn × t6, respectively. , And Vbn × t7. That is, q4 = q5 = q6 = q7 = 0. The M3-M4 staying number and the M4-M5 staying number are examples, and are not limited thereto. For convenience of explanation, the state of q4 = q5 = 0 is taken as an example.

  Next, the number of staying workpieces after the production facility M5 is stopped will be described.

  In this case, as shown in FIG. 41, the X-M1 staying number, the M1-M2 staying number, and the M2-M3 staying number after the production facility M5 is stopped are respectively the staying numbers immediately before the production facility M5 is stopped. The same value as On the other hand, the M3-M4 staying number and the M4-M5 staying number are Vbn × t4 + q4 and Vbn × t5 + q5, respectively. If a sufficient time has elapsed after the stop, q4 = b4 and q5 = b5. Further, the M5-M6 staying number and the M6-M7 staying number are zero. That is, the state of q6 = q7 = 0 continues.

  On the other hand, when the production facility M5 resumes operation after T seconds (assuming t6 + t7 <T) after the production facility M5 is stopped, the product is unloaded to Y after T + t6 + t7 seconds have passed since the production facility M5 stopped. After that.

  Therefore, the loss number L when the production facility M5 is stopped for T seconds is V4 × T as shown in the following formula (12).

L = Vbn × {(T + t6 + t7) − (t6 + t7)} = Vbn × T (12)
As described above, when the production facility M5 that is a bottleneck is stopped, a production loss is generated by the number obtained by multiplying the bottleneck production capacity by the stop time.

  When the operation of the production facility M5 is resumed as described above, the production facility M3 and the production facility M5 are bottlenecks, and thus do not necessarily return to the state of q4 = q5 = 0. That is, when the stop time becomes longer, the state in the buffer section of the production line changes as shown in the location of the number of stays after the steady state in FIG.

  Further, when the production facility M3 that is a bottleneck is stopped for the T seconds and when the production facility M4 sandwiched between the bottlenecks is stopped for the T seconds, the same loss as when the production facility M5 is stopped for T seconds. Number is generated.

  Next, the number of losses when the production facility M2, which is the production facility upstream of the bottleneck (production facilities M3 and M5), stops for T seconds will be described with reference to FIG.

  First, the number of staying workpieces immediately before the production facility M2 stops will be described.

  In this case, as shown in FIG. 42, the X-M1 staying number, the M1-M2 staying number, the M2-M3 staying number, the M3-M4 staying number, the M4-M5 staying number, and the M5-M6 immediately before the production facility M2 is stopped. The staying number and the M6-M7 staying number are the same as those shown in FIG. That is, the number of stays described above is the same value as when the production facility M5 is assumed to have stopped.

  Next, the number of staying workpieces after the production facility M2 is stopped will be described.

  In this case, the number of stays X-M1 and the number of stays M1-M2 after the production facility M2 is stopped are the same as the number of stays immediately before the stop of the production facility M2. On the other hand, the M2-M3 stay number, the M3-M4 stay number, the M4-M5 stay number, the M5-M6 stay number, and the M6-M7 stay number are 0. This is because downstream of the production facility M2, production is performed as long as workpieces are supplied even after the production facility M2 is stopped.

  By the way, since the production facilities M3 and M5 located downstream of the production facility M2 are bottlenecks, immediately after the production facility M2 is stopped, q3 works are accumulated in the buffer unit B3. Therefore, in the production line, after the production facility M2 is stopped, the product continues to be carried out to Y until t3 + q3 / Vbn + t4 + t5 + t6 + t7 seconds elapses.

  On the other hand, when the production facility M2 resumes operation after T seconds (t3 + q3 / Vbn + t4 + t5 + t6 + t7 <T) after the production facility M2 is stopped, the product is carried out to Y because T + t3 + t4 + t5 + t6 + t7 after the production facility M2 is stopped. After a second has elapsed.

  Therefore, the loss number L when the production facility M2 is stopped for T seconds is Vbn × T−q3 as shown in the following equation (13). However, in this case, the value at the moment when the production facility M2 stops is used as q3.

L = Vbn × {(T + t3 + t4 + t5 + t6 + t7) − (t3 + q3 / Vbn + t4 + t5 + t6 + t7)} = Vbn × T−q3 (13)
However, in the above description, the state where q4 = q5 = 0 immediately before the stop of the production facility M2 is described as an example, but q4 = q5 = 0 immediately before the stop of the production facility M2. There may be no. For example, the case where the production facility M5 is restarted after the production facility M5 is first stopped and the production facility M2 is stopped after the restart is the above case. In this case, the loss number L when the production facility M2 is stopped for T seconds is Vbn × T− (q3 + q4 + q5) as shown in the following formula (14). In this case, the values at the moment when the production facility M2 stops are used as q3 to q5, respectively.

L = Vbn × {(T + t3 + t4 + t5 + t6 + t7) − (t3 + q3 / Vbn + t4 + q4 / Vbn + t5 + q5 / Vbn + t6 + t7)} = Vbn × T− (q3 + q4 + q5) (14)
That is, Formula (13) shows a case where q4 = q5 = 0 in Formula (14).

  As described above, when the production facility upstream of the bottleneck stops, the number of bottleneck production capacity multiplied by the stop time accumulates in the buffer section between the stopped production facility and the downstream bottleneck. A production loss is caused by the number obtained by subtracting the number of workpieces.

  When the operation of the production facility M2 resumes as described above, the production facility M2 is located upstream of the production facility M3 and the production facility M5. The staying number immediately before the stop is the same as the staying number when the stationary state is reached after the stop.

  Next, the number of losses when the production equipment M6, which is the production equipment downstream of the bottleneck (production equipment M3 and M5), stops for T seconds will be described with reference to FIG.

  First, the number of staying workpieces immediately before the production facility M6 stops will be described.

  In this case, as shown in FIG. 43, immediately before the stop of the production facility M6, the number of staying X-M1, the number of staying M1-M2, the number of staying M2-M3, the number of staying M3-M4, the number of staying M4-M5, M5-M6 The staying number and the M6-M7 staying number are the same as those shown in FIGS. 41 and 42. That is, the number of stays described above is the same value as when the production facility M2 is assumed to have stopped.

  Next, the number of staying workpieces after the production facility M6 is stopped will be described.

  In this case, the X-M1 staying number, the M1-M2 staying number, and the M2-M3 staying number after the production facility M6 is stopped are the same values as the staying numbers immediately before the production facility M6 is stopped. On the other hand, the M3-M4 staying number, the M4-M5 staying number, and the M5-M6 staying number are Vbn × t4 + q4, Vbn × t5 + q5, and Vbn × t6 + q6, respectively. This is because the workpiece is sent from X even when the production facility M6 is stopped. Further, the M6-M7 staying number is zero. This is because downstream of the production facility M6, production is performed as long as the workpiece is supplied even after the production facility M6 is stopped. That is, the product continues to be carried out to Y until t7 seconds elapse after the production facility M6 stops.

