Bottleneck position analysis method, analysis equipment and computer storage medium

Abstract

The present invention provides a bottleneck workstation analysis method, analysis equipment and computer storage medium. The bottleneck workstation analysis method comprises the following steps: generating beat wall information according to the production beat of the production line; preliminarily determining the bottleneck workstation information according to the beat wall information; and re-determining the bottleneck workstation information according to the preliminarily determined material shortage situation of the bottleneck workstation, the material shortage situation of the previous workstation and the material shortage situation of the next workstation. In the above bottleneck workstation analysis method, the bottleneck workstation information can be preliminarily determined by the beat wall information, and then the bottleneck workstation information can be re-determined by the preliminarily determined material shortage situation of the bottleneck workstation, the previous workstation and the next workstation, so that the determination of the bottleneck workstation is more efficient and accurate.

Description

Technical Field

[0001] The invention belongs to the technical field of flexible manufacturing, and in particular relates to a bottleneck position analysis method, analysis equipment and computer storage medium of an automated production line. Background Art

[0002] As the automation level of production lines increases, the capacity impact between the various workstations of the production line is very large. If a bottleneck occurs at a certain workstation, it will affect the capacity of the entire production line. Generally, it is necessary to analyze the capacity of the production line to find the bottleneck workstation. At present, the common practice is to use PLC to count the beats, from the beginning to the end of the workstation, accumulate and count several process cycles, and then manually calculate the characteristic values ​​to obtain the beat of the workstation. The above methods take a long time, are inefficient, and have calculation errors. Production managers are unable to make process adjustments and optimizations based on actual production conditions, which limits the improvement of production efficiency and production quality. Summary of the invention

[0003] In order to overcome the deficiencies of the prior art, the present invention provides a bottleneck station analysis method, analysis equipment and computer storage medium for an automated production line to solve the problem of low efficiency and inaccuracy in finding the bottleneck station in the prior art.

[0004] One embodiment of the present invention provides a bottleneck workstation analysis method, comprising the following steps:

[0005] Generate beat wall information according to the production beat of the production line;

[0006] Preliminarily determine the bottleneck workstation information based on the beat wall information;

[0007] Based on the initially determined bottleneck station's material shortage situation, the previous station's material shortage situation, and the next station's material shortage situation, the bottleneck station information is determined again.

[0008] In one embodiment, in the process of re-determining the bottleneck station information,

[0009] If the initially determined bottleneck stations are mostly full, the next station will be slow;

[0010] If the initially determined bottleneck workstation has many vacant positions, the previous workstation is slow;

[0011] If the initially determined bottleneck workstation has fewer empty and full states, then it is actually determined as the bottleneck workstation.

[0012] In one embodiment, the bottleneck workstation analysis method further includes the following steps:

[0013] After obtaining the information of the actually determined bottleneck workstation, the actually determined bottleneck workstation is adjusted.

[0014] In one embodiment, the rhythm wall information includes: the workstation cycle rhythm and the workstation effective rhythm of each workstation.

[0015] In one embodiment, the process of preliminarily determining bottleneck workstation information based on the beat wall information includes:

[0016] The workstation cycle beats of each workstation are compared in pairs to obtain the first cycle beat with the highest workstation cycle beat and the second cycle beat with the second highest workstation cycle beat;

[0017] The effective beats of each workstation are compared in pairs to obtain the first effective beat with the highest effective beat and the second effective beat with the second highest effective beat;

[0018] Determine whether each workstation includes the first cycle beat and the first effective beat, or the first cycle beat and the second effective beat, or the second cycle beat and the first effective beat, or the second cycle beat and the second effective beat. If so, the workstation is taken as the preliminarily determined bottleneck workstation.

