JP6108983B2 - Production system, production management device, and production management program - Google Patents

Description

  The present invention relates to a production system, a production management apparatus, and a production management program in which a plurality of production facilities installed on a production line produce a target product based on a production instruction from a host system.

  Conventionally, in a production line in which multiple production facilities installed in each process perform assembly processing in order, production instructions from the host system to each production facility are collectively managed using a shift register corresponding to each process (For example, refer to Patent Documents 1 and 2).

Patent Document 1 discloses a configuration in which a serial number is assigned to production instruction information from a production management host computer and is collectively managed by a production instruction information storage unit having a plurality of shift registers. With this configuration, production instruction information is searched using the serial number as a key, and input to a shift register corresponding to an arbitrary process allows the flow of production instruction information to be branched / merged in accordance with line branching / merging. It is possible.
Patent Document 2 discloses a configuration in which a pointer is assigned instead of a serial number and production management similar to that of Patent Document 1 is performed.

JP-A-6-227462 JP-A-6-231113

Patent Documents 1 and 2 are configured to sequentially send production instruction information in accordance with the flow of individual workpieces (target products) on the production line. Each process such as an automobile production line produces one workpiece at a time. It discloses the management of the production method (single-flow production method) delivered to the next process. However, management of a production method (lot production method) in which a plurality of workpieces are collectively produced in each process and transferred to the next process is not disclosed.
Therefore, the production line corresponding to both the single-flow production method and the lot production method has a problem that it cannot be managed.

  The present invention has been made to solve the above-described problems, and an object of the present invention is to provide a production system that supports both the single-flow production method and the lot production method.

  The production system according to the present invention includes a storage device storing a plurality of production facilities installed on a production line, and a database including a plurality of production instruction fields for registering codes indicating the order in which the production facilities produce the target product, respectively. A facility management device that transmits a production start signal of the target product to the production facility in the order of the code, and a process management device that registers the input code in the production instruction field, in accordance with the registration status of the code by the process management device A single-stream production system in which the upstream production facility produces the target products one by one and delivers them to the downstream production facility, or the upstream production facilities collectively produce the target products and downstream production facilities It is switched to one of the lot production methods delivered to the factory.

  According to the present invention, since it is configured as described above, it is possible to obtain a production system corresponding to both the single-flow production method and the lot production method.

It is a block diagram which shows the structure of the production system which concerns on Embodiment 1 of this invention. It is a block diagram which shows the detailed structure of the memory | storage device, equipment management apparatus, and production equipment which concern on Embodiment 1 of this invention. It is explanatory drawing which shows the data structure of the database which concerns on Embodiment 1 of this invention. It is a flowchart which shows operation | movement of the equipment module which concerns on Embodiment 1 of this invention. It is a flowchart which shows operation | movement of the equipment module which concerns on Embodiment 1 of this invention. It is explanatory drawing which shows the transition of the database at the time of making the production system which concerns on Embodiment 1 of this invention respond | corresponds to a lot production system. It is explanatory drawing which shows the flow of the object product at the time of making the production system which concerns on Embodiment 1 of this invention respond | corresponds to a lot production system. It is explanatory drawing which shows transition of the database at the time of making the production system which concerns on Embodiment 1 of this invention correspond to a production system by flowing one piece. It is explanatory drawing which shows the flow of the object product at the time of making the production system which concerns on Embodiment 1 of this invention flow one piece, and making it respond | correspond to a production system. It is explanatory drawing which shows the transition of the database at the time of making a target product line out in the production system which concerns on Embodiment 1 of this invention. It is explanatory drawing which shows the flow of the target product at the time of making a target product line out in the production system which concerns on Embodiment 1 of this invention.

Hereinafter, in order to explain the present invention in more detail, modes for carrying out the present invention will be described with reference to the accompanying drawings.
Embodiment 1 FIG.
FIG. 1 is a configuration diagram illustrating a configuration of a production system according to the first embodiment. The production system according to Embodiment 1 reads and writes information in the database 21, a process management device 1 that inputs instruction information from a host system, a storage device 2 that stores a database 21 that registers various information related to the production system, and the like. A facility management device 3 and a plurality of production facilities 4 installed in each process on the production line are provided.
FIG. 2 is a configuration diagram showing the detailed configuration of the database 21 stored in the storage device 2, the equipment module 31 provided in the equipment management device 3, and the controller 41 provided in the production equipment 4.

