Production management system and storage medium storing production management program

Abstract

The present invention provides a production management system that can identify production line devices that are the cause of a decrease in production efficiency and can notify operators of a decrease in production efficiency for the entire production line. The production line device, which is composed of a metering device (12), a packaging device (13), an inspection device (14), and a case packer (15), and a host computer (16) are configured to communicate with each other via a network (17). When a predetermined event occurs, each production line device sends event data indicating the occurrence of the event to the host computer (16). When it is determined that production efficiency has decreased based on the received event data, the host computer (16) identifies the production line device that is the cause of the decrease in production efficiency and outputs an alarm indicating that production efficiency is decreasing.

Description

Technical Field

[0001] The present invention relates to a production management system for managing the production status of, for example, a production line for producing meat, fish, processed foods, pharmaceuticals, and the like. Background Art

[0002] For example, in production lines for meat, fish, processed foods, and pharmaceuticals, the manufactured items are measured and packaged to a specified weight. Inspections for foreign matter and final weight are performed, and products judged as acceptable in these inspections are packaged as final products before shipment.

[0003] Patent Document 1 describes a production line composed of a plurality of line devices including a weighing machine, a packaging machine, a product inspection machine, or a case packing machine.

[0004] In such a production line, when an abnormality occurs in a sensor or the like of each device, the operator of the production line is informed of the abnormality.

[0005] Patent Document 1: Japanese Patent Application Publication No. 2019-147580

[0006] However, when multiple production line devices are operating in coordination, if production continues in an inefficient state even though no abnormal state such as an error or alarm has occurred in any device, it is difficult to determine in which device the efficiency is declining.

[0007] In detail, when multiple production line devices are working in coordination, especially when the devices are arranged in a series, even if a slight abnormality such as a slight deviation in the timing of the operation or uneven transportation of the produced items occurs in any device, as long as the abnormality is within the allowable range of each device, the device will not have any errors or alarms, and as time passes, any device will reach an abnormal state such as an error or alarm. As a result, the devices will be unable to perform their original performance and continue to produce in an inefficient state.

[0008] Specifically, a collaborative device that controls its own operation by sending and receiving signals to other devices before and after it depends on the signals it receives from these other devices to initiate its own operation. In particular, a collaborative device that initiates its operation by receiving a signal input is in a state of waiting for signal input if no signal input is present. Typically, the actions taken by other devices before and after it upon receiving an error or alarm signal from its own device vary depending on the equipment structure of the production line. Therefore, without certain measures, an abnormality signal will not be output until the device reaches an abnormal state, such as one incapable of continuing its own operation.

[0009] In this way, the operator of the production line cannot realize that the production line continues to operate in an inefficient state, and naturally cannot understand which production line device is the cause. Summary of the Invention

[0010] The first mode of the production management system of the present invention is a production management system for managing a production line for producing goods, which comprises: a plurality of production line devices constituting the production line; and a main computer configured to be able to communicate with the production line devices, wherein when a predetermined event occurs, the production line device sends event data indicating that the event has occurred to the main computer, and when it is determined based on the received event data that the production efficiency of the production line has decreased, the main computer determines the production line device that is the cause of the decrease in the production efficiency of the production line.

[0011] This configuration determines whether production efficiency has decreased based on event data transmitted from each production line device. If production efficiency has decreased, the production line device that is the cause of the decrease in production efficiency is identified. This makes it possible to identify the production line device that is the cause of the decrease in production efficiency.

[0012] Furthermore, in the production management system of the second mode of the present invention, in the production management system of the first mode, when a stop request is sent to the preceding production line device in the specified production line device as the event data, the main computer determines that the production efficiency of the production line has decreased, and sets the final production line device to which the stop request is sent as the production line device that is the cause of the decrease in production efficiency.

[0013] According to this configuration, when a stop request is issued, it is determined that the production line's production efficiency has decreased, and the final production line device that issued the stop request is identified as the production line device that caused the decrease in production efficiency. Therefore, it is possible to identify the production line device that caused the decrease in production efficiency, which could not have been identified among the production line devices that received the stop request.

[0014] Furthermore, in the production management system of the third mode of the present invention, in the production management system of the first mode, when, after the specified event occurs in the production line device, the same event does not occur even after a specified time has passed, the main computer determines that the production efficiency of the production line has decreased, and sets the production line device as the production line device that is the cause of the decrease in production efficiency.

[0015] According to this configuration, if a production line device that repeats the same process does not proceed even after a predetermined time has passed, it is determined that production efficiency is decreasing, and the production line device is identified as the production line device causing the decrease in production efficiency. Therefore, the production line device causing the decrease in production efficiency can be identified.

[0016] Furthermore, in the production management system of the fourth mode of the present invention, in the production management system of the first mode, in the production line device, when the specified event does not occur even after a specified time has passed with respect to the notification of the specified event from the adjacent production line device, the main computer determines that the production efficiency of the production line has decreased, and sets the production line device as the production line device that is the cause of the decrease in production efficiency.

[0017] According to this configuration, if there is no response to a request signal from an adjacent production line device even after a predetermined period of time, it is determined that production efficiency is decreasing, and the adjacent production line device is identified as the production line device causing the decrease in production efficiency. Therefore, the production line device causing the decrease in production efficiency can be identified.

[0018] Furthermore, the production management system of the fifth mode of the present invention is further provided with a display device for displaying specified information in the production management system of the first mode. After the production line has been operating for a certain period of time, the main computer displays the number of requests sent from the specified production line device to the previous-level production line device within the certain period and the number of operations of the previous-level production line device in parallel graphs on the display device as cumulative values ​​for each elapsed time.

[0019] According to this configuration, it is possible to visually grasp the relationship between the passage of time and production performance, which is difficult to grasp during the operation of the production line.