[0019] In one embodiment, the process of preliminarily determining bottleneck workstation information based on the beat wall information includes:

[0020] Comparing the workstation cycle beat of each workstation with the preset cycle beat, and obtaining a third cycle beat whose cycle beat is higher than the preset cycle beat;

[0021] Compare the effective beat of each workstation with the preset effective beat, and obtain a third effective beat whose effective beats are higher than the preset effective beat;

[0022] It is determined whether each workstation includes both the third cycle beat and the third effective beat. If so, the workstation is taken as a preliminarily determined bottleneck workstation.

[0023] In one of the embodiments, the material shortage situation includes: absolute value statistics of the workstation status and relative value statistics of the workstation status.

[0024] In one embodiment, the absolute value statistics of the workstation status include:

[0025] The duration that the workstation is vacant;

[0026] The duration that the station is full; and

[0027] The duration that the workstation is in equipment failure.

[0028] In one embodiment, the relative value statistics of the workstation status include:

[0029] The ratio of the duration of the workstation being in automatic state to the total time;

[0030] The ratio of the duration of the workstation being in manual mode to the total time;

[0031] The ratio of the duration of the equipment failure state to the total time of the workstation;

[0032] The ratio of the duration of the workstation being in a material shortage state to the total time;

[0033] The ratio of the duration of time that the workstation is in a blocked state to the total time.

[0034] One embodiment of the present invention further provides a bottleneck station analysis device, comprising:

[0035] at least one processor; and,

[0036] A memory connected to the at least one processor; wherein the memory stores instructions executable by the at least one processor, and the instructions are executed by the at least one processor so that the at least one processor can implement the bottleneck workstation analysis method as described in any one of the above embodiments when executing.

[0037] One embodiment of the present invention further provides a computer storage medium, wherein the computer readable storage medium stores a computer program, and when the computer program is executed by a processor, the steps of the bottleneck workstation analysis method described in any one of the above embodiments are implemented.

[0038] In the bottleneck workstation analysis method provided in the above embodiment, the bottleneck workstation information can be preliminarily determined through the beat wall information, and then the bottleneck workstation information can be determined again through the material shortage conditions of the preliminarily determined bottleneck workstation, its previous workstation, and its next workstation, thereby making the determination of the bottleneck workstation more efficient and accurate. BRIEF DESCRIPTION OF THE DRAWINGS

[0039] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on the structures shown in these drawings without paying creative work.

[0040] Figure 1 A schematic diagram of a flow chart of a bottleneck workstation analysis method provided by one embodiment of the present invention;

[0041] Figure 2 yes Figure 1 Schematic diagram of the beat wall generated in;

[0042] Figure 3 for Figure 1 A schematic diagram of a process flow of one embodiment of preliminarily determining a bottleneck workstation;

[0043] Figure 4 for Figure 1 A schematic diagram of a flow chart of another embodiment of preliminarily determining a bottleneck station;

[0044] Figure 5 yes Figure 1 Absolute value statistical chart of the workstation status in the case of material shortage;

[0045] Figure 6 yes Figure 1 Statistical chart of relative values ​​of workstation status in the case of material shortage and blockage;

[0046] Figure 7 A schematic diagram of a module of a bottleneck station analysis device provided in one embodiment of the present invention. DETAILED DESCRIPTION

[0047] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0048] It should be noted that if the embodiments of the present invention involve directional indications (such as up, down, left, right, front, back, etc.), the directional indications are only used to explain the relative position relationship, movement status, etc. between the components in a certain specific posture. If the specific posture changes, the directional indication will also change accordingly.

[0049] In addition, if there are descriptions involving "first", "second", etc. in the embodiments of the present invention, the descriptions of "first", "second", etc. are only used for descriptive purposes and cannot be understood as indicating or implying their relative importance or implicitly indicating the number of technical features indicated. Therefore, the features limited to "first" and "second" may explicitly or implicitly include at least one of the features. In addition, if "and / or" or "and / or" appears in the full text, its meaning includes three parallel solutions. Taking "A and / or B" as an example, it includes solution A, solution B, or solutions that satisfy both A and B. In addition, the technical solutions between the various embodiments can be combined with each other, but it must be based on the ability of ordinary technicians in this field to implement. When the combination of technical solutions is contradictory or cannot be implemented, it should be deemed that such combination of technical solutions does not exist and is not within the scope of protection required by the present invention.

[0050] In order to better describe the technical solution in this application, some technical terms are explained below:

[0051] Workstation: A production line is divided into multiple workstations, each of which is a fixed area for processing a specific process.

[0052] Production tact: In the production process, all the production actions that complete a process are usually called a production tact. Each production tact may consist of one action group or multiple action groups, and each action group consists of many production actions.

[0053] Process timing Gantt chart: With the workstation as the basic unit, the vertical axis is the process action, the horizontal axis is time, and the workstation process flow is digitally displayed.

[0054] Action stability: reflects the fluctuation of the action duration of the equipment, and calculates the difference between the deviation of each action duration and the action average value.

[0055] Material blocking: If a workstation is in a material blocking state, the next material discharge condition is not met, and the subsequent workstation is in a shutdown waiting state before processing is completed.

[0056] Material shortage: If a workstation is in a material blocking state, the feeding conditions of the previous step are not met, and the previous workstation is in a stopped waiting state before processing is completed.

[0057] See also Figure 1 One embodiment of the present invention provides a bottleneck workstation analysis method. The bottleneck workstation analysis method comprises the following steps:

[0058] Generate beat wall information according to the production beat of the production line;

[0059] Preliminarily determine the bottleneck workstation information based on the beat wall information;

[0060] Based on the initially determined bottleneck station's material shortage situation, the previous station's material shortage situation, and the next station's material shortage situation, the bottleneck station information is determined again.

[0061] In the bottleneck workstation analysis method provided in the above embodiment, the bottleneck workstation information can be preliminarily determined through the beat wall information, and then the bottleneck workstation information can be determined again through the material shortage conditions of the preliminarily determined bottleneck workstation, its previous workstation, and its next workstation, thereby making the determination of the bottleneck workstation more efficient and accurate.

[0062] Specifically, the bottleneck position analysis method provided in the embodiment of the present invention can be applied to an automated production line to detect the bottleneck position on the automated production line. The automated production line can produce various types of products, including automobiles, air conditioners, refrigerators or mobile phones.

[0063] In one embodiment, the beat wall information generated according to the production beat of the production line is as follows: Figure 2 As shown. The beat wall information includes the station cycle beat and station effective beat of any station in the production line. For example, in an automated production line, its stations include station 1, station 2, station 3, station 4, station 5, station 6 and other station information. At this time, the beat wall shows the time information of the station cycle beat and station effective beat of several stations such as station 1-station 6. For example, from Figure 2 It can be seen from the given beat wall that in this embodiment, the station cycle beat in station 1 is 352 seconds, and the station effective beat is 200 seconds; the station cycle beat in station 2 is 350 seconds, and the station effective beat is 80 seconds; the station cycle beat in station 3 is 351 seconds, and the station effective beat is 140 seconds; the station cycle beat in station 4 is 350 seconds, and the station effective beat is 90 seconds; the station cycle beat in station 5 is 348 seconds, and the station effective beat is 110 seconds; the station cycle beat in station 6 is 350 seconds, and the station effective beat is 150 seconds. At this time, the station with relatively high station cycle beat and station effective beat is the initially determined bottleneck station. For example, in this embodiment, the station cycle beat and station effective beat in station 1 are higher than the station cycle beat and station effective beat of other stations. Therefore, station 1 is preliminarily determined as the bottleneck station.

[0064] Please also see Figure 3 In one embodiment, the process of preliminarily determining the bottleneck workstation information according to the beat wall information includes:

[0065] The workstation cycle beats of each workstation are compared in pairs to obtain the first cycle beat with the highest workstation cycle beat and the second cycle beat with the second highest workstation cycle beat;

[0066] The effective beats of each workstation are compared in pairs to obtain the first effective beat with the highest effective beat and the second effective beat with the second highest effective beat;

[0067] Determine whether each workstation includes the first cycle beat and the first effective beat, or the first cycle beat and the second effective beat, or the second cycle beat and the first effective beat, or the second cycle beat and the second effective beat. If so, the workstation is taken as the preliminarily determined bottleneck workstation.

[0068] Specifically, the workstation cycle beats of each workstation are compared in pairs to obtain the first cycle beat with the highest workstation cycle beat and the second cycle beat with the second highest workstation cycle beat. In this embodiment, the workstation with the highest workstation cycle beat is workstation 1, that is, the first cycle beat is 352 seconds; the workstation with the second highest workstation cycle beat is workstation 3, that is, the second cycle beat is 351 seconds.

[0069] Specifically, the effective beats of each workstation are compared in pairs to obtain the first effective beat with the highest effective beat and the second effective beat with the second highest effective beat. In this embodiment, the workstation with the highest effective beat is workstation 1, that is, the first effective beat is 200 seconds. The workstation with the second highest effective beat is workstation 6, that is, the second effective beat is 150 seconds.

[0070] Specifically, it is determined whether each station includes the first cycle beat and the first effective beat, or the first cycle beat and the second effective beat, or the second cycle beat and the first effective beat, or the second cycle beat and the second effective beat. If so, the station is used as a preliminarily determined bottleneck station. In this embodiment, station 1 includes both the first cycle beat and the first effective beat. Therefore, station 1 can be used as a preliminarily determined bottleneck station. Station 3 only includes the second cycle beat, but does not include the first effective beat or the second effective beat. Therefore, station 3 does not belong to the bottleneck station. Similarly, station 6 only includes the second effective beat, but does not include the first cycle beat and the second cycle beat. Therefore, station 6 does not belong to the bottleneck station either. Stations 2, 4, and 5 do not include the first cycle beat and the second cycle beat, nor the first effective beat and the second effective beat, and are also not bottleneck stations.

[0071] As required, the process of preliminarily determining the bottleneck workstation information based on the beat wall information is not limited to the above implementation method. Figure 4 In another embodiment, the process of preliminarily determining the bottleneck workstation information according to the beat wall information includes:

[0072] Comparing the workstation cycle beat of each workstation with the preset cycle beat, and obtaining a third cycle beat whose cycle beat is higher than the preset cycle beat;

[0073] Compare the effective beat of each workstation with the preset effective beat, and obtain a third effective beat whose effective beats are higher than the preset effective beat;

[0074] It is determined whether each workstation includes both the third cycle beat and the third effective beat. If so, the workstation is taken as a preliminarily determined bottleneck workstation.

[0075] For example, the preset cycle beat is set to 350 seconds, and the preset effective beat is set to 150 seconds. At this time, the third cycle beat higher than the preset cycle beat is the station cycle beat of station 1, 352 seconds, and the station cycle beat of station 2, 351 seconds. At this time, the third effective beat higher than the preset effective beat is the station effective beat of station 1, 200 seconds. It can be seen from this that the station that includes both the third cycle beat and the third effective beat is station 1, and station 1 is taken as the initially determined bottleneck station.

[0076] In one of the embodiments, the material shortage situation includes: absolute value statistics of the workstation status and relative value statistics of the workstation status.

[0077] In one embodiment, the absolute value statistics of the workstation status include:

[0078] The duration that the workstation is vacant;

[0079] The duration that the station is full; and

[0080] The duration that the workstation is in equipment failure.

[0081] Figure 5 This is a statistical chart of absolute values ​​of workstation status provided by one embodiment of the present invention. Figure 5 As shown, the duration of the vacant state in station 1 is 1800min, and the duration of the equipment failure is 60min. This indicates that there is only a shortage of material in station 1, but no blockage. This situation indicates that the station is short of material for a long time, and the next station (i.e., station 2) is faster. For another example, the duration of the vacant state in station 2 is 1520min, the duration of the full state is 930min, and the duration of the equipment failure is 60min. This situation shows that there is a blockage in the station, and the next station is slow. At this time, the step of "determining the bottleneck station information again based on the initially determined bottleneck station blockage and shortage of material situation, the previous station blockage and shortage of material situation, and the next station blockage and shortage of material situation" is specifically: according to the shortage and blockage of material situation of station 1 (the initially determined bottleneck station) and the shortage and blockage of material situation of station 2 (the next station), the bottleneck station information is determined again. In the actual production process, after obtaining the preliminary determined bottleneck station and the re-determined bottleneck station information, it is necessary to observe at the production site of the production line to verify the correctness of the conclusion.

[0082] In one embodiment, the relative value statistics of the workstation status include:

[0083] The ratio of the duration of the workstation being in automatic state to the total time;

[0084] The ratio of the duration of the workstation being in manual mode to the total time;

[0085] The ratio of the duration of the equipment failure state to the total time of the workstation;

[0086] The ratio of the duration of the workstation being in a material shortage state to the total time;

[0087] The ratio of the duration of time that the workstation is in a blocked state to the total time.

[0088] Figure 6A relative value statistical chart of workstation status provided by another embodiment of the present invention. Figure 6 It can be seen that the ratio of the duration of station 1 in the automatic state to the total time is 10%, the ratio of the duration of station 1 in the lack of material state to the total time is 32%, and the ratio of the duration of station 2 in the automatic state to the total time is 14%, the ratio of the duration of station 2 in the lack of material state to the total time is 34%, and the ratio of the duration of station 2 in the blocked material state to the total time is 52%. At this time, Figure 4 It can be seen that station 1 is not a bottleneck station.

[0089] In one embodiment, in the process of re-determining the bottleneck station information,

[0090] If the initially determined bottleneck stations are mostly full, the next station will be slow;

[0091] If the initially determined bottleneck workstation has many vacant positions, the previous workstation is slow;

[0092] If the initially determined bottleneck workstation has fewer empty and full states, then it is actually determined as the bottleneck workstation.

[0093] In fact, when determining the bottleneck workstation, the meanings of the empty state and full state include:

[0094] The duration of the empty state is less than a preset value, or the duration of the full state is less than a preset value.

[0095] Alternatively, the ratio of the duration of the empty state to the total time is less than a preset ratio, or the ratio of the duration of the full state to the total time is less than a preset ratio.

[0096] The corresponding preset value or preset ratio can be determined by the production line staff according to the actual situation. For example, the preset value can be set to 30%. At this time, when the ratio of the duration of the empty state of a certain workstation to the total time is less than 30%, and the ratio of the duration of the full state of a certain workstation to the total time is also less than 30%, then the workstation can be determined as the actual bottleneck workstation.

[0097] In one embodiment, the bottleneck workstation analysis method further includes the following steps:

[0098] After obtaining the information of the actually determined bottleneck workstation, the actually determined bottleneck workstation is adjusted. In this embodiment, the method of adjusting the actually determined bottleneck workstation includes: replacing equipment, updating the control program of the equipment, or adjusting the working parameters of the equipment. In fact, those skilled in the art can select the method of adjusting the actually determined bottleneck workstation according to actual needs, which will not be described in detail here.

[0099] In one of the embodiments, the material shortage situation includes: absolute value statistics of the workstation status and relative value statistics of the workstation status.

[0100] See also Figure 7 One embodiment of the present invention further provides a bottleneck station analysis device 200, comprising:

[0101] at least one processor 210; and,

[0102] A memory 220 connected to the at least one processor 210; wherein the memory 220 stores instructions executable by the at least one processor 210, and the instructions are executed by the at least one processor 210 so that the at least one processor 210 can implement the bottleneck workstation analysis method as described in any one of the above embodiments when executing. In this embodiment, the memory 220 stores a computer program 240. The processor 210 and the memory 220 are connected via a communication bus 230.

[0103] One embodiment of the present invention further provides a computer storage medium, wherein the computer readable storage medium stores a computer program, and when the computer program is executed by a processor, the steps of the bottleneck workstation analysis method described in any one of the above embodiments are implemented.

[0104] The above description is only a preferred embodiment of the present invention, and does not limit the patent scope of the present invention. All equivalent structural changes made by using the contents of the present invention specification and drawings under the inventive concept of the present invention, or directly / indirectly applied in other related technical fields are included in the patent protection scope of the present invention.

Claims

1. A bottleneck station analysis method, characterized in that: The following steps are involved: Generate beat wall information according to the production beat of the production line; The bottleneck workstation information is preliminarily determined based on the beat wall information, and the workstation cycle beats of each workstation are compared in pairs to obtain the first cycle beat with the highest workstation cycle beat and the second cycle beat with the second highest workstation cycle beat; Compare the effective beats of each workstation in pairs, and obtain the first effective beat with the highest effective beat and the second effective beat with the second highest effective beat, and judge whether each workstation includes the first cycle beat and the first effective beat, or the first cycle beat and the second effective beat, or the second cycle beat and the first effective beat, or the second cycle beat and the second effective beat. If so, the workstation is taken as the initially determined bottleneck workstation; Based on the initially determined material shortage situation of the bottleneck station, the material shortage situation of the previous station and the material shortage situation of the next station, the bottleneck station information is determined again.

2. The bottleneck position analysis method according to claim 1, characterized in that: In the process of re-determining the bottleneck workstation information, If the initially determined bottleneck workstations are mostly full, the next workstation will be slow; If the initially determined bottleneck workstation has many vacant positions, the previous workstation is slow; If the initially determined bottleneck workstation has few empty and full statuses, it is actually determined as the bottleneck workstation.

3. The bottleneck position analysis method according to claim 2, characterized in that: The following steps are also included: After obtaining the information of the actually determined bottleneck workstation, the actually determined bottleneck workstation is adjusted.

4. The bottleneck position analysis method according to claim 1, characterized in that: The rhythm wall information includes: the workstation cycle rhythm and the workstation effective rhythm of each workstation.

5. The bottleneck position analysis method according to claim 4, characterized in that: The process of preliminarily determining the bottleneck workstation information based on the beat wall information includes: Comparing the workstation cycle beat of each workstation with the preset cycle beat, and obtaining a third cycle beat whose cycle beat is higher than the preset cycle beat; Compare the effective beat of each workstation with the preset effective beat, and obtain a third effective beat whose effective beats are higher than the preset effective beat; It is determined whether each workstation includes both the third cycle beat and the third effective beat. If so, the workstation is taken as a preliminarily determined bottleneck workstation.

6. The bottleneck position analysis method according to claim 1, characterized in that: The material shortage situation includes: absolute value statistics of workstation status and relative value statistics of workstation status.

7. The bottleneck position analysis method according to claim 6, characterized in that: The absolute value statistics of the workstation status include: The duration that the workstation is vacant; The duration that the station is full; and The duration that the workstation is in equipment failure.

8. The bottleneck position analysis method according to claim 7, characterized in that: The relative value statistics of the workstation status include: The ratio of the duration of the workstation being in automatic state to the total time; The ratio of the duration of the workstation being in manual mode to the total time; The ratio of the duration of the equipment failure state to the total time of the workstation; The ratio of the duration of the workstation being in a material shortage state to the total time; The ratio of the duration of time that the workstation is in a blocked state to the total time.

9. A bottleneck station analysis device, characterized in that: include: at least one processor; as well as, A memory connected to the at least one processor; wherein the memory stores instructions executable by the at least one processor, and the instructions are executed by the at least one processor so that the at least one processor can implement the bottleneck workstation analysis method as described in any one of claims 1-8 when executing.

10. A computer storage medium, characterized in that: The computer storage medium stores a computer program, and when the computer program is executed by the processor, the steps of the bottleneck workstation analysis method according to any one of claims 1 to 8 are implemented.

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