  On the other hand, when the production facility M6 resumes operation after T seconds (assuming t6 <T) after the production facility M6 is stopped, the product is unloaded to Y after T + t6 seconds have elapsed since the production facility M6 stopped. After that.

  Therefore, the loss number L when the production facility M6 is stopped for T seconds is Vbn × T−q6 as shown in the following formula (15). In this case, however, the value immediately before the production facility M6 resumes operation is used as q6. This is different from the case where the production facility upstream of the bottleneck is stopped.

L = Vbn × {(T + t6) − (t6 + q6 / Vbn)} = Vbn × T-q6 (15)
As described above, when the production facility downstream of the bottleneck stops, the number of bottleneck production capacity multiplied by the stop time accumulates in the buffer section between the downstream bottleneck and the stopped production facility. A production loss is caused by the number obtained by subtracting the number of workpieces.

  When the operation of the production facility M6 is resumed as described above, the production facility M3 and the production facility M5 are bottlenecks, and thus do not necessarily return to the state of q4 = q5 = 0. That is, when the stop time becomes longer, the state in the buffer section of the production line changes as shown in the location of the number of stays after the steady state in FIG.

  In addition, each calculation of said Formula (12)-(15) is performed by the difference calculation part 164b similarly to the case where there is one bottleneck.

  When there are two bottlenecks as described above, the two bottlenecks and the production facility sandwiched between the two bottlenecks are regarded as a single facility. If this group of facilities is virtually considered as one bottleneck (hereinafter referred to as a virtual bottleneck), it can be organized as follows.

  First, when the production facility upstream of the virtual bottleneck has been stopped for T seconds, the work stored in the buffer section between the stopped production facility and the virtual bottleneck immediately before the stop from Vbn × T. The number obtained by subtracting the number is the number of losses.

  In addition, when the production facility downstream of the virtual bottleneck is stopped for T seconds, it is stored from Vbn × T in the buffer unit between the virtual bottleneck and the stopped production facility immediately before the restart of operation. The number of workpieces minus the number of workpieces.

  Further, when the virtual bottleneck is stopped for T seconds (that is, when one of the two bottlenecks and the production equipment sandwiched between the two bottlenecks is stopped), Vbn × T is lost. It becomes the number.

  By the way, in the above description, the case where there are two bottlenecks has been described as an example. In this case, the configuration of the difference calculation unit 164b is between the production facility stopped due to a malfunction of its own facility and the bottleneck that is farthest from the production facility on the production line among the plurality of bottlenecks. The total number of the workpieces stored in the respective buffer units located at the time of the stop may be calculated.

  As described above, when there are a plurality of bottlenecks in the production line, the production line management apparatus 100 determines that the maximum number acquisition unit 164a generates a production facility out of the plurality of bottlenecks and the production facility stopped due to a malfunction of the own facility. In this configuration, each piece of information indicating the maximum number of buffer devices located between the bottleneck that is farthest from the production facility on the line is acquired from the storage device 161.

  As described above, when there are a plurality of bottlenecks in the production line, from the value obtained by multiplying the production number indicated by the production number information stored in the storage device 151 by the stop time of the production facility, By subtracting the sum of the maximum number of each buffer device located between the bottleneck that is the farthest from the production facility on the production line, out of a plurality of bottlenecks, it is stopped once (continuous Production loss due to (stop).

  Therefore, the maximum of each buffer device located between the production facility stopped due to a malfunction of its own facility and the bottleneck that is farthest from the production facility on the production line among the plurality of bottlenecks. The maximum number acquisition unit 164a acquires each piece of information indicating the number from the storage device 151, whereby the total production loss can be calculated for each production facility.

  In addition, when there are a plurality of bottlenecks in the production line, the production line management apparatus 100 determines that the difference calculation unit 164b includes a production line that is stopped due to a malfunction of the own equipment and a line of the production line among the plurality of bottlenecks. It is the structure which calculates the total number at the time of the stop of the workpiece | work currently stored in each buffer apparatus located between the bottlenecks where the distance with this production equipment is furthest in the upper part.

  When there are a plurality of bottlenecks in the production line, the value obtained by multiplying the production number indicated by the production number information stored in the storage device 151 by the stop time of the production facility is used to determine the number of bottlenecks. Of these, the production loss due to one stop (continuous stop) by subtracting the sum of the maximum number of each buffer device located between the bottleneck that is farthest from the production facility on the production line. Is obtained.

  Therefore, from the value obtained by multiplying the production quantity indicated by the production quantity information stored in the storage device 151 by the production equipment stop time, the production equipment stopped due to a malfunction of the own equipment, and the plurality of bottles The difference calculation unit 164b subtracts the total number of workpieces stored in each buffer unit located between the bottleneck that is farthest from the production facility on the production line among the necks at the time of the stop. Thus, the total production loss can be calculated for each production facility.

  In addition, the production line management apparatus 100 includes a sensor for detecting the passage of the workpiece at each position where the workpiece is loaded into the buffer unit and the position where the workpiece is unloaded from the buffer unit. The calculation unit 138 is configured to detect the number of workpieces based on the detection result of the sensor.

  According to this configuration, each buffer unit is stored in each buffer unit by the pair of sensors provided at a position where the work is carried into the buffer unit and a position where the work is carried out from the buffer unit. The number of workpieces can be detected.

  Further, the production line management device 100 is configured such that when the production facility stopped due to a malfunction of its own facility is located downstream of the bottleneck, the buffer unit number calculation unit 138 detects the number of workpieces immediately before the recovery. It is.

  When a production facility that has stopped due to a malfunction of its own equipment is located downstream of the bottleneck, immediately after the stoppage, it is stored in each buffer unit located between the downstream production facility and the bottleneck. There are cases when the workpiece is zero.

  Therefore, even if the total sum of production losses is calculated using the total number of workpieces stored in each buffer section located between the production equipment that has been stopped due to a malfunction of its own equipment and the bottleneck, High production loss value cannot be obtained.

  However, as in the above configuration, with respect to the production equipment located downstream of the bottleneck, the buffer unit number calculation unit 138 detects the number of workpieces immediately before the recovery, so that the detection means detects the workpieces when the stop is stopped. The production loss value can be obtained with higher accuracy than in the case where the number is detected.

  In addition, the production line management device 100 is configured such that the display control unit 166 causes the display device 122 to display production facility names in descending order of the value of the addition result by the addition unit 164c. Therefore, the user can visually recognize the maintenance order of production facilities based on the viewpoint of production efficiency.

  Further, the production line management apparatus 100 includes an association unit that associates information indicating a stop cause with information indicating each stop, and the difference calculation unit 164b calculates a difference for each type of the stop cause, The adding unit 164c adds the difference for each type of stop cause, and the display control unit 166 further displays the addition result calculated for each type of stop cause on the display device 122.

  According to this configuration, the association unit can associate the information indicating the cause of the stop with the information indicating each stop. Further, the difference calculation unit 164b can calculate a difference for each type of stop cause. Furthermore, the difference can be calculated for each type of stop cause by the adder 164c. Therefore, the display control unit 166 causes the display device 122 to display the addition result calculated for each type of stop cause, so that the user knows the total number of production losses for each type of stop cause for each production facility. It becomes possible.