[0020] Furthermore, in the production management system of the sixth mode of the present invention, in the production management system of the fifth mode, the main computer identifies the area in the display chart where the production efficiency is decreasing, and, on the condition that the operating part enters the area of ​​the identified display, displays the reason for the decrease in production efficiency in character information.

[0021] According to this configuration, it is easy to grasp the correlation between the transition of production performance and the cause of the decrease in production efficiency.

[0022] Furthermore, the production management system of the seventh mode of the present invention is a production management system for managing a production line for producing goods, which comprises: a plurality of production line devices constituting the production line; and a main computer configured to be able to communicate with the production line devices, wherein when a predetermined event occurs, the production line device sends event data indicating that the event has occurred to the main computer, and when it is determined based on the received event data that the production efficiency of the production line has decreased, the main computer outputs an alarm.

[0023] This configuration determines whether production efficiency has decreased based on event data sent from each line device and outputs an alarm. Therefore, a decrease in production efficiency for the entire line can be detected and a warning can be issued before any line device becomes abnormal.

[0024] Furthermore, in the production management system of the 8th mode of the present invention, in the production management system of the 7th mode, in the production line device, if after the occurrence of the specified event, the same event does not occur even after a specified time has passed, the main computer determines that the production efficiency of the production line has decreased.

[0025] According to this configuration, if a production line device that repeats the same process does not perform the process even after a predetermined time has passed, it is determined that production efficiency is decreasing. Therefore, before any production line device becomes abnormal, a decrease in production efficiency of the entire production line can be detected and a warning can be issued.

[0026] Furthermore, in the production management system of the 9th mode of the present invention, in the production management system of the 7th mode, in the production line device, when the specified event does not occur even after a specified time has passed with respect to the notification of the specified event from the adjacent production line device, the main computer determines that the production efficiency of the production line has decreased.

[0027] According to this configuration, if there is no response to a request signal from an adjacent production line device after a predetermined period of time, it is determined that production efficiency is decreasing. Therefore, before any production line device becomes abnormal, a decrease in production efficiency of the entire production line can be detected and a warning can be issued.

[0028] Furthermore, a production management system according to a tenth aspect of the present invention is the production management system according to the seventh aspect, wherein the event includes at least completion of processing of a product in the production line device.

[0029] According to this structure, if a production line device does not perform any further processing even after a predetermined time has passed after processing a product, it is determined that production efficiency is decreasing. Therefore, before any production line device becomes abnormal, the decline in production efficiency of the entire production line can be detected and a warning can be issued.

[0030] Furthermore, the 11th mode of the production management system of the present invention is further provided with a display device for displaying specified information in the 7th mode of the production management system. After the production line has been operating for a certain period of time, the main computer displays the number of requests sent from the specified production line device to the previous-level production line device within the certain period of time and the number of operations of the previous-level production line device in parallel graphs on the display device as cumulative values ​​for each elapsed time.

[0031] According to this configuration, it is possible to visually grasp the relationship between the passage of time and production performance, which is difficult to grasp during the operation of the production line.

[0032] Furthermore, in the production management system of the 12th mode of the present invention, in the production management system of the 11th mode, the main computer identifies the area in the display chart where the production efficiency is decreasing, and, on the condition that the operating part enters the area of ​​the identified display, displays the reason for the decrease in production efficiency in character information.

[0033] According to this configuration, it is easy to grasp the correlation between the transition of production performance and the cause of the decrease in production efficiency.

[0034] Furthermore, the storage medium storing a production management program of the 13th mode of the present invention stores a production management program of a production management system, wherein the production management system includes a production line including a plurality of production line devices and a host computer configured to communicate with the production line devices, and when one or more pre-set events are sent, the production line device sends event data indicating the occurrence of the event to the host computer, and the storage medium is used to enable the host computer to implement the following function: when it is determined that the production efficiency of the production line has decreased based on the received event data, determining the production line device that is the cause of the decrease in the production efficiency of the production line.

[0035] This configuration determines whether production efficiency has decreased based on event data transmitted from each production line device. If production efficiency has decreased, the production line device that is the cause of the decrease in production efficiency is identified. This makes it possible to identify the production line device that is the cause of the decrease in production efficiency.

[0036] Furthermore, the storage medium storing a production management program of the 14th mode of the present invention stores a production management program of a production management system, wherein the production management system comprises a production line including a plurality of production line devices and a host computer configured to communicate with the production line devices, and when a predetermined event occurs, the production line device sends event data indicating that the event has occurred to the host computer, and the storage medium is used to enable the host computer to implement the following function: when it is determined that the production efficiency of the production line has decreased based on the received event data, an alarm is output.

[0037] This configuration determines whether production efficiency has decreased based on event data sent from each line device and outputs an alarm. Therefore, a decrease in production efficiency for the entire line can be detected and a warning can be issued before any line device becomes abnormal.

[0038] Effects of the Invention

[0039] The present invention can provide a production line device that can identify the cause of reduced production efficiency and a production management system that can notify operators of the reduction in production efficiency of the entire production line before any device reaches an abnormal state. BRIEF DESCRIPTION OF THE DRAWINGS

[0040] Figure 1 It is a schematic configuration diagram of a production management system according to the first and second embodiments of the present invention.

[0041] Figure 2 It is a diagram showing an example of transmission data of each production line device in the production management system according to the first and second embodiments of the present invention.

[0042] Figure 3 This is a sequence diagram showing an example of when a stop request signal is transmitted from the inspection device of the production management system according to the first embodiment of the present invention.

[0043] Figure 4 This is a timing chart showing an example in which data transmitted from each line device of the production management system according to the second embodiment of the present invention is delayed compared to a normal state.

[0044] Figure 5 This is a sequence diagram showing an example in which data transmitted from each line device in the production management system according to the second embodiment of the present invention differs between adjacent devices.