The process management apparatus 1 is configured by a computer including a semiconductor integrated circuit or a one-chip microcomputer mounted with a CPU (Central Processing Unit), and is connected to the storage device 2 via a wired or wireless communication line. The process management device 1 includes an operation input unit (not shown), transmits the instruction information input by the host system or the production manager to the storage device 2 and registers it in the database 21.
Here, the instruction information includes product information such as a serial number and a model number code of a target product to be produced, a code such as a serial number that indicates the order in which each target product is produced for each production facility 4, and the production facility 4 And a selection signal for selecting whether to operate by a single production method or a lot production method.

The storage device 2 includes a storage medium such as a hard disk drive (HDD) or a solid state drive (SSD), and is connected to the facility management device 1 and the process management device 3 via a wired or wireless communication line. The memory | storage device 2 has memorize | stored the database 21 which registers the instruction information received from the process management apparatus 1, and the information received from the facility management apparatus 3 mentioned later.
FIG. 3 shows a specific example of the data structure of the database 21. The database 21 has a field for registering product information of target products together and a field for registering information related to the production status of each production facility 4 together. Further, it has a table-like data structure for registering information on the target product corresponding to each record.

The facility management device 3 is configured by a computer including a semiconductor integrated circuit or a one-chip microcomputer mounted with a CPU, and is connected to the storage device 2 and the production facility 4 through a wired or wireless communication line. In addition, a plurality of equipment modules 31 which are independent software modules for communicating with the controllers 41 of the corresponding production equipment 4 and reading / writing information on the fields of the corresponding production equipment 4 in the database 21 are provided.
The equipment module 31 checks the product information registered in the database 21 and the production instruction flag of the corresponding production equipment 4. When a serial number is registered in the production instruction flag, a production start signal for the target product is transmitted to the controller 41 of the corresponding production facility 4.
When the production start signal for the target product is transmitted, “done” is registered in the instructed flag of the corresponding production facility 4 in the database 21. When a production completion signal is received from the corresponding controller 41, OK is registered in the production result flag of the corresponding production facility 4 in the database 21 if the production result is normal, and NG is registered if an abnormality occurs. To do.
In addition, as a specific example when abnormality has occurred, there is a case where a defect occurs in the target product in the process and the product is lined out.

The production facility 4 is a machine tool or the like installed in each process on the production line, and is connected to the facility management apparatus 3 through a wired or wireless communication line. Further, a controller 41 including a PLC (Programmable Logic Controller) and a robot controller is provided.
When receiving the production start signal of the target product from the corresponding equipment module 31, the controller 41 controls the production equipment 4 so as to start production of the target product. Further, when the production of the target product is completed, a production completion signal including information on whether or not the product has been normally produced is transmitted to the corresponding equipment module 31, and the production product 4 in the process (downstream process) immediately after the target product is transmitted. To hand over.
Further, when the produced target product is delivered to the downstream process and a new target product can be produced, the controller 41 transmits an instruction acceptance signal to the corresponding equipment module 31.

  In addition, although the example provided with the two production facilities 4a and 4b was shown in FIGS. 1-3, the number of production facilities is not restricted to two, and how many may be sufficient. When there are n production facilities (n is a natural number of 2 or more), the facility management apparatus 3 includes n facility modules 31 corresponding to each, and the database 21 includes n fields corresponding to each. To do.

Next, operation | movement of the equipment module 31 which concerns on Embodiment 1 is demonstrated using FIG.
FIG. 4 is a flowchart showing an operation in which the equipment module 31 instructs the controller 41 to start production.

When the instruction information is input to the process management device 1 or when a predetermined condition is satisfied such as a specific time, each equipment module 31 checks the production instruction flag of the corresponding production equipment 4 in the database 21 and is the youngest. The record in which the number is registered is confirmed (step ST11).
Next, it is determined whether or not there is a process (upstream process) immediately before itself on the production line (step ST12).