[Embodiment 3]
Still another embodiment of the present invention will be described below with reference to FIGS. For convenience of explanation, members having the same functions as those shown in the drawings of Embodiments 1 and 2 are given the same reference numerals, and descriptions thereof are omitted.

  The production line management device according to the present embodiment is the same as the production line management device 100 of the second embodiment, except that a recovery order instruction device is provided instead of the maintenance order determination device 125 in the operation status management device 116. It has a configuration (see FIG. 44). Further, description will be made assuming that the sensor 117a, 117b, 117c,... Further, the stop cause classification device 120 is provided with a buffer unit number calculation unit (detection means) 138 and a storage unit 139 (see FIG. 38).

  The restoration order instructing device 126 is information indicating the production facility stopped by the trouble and the production facility stopped by the worker based on the stop information stored in the memory 151a of the storage device 151 in the information processing device 123. To get. That is, the restoration order instruction device 126 acquires information indicating the production facility that has stopped due to a malfunction of the own facility. Further, as shown in FIG. 44, the restoration order instructing device 126 includes a total number calculating unit (total number calculating unit) 171, a specifying unit (specifying unit) 172, and a display control unit (notification control unit) 173.

  Hereinafter, a case where there are two production facilities in the production line that are stopped due to a trouble or that are stopped by a worker will be described as an example.

  In this case, the recovery order instruction device 126 performs the following processing. In the following, when the production facility upstream of the bottleneck and the production facility downstream are stopped, when two production facilities upstream of the bottleneck are stopped, the production facility downstream of the bottleneck is 2 The description will be divided into three cases where one is stopped.

  First, the case where the production facility (one unit) on the upstream side of the bottleneck and the production facility (one unit) on the downstream side are stopped will be described. In this case, first, the total number calculation unit 171 of the recovery order instruction device 126 determines the number of workpieces stored in the buffer unit located between the upstream production facility and the bottleneck (the buffer unit includes a plurality of buffer units). In this case, the total number of workpieces) and the number of workpieces (total) accumulated in the buffer unit located between the bottleneck and the downstream production facility are calculated. Then, the specifying unit 172 compares the two numbers (sums).

  Here, as a result of the comparison, the number of workpieces stored in the buffer unit located between the upstream production facility and the bottleneck is reduced to the buffer unit located between the bottleneck and the downstream production facility. When there are more than the number of accumulated workpieces, the display control unit 173 of the restoration order instructing device 126 displays an indication that the downstream production facility is restored first, and then the upstream production facility is restored. Let the device 122 do. On the other hand, the number of workpieces stored in the buffer unit located between the bottleneck and the downstream production equipment was stored in the buffer unit located between the upstream production equipment and the bottleneck. When the number is greater than the number of workpieces, the display control unit 173 causes the display device 122 to display that the upstream production facility is restored first, and then the downstream production facility is restored.

  The reason why the display control unit 173 displays such a restoration order on the display device 122 is as follows. In the following description, it is assumed that the bottleneck is the production facility M4, the stopped upstream production facility is the production facility M2, and the stopped downstream production facility is the production facility M6.

  First, the number of losses when the production facility M2 is restored first and then the production facility M6 is restored is examined. The stop time of the production facility M2 is T1 (where t7 <T1), and the stop time of the production facility M6 is T1 + T2. Further, in order to simplify the explanation, it is assumed that the production facility M2 and the production facility M6 are stopped substantially simultaneously.

  First, the number of staying workpieces immediately before the production facilities M2 and M6 are stopped will be described.

  In this case, as shown in FIG. 45 (a), the X-M1 staying number, M1-M2 staying number, M2-M3 staying number, and M3-M4 staying number immediately before the stop of the production facilities M2 and M6 are respectively V4 * t1 + q1, V4 * t2 + q2, V4 * t3 + q3, and V4 * t4 + q4. Further, the M4-M5 staying number, the M5-M6 staying number, and the M6-M7 staying number immediately before the stop of the production facilities M2 and M6 are V4 × t5, V4 × t6, and V4 × t7, respectively.

  Next, the number of staying workpieces after the production facilities M2 and M6 are stopped will be described.

  In this case, the product is carried out to Y as shown in FIG. 45B for t7 seconds after the production facilities M2 and M6 are stopped. The X-M1 staying number and the M1-M2 staying number after the production facilities M2 and M6 are stopped are the same values as the staying numbers immediately before the production facilities M2 and M6 are stopped, respectively. On the other hand, the M2-M3 stay number, the M3-M4 stay number, the M4-M5 stay number, and the M5-M6 stay number are V4 × t3 + q3-A, V4 × t4 + q4-B, V4 × t5 + C, and V4 × t6 + D, respectively. It becomes. However, A, B, C, and D are variables related to time and satisfy A + B = C + D. Such a staying number is because the production facility M6 is stopped.

  Further, the M6-M7 staying number is zero. This is because downstream of the production facility M2, production is performed as long as workpieces are supplied even after the production facility M2 is stopped.

  Here, when the production facility M2 is restored first, the X-M1 staying number, the M1-M2 staying number, the M2-M3 staying number, the M3-M4 staying number, the M4-M5 staying number, the M5-M6 staying number, and The M6-M7 residence numbers are V4 × t1 + q1, V4 × t2 + q2, V4 × t3 + q3, V4 × t4 + q4, V4 × t5 + q5, and V4 × t6 + q6, respectively. That is, the workpiece starts to be supplied from the production facility M2 to the production facility M3, and the number of M2-M3 stays, M3-M4 stays, M4-M5 stays, and M5-M6 stays changes. However, since the production facility M6 has not been restored, the M6-M7 staying number still remains zero.

  When the production facility M6 is restored after the production facility M2 is restored and T2 has elapsed, the number of losses in the production line is V4 × (T1 + T2) − (q5 + q6) as shown in the following equation (16). It becomes.

L = V4 * (T1 + T2)-{(V4 * t5 + q5-V4 * t5) + (V4 * t6 + q6-V4 * t6)} = V4 * (T1 + T2)-(q5 + q6) (16)
That is, the above equation (16) is the same as the equation (6) shown in the second embodiment in which T is replaced by T1 + T2 and b5 and b6 are respectively q5 and q6.

  Thus, the reason why the number of losses is reduced by (q5 + q6) from V4 × (T1 + T2) is as follows. First, as the operation of the production facility M6 resumes, the workpieces stored in the buffer units B5 and B6 are sequentially processed. Since the bottleneck is upstream of the production facility M6, the number of workpieces stored in the buffer units B5 and B6 decreases sequentially and becomes zero after a certain amount of time has passed. As a result, when the production facilities M2 and M6 are stopped, the number of losses is reduced by the number of workpieces stored in the buffer unit B5 and the buffer unit B6 (see FIG. 45B).

