Production management system and storage media containing production management programs

Abstract

This invention provides a production management system that detects abnormal trends in production line equipment constituting a production line and can identify malfunctions in the production line equipment at an early stage. The system includes production line equipment, namely metering and packaging equipment, inspection equipment, and a main computer, configured to communicate with each other via a network. The inspection equipment sends its inspection results to the main computer, and the metering and packaging equipment send their processing results to the main computer. The main computer detects abnormal trends in the production line equipment based on the inspection and / or processing results and outputs alarms.

Description

Technical Field

[0001] This invention relates to a production management system, for example, for managing the production status in a production line for producing meat, fish, processed food, pharmaceuticals, etc. Background Technology

[0002] For example, in production lines for meat, fish, processed foods, and pharmaceuticals, the manufactured items are packaged according to a specified weight, and inspections are conducted to check for foreign matter contamination and to check the final weight. Products that pass these inspections are then packaged and shipped as final products.

[0003] Patent document 1 describes a production line consisting of multiple production line devices, including a measuring machine, a packaging machine, a product inspection machine, or a case packing machine.

[0004] In this type of production line, when an anomaly occurs in the sensors or other components of the various devices, the production line operators are informed of the anomaly.

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

[0006] However, when multiple production line devices operate in coordination, it is difficult to detect an abnormal trend that occurs in any one device, even if it has not yet reached an abnormal state such as an error or alarm. Summary of the Invention

[0007] Therefore, the object of the present invention is to provide a production management system that detects abnormal trends in the production line equipment constituting the production line and can detect malfunctions of the production line equipment at an early stage.

[0008] The first embodiment of the present invention provides a production management system for managing a production line for producing goods. The production management system comprises: a production line device; an inspection device, which, together with the production line device, constitutes the production line and is located downstream of the production line device; and a main computer capable of communicating with both the production line device and the inspection device. The inspection device sends inspection result information, related to the inspection results within its own device, to the main computer. The production line device sends processing result information, related to the processing results within its own device, to the main computer. When the inspection result information and / or the processing result information meet predetermined conditions, the main computer determines that the production line device exhibits an abnormal trend and outputs an alarm.

[0009] According to this structure, if an abnormal trend is detected in the production line equipment based on inspection and / or processing results, an alarm is output. Therefore, it is possible to detect abnormal trends in the production line equipment and identify malfunctions at an early stage.

[0010] Furthermore, in the production management system of the second aspect of the present invention, one of the production line devices is a measuring device for measuring the weight of the product. When the weight of the product in the inspection result information is undesirably too heavy or too light, the main computer determines that the measuring device has an abnormal trend.

[0011] According to this structure, when the product weight information in the inspection results is undesirably too heavy or too light, it is determined that the production line device used to measure the product weight has an abnormal trend. Therefore, it is possible to detect abnormal trends in the production line device and identify malfunctions at an early stage.

[0012] Furthermore, in the production management system of the third aspect of the present invention, the production line device includes a measuring device for measuring the weight of the product and a packaging device for packaging the product. If the standard deviation of the weight of the product in the inspection result information is greater than a predetermined value, and the weight in the processing result information from the measuring device is within a predetermined range near the target weight, the main computer determines that the packaging device has an abnormal trend.

[0013] According to this structure, if the standard deviation of the product weight in the inspection result information is greater than a specified value, and the weight in the processing result information of the production line device (i.e., the metering device) that measures the product weight is within a specified range near the target weight, then it is determined that the production line device (i.e., the packaging device) for packaged products has an abnormal trend. Therefore, it is possible to detect abnormal trends in the production line device and identify production line device malfunctions at an early stage.

[0014] Furthermore, the production management system of the fourth aspect of the present invention manages the production line of the manufactured goods. The production management system includes: a production line device constituting the production line; and a main computer configured to communicate with the production line device. One of the production line devices is a packaging device. The packaging device sends information on the decreasing trend of the heater temperature and / or pressure of its own device as processing result information to the main computer, and sends information on products that are processed in the range of the decreasing trend to a distribution device located after its own device, so as to exclude the product from the production line. When an abnormal trend of the packaging device is detected according to the processing result information, the main computer outputs an alarm.

[0015] According to this structure, if an abnormal trend is detected in the packaging device based on the processing results, an alarm is output. Therefore, it is possible to detect abnormal trends in the packaging device and identify packaging device malfunctions at an early stage. Furthermore, it can effectively remove potentially defective products from the production line.