If it is determined in ST12 that “there is an upstream process (Yes)”, it is determined whether or not the target product is normally produced in the upstream process (step ST13). That is, the production result flag of the production facility 4 in the upstream process registered in the database 21 is checked to confirm whether the record of the target product is OK or NG.
If it is determined in ST12 that there is no upstream process (No), ST13 is skipped.

  If the record of the target product in the upstream process is OK in ST13, it is determined whether or not a production instruction for the product has already been made (step ST14). That is, the instructed flag of the corresponding production facility 4 in the database 21 is checked to determine whether or not “completed” is registered.

If it is determined in ST14 that “the production start instruction for the target product has not yet been made (Yes)”, a production start signal is transmitted to the corresponding controller 41. Further, “done” is registered in the instructed flag of the corresponding production facility 4 in the database 21 (step ST15).
Next, it is determined whether or not an instruction acceptable signal has been received from the corresponding controller 41 (step ST16). If the instruction acceptable signal is received, the equipment module 31 returns to the processing of ST11, checks the production instruction flag of the corresponding production equipment 4 again, and confirms the record in which the next young number is registered.

When the production result of the upstream process is not OK in ST13, it is next determined whether or not it is NG (step ST17). When it is NG in ST17 (that is, when an abnormality occurs in the upstream process), the target product is excluded from the production target by skipping the record of the target product (step ST18).
Also, in ST14, when it is determined that “instruction to start production of the target product has already been issued (No)”, the production start signal of the target product is duplicated by skipping the record of the target product in the same manner. (ST18).

FIG. 5 is a flowchart showing an operation in which the equipment module 31 registers the production result of each production equipment 4 in the database 21.
The equipment module 31 determines whether or not a production completion signal for the target product has been received from the controller 41 after transmitting the production start signal for the target product to the corresponding controller 41 (that is, after ST15 in FIG. 4) ( Step ST21).
If it is determined in ST21 that "production completion signal has been received (Yes)", it is determined whether or not the production result is normal, and OK or NG is registered in the production result flag of the corresponding production facility 4 in the database 21. (Step ST22).

Next, the operation when the production system according to the first embodiment is made compatible with the lot production method will be described with reference to FIGS. FIG. 6 is an explanatory diagram showing the transition of the database 21, and FIG. 7 is an explanatory diagram showing the operation of the production facilities 4a and 4b and the flow of the target product.
In FIG. 6, a field surrounded by a dotted line in the database 21 indicates a field in which information is registered by the process management apparatus 1, and a field surrounded by a one-dot chain line indicates a field in which the facility management module 31 registers information. In FIG. 7, serial numbers surrounded by solid lines indicate target products that have been produced by each production facility 4, and serial numbers surrounded by broken lines indicate target products that are being produced at each production facility 4.
As shown in FIGS. 6 and 7, here, an example is shown in which two production equipments 4 a and 4 b are used to produce a total of four target products, each of two types of target products. Serial numbers 10001 to 10004 are assigned to the four target products, respectively. In addition, it is assumed that the production facility 4a is installed in the upstream process of the production facility 4b.
In addition, when each figure is arranged in the time series of processing, FIG. 6 (a), FIG. 7 (a), FIG. 7 (b), FIG. 6 (b), FIG. 6 (c), FIG. 7 (d) and FIG. 6 (d).

  When the lot production method is selected, first, the process management apparatus 1 registers the product information of the target products 10001 to 10004 in the database 21 as shown in FIG. In addition, a serial number is registered in the production instruction flag of the production facility 4a that first produces the target product.

Next, each equipment module 31a, 31b checks the production instruction flag of the corresponding production equipment 4a, 4b. Among these, only the equipment module 31a whose serial number is registered in the production instruction flag transmits a production start signal of the target product 10001 with the smallest number registered to the controller 41a. Also, “done” is registered in the production instruction completion flag of the target product 10001.
As shown in FIG. 7A, the controller 41a receives a production start signal from the equipment module 31a and starts production of the target product 10001. When the production of the target product 10001 is completed, a production completion signal is transmitted to the equipment module 31a.
The equipment module 31a refers to the production result information included in the production completion signal, and registers OK indicating normal production in the production result flag.

Hereinafter, similarly, the production facility 4a sequentially produces the target products 10002 and 10003. Finally, the target product 10004 is produced as shown in FIG.
When all target products are normally produced by the production equipment 4a, as shown in FIG. 6B, the production instruction flag of the production equipment 4a is registered in all records, and the production result flag is OK is registered in all records.