[0045] Figure 6 It is a diagram showing an example of a graph of the operation performance of the production management system according to the first and second embodiments of the present invention. DETAILED DESCRIPTION

[0046] Hereinafter, a production management system according to an embodiment of the present invention will be described in detail with reference to the accompanying drawings.

[0047] [First embodiment]

[0048] exist Figure 1 In the first embodiment of the present invention, the production management system 1 involves receiving raw materials such as food and beverages manufactured and processed in the upstream manufacturing process, and packaging them in prescribed weight portions in the metering process and packaging process to make them products. In the inspection process, the weight, foreign matter mixing and packaging status of the products are inspected, and in the boxing process, the production line is managed to box the products judged as qualified products according to the inspection results.

[0049] The production line is composed of a supply device 11, a weighing device 12, a packaging device 13, an inspection device 14, and a case packer 15, each of which performs different processes. These devices (11, 12, 13, 14, 15) are also referred to as production line devices. Typically, these devices (11, 12, 13, 14, 15) are arranged in a series, with conveying mechanisms such as belt conveyors being provided between the preceding and following processes of the production line and between the devices in each process.

[0050] In addition, if Figure 1 As shown, it is not limited to the situation where the devices (11 to 15) are arranged adjacent to each other. For example, it can also be the following situation, that is, the supply device 11 to the packaging device 13 are arranged adjacent to each other in the raw material area where the raw materials before packaging are operated, and the inspection device 14 and the cartoning machine 15 are arranged adjacent to each other in the product area where the products after packaging are operated, and the two divided areas are connected by a conveying mechanism composed of a belt conveyor and a chute.

[0051] The supply device 11 receives raw materials produced in an upstream production process and supplies a predetermined amount of raw materials to the weighing device 12 .

[0052] The weighing device 12 collects or combines the raw materials supplied from the supply device 11 to a predetermined weight and discharges the collected materials to the packaging device 13 .

[0053] The weighing device 12 may have a combined weighing mechanism that temporarily stores the raw materials received from the supply device 11 in a storage container, distributes them into multiple weighing containers in specified quantities, and combines the measured values ​​obtained by each weighing container to discharge raw materials within a specified weight range.

[0054] The packaging device 13 packages the raw material of a predetermined weight discharged from the weighing device 12 with a packaging material and discharges the raw material to the inspection device 14 .

[0055] The inspection device 14 inspects the weight, foreign matter contamination, etc. of the packaged products discharged from the packaging device 13 , and discharges the packaged products that are found to be normal and are thus determined to be acceptable products to the case packer 15 .

[0056] The case packer 15 packs the packaged products discharged from the inspection device 14 into cases, seals the cases, and discharges the cases to downstream processes.

[0057] The host computer 16 is composed of a computer unit including a CPU (Central Processing Unit), a RAM (Random Access Memory), a ROM (Read Only Memory), a hard disk device, and input / output ports (not shown).

[0058] The supply device 11, weighing device 12, packaging device 13, inspection device 14, case packer 15, and host computer 16 are connected to a network 17. The supply device 11, weighing device 12, packaging device 13, inspection device 14, case packer 15, and host computer 16 can communicate with each other via the network 17.

[0059] The host computer 16 is pre-set with the arrangement of each device in the production line, and stores information on other devices arranged before and after one device in association with, for example, device-specific IDs.

[0060] exist Figure 1 In the example shown, the following contents are stored in the main computer 16, namely, a supply device 11 is configured in the supply process, a metering device 12 is configured in the metering process, a packaging device 13 is configured in the packaging process, an inspection device 14 is configured in the inspection process, and a boxing machine 15 is configured in the boxing process.

[0061] Furthermore, when a plurality of devices exist in any one process and each device can communicate with the host computer 16 , it may be configured so that it is possible to set whether each device is arranged in series or in parallel.

[0062] The host computer 16 receives inspection information (event data) such as inspection results and operation history transmitted from each device in the production line via the network 17 , and stores and manages the information in a hard disk device.

[0063] The operation history of the device mentioned here is not limited to the start and stop of the operation of each device. For example, it includes the detection of excessive or insufficient supply of raw materials from the upstream process in the supply device 11, the opening detection of the cover accompanied by the stop of operation and the passing detection of the raw materials discharged by the supply device, etc., the storage amount detection of the supplied raw materials and the zeroing processing of the metering mechanism (not shown) in the metering device 12, the temperature stabilization waiting of the heat sealing part and the replacement of the paper roll of the packaging material in the packaging device 13, the moving-in detection of the items in the inspection device 14, the output of the inspection results, the reset processing of the inspection mechanism (not shown), the stabilization waiting period, the exhaustion of the packaging material of the cartoning machine 15, and other action information inherent to each device, and is sent to the main computer 16 as event data.

[0064] Furthermore, a device-specific ID is allocated to the event data, and this can be used as identification information for digitally identifying which event data is transmitted from which device.

[0065] Furthermore, the host computer 16 may include a mechanism for adding received time information to event data transmitted from each device, adding the received time information as a timestamp. This allows the host computer 16 to record the time information for approximately the same point in time, even if the event data from any device does not contain time information. This eliminates the functional limitations of the device-side control software. Furthermore, even if the times set for each device differ, the impact is minimal.

[0066] like Figure 2 As shown, when a predetermined event occurs, the weighing device 12, the packaging device 13, the inspection device 14, and the box packer 15 transmit the transmission data as event data to the data transmission destination. Figure 2 In FIG. 1 , the “system” of the data transmission destination is the part that is transmitted to the host computer 16 .