[0016] Furthermore, the production management system of the fifth aspect of the present invention, in addition to the production management system of the first aspect of the present invention, also includes a display device. When it is determined that the production line device has an abnormal trend, the host computer displays the abnormal trend of the production line device on the display device.

[0017] According to this structure, when an abnormal trend is determined to exist in a specified production line device, the host computer displays the abnormal trend on the display device. Therefore, it is possible to easily identify when a specified production line device is in an abnormal state.

[0018] Furthermore, the production management system of the sixth aspect of the present invention, in addition to the production management system of the second aspect of the present invention, also includes a display device. When it is determined that the production line device has an abnormal trend, the host computer displays the abnormal trend of the production line device on the display device.

[0019] According to this structure, when an abnormal trend is determined to exist in a specified production line device, the host computer displays the abnormal trend on the display device. Therefore, it is possible to easily identify when a specified production line device is in an abnormal state.

[0020] Furthermore, the production management system of the seventh embodiment of the present invention, in addition to the production management system of the third embodiment of the present invention, also includes a display device. When it is determined that the production line device has an abnormal trend, the host computer displays the abnormal trend of the production line device on the display device.

[0021] According to this structure, when an abnormal trend is determined to exist in a specified production line device, the host computer displays the abnormal trend on the display device. Therefore, it is possible to easily identify when a specified production line device is in an abnormal state.

[0022] Furthermore, the production management system of the eighth aspect of the present invention, in addition to the production management system of the fourth aspect of the present invention, also includes a display device. When it is determined that the production line device has an abnormal trend, the host computer displays the abnormal trend of the production line device on the display device.

[0023] According to this structure, when an abnormal trend is determined to exist in a specified production line device, the host computer displays the abnormal trend on the display device. Therefore, it is possible to easily identify when a specified production line device is in an abnormal state.

[0024] Furthermore, in the production management system of the ninth aspect of the present invention, in the production management system of the first aspect of the present invention, the main computer outputs the loss generation status in the production line based on the received processing result information and / or the inspection result information, i.e., the device result information.

[0025] Based on this structure, the system outputs the status of losses in the production line according to the device output information from each device. Therefore, in addition to detecting abnormal trends in the production line devices, it is also possible to determine where the loss occurred in the production line.

[0026] Furthermore, in the production management system of the 10th aspect of the present invention, in the production management system of the 9th aspect of the present invention, the production line device and / or the inspection device send information indicating the number of products processed by their own devices as device result information to the main computer, and the main computer calculates and outputs the number of product losses between multiple production line devices or the number of product losses between the production line device and the inspection device based on the received device result information.

[0027] Based on this structure, the number of products lost between production line units or between a production line unit and an inspection unit is calculated and output according to the number of processed products from the unit's output information. Therefore, in addition to detecting abnormal trends in production line units, it is possible to pinpoint exactly where the loss occurred on the production line.

[0028] Furthermore, in the production management system of the 10th embodiment of the present invention, when the number of product losses exceeds a predetermined threshold, the main computer outputs an alarm in the production management system of the 11th embodiment of the present invention.

[0029] Therefore, in addition to detecting abnormal trends in production line equipment, it can also identify situations where losses exceed thresholds at an early stage.

[0030] Furthermore, the production management system of the 12th embodiment of the present invention, in addition to the production management system of the 9th embodiment of the present invention, also includes a display device, on which the host computer displays the loss generation status in the production line.

[0031] According to this structure, the main computer displays the loss occurrence status in the production line on the display device. Therefore, in addition to detecting abnormal trends in the production line devices, it is also possible to easily identify the loss occurrence status in each device.

[0032] Furthermore, the production management system of the 13th embodiment of the present invention, in addition to the production management system of the 11th embodiment of the present invention, also includes a display device, on which the host computer displays the alarm message.

[0033] Based on this structure, the main computer displays alarm messages on the display device. Therefore, in addition to detecting abnormal trends in the production line equipment, it is also possible to easily identify situations where losses exceed a predetermined threshold.

[0034] Furthermore, in the 14th embodiment of the present invention, the storage medium storing the production management program stores the production management program of the production management system, which includes a production line for producing goods, a production line device, an inspection device that constitutes the production line together with the production line device and is located downstream of the production line device, and a main computer capable of communicating with the production line device and the inspection device. The inspection device sends information related to the inspection results in its own device, i.e., inspection result information, to the main computer. The production line device sends information related to the processing results in its own device, i.e., processing result information, to the main computer. The storage medium stores a production management program for enabling the main computer to perform the following functions: when the inspection result information and / or the processing result information meet the specified conditions, it determines that the production line device has an abnormal trend and outputs an alarm.