Next, as shown in FIG. 6C, the process management device 1 registers a serial number in the production instruction flag of the production facility 4b in the downstream process.
As shown in FIG. 7C, the production facility 4 b receives the target products 10001 to 10004 from the production facility 4 a and starts production sequentially from the target product 10001. Then, the target products 10001, 10002, and 10003 are produced in order, and finally, the product 10004 is produced as shown in FIG.
When all target products are normally produced by the production facility 4b, as shown in FIG. 6D, the production instruction flag of the production facility 4b is registered in all records, and the production result flag is OK is registered in all records.

  As described above, the process management device 1 first registers the serial number in the production instruction flag of the production facility 4a in the upstream process, and the production result of the last target product 10004 is registered in the production result flag of the production facility 4a. Later, by registering a serial number in the production instruction flag of the production facility 4b in the downstream process, the production facilities 4a and 4b in each process collectively produce a plurality of target products 10001-10004 and deliver them to the next process. It can be adapted to the production method.

Next, the operation when the single production system according to the first embodiment is made to correspond to the production method will be described with reference to FIGS. FIG. 8 is an explanatory diagram showing the transition of the database 21, and FIG. 9 is an explanatory diagram showing the operation of the production facilities 4a and 4b and the flow of the target product.
In FIG. 8, a field surrounded by a dotted line in the database 21 indicates a field in which information is registered by the process management apparatus 1, and a field surrounded by a one-dot chain line indicates a field in which the facility management module 31 registers information. In FIG. 9, serial numbers surrounded by solid lines indicate target products that have been produced by each production facility 4, and serial numbers surrounded by broken lines indicate target products that are being produced by each production facility 4.
Further, as in the description of the lot production method, an example is shown in which two target products of two types of model numbers are produced, using two production facilities 4a and 4b, for a total of four target products. Serial numbers 10001 to 10004 are assigned to the four target products, respectively. In addition, it is assumed that the production facility 4a is installed in the upstream process of the production facility 4b.

  When the single production method is selected, first, the process management apparatus 1 registers the product information of the target products 10001 to 10004 in the database 21 as shown in FIG. Further, serial numbers are registered in the production instruction flags of all the production facilities 4a and 4b that produce the target product.

Next, each equipment module 31a, 31b checks the production instruction flag of the corresponding production equipment 4a, 4b.
As shown in FIG. 9A, the equipment module 31a corresponding to the upstream process transmits a production start signal of the target product 10001 with the lowest number registered to the controller 41a. Also, “done” is registered in the production instruction completion flag of the target product 10001.
As shown in FIG. 9A, the controller 41a receives a production start signal from the equipment module 31a and starts production of the target product 10001. When the production of the target product 10001 is completed, a production completion signal is transmitted to the equipment module 31a.
The equipment module 31a refers to the production result information included in the production completion signal, and registers OK indicating normal production in the production result flag.
Hereinafter, as shown in FIGS. 8B and 9B, the production facility 4a sequentially produces the target products 10002, 10003, and 10004.

On the other hand, as shown in FIG. 8A, the equipment module 31b corresponding to the downstream process has the production result flag in the upstream process of the target product 10001 in which the lowest number is registered when the production instruction flag is first checked. Since it is NULL, the production instruction signal is not transmitted as shown in FIG.
After that, when the production facility 4a produces the target product 10001 and the facility module 31a confirms that OK is registered in the production result flag, the facility module 31b transmits a production start signal for the target product 10001 to the controller 41b. Also, “done” is registered in the production instruction completion flag of the target product 10001.
When the production facility 4b receives the production start signal from the facility module 31b, the production facility 4b starts production of the target product 10001 delivered from the production facility 4a.
After that, when the production facility 4a produces the target product 10002 and confirms that the facility module 31a has registered OK in the production result flag, the facility module 31b transmits a production start signal for the target product 10002 to the controller 41b. In addition, “done” is registered in the production instruction completion flag of the target product 10002.
Hereinafter, as shown in FIGS. 8B and 9B, as soon as it is confirmed that OK is registered in the production result flag of the production facility 4a, the production facility 4b is delivered from the production facility 4a. 10002 to 10004 will be produced sequentially.