[0067] The metering device 12 receives a combination request signal (described later) from the subsequent packaging device 13. When the raw materials can be received or when it is determined that the received raw materials are insufficient, the metering device 12 outputs a supply request signal to the supply device 11. Based on the time when the supply request signal is sent as event data in the metering device 12, the time information of the request for the supply of raw materials is sent to the main computer 16.

[0068] When it is determined that the supply of the raw material is sufficient, the weighing device 12 stops outputting the supply request signal to the supply device 11 and transmits the time information of the completion of the supply of the raw material to the host computer 16 according to the time when the supply request signal is stopped.

[0069] The weighing device 12 receives and weighs the raw materials supplied from the supply device 11 , collects or combines them so as to fall within a predetermined weight range, and transmits the weighed values ​​of the discharged raw materials to the host computer 16 .

[0070] When the discharge of the raw materials is completed, the weighing device 12 transmits a discharge signal to the packaging device 13 and transmits information on the time when the discharge is completed to the host computer 16 .

[0071] When it is determined that packaging is ready, the packaging device 13 transmits a combination request signal to the weighing device 12 requesting the raw materials to be assembled or combined at a predetermined weight, and transmits information on the time when the combination request signal was transmitted to the host computer 16 .

[0072] The packaging device 13 transmits the packaging results such as packaging OK (normal packaging) or packaging NG (incorrect packaging) and the time data thereof to the host computer 16. The packaging results are also transmitted to the subsequent inspection device 14.

[0073] The inspection device 14 transmits an inspection result (e.g., "OK" or "NG") and the time of completion of the inspection to the host computer 16 as a result of inspecting the product. The inspection device 14 may include a sorting device (not shown) that removes products that have failed inspection and products that have failed packaging received from the packaging device 13 from the production line. This allows only normal products to be efficiently discharged to the subsequent case packer 15.

[0074] When it is determined that the supply of products to the subsequent device, i.e., the cartoning machine 15, is stopped due to exceeding the processing capacity, abnormality of the subsequent device, etc., the inspection device 14 sends a stop request signal to the preceding device, i.e., the packaging device 13, and sends information indicating the reason for sending the stop request signal (reason code) and the time information when the stop request signal was sent to the main computer 16.

[0075] The boxing machine 15 boxes a predetermined number of products received from the inspection device 14 and transmits a boxing result such as boxing OK or boxing NG and information on the time when boxing was completed to the host computer 16 .

[0076] When it is determined that the supply of products is stopped due to insufficient packaging materials (such as corrugated paper, wrapping paper), the cartoning machine 15 sends a stop request signal to the preceding device, i.e., the inspection device 14, and sends information indicating the reason for sending the stop request signal (reason code) and the time information when the stop request signal was sent to the main computer 16.

[0077] In this embodiment, the host computer 16 detects that production efficiency is decreasing based on the timing information of the transmission data sent from the weighing device 12, packaging device 13, inspection device 14 and cartoning machine 15, and identifies the device that is causing the decrease in production efficiency.

[0078] When the host computer 16 detects that a stop request signal has been sent from a subsequent device to a previous device in the production line, the host computer 16 identifies the final device that has sent the stop request signal as the device causing the decline in production efficiency.

[0079] For example, when the packaging device 13 receives a stop request signal from the inspection device 14, in the packaging device 13, it is not known whether the cause of the stop occurred in the subsequent inspection device 14 or the further subsequent cartoning machine 15, but in the main computer 16, the device that initially sent the stop request signal can be determined, and thus the device that is the cause of the decline in production efficiency can be determined.

[0080] Furthermore, when the transmission data transmitted from each device is delayed compared to the normal state, the host computer 16 determines that the device is causing the decline in production efficiency.

[0081] For example, if the inspection device 14 does not issue an inspection result even after a predetermined time has passed after receiving the product from the packaging device 13 (receiving the packaging result), the host computer 16 determines that the inspection device 14 is causing a decrease in production efficiency.

[0082] Furthermore, when processing corresponding to notification of transmission data from an adjacent device is delayed in each device, the host computer 16 determines that the device is causing a decrease in production efficiency.

[0083] For example, if the weighing device 12 does not send a combined discharge signal even after a predetermined time has passed since the packaging device 13 sent a combined request signal, the host computer 16 determines that the weighing device 12 is causing a decrease in production efficiency.

[0084] For example, in Figure 3 In the illustrated case, in step S1 , if packaging is ready, the packaging device 13 sends a combination request signal to the weighing device 12 .

[0085] In step S2 , the weighing device 12 collects or combines the raw materials to a predetermined weight and discharges the raw materials to the packaging device 13 . In step S3 , the weighing device 12 transmits a discharge signal to the packaging device 13 .

[0086] In step S4 , the packaging device 13 packages the raw material discharged from the weighing device 12 and discharges the raw material to the inspection device 14 as a product.

[0087] In step S5 , the inspection device 14 inspects the product discharged from the packaging device 13 .

[0088] In step S6 , when the discharge of the product is completed and the next package is ready, the packaging device 13 sends a combination request signal to the weighing device 12 .

[0089] In step S7 , the weighing device 12 collects or combines the raw materials to a predetermined weight and discharges the raw materials to the packaging device 13 . In step S8 , the weighing device 12 transmits a discharge signal to the packaging device 13 .

[0090] In step S9 , the packaging device 13 packages the raw material discharged from the weighing device 12 and discharges the raw material to the inspection device 14 as a product.

[0091] In step S10 , the inspection device 14 inspects the product discharged from the packaging device 13 .

[0092] At this time, since the capacity of the inspection device 14 is exceeded, etc., the inspection device 14 transmits a stop request signal to the packaging device 13 in step S11 .

[0093] In this case, the packaging device 13 does not know whether the cause lies with the subsequent inspection device 14 or the case packer 15. However, the host computer 16 has only received the stop request signal from the inspection device 14, so it can determine that the cause of the decline in production efficiency lies with the inspection device 14.