[0035] According to this structure, if an abnormal trend is detected in the production line unit based on inspection and / or processing results, an alarm is output. Therefore, it is possible to detect abnormal trends in the production line unit and identify production line unit malfunctions at an early stage.

[0036] Furthermore, in the 15th embodiment of the present invention, a storage medium storing a production management program stores a production management system comprising a production line for producing articles, production line devices constituting the production line, and a main computer configured to communicate with the production line devices. One of the production line devices is a packaging device, which sends information on the decreasing trend of its own heater temperature and / or pressure as processing result information to the main computer, and sends information on products processed within the range of the decreasing trend to a distribution device located downstream of its own device, so as to exclude the product from the production line. The storage medium enables the main computer to perform the following function: when an abnormal trend of the packaging device is detected based on the processing result information, an alarm is output.

[0037] According to this structure, if an abnormal trend is detected in the packaging device based on the processing results, an alarm is output. Therefore, it is possible to detect abnormal trends in the packaging device and identify packaging device malfunctions at an early stage. Furthermore, it can effectively remove potentially defective products from the production line.

[0038] Invention Effects

[0039] This invention provides a production management system that can detect abnormal trends in production line equipment constituting a production line and can detect malfunctions of the production line equipment at an early stage. Attached Figure Description

[0040] Figure 1This is a schematic structural diagram of a production management system according to one embodiment of the present invention.

[0041] Figure 2 This is a diagram showing an example of the operation of a production management system according to an embodiment of the present invention.

[0042] Figure 3 This is a diagram illustrating an example of the output of the production progress of the main computer in a production management system based on a variation of the present invention.

[0043] Figure 4 This is a diagram showing an example of the output of a production progress curve from the main computer of a production management system based on a variation of the present invention. Detailed Implementation

[0044] Hereinafter, the production management system according to the embodiments of the present invention will be described in detail with reference to the accompanying drawings.

[0045] exist Figure 1 In one embodiment of the present invention, the production management system 1 manages the production line, which receives raw materials such as food and beverages manufactured and processed in the upstream manufacturing process, collects and packages them into products in a predetermined weight in the metering and packaging process, and inspects the weight of the packaged products, foreign matter contamination, and packaging status in the inspection process.

[0046] The production line is configured to include a metering device 12, a packaging device 13, and an inspection device 14 that perform different processes. The metering device 12 and the packaging device 13 are also referred to as production line devices. Typically, the devices (12 to 14) are arranged in a series, and conveying mechanisms such as belt conveyors are arranged between the preceding and following processes of the production line and between the devices in each process.

[0047] In addition, such as Figure 1 As shown, the arrangement is not limited to the adjacent arrangement of the devices (12-14). For example, the metering device 12 and the packaging device 13 may be arranged adjacently in the raw material area where the raw materials are processed before packaging, and the inspection device 14 may be arranged adjacently in the product area where the products are processed after packaging. The two areas are connected by a conveying mechanism consisting of a belt conveyor and a chute.

[0048] The metering device 12 collects or combines the supplied raw materials in a manner that constitutes a predetermined weight and discharges them into the packaging device 13.

[0049] The metering device 12 may have a combined metering mechanism that temporarily stores the received raw materials in a storage container, distributes them into multiple metering containers in a specified amount, and performs combined calculations on the metering values ​​obtained from each metering container to discharge raw materials within a specified weight range.

[0050] The packaging device 13 uses packaging material to package a predetermined weight of raw materials discharged from the metering device 12 and discharges them to the inspection device 14. The packaging device 13 can, for example, detect the amount of packaging material used from the start of the production line to the present.

[0051] The inspection device 14 inspects the weight of the packaged products discharged from the packaging device 13 for foreign matter contamination, and discharges the packaged products that pass the inspection and are deemed to be qualified to the next process.

[0052] The main computer 16 consists of a computer unit equipped with a CPU (Central Processing Unit), RAM (Random Access Memory), ROM (Read Only Memory), hard disk drive, and input / output ports (not shown).

[0053] Measuring device 12, packaging device 13, inspection device 14, and main computer 16 are connected to network 17. Measuring device 12, packaging device 13