  As described above, the process management apparatus 1 registers the serial numbers in advance in the production instruction flags of all the production facilities 4a and 4b at the start of production, so that the production facilities 4a and 4b in each process have a plurality of target products 10001. ˜10004 can be produced one by one and transferred to the next process.

Next, the operation when the target product is lined out in the production system according to the first embodiment will be described with reference to FIGS. FIG. 10 is an explanatory diagram showing the transition of the database 21, and FIG. 11 is an explanatory diagram showing the operation of the production facilities 4a and 4b and the flow of the target product.
10 and 11 show a state in which the target product 10002 is lined out in the production facility 4a in the upstream process while the four target products 10001 to 10004 are being produced by the single-flow production method.

  When the target product 10002 is lined out in the production facility 4a, the controller 41a transmits a production completion signal indicating that the target product 10002 has not been normally produced to the facility module 31a. The equipment module 31a registers NG in the corresponding production result flag in the database 21, as shown in FIG.

  On the other hand, the facility module 31b checks the production result flag of the upstream process registered in the database 21 when the production of the target product 10001 is completed and then the production of the target product 10002 is started. At this time, if it is confirmed that NG is registered in the record of the target product 10002 in the upstream process, the production of the target product 10002 is skipped and the production of the target product 10003 is started as shown in FIG.

  As described above, even when the target product 10002 is lined out by the production facility 4a in the upstream process, the production facility 4b in the downstream process skips only the production of the target product 10002, and the remaining target products 10003 and 10004. Production can continue normally.

  In the lot production method, when the target product 10002 is lined out in the production facility 4a in the upstream process, similarly, the production facility 4b in the downstream process skips only the production of the target product 10002, and the remaining target product 10003. The production of 10004 can be continued normally.

As described above, the production system according to the first embodiment registers a plurality of production facilities 4a and 4b installed on the production line and serial numbers indicating the order in which the production facilities 4a and 4b produce the target product. A storage device 2 that stores a database 21 including a plurality of production instruction flags, a facility management device 3 that transmits a production start signal of the target product to the production facilities 4a and 4b in the order of serial numbers, and a production instruction for the input serial number The process management apparatus 1 for registering in the flag is provided, and the process management apparatus 1 is configured to switch to either a single production system or a lot production system according to the registration status of the serial number by the process management apparatus 1.
Therefore, it is possible to obtain a production system that supports both the single-flow production method and the lot production method.

Further, the database 21 has a table-like data structure for registering information for each target product, and the process management apparatus 1 receives a serial number and a selection signal for selecting either a single production method or a lot production method. When an operation input unit for inputting instruction information is included and a single production method is selected, a serial number is registered in advance in a production instruction flag of a plurality of production facilities 4a and 4b, and a lot production method is selected. After the production equipment 4a in the process produces the last target product, the serial number is registered in the production instruction flag of the production equipment 4b in the downstream process.
Therefore, it is possible to switch between the single production method and the lot production method with a simple operation without rewriting the control program of each device.

Further, the database 21 includes a plurality of production result flags for registering either OK indicating that the production facilities 4a and 4b have normally produced the target product or NG indicating that an abnormality has occurred, and the target product. The facility management device 3 registers OK or NG included in the production completion signal of the target product received from the production facilities 4a and 4b in the production result flag, and has an upstream data structure. The production start signal of the target product whose OK is registered in the production result flag of the process production facility 4a is transmitted to the production facility 4b in the downstream process in the order of the serial number, and NG is displayed in the production result flag of the production facility 4a in the upstream process It is configured to skip production in the production facility 4b in the downstream process of the registered target product.
Therefore, even if the target product is lined out in the upstream process, it prevents the target product from linking with the product information when the target product is delivered between processes, and the remaining target product is produced. Can continue.

The facility management apparatus 3 is configured to include a plurality of facility modules 31a and 31b that are connected to the corresponding production facilities 4a and 4b, respectively, and independently check the database 21 and register information in the database 21. did.
Therefore, even if the number and arrangement of the production facilities 4 are changed, it can be easily handled without changing the hardware configuration of the facility management apparatus 3.