[0094] Then, in step S12 , when the discharge of the product is completed and preparation for the next package is ready, the packaging device 13 transmits a combination request signal to the weighing device 12 .

[0095] Here, if the weighing device 12 cannot perform combined discharge due to insufficient supply of raw materials or the like and a predetermined time has passed, the host computer 16 determines that the weighing device 12 is responsible for the decrease in production efficiency.

[0096] Then, in step S13 , the weighing device 12 collects or combines the raw materials to a predetermined weight and discharges the raw materials to the packaging device 13 . In step S14 , the weighing device 12 transmits a discharge signal to the packaging device 13 .

[0097] In step S15 , the packaging device 13 packages the raw material discharged from the weighing device 12 and discharges the raw material to the inspection device 14 as a product.

[0098] In step S16 , the inspection device 14 inspects the product discharged from the packaging device 13 .

[0099] In step S17 , when the discharge of the product is completed and the next package is ready, the packaging device 13 sends a combination request signal to the weighing device 12 .

[0100] In the host computer 16 , for example, after a day's production is completed, the day's operating results can be displayed on a display device.

[0101] like Figure 4 As shown, the host computer 16 displays, for example, in a graph the relationship between the time elapsed since the start of production, the number of combination request signals sent from the packaging device 13 to the weighing device 12, i.e., the combination request number NA, and the number of raw materials discharged from the weighing device 12 to the packaging device 13, i.e., the combination discharge number NB. This allows for visual understanding of the relationship between the passage of time and actual production performance, which is difficult to grasp during production line operation. This relationship can be effectively utilized for subsequent production efficiency improvements and can also be saved as part of a so-called daily production report, allowing comparison with past performance or with the performance of multiple production lines.

[0102] The host computer 16 then visually displays the portion where the production efficiency is decreasing based on the number of combined requests NA and the number of combined discharges NB on the graph, for example, by color-coding or enclosing a circle.

[0103] For example, if an operating element such as a cursor is superimposed on a circled portion indicating decreased production efficiency, the host computer 16 displays the cause of the decreased production efficiency in a message area adjacent to the graph display area. Overlaying the graph display area to display a pop-up display makes it easier to understand the correlation between changes in actual production performance and the cause of the decreased production efficiency.

[0104] exist Figure 6 If a cursor is placed over a circle indicated by an X, the host computer 16 displays a message indicating the reason why neither the number of combined requests NA nor the number of combined discharges NB has increased since time t1. For example, if a stop request signal is recorded in the data received from the inspection device 14 at a time close to time t1, the message "Operation rate has decreased due to a production stop command from a downstream device" will be displayed.

[0105] If a cursor is placed on a circle indicated by a Y, the host computer 16 displays a message indicating the reason why the combined discharge count NB has not increased since time t2. For example, if the supply request signal from the metering device 12 is continuously recorded as being on at a time close to time t2, or if the supply request signal is not recorded as being off, the message will be displayed as "supply request signal continuously output," "supply quantity insufficient," or "operation rate decreased due to insufficient supply quantity."

[0106] If the cursor is placed over the circle represented by Z, the host computer 16 displays a message indicating the reason why the rate of increase in the combined discharge count NB, i.e., the slope of the graph, remains low, despite no other event data associated with a decrease in efficiency being recorded around time t3. In this case, the cause is likely to be transfer between or within processes in the packaging area of ​​the production line, where raw materials subject to fluctuations and requiring adjustment are handled. Therefore, for example, if the number of packaged results from the packaging device 13 decreases, a message such as "Operation rate decreases due to bridging of weighed items" will be displayed.

[0107] Thus, in the first embodiment, the host computer 16 detects a decrease in production efficiency based on event data sent from the weighing device 12, packaging device 13, inspection device 14, and case packer 15, and identifies the device causing the decrease in production efficiency.

[0108] Thus, if a decrease in production efficiency is detected based on event data transmitted from each device, the device causing the decrease in production efficiency is identified, and the device causing the decrease in production efficiency can be grasped.

[0109] Furthermore, when a stop request is sent to a preceding device in each device, the host computer 16 determines that the last device to which the stop request has been sent is the device causing the decrease in production efficiency.

[0110] This makes it possible to identify a device that is the cause of the reduction in production efficiency, which cannot be identified among the devices that received the stop request.

[0111] Furthermore, when a predetermined event does not occur in each device even after a predetermined time has passed after the predetermined event occurs, the host computer 16 determines that production efficiency is decreasing and identifies the device as the cause of the decrease in production efficiency.

[0112] Thus, if a device that repeats the same process does not perform the process even after a predetermined time has passed, it is determined that production efficiency is decreasing, and the device is identified as the device causing the decrease in production efficiency.

[0113] Furthermore, in each device, when no predetermined event occurs even after a predetermined time has passed in response to notification of a predetermined event from an adjacent device on the assembly line, the main computer 16 determines that production efficiency is decreasing and sets the device as the cause of the decrease in production efficiency.

[0114] Thus, for example, if the packaging device 13 does not transmit a combination request signal even after a predetermined time has passed after the weighing device 12 transmits a combination discharge signal, it is determined that production efficiency is decreasing, and the packaging device 13 is identified as the device causing the decrease in production efficiency. This makes it possible to identify the device causing the decrease in production efficiency.

[0115] [Second embodiment]

[0116] The basic structure of the production management system 1 according to the second embodiment of the present invention is the same as that of the production management system according to the first embodiment. Figure 1 The schematic structure shown, Figure 2 The transmission data shown, the basic operation of each device 11 to 16, etc. are the same as those in the first embodiment.