  Next, the number of losses when the production facility M6 is restored first and then the production facility M2 is restored is examined. The stop time of the production facility M6 is T2 (where t7 <T2), and the stop time of the production facility M2 is T2 + T1. Further, in order to simplify the explanation, it is assumed that the production facility M2 and the production facility M6 are stopped substantially simultaneously.

  In this case, as shown in FIG. 46 (a), the X-M1 staying number, the M1-M2 staying number, the M2-M3 staying number, and the M3-M4 staying number, M4-M5, immediately before the production facilities M2 and M6 are stopped. The staying number, the M5-M6 staying number, and the M6-M7 staying number are the same as those shown in FIG. In addition, after stopping the production facilities M2 and M6, X-M1 staying number, M1-M2 staying number, M3-M4 staying number, M4-M5 staying number, M5-M6 staying number, and M6-M7 staying number These are the same as in the case shown in FIG.

  Here, when the production facility M6 is restored first, as shown in FIG. 46 (b), the production facilities M2 and M6 are stopped, and the product is carried out to Y after T2 + t7 seconds. If it takes some time to restore the production facility M2, the sum of the number of workpieces on the belt conveyors C3 to C6 and the number of workpieces stored in the buffer units B3 to B6 immediately before the restoration of the production facility M6 is obtained. The same number of workpieces are unloaded from the production facility M6 before the recovery of the production facility M2. In this case, as shown in FIG. 46 (b), the workpiece is unloaded from the production facility M6 over t3 + t4 + t5 + t6 + q3 / V4 + q4 / V4 seconds.

  Thereafter, when the production facility M2 is restored, the product is carried out to Y at t3 + t4 + t5 + t6 + t7 seconds after the production facility M2 is restored.

  Therefore, the loss number L in this case is V4 × (T1 + T2) − (q3 + q4) as shown in the following equation (17).

L = V4 × (T2 + t7−t7) + V4 {(T1 + T2 + t3 + t4 + t5 + t6 + t7) − (T2 + t3 + t4 + t5 + t6 + t7 + q3 / V4)} = V4 × T2 + V4 × T1−q3−q4 = V4 (T1 + 4)
As described above, when the production facility M2 is first restored and then the production facility M6 is restored, the number of losses is V4 × (T1 + T2) − (q5 + q6). On the other hand, when the production facility M6 is restored first and then the production facility M2 is restored, the number of losses is V4 × (T1 + T2) − (q3 + q4).

  Therefore, if the value of q5 + q6 is compared with the value of q3 + q4, and the value of q5 + q6 is larger, the number of losses can be reduced when the production facility M2 is restored first than when the production facility M6 is restored first. On the other hand, if the value of q3 + q4 is larger, the number of losses can be reduced when the production facility M6 is restored first than when the production facility M2 is restored first.

  For the above reason, the display control unit 173 of the recovery order instruction device 126 displays the above-described recovery order on the display device.

  Next, a case where two production facilities upstream of the bottleneck are stopped will be described.

  In this case, the display control unit 173 of the restoration order instruction device 126 instructs to restore the production facility closer to the bottleneck first and then restore the production facility upstream of the production facility. The display is displayed on the display device 122. In other words, the display control unit 173 causes the display device 122 to display that it is instructed to recover in order from the production facility closest to the bottleneck.

  The reason why the display control unit 173 displays the restoration order on the display device is as follows.

  First, the number of losses when the production facility M2 is restored first and then the production facility M3 is restored is examined. Note that the stop time of the production facility M2 is T1 (where t4 + t5 + t6 + t7 + q4 / V4 <T1), and the stop time of the production facility M3 is T1 + T2. Further, in order to simplify the explanation, it is assumed that the production facility M2 and the production facility M3 are stopped substantially simultaneously.

  First, the number of staying workpieces immediately before the stop of the production facilities M2 and M3 will be described.

  In this case, as shown in FIG. 47 (a), the X-M1 staying number, the M1-M2 staying number, the M2-M3 staying number, and the M3-M4 staying number, M4-M5, immediately before the production facilities M2 and M3 are stopped. The staying number, the M5-M6 staying number, and the M6-M7 staying number are the same as those shown in FIGS. 45 (a) and 46 (a), respectively.

  Next, the number of staying workpieces after the production facilities M2 and M3 are stopped will be described.

  In this case, the X-M1 staying number, the M1-M2 staying number, and the M2-M3 staying number after the production facilities M2 and M6 are stopped are the same values as the staying numbers immediately before the production facilities M2 and M3 are stopped, respectively. It becomes. On the other hand, the M3-M4 staying number, the M4-M5 staying number, the M5-M6 staying number, and the M6-M7 staying number are 0. This is because production is performed downstream of the production facility M3 as long as the workpiece is supplied even after the production facilities M2 and M3 are stopped. That is, the product continues to be carried out to Y until t4 + t5 + t6 + t7 + q4 / V4 seconds elapse after the production facilities M2 and M6 are stopped.

  Here, when the production facility M2 is restored first, the X-M1 staying number, the M1-M2 staying number, the M2-M3 staying number, the M3-M4 staying number, the M4-M5 staying number, the M5-M6 staying number, and The number of staying M6-M7 is the same as the number of staying workpieces after the production facilities M2 and M3 are stopped. That is, since the production facility M3 has not been restored, the M3-M4 staying number, the M4-M5 staying number, the M5-M6 staying number, and the M6-M7 staying number still remain zero.

  When the production facility M3 is restored after the production facility M2 is restored and T2 elapses, the product is carried out to Y after t4 + t5 + t6 + t7 seconds from the restoration of the production facility M3. As indicated by (18), V4 × (T1 + T2) −q4.

L = V4 {(T1 + T2 + t4 + t5 + t6 + t7)-(t4 + t5 + t6 + t7 + q4 / V4)} = V4 (T1 + T2) -q4 (18)
Next, the number of losses when the production facility M3 is restored first and then the production facility M2 is restored is examined. The stop time of the production facility M3 is T2 (where t7 <T2), and the stop time of the production facility M2 is T2 + T1. Also in this case, in order to simplify the description, it is assumed that the production facility M2 and the production facility M3 are stopped almost simultaneously.

  In this case, as shown in FIG. 48 (a), the X-M1 staying number, the M1-M2 staying number, the M2-M3 staying number, and the M3-M4 staying number, M4-M5, immediately before the production facilities M2 and M3 are stopped. The staying number, the M5-M6 staying number, and the M6-M7 staying number are the same as those shown in FIG. 47 (a). In addition, after stopping the production facilities M2 and M3, X-M1 staying number, M1-M2 staying number, M3-M4 staying number, M4-M5 staying number, M5-M6 staying number, and M6-M7 staying number These are the same as those shown in FIG.

  Here, when the production facility M3 is restored first, as shown in FIG. 48B, the production facilities M2 and M3 are stopped, and the product is carried out to Y after T2 + t4 + t5 + t6 + t7 seconds. If it takes some time to restore the production facility M3, the number of workpieces equal to the sum of the number of workpieces on the belt conveyor C3 and the number of workpieces stored in the buffer B3 immediately before the restoration of the production facility M3 is It is unloaded from the production facility M3 before the recovery of the production facility M2. In this case, as shown in FIG. 48B, the workpiece is unloaded from the production facility M3 over t3 + q3 / V4 seconds.