In the first embodiment, the example in which the process management device 1, the storage device 2, and the facility management device 3 are configured by independent hardware has been described. However, the configuration of the production management device in which these are realized by one computer. It is good.
In this case, the production management apparatus includes an arithmetic unit such as a semiconductor integrated circuit or a one-chip microcomputer on which a CPU is mounted, and a storage medium such as an HDD or an SSD. In addition, the production management program describing the processing contents of the process management device 1 and the facility management device 3 and the database 21 are stored in a storage medium, and the arithmetic unit reads the production management program and the database 21 from the storage medium and performs each processing. Execute.

  The specific data structure of the database 21 is not limited to the examples shown in FIGS. For example, the arrangement order of the fields may be arbitrarily changed according to the interface of the operation input unit of the process management device 1. Moreover, you may replace a record and a field.

  1 and 2, the configuration in which each of the plurality of production facilities 4 includes one controller 41 is illustrated, but the configuration in which one controller 41 controls the plurality of production facilities 4 may be employed.

  In addition, within the scope of the invention, the invention of the present application can be modified with any component of the embodiment or omitted with any component of the embodiment.

DESCRIPTION OF SYMBOLS 1 Process management apparatus 2 Storage apparatus 3 Equipment management apparatus 4, 4a, 4b Production equipment 21 Database 31, 31a, 31b Equipment module 41, 41a, 41b Controller

Claims (6)

Multiple production facilities installed on the production line;
A storage device storing a database including a plurality of production instruction fields each registering a code indicating the order in which the production equipment produces the target product;
A facility management device for transmitting a production start signal of the target product to the production facility in the order of the codes;
A process management device for registering the input code in the production instruction field;
Depending on the registration status of the code by the process management device, the production facility in the upstream process produces the target product one by one and delivers it to the production facility in the downstream process, or in the upstream process The production system is switched to any one of the lot production methods in which the target products are collectively produced and delivered to the production facility in a downstream process. The database has a table-like data structure for registering information for each target product,
The process management apparatus is
An input unit for inputting instruction information including the code and a selection signal for selecting one of the single-flow production method and the lot production method;
When selecting the single-flow production method, register the code in the production instruction field of a plurality of the production equipment in advance,
The said code | symbol is registered into the said production instruction field of the said production equipment of a downstream process after the said production equipment of an upstream process produces the said last target product when the said lot production system is selected. The production system described. The database includes a plurality of production result fields for registering either normal information indicating that the production facility has normally produced the target product or abnormal information indicating that an abnormality has occurred, and the target product. Each table has a table-like data structure for registering information,
The facility management apparatus is
Registering the normal information or the abnormal information included in the production completion signal of the target product received from the production facility in the production result field,
The production start signal of the target product in which the normal information is registered in the production result field of the production facility in the upstream process is transmitted to the production facility in the downstream process in the order of the codes, and the production facility in the upstream process The production system according to claim 1, wherein production in the production facility in a downstream process of the target product in which the abnormality information is registered in a production result field is skipped.   2. The facility management apparatus includes a plurality of software modules that are respectively connected to the corresponding production facilities and that independently check the database and register information in the database. Production system. A storage unit that stores a database including a plurality of production instruction fields that respectively register codes indicating the order in which a plurality of production facilities produce target products;
A facility management unit that transmits a production start signal of the target product to the production facility in the order of the codes;
A process management unit for registering the input code in the production instruction field,
Depending on the registration status of the code by the process management unit, the production facility in the upstream process produces the target product one by one and delivers it to the production facility in the downstream process, or in the upstream process The production management device is switched to one of a lot production method in which the production facility collectively produces the target product and delivers it to the production facility in a downstream process. Computer
Storage means for storing a database including a plurality of production instruction fields each registering a code indicating the order in which a plurality of production facilities produce target products;
Facility management means for transmitting a production start signal of the target product to the production facility in the order of the codes;
A production management program for functioning as a process management means for registering the input code in the production instruction field,
Depending on the registration status of the code by the process management means, the production facility in the upstream process produces the target product one by one and delivers it to the production facility in the downstream process, or in the upstream process The production management program, wherein the production facility collectively produces the target product and switches to one of the lot production methods that are delivered to the production facility in a downstream process.

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