[0117] In the second embodiment, the host computer 16 detects a decrease in production efficiency for the entire production line based on the time information of the data transmitted from the weighing device 12, the packaging device 13, the inspection device 14, and the case packer 15, and outputs an alarm. The alarm is output, for example, as a message to a display device (not shown) connected to the host computer 16, or in a manner that can be visually or audibly recognized on a production status monitor appropriately installed near the production line.

[0118] If data transmitted from each device is delayed compared to normal, the host computer 16 determines that the production efficiency of the entire production line is declining. In other words, if data transmitted from each device is delayed compared to normal, the host computer 16 identifies the delayed device, determines that the production efficiency of the entire production line is declining, and issues an alarm. Furthermore, each device can automatically issue an alarm if an event occurs that is delayed compared to normal.

[0119] In addition, the "normal state" mentioned here is not limited to the devices in the production line operating without entering an abnormal state, but refers to the operation rate of the entire production line being maintained above a specified reference value. Specifically, it means that based on the data sent from the devices in the production line to the main computer 16, the devices operate in coordination according to a pre-set reference sequence.

[0120] Furthermore, the host computer 16 stores a reference ranking set according to the functions of the devices constituting the production line and the arrangement in the production line.

[0121] The host computer 16 may be configured to store a plurality of reference sortings in the form of sortings SQ1, SQ2, ... for each production line or according to a target production efficiency of a certain production line, and to be switchable.

[0122] Furthermore, when one device outputs a signal to another device, a signal of the same content is also output to the host computer 16. However, for example, when a level signal is output to another device from one device with a request signal turned on as a high level and with a request signal turned off as a low level, an analog input port (not shown) can be allocated to the host computer 16, or a data signal can be sent from other devices on the receiving side via the network 17.

[0123] For example, in Figure 4 In the illustrated case, the arrow portion indicated by A is a normal state. In step S1 , if packaging is ready, the packaging device 13 transmits a combination request signal to the weighing device 12 .

[0124] In step S2, if a supply request signal is sent from the metering device 12 to the supply device 11 and raw materials are supplied from the supply device 11 to the metering device 12, then in step S3, the metering device 12 collects or combines the raw materials in a manner to achieve a specified weight and discharges them to the packaging device 13, and in step S4, a discharge signal is sent to the packaging device 13.

[0125] Furthermore, in step S2, even if the supply request signal is not transmitted from the metering device 12, the supply device 11 can operate to supply a predetermined amount at predetermined intervals. In this case, the metering device 12 outputs a supply stop signal to the supply device 11 to prevent the supply device 11 from receiving more raw material than required. This prevents the metering device 11 from accumulating raw material or agglomerating and causing clogging.

[0126] In step S5 , when packaging is completed and preparation for the next packaging is ready, the packaging device 13 sends a combination request signal to the weighing device 12 .

[0127] In step S6, if a supply request signal is sent from the metering device 12 to the supply device 11 and raw materials are supplied from the supply device 11 to the metering device 12, then in step S7, the metering device 12 collects or combines the raw materials in a manner to achieve a specified weight and discharges them to the packaging device 13, and in step S8, a discharge signal is sent to the packaging device 13.

[0128] Here, as indicated by the arrow B, even a slight delay in the combination request signal from the packaging device 13 in step S9 may lead to a decrease in the production efficiency of the entire production line.

[0129] If the packaging device 13 does not send a combination request signal even after a predetermined time has passed after the metering device 12 sends a discharge signal, the host computer 16 outputs an alarm. Alternatively, if the packaging device 13 does not send a combination request signal even after a predetermined time has passed after the metering device 12 sends a discharge signal, the metering device 12 may output an alarm on its own.

[0130] Then, in step S10, if a supply request signal is sent from the metering device 12 to the supply device 11 and raw materials are supplied from the supply device 11 to the metering device 12, then in step S11, the metering device 12 combines the raw materials in a manner to achieve a specified weight and discharges them to the packaging device 13, and in step S12, a discharge signal is sent to the packaging device 13.

[0131] In step S13, when packaging is completed and preparation for the next packaging is ready, the packaging device 13 sends a combination request signal to the weighing device 12. Then, the weighing device 12 sends a supply request signal to the supply device 11.

[0132] Here, as shown by the arrow C, if the supply of raw materials from the supply device 11 in step S14 is delayed, the delay will also affect the discharge of the combination of the metering device 12 in step S15 and the sending of the combination discharge signal in step S16, resulting in a decrease in production efficiency.

[0133] In this case, if the weighing device 12 does not transmit the combined discharge result or discharge signal even after a predetermined time has passed after the packaging device 13 transmits the combined discharge request signal, the host computer 16 outputs an alarm. Alternatively, if the weighing device 12 does not transmit the discharge signal even after a predetermined time has passed after the packaging device 13 transmits the combined discharge request signal, the packaging device 13 may output an alarm on its own device.

[0134] Furthermore, when the data transmitted from each device has a difference in the order of signal transmission, such as a difference from a predetermined order between adjacent devices, the host computer 16 determines that the production efficiency is decreasing.

[0135] For example, in Figure 5 In the illustrated case, in step S21, the packaging device 13 discharges the packaged products to the inspection device 14. In step S22, the inspection device 14 inspects the products, and in step S23, the inspection device 14 discharges the products that have been determined to be acceptable. In step S24, the case packer 15 packs the products into cases, seals them, and discharges them.

[0136] Here, the inspection device 14 can perform inspections within a shorter time than the operating interval of the packaging device 13. Therefore, the signal requesting product discharge is not sent to the preceding packaging device 13. In other words, the packaging device 13 discharges packaged products to the inspection device 14 without receiving a signal from the subsequent inspection device 14. Similarly, the inspection device 14 discharges products determined to be acceptable to the case packer 15 without receiving a signal from the case packer 15.