  Thereafter, when the production facility M2 is restored, the product is carried out to Y at t3 + t4 + t5 + t6 + t7 seconds after the production facility M2 is restored.

  Therefore, the loss number L in this case is V4 × (T1 + T2) − (q3 + q4) as shown in the following equation (19).

L = V4 × {(T2 + t4 + t5 + t6 + t7) − (t4 + t5 + t6 + t7 + q4 / V4)} + V4 × {(T1 + T2 + t3 + t4 + t5 + t6 + t7) − (T2 + t3 + t4 + t5 + t6 + t1 + T3 + V4) (T1 + T3 + 4)
As described above, when the production facility M2 is first restored and then the production facility M3 is restored, the number of losses is V4 × (T1 + T2) −q4. On the other hand, when the production facility M3 is restored first and then the production facility M2 is restored, the number of losses is V4 × (T1 + T2) − (q3 + q4).

  Therefore, if the production facility M3 is restored first, the number of losses can be reduced as compared with the production facility M2 restored first. For the above reason, the display control unit 173 of the recovery order instruction device 126 displays the above-described recovery order on the display device.

  Finally, a case where two production facilities downstream of the bottleneck are stopped will be described.

  In this case, the display control unit 173 of the restoration order instruction device 126 instructs to restore the production facility closer to the bottleneck first, and then to restore the production facility downstream of the production facility. The display is displayed on the display device 122. That is, as in the case where two production facilities upstream of the bottleneck are stopped, the display control unit 173 displays on the display device 122 an instruction to restore from the production facility closest to the bottleneck. Make it.

  The reason why the display control unit 173 displays such a restoration order on the display device 122 is as follows.

  First, the number of losses when the production facility M5 is restored first and then the production facility M6 is restored is examined. Note that the stop time of the production facility M5 is T1 (where t7 <T1), and the stop time of the production facility M6 is T1 + T2. Further, in order to simplify the explanation, it is assumed that the production facility M5 and the production facility M6 are stopped substantially simultaneously.

  In this case, as shown in FIG. 49 (a), the X-M1 staying number, the M1-M2 staying number, the M2-M3 staying number, and the M3-M4 staying number, M4-M5, immediately before the production facilities M5 and M6 are stopped. The staying number, the M5-M6 staying number, and the M6-M7 staying number are the same as those shown in FIGS. 45A and 47A, respectively.

  Next, the number of staying workpieces after the production facilities M5 and M6 are stopped will be described.

  In this case, the X-M1 staying number, the M1-M2 staying number, the M2-M3 staying number, and the M3-M4 staying number after the production facilities M5 and M6 are stopped are respectively just before the production facilities M5 and M6 are stopped. It becomes the same value as the number of staying. On the other hand, the M4-M5 staying number is V4 × t5 + q5 because the production facility M5 is stopped. That is, the work is stored in the buffer B5. Further, the M5-M6 staying number remains V4 × t6 because the production facility M6 is stopped.

  Further, as shown in FIGS. 49 (a) and 49 (b), the M6-M7 staying number becomes 0 after t7 seconds from the stop of the production facilities M5 and M6. This is because production is performed downstream of the production facility M6 as long as the workpiece is supplied even after the production facilities M5 and M6 are stopped. That is, after the production facilities M5 and M6 are stopped, the product continues to be carried out to Y until t7 seconds elapse.

  Here, when the production facility M5 is restored first, the X-M1 staying number, the M1-M2 staying number, the M2-M3 staying number, the M3-M4 staying number, and the M4-M5 staying number are respectively the production facility M5. And the same as the number of staying workpieces after the stop of M6. Further, the M5-M6 staying number is V4 × t6 + q6 because the production facility M6 has not been restored. That is, the work is stored in the buffer B6. The M6-M7 staying number is still 0 because the production facility M6 has not been restored.

  When the production facility M6 is restored after the production facility M5 is restored and T2 has elapsed, as shown in FIG. 49 (b), the product is unloaded to Y after t7 seconds from the restoration of the production facility M6. The loss number L in the line is V4 × (T1 + T2) − (q5 + q6) as shown in the following formula (20).

L = V4 * {(T1 + T2 + t7) -t7}-(q5 + q6) = V4 * (T1 + T2)-(q5 + q6) (20)
Thus, the reason why the number of losses is reduced by (q5 + q6) from V4 × (T1 + T2) is as follows. First, as the operation of the production facility M6 resumes, the workpieces stored in the buffer units B5 and B6 are sequentially processed. Since the bottleneck is upstream of the production facility M6, the number of workpieces stored in the buffer units B5 and B6 decreases sequentially and becomes zero after a certain amount of time has passed. As a result, the number of losses is reduced by the number of workpieces stored in the buffer unit B5 and the buffer unit B6 by stopping the production facility M6 (see FIG. 49B).

  Next, the number of losses when the production facility M6 is restored first and then the production facility M5 is restored is examined. The stop time of the production facility M6 is T2 (where t7 <T2), and the stop time of the production facility M5 is T2 + T1. Also in this case, in order to simplify the description, it is assumed that the production facility M5 and the production facility M6 are stopped almost simultaneously.

  In this case, as shown in FIG. 50 (a), the X-M1 staying number, the M1-M2 staying number, the M2-M3 staying number, and the M3-M4 staying number, M4-M5, immediately before the production facilities M5 and M6 are stopped. The staying number, the M5-M6 staying number, and the M6-M7 staying number are the same as those shown in FIG. In addition, after stopping the production facilities M5 and M6, X-M1 staying number, M1-M2 staying number, M3-M4 staying number, M4-M5 staying number, M5-M6 staying number, and M6-M7 staying number These are the same as those shown in FIG.

  Here, when the production equipment M6 is restored first, as shown in FIG. 50B, the production equipment M5 and M6 are stopped and the product is carried out to Y after t7 seconds. When it takes some time to restore the production facility M6, the number of workpieces equal to the sum of the number of workpieces on the belt conveyor C6 and the number of workpieces stored in the buffer B6 immediately before the restoration of the production facility M6 is It is unloaded from the production facility M6 before the recovery of the production facility M5. In this case, as shown in FIG. 50B, the workpiece is unloaded from the production facility M6 for t6 seconds.

  Thereafter, when the production facility M5 is restored, the product is carried out to Y at t6 + t7 seconds after the production facility M5 is restored.

  Therefore, the loss number L in this case is V4 × (T1 + T2) −q5 as shown in the following formula (21).

L = V4 * {(T1 + T2 + t6 + t7) -t6-t7} -q5 = V4 * (T1 + T2) -q5 (21)
Thus, the reason why the number of losses is reduced by q5 from V4 × (T1 + T2) is as follows. First, with the stop of the production facility M5, the workpieces stored in the buffer B5 are sequentially processed. Since the bottleneck is upstream of the production facility M5, the number of workpieces stored in the buffer B5 decreases sequentially and becomes zero after a certain period of time. As a result, when the production facility M5 is stopped, the number of losses is reduced by the number of workpieces stored in the buffer unit B5 (see FIG. 50B).

  As described above, when the production facility M5 is first restored and then the production facility M6 is restored, the number of losses is V4 × (T1 + T2) − (q5 + q6). On the other hand, when the production facility M6 is restored first and then the production facility M5 is restored, the number of losses is V4 × (T1 + T2) −q5.

  Therefore, if the production facility M5 is restored first, the number of losses can be reduced as compared with the production facility M6 restored first. For the above reason, the display control unit 173 of the recovery order instruction device 126 displays the above-described recovery order on the display device.

  As described above, the production line management apparatus according to the present embodiment includes a buffer unit number calculation unit (detection unit) 138 that detects the number of workpieces stored in each buffer unit, and a plurality of production facilities. If it is stopped due to equipment failure, the total number of workpieces stored in each buffer part located between the production equipment stopped due to the equipment failure and the bottleneck is the buffer part immediately after the stop. Based on the detection result of the number calculation unit 138, the total number calculation unit (total number calculation means) 171 that calculates for each production facility that has stopped, and the production facility that has the smallest total number based on the calculation result of the total number calculation unit 171 A specifying unit (specifying unit) 172 for specifying the display unit, and a display control unit (notification control unit) 173 for causing the display device 122 to display the production facility specified by the specifying unit 172. It is formed.

  According to the above configuration, the number of workpieces stored in each buffer unit can be detected by the buffer unit number calculating unit 138. Further, when a plurality of production facilities are stopped due to a failure of the own facility, the total number calculation unit 171 determines the production facility stopped due to the failure of the own facility based on the detection result of the detection means immediately after the stop. The total number of workpieces stored in each buffer unit positioned between the bottleneck can be calculated for each production facility that is stopped. Further, the specifying unit 172 can specify the production facility with the smallest total number based on the calculation result of the total number calculating unit 171.

  Here, when multiple production facilities are stopped, the number of workpieces collected in each buffer device located between the own facility and the bottleneck is small. When processing is started, the production loss in the production line is minimized.

  Therefore, the display control unit 173 displays the production facility specified by the specifying unit 172 on the display device 122, so that the user can know the production facility to be restored first. Therefore, it is possible to improve production efficiency in the production line.

  In addition, when all the production facilities that are stopped due to a malfunction of the own equipment are located on the upstream side or the downstream side of the bottleneck, the display control unit 173 displays the production line management device. Of these, the production equipment that is closest to the bottleneck on the production line is displayed on the display device.

  When all of the production facilities that are stopped due to a malfunction of the own equipment are located upstream or downstream of the bottleneck, restoration processing is started from the production facility closest to the bottleneck on the production line. The production loss on the production line is minimized by starting the process.

  Therefore, in the above case, without calculating the total number, as in the configuration of the present invention, simply from the bottleneck on the production line among the production facilities that are stopped due to the malfunction of the own facility. The display control unit 173 causes the display device 122 to display the production facility with the shortest distance so that the user can know the production facility to be restored first.

  In addition, the configuration of the production line management apparatus is configured such that when the buffer unit number calculating unit 138 that detects the number of workpieces stored in each buffer unit and a plurality of production facilities are stopped due to a failure of the own facility, Based on the detection result of the buffer unit number calculation unit 138 immediately after the stop, the total number of workpieces stored in each buffer unit located between the production facility and the bottleneck that are stopped due to the malfunction of the facility, A total number calculation unit 171 calculated for each production facility that has stopped, a specification unit 172 that specifies production facilities in descending order of the total number based on the calculation result of the total number calculation unit 171, and a production facility specified by the specification unit 172 It is good also as a structure provided with the display control part 173 displayed on the display apparatus 122.

  In this configuration, the specifying unit 172 can specify the production equipment in descending order of the total number based on the calculation result of the total number calculating unit 171.

  Here, when multiple production facilities are stopped, among the production facilities that are stopped due to malfunctions of the own equipment, production with a small number of workpieces accumulated in each buffer section located between the own equipment and the bottleneck When the recovery process is started from the equipment, the production loss in the production line is minimized.

  Therefore, by causing the display control unit 173 to display the order specified by the specifying unit 172 on the display device 122, the user can know the order in which the stopped production equipment should be restored. Therefore, it is possible to improve production efficiency in the production line.

  In addition, the production line management device according to the present invention has the total number calculation unit 171 on the downstream side of the bottleneck when the production facilities that are stopped due to the malfunction of the own equipment are located on the upstream side and the downstream side of the bottleneck. Regarding the production equipment that is located, the total number of workpieces is calculated using a predetermined numerical value (for example, the maximum number) instead of the number of workpieces detected by the buffer unit number calculating unit 138. I can say that.

  When the production equipment that is stopped due to a malfunction of its own equipment is located on the upstream side and downstream side of the bottleneck, immediately after the stop, each buffer device located between the downstream production equipment and the bottleneck In some cases, the number of workpieces stored in the workpiece becomes zero.

  Therefore, based on the total number of workpieces stored in each buffer unit located between the production facility that is stopped due to a malfunction of its own facility and the bottleneck, the production facility with the smallest total number is identified or the total number Even if the production equipment is specified in the order of few and the production equipment to be restored first or the order to be restored is notified, there is a possibility that the equipment or order that minimizes the production loss may not be notified.

  However, as described above, for the production equipment located downstream of the bottleneck, the total number of workpieces is calculated using a predetermined numerical value instead of the number of workpieces detected by the buffer unit number calculating unit 138. As a result, it is possible to increase the accuracy with which the equipment or order that minimizes the production loss is notified in comparison with the downstream side detection by the buffer unit number calculation unit 138.

  In the above description, the configuration in which the buffer unit is provided separately from the production facility has been described as an example. However, the production facility may have a configuration in which the buffer unit is provided in the own facility.

  In the second and third embodiments, the configuration in which the display control unit displays predetermined information on the display device 122 is described as an example. However, the present invention is not limited to this. It is good also as a structure which notifies a user with an audio | voice etc. instead of a display.

  The present invention is not limited to the above-described embodiments, and various modifications can be made within the scope shown in the claims. That is, embodiments obtained by combining technical means appropriately modified within the scope of the claims are also included in the technical scope of the present invention.

  Note that each unit (excluding some configurations such as a storage device and a display screen of a notification unit) and each processing step of the production line management device of the above embodiment are performed by a calculation means such as a CPU such as a ROM (Read Only Memory) or a RAM. It can be realized by executing a program stored in a storage means such as a keyboard and controlling an input means such as a keyboard, an output means such as a display, or a communication means such as an interface circuit. Therefore, various functions and various processes of the production line management apparatus according to the present embodiment can be realized simply by a computer having these means reading the recording medium storing the program and executing the program. In addition, by recording the program on a removable recording medium, the various functions and various processes described above can be realized on an arbitrary computer.

  As this recording medium, a program medium such as a memory (not shown) such as a ROM may be used for processing by the microcomputer, or a program reader is provided as an external storage device (not shown). It may be a program medium that can be read by inserting a recording medium therein.

  In any case, the stored program is preferably configured to be accessed and executed by the microprocessor. Furthermore, it is preferable that the program is read out, and the read program is downloaded to a program storage area of the microcomputer and the program is executed. It is assumed that this download program is stored in advance in the main unit.

  The program medium is a recording medium configured to be separable from the main body, such as a tape system such as a magnetic tape or a cassette tape, a magnetic disk such as a flexible disk or a hard disk, or a disk such as a CD / MO / MD / DVD. Fixed disk, IC card (including memory card), etc., or semiconductor ROM such as mask ROM, EPROM (Erasable Programmable Read Only Memory), EEPROM (Electrically Erasable Programmable Read Only Memory), flash ROM, etc. In particular, there are recording media that carry programs.

  In addition, if the system configuration is capable of connecting to a communication network including the Internet, the recording medium is preferably a recording medium that fluidly carries the program so as to download the program from the communication network.

  Further, when the program is downloaded from the communication network as described above, it is preferable that the download program is stored in the main device in advance or installed from another recording medium.

  It can be used for various production lines with multiple production facilities.

It is the functional block diagram which showed the structure of the management apparatus which concerns on embodiment of this invention. It is the figure which showed the data memorize | stored in the equipment information storage part of the said management apparatus. It is the figure which showed the data memorize | stored in the worker information storage part of the said management apparatus. It is the figure which showed the example of a structure of the production line. It is the flowchart which showed a part of processing flow of the said management apparatus. It is the flowchart which showed the remaining part of the said processing flow. It is the figure which showed schematic structure of the production line management apparatus. It is the figure which showed the 1st correspondence information at a certain time when a workpiece | work exists in the predetermined location of a line. It is the figure which showed the 1st correspondence information at a certain time when a workpiece | work does not exist in the predetermined location of a line. It is the figure which showed the 4th corresponding | compatible information at a certain time when a production facility is stopped. It is the figure which showed the 4th corresponding | compatible information at a certain time in case the production equipment is not stopped. It is the figure which showed schematic structure of the stop cause classification device in the said operating condition management system. It is the figure which showed the 1st corresponding information group. It is the figure which showed the 2nd corresponding information group. It is the figure which showed the 4th corresponding | compatible information group. It is the figure which showed the 1st corresponding information group to which the flag was attached | subjected. It is the figure which showed the 2nd corresponding information group to which the flag was attached | subjected. It is the figure which showed the operating condition of the production facility judged based on the output of a sensor. It is a figure showing the 4th correspondence information group to which the information of operation or trouble stop was added to the 4th correspondence information. It is the figure which showed the 4th corresponding | compatible information group to which the information of operation or carrying out waiting stop was added to the 4th corresponding | compatible information. It is the flowchart which showed the processing flow in the said stop cause classification device. It is the figure which showed schematic structure of the information processing apparatus in the operation condition management apparatus in the production line management apparatus which concerns on this Embodiment. It is the figure which showed the 4th corresponding | compatible information group to which the information of operation | movement or the stop by a worker was added to the 4th corresponding | compatible information. It is the figure which showed the login screen displayed on the display screen of a display apparatus. It is the figure which showed the screen for input displayed on the display screen of a display apparatus. It is the figure which showed the said input screen after the stop cause information and treatment content information were input. It is the functional block diagram which showed the structure of the maintenance order determination apparatus of a production line management apparatus. The production capacity for each production facility is associated with the maximum number of workpieces that can be stored in the buffer unit between the production facility and the production facility upstream of the production facility for each production facility. It is the figure which showed the table shown. It is the figure which showed the production line provided with production equipment M1, M2, ... and M7 from the upstream. (A) is a figure for demonstrating the sum total of the number of the workpiece | work staying in the belt conveyor and the buffer part just before a stop of the production equipment M4 which is a bottleneck, and a stop, (b) is a bottle. It is a term chart which showed the production quantity of the product per unit time when a neck stops for T seconds. (A) is a figure for demonstrating the sum total of the number of the workpiece | work staying in the belt conveyor and the buffer part just before a stop of the production equipment M2 which is a production equipment of the upstream of a bottleneck, and after a stop, (B) is a term chart showing the production quantity of the product per unit time when the production facility M2 is stopped for T seconds. (A) is a figure for demonstrating the sum total of the number of the workpiece | work staying in the belt conveyor and the buffer part just before a stop of the production equipment M6 which is a production equipment of the downstream of a bottleneck, and after a stop, (B) is a term chart showing the production quantity of the product per unit time when the production facility M6 is stopped for T seconds. It is the figure which showed the number of loss etc. which are displayed on the display device. It is the figure which carried out the Pareto display of the sum total of the loss number for every production equipment. It is the figure which showed the loss number and stop time for every stop cause regarding the selected production equipment. It is the figure which carried out the Pareto display of the sum total of the number of loss for every said stop cause. It is the figure which showed schematic structure of the production line management apparatus which concerns on another form. It is the functional block diagram which showed the structure of the stop cause classification | category apparatus of the production line management apparatus of FIG. (A) is the figure which showed the number of the workpiece | work which passed the sensor located in the entrance of buffer part B1 in a certain time, (b) is located in the exit of buffer part B1 in a certain time. It is the figure which showed the number of the workpiece | work which passed the sensor, (c) is the figure which showed the number of the workpiece | work collected in the buffer part B1 in a certain time. It is the figure which showed the production line in which the bottleneck exists in a production line. It is a figure for demonstrating the sum total of the number of the workpiece | work staying in the belt conveyor and the buffer part immediately after stopping the production equipment M5 which is one of the bottlenecks, after stopping, and after returning to a steady state. . It is a figure for demonstrating the sum total of the number of the workpiece | work staying in the belt conveyor and the buffer part just after a stop of the production equipment M2 of the upstream of a bottleneck, after a stop, and after returning to a steady state after a stop. It is a figure for demonstrating the sum total of the number of the workpiece | work staying in the belt conveyor and the buffer part immediately after a stop of the production equipment M6 of the downstream of a bottleneck, after a stop, and after returning to a steady state after a stop. It is the block diagram which showed the structure of the operation condition management apparatus in another production line management apparatus. (A) shows the number of workpieces retained in the belt conveyor and the buffer unit immediately before and after the stop of the production facility M2 on the upstream side of the bottleneck and the production facility M6 on the downstream side and after the recovery of the production facility M2. (B) is a term chart showing the production quantity of products per unit time when the production facility M2 is stopped for T1 seconds and the production facility M6 is stopped for T1 + T2 seconds. (A) shows the number of workpieces retained in the belt conveyor and the buffer unit immediately before and after the stop of the production facility M2 upstream of the bottleneck and after the stop of the production facility M6, and after the recovery of the production facility M6. (B) is a term chart showing the production quantity of products per unit time when the production facility M2 is stopped for T1 + T2 seconds and the production facility M6 is stopped for T2 seconds. (A) shows the total of the number of workpieces retained in the belt conveyor and the buffer unit immediately before and after the stop of the production facility M2 and the production facility M3 upstream of the bottleneck and after the recovery of the production facility M2. It is a figure for demonstrating, (b) is a term chart which showed the production quantity of the product per unit time when the production equipment M2 stops for T1 second and the production equipment M3 stops for T1 + T2 seconds. (A) shows the total of the number of workpieces retained in the belt conveyor and the buffer unit immediately before and after the stop of the production facility M2 and the production facility M3 upstream of the bottleneck and after the recovery of the production facility M3. It is a figure for demonstrating, (b) is a term chart which showed the production quantity of the product per unit time when the production equipment M2 stops for T1 + T2 seconds and the production equipment M3 stops for T2 seconds. (A) shows the total of the number of workpieces retained on the belt conveyor and the buffer unit immediately before and after the stop of the production facility M5 and the production facility M6 on the downstream side of the bottleneck and after the recovery of the production facility M5. It is a figure for demonstrating, (b) is a term chart which showed the production quantity of the product per unit time when the production equipment M5 stops for T1 second and the production equipment M6 stops for T1 + T2 seconds. (A) shows the total of the number of workpieces retained in the belt conveyor and the buffer unit immediately before and after the stop of the production facility M5 and the production facility M6 on the downstream side of the bottleneck and after the recovery of the production facility M6. It is a figure for demonstrating, (b) is a term chart which showed the production quantity of the product per unit time when the production equipment M5 stops for T1 + T2 seconds and the production equipment M6 stops for T2 seconds.

Explanation of symbols

1 Management device (Production line management device)
12 storage device 13 stop information reception unit 15 identification information reception unit 16 loss value calculation unit 17 pattern selection unit 18 notification unit 19 identification unit 20 start information reception unit 21 end information reception unit 23 time association unit 24 recovery time calculation unit 25 setting Unit 26 Notification Unit 31 Capability Information Corresponding Unit 41 Facility Information Storage Unit 42 Worker Information Storage Unit 51 First Calculation Unit 52 Second Calculation Unit 53 Third Calculation Unit 54 Fourth Calculation Unit 100 Production Line Management Device 115 Server Device 116 Operation status management device 120 Stop cause classification device 122 Display device 123 Information processing device 138 Buffer unit number calculation unit (detection means)
140 Operation status acquisition unit 141 Data association unit 151 Storage device 161 Storage unit (storage device)
162 Stop time calculation unit (stop time calculation unit)
163 Storage unit 164 Loss number calculation unit 164a Maximum number acquisition unit (maximum number acquisition means)
164b Difference calculation unit (difference calculation means)
164c Adder (addition means)
165 Operation rate calculation unit 166 Display control unit (display control means)
171 Total number calculation unit (total number calculation means)
172 Identification part (identification means)
173 Display control unit (display control means)

Claims (8)

In a production line management device for managing a production line provided with a buffer device for each production facility between a transport means for transporting a workpiece to a downstream production facility and the production facility,
Of all the production facilities, if the production facility with the smallest number of production per unit time is the bottleneck,
Detecting means for detecting the number of workpieces stored in each buffer device;
When multiple production facilities are stopped due to a failure of the own facility, the total number of workpieces stored in each buffer device located between the production facility stopped due to the failure of the own facility and the bottleneck , Based on the detection result of the detection means immediately after the stop, a total number calculation means for calculating for each production facility that is stopped,
Based on the calculation result of the total number calculating means, specifying means for specifying production equipment in order from the smallest total number;
A production line management apparatus comprising: a notification control unit that causes a notification device to notify the order of the production facilities specified by the specifying unit. In a production line management device for managing a production line provided with a buffer device for each production facility between a transport means for transporting a workpiece to a downstream production facility and the production facility,
Of all the production facilities, if the production facility with the smallest number of production per unit time is the bottleneck,
Detecting means for detecting the number of workpieces stored in each buffer device;
When multiple production facilities are stopped due to a failure of the own facility, the total number of workpieces stored in each buffer device located between the production facility stopped due to the failure of the own facility and the bottleneck , Based on the detection result of the detection means immediately after the stop, a total number calculation means for calculating for each production facility that is stopped,
Based on the calculation result of the total number calculating means, a specifying means for specifying a production facility having the smallest total number;
A production line management device comprising: a notification control unit that causes a notification device to notify the production facility identified by the identification unit.   When all of the production facilities that are stopped due to a malfunction of the own equipment are located upstream or downstream of the bottleneck, the notification control means is on the production line line of the stopped production facilities. 3. The production line management device according to claim 2, wherein the notification device notifies the production facility closest to the bottleneck. When production facilities that are stopped due to a malfunction of their own facilities are located upstream and downstream of the bottleneck,
The total number calculation means calculates the total number of the workpieces using a predetermined numerical value instead of the number of workpieces detected by the detection means for the production facility located downstream of the bottleneck. The production line management device according to any one of claims 1 to 3. In a production line management method for managing a production line provided for each production facility with a buffer device that temporarily accumulates workpieces between the production facility and a conveying means that conveys the workpiece to a downstream production facility,
Of all the production facilities, if the production facility with the smallest number of production per unit time is the bottleneck,
A detection step of detecting the number of workpieces stored in each buffer device by the detection means;
When a plurality of production facilities are stopped due to a failure of the own facility, the total number calculation means stores the buffer in each buffer device located between the production facility stopped due to the failure of the own facility and the bottleneck. A total number calculating step for calculating the total number of workpieces based on the detection result of the detection means immediately after the stop for each production facility that is stopped;
Based on the calculation result in the total number calculating step, the specifying unit specifies the production equipment in ascending order of the total number by the specifying unit;
A production line management method comprising: a notification control step for causing a notification device to notify the order of the production facilities specified in the specifying step by a notification control means. In a production line management method for managing a production line provided for each production facility with a buffer device that temporarily accumulates workpieces between the production facility and a conveying means that conveys the workpiece to a downstream production facility,
Of all the production facilities, if the production facility with the smallest number of production per unit time is the bottleneck,
A detection step of detecting the number of workpieces stored in each buffer device by the detection means;
When a plurality of production facilities are stopped due to a failure of the own facility, the total number calculation means stores the buffer in each buffer device located between the production facility stopped due to the failure of the own facility and the bottleneck. A total number calculating step for calculating the total number of workpieces based on the detection result of the detection means immediately after the stop for each production facility that is stopped;
Based on the calculation result in the total number calculating step, a specifying step for specifying a production facility with the smallest total number by specifying means;
A production line management method comprising: a notification control step of causing a notification device to notify the production facility specified in the specifying step by a notification control means. The program for functioning a computer as each means of the production line management apparatus of any one of Claim 1 to 4 . A computer-readable recording medium on which the program according to claim 7 is recorded.

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