[0137] Next, in step S25, the packaging device 13 discharges the packaged products to the inspection device 14. In step S26, the inspection device 14 inspects the products, and in step S27, the inspection device 14 discharges the products that have been determined to be acceptable. In step S28, the case packer 15 packs the products into cases, seals them, and discharges them.

[0138] Here, in step S29, after the packaging device 13 discharges the packaged product to the inspection device 14, if the product is not discharged from the packaging device 13 and the inspection result in the inspection device 14 is not sent during the period indicated by the arrow D, production efficiency will be reduced.

[0139] When the main computer 16 does not receive the inspection results from the inspection device 14 or the packaging results from the packaging device 13 even after a prescribed period of time has passed after receiving the packaging results from the packaging device 13, it determines that the product cannot be produced or that the production efficiency is decreasing due to poor switching in the assembly line, and outputs an alarm.

[0140] Then, in step S30 , the packaging device 13 discharges the packaged products to the inspection device 14 . In step S31 , the inspection device 14 inspects the products. In step S32 , the inspection device 14 discharges the products determined to be acceptable.

[0141] Here, as indicated by the arrow E, after the inspection device 14 discharges the product in step S32, if the product is not discharged from the inspection device 14 and the case is not packed in the case packing machine 15 even after a prescribed time has passed, the product will not be discharged from the case packing process to the downstream process, which will lead to a decrease in production efficiency.

[0142] If, after receiving the inspection results from the inspection device 14, the main computer 16 does not receive the packaging results from the cartoning machine 15 or the inspection results from the inspection device 14 even after a specified time has passed, it determines that the product cannot be produced or that a poor connection has occurred in the assembly line, and that production efficiency is declining, and outputs an alarm.

[0143] In the host computer 16 , for example, after a day's production is completed, the day's operating results can be displayed on a display device.

[0144] like Figure 6 As shown, the host computer 16 displays, for example, in a graph the relationship between the time elapsed since the start of production, the number of combination request signals sent from the packaging device 13 to the weighing device 12 (combination request number NA), and the number of raw materials discharged from the weighing device 12 to the packaging device 13 (combination discharge number NB). This allows for visual understanding of the relationship between the passage of time and actual production performance, which is difficult to grasp during production line operation. This relationship can be effectively utilized for future production efficiency improvements and can be saved as part of a so-called daily production report, allowing comparison with past performance or with the performance of multiple production lines.

[0145] The host computer 16 then visually displays the portion where the production efficiency is decreasing based on the number of combined requests NA and the number of combined discharges NB on the graph, for example, by color-coding or enclosing a circle.

[0146] For example, if an operating element such as a cursor is superimposed on a circled portion indicating decreased production efficiency, the host computer 16 displays the cause of the decreased production efficiency in a message area adjacent to the graph display area. Overlaying the graph display area to display a pop-up display makes it easier to understand the correlation between changes in actual production performance and the cause of the decreased production efficiency.

[0147] exist Figure 6If the cursor is placed over the circle indicated by an X, the host computer 16 displays a message indicating the reason why neither the number of combined requests NA nor the number of combined discharges NB has increased since time t1. For example, if the data received from the packaging device 13 indicates a change in packaging material at a time close to time t1, the message will read "Packaging material change" or "Operational downgrade due to packaging material change."

[0148] If a cursor is placed on a circle indicated by a Y, the host computer 16 displays a message indicating the reason why the combined discharge count NB has not increased since time t2. For example, if the supply request signal from the metering device 12 is continuously recorded as being on at a time close to time t2, or if the supply request signal is not recorded as being off, the message will be displayed as "supply request signal continuously output," "supply quantity insufficient," or "operation rate decreased due to insufficient supply quantity."

[0149] If the cursor is placed over the circle represented by Z, the host computer 16 displays a message indicating the reason why the rate of increase in the combined discharge count NB, i.e., the slope of the graph, remains low, despite no other event data associated with a decrease in efficiency being recorded around time t3. In this case, the cause is likely to be transfer between or within processes in the packaging area of ​​the production line, where raw materials subject to fluctuations and requiring adjustment are handled. Therefore, for example, if the number of packaged results from the packaging device 13 decreases, a message such as "Operation rate decreases due to bridging of weighed items" will be displayed.

[0150] As described above, in the second embodiment, the host computer 16 detects a decrease in production efficiency based on event data transmitted from the weighing device 12, the packaging device 13, the inspection device 14, and the case packer 15, and outputs an alarm.

[0151] Thus, if a decrease in production efficiency is detected based on event data transmitted from each device, an alarm is output, thereby enabling detection of a decrease in production efficiency and issuing a warning before an abnormal state occurs.

[0152] Furthermore, when the same event does not occur in each device even after a predetermined time has passed since a predetermined event occurred, the host computer 16 determines that the production efficiency has decreased.

[0153] Thus, in a device that repeats the same process, if the process is not performed even after a predetermined time has passed, it can be detected as a decrease in production efficiency. This allows detection of the decrease in production efficiency before an abnormal state occurs and a warning to be issued.

[0154] Furthermore, when no predetermined event occurs even after a predetermined time has passed in response to notification of a predetermined event from an adjacent device on the production line, the host computer 16 determines that production efficiency has decreased.

[0155] Thus, for example, if the packaging device 13 does not send a combination request signal even after a predetermined time has passed after sending a combination discharge signal from the weighing device 12, it can be detected as a decrease in production efficiency, thereby detecting a decrease in production efficiency before an abnormal state occurs and issuing a warning.

[0156] Furthermore, in the first and second embodiments, the alarms and operating performance graphs are displayed on the display device of the host computer 16 . However, the information may be transmitted to an information device such as a tablet terminal connected to the network 17 and displayed.

[0157] The first and second embodiments of the present invention are disclosed above, but it is obvious that those skilled in the art can make additional changes without departing from the scope of the present invention. Of course, all such modifications and equivalents are included in the present technical solution.

[0158] Explanation of symbols

[0159] 1-Production management system, 11-Supply device (production line device for the supply process), 12-Measuring device (production line device for the measuring process), 13-Packaging device (production line device for the packaging process), 14-Inspection device (production line device for the inspection process), 15-Cartoning machine (production line device for the cartoning process), 16-Main computer, 17-Network.

Claims

1. A production management system for managing a production line for producing goods, the production management system comprising: A plurality of production line devices constituting the production line, wherein: The plurality of production line devices include metering devices and packaging devices; and a host computer configured to communicate with the production line device; When the packaging device sends a combination request signal to request that the raw materials be collected or combined to a predetermined weight, or when the weighing device sends a discharge signal to indicate that the raw materials are collected or combined to have a predetermined weight, the production line device sends event data indicating that at least one of the combination request or the discharge signal has occurred to the host computer. When it is determined based on the received event data that the production efficiency of the production line has decreased, the main computer determines which of the multiple production line devices is the cause of the decrease in production efficiency of the production line by comparing the number of combination request signals sent by the packaging device with the number of discharge signals sent by the metering device.

2. The production management system according to claim 1, wherein: When a stop request is sent to the preceding production line device in the specified production line device as the event data, the main computer determines that the production efficiency of the production line has decreased, and sets the final production line device that sent the stop request as the production line device that is the cause of the decrease in production efficiency.

3. The production management system according to claim 1, wherein: After the specified event occurs in the production line device, if no specified event occurs even after a specified time has passed, the host computer determines that the production efficiency of the production line has decreased, and sets the production line device as the production line device that is the cause of the decreased production efficiency.

4. The production management system according to claim 1, wherein: In the production line device, when the specified event does not occur even after a specified time has passed with respect to notification of the specified event from the adjacent production line device, the main computer determines that the production efficiency of the production line has decreased, and sets the production line device as the production line device that is the cause of the decrease in production efficiency.

5. The production management system according to claim 1, further comprising: A display device displays prescribed information, After the production line has been running for a certain period of time, the main computer displays the number of requests sent from the specified production line device to the previous level production line device within the certain period and the number of operations of the previous level production line device in parallel graphs on the display device as cumulative values ​​for each elapsed time.

6. The production management system according to claim 5, wherein: The host computer identifies areas in the display chart where production efficiency is declining, Furthermore, under the condition that the operating element enters the identification display area, the reason for the decrease in production efficiency is displayed in text information.

7. A production management system for managing a production line for producing goods, the production management system comprising: A plurality of production line devices constituting the production line, wherein: The plurality of production line devices include metering devices and packaging devices; and A host computer configured to communicate with the production line device, When the packaging device sends a combination request signal to request that the raw materials be collected or combined to a predetermined weight, or when the weighing device sends a discharge signal to indicate that the raw materials are collected or combined to have a predetermined weight, the production line device sends event data indicating that at least one of the combination request or the discharge signal has occurred to the host computer. When it is determined based on the received event data that the production efficiency of the production line has decreased, the host computer outputs an alarm by comparing the number of combination request signals transmitted by the packaging device with the number of discharge signals transmitted by the weighing device.

8. The production management system according to claim 7, wherein: In the production line device, if a predetermined event does not occur even after a predetermined time has passed after the predetermined event occurs, the host computer determines that the production efficiency of the production line has decreased.

9. The production management system according to claim 7, wherein: In the production line device, if a predetermined event does not occur even after a predetermined time has passed in response to notification of the predetermined event from the adjacent production line device, the host computer determines that the production efficiency of the production line has decreased.

10. The production management system according to claim 7, wherein: The event at least includes the completion of processing of the product in the production line device.

11. The production management system according to claim 7, wherein: A display device displays prescribed information, After the production line has been running for a certain period of time, the main computer displays the number of requests sent from the specified production line device to the previous level production line device within the certain period and the number of operations of the previous level production line device in parallel graphs on the display device as cumulative values ​​for each elapsed time.

12. The production management system according to claim 11, wherein: The host computer identifies areas in the display chart where production efficiency is declining, Furthermore, under the condition that the operating element enters the identification display area, the reason for the decrease in production efficiency is displayed in text information.

13. A storage medium storing a production management program of a production management system, wherein the production management system comprises a plurality of production line devices, wherein: The plurality of production line devices include a production line of a metering device and a packaging device, and a host computer configured to communicate with the production line device, wherein the production line device sends event data indicating that the packaging device sends a combination request signal to request that the raw materials be gathered or combined into a predetermined weight, or that the metering device sends a discharge signal to indicate that the raw materials are gathered or combined into a predetermined weight, to the host computer, wherein the storage medium includes: The main computer stores a production management program for realizing the following function, namely, when it is determined that the production efficiency of the production line has decreased based on the received event data, the production line device is determined to determine which of the multiple production line devices is the cause of the decrease in production efficiency of the production line by comparing the number of combination request signals sent by the packaging device with the number of discharge signals sent by the metering device.

14. A storage medium storing a production management program of a production management system, wherein the production management system comprises a plurality of production line devices, wherein: The plurality of production line devices include a production line of weighing devices and packaging devices, and a host computer configured to communicate with the production line devices, wherein the production line devices transmit to the host computer event data indicating that the packaging device sends a combination request signal requesting that raw materials be gathered or combined to a predetermined weight, or that the weighing device sends a discharge signal indicating that raw materials are gathered or combined to have a predetermined weight, and the program enables the following functions to be implemented: When it is determined based on the received event data that the production efficiency of the production line has decreased, an alarm is output to the host computer by comparing the number of combination request signals sent by the packaging device with the number of discharge signals sent by the weighing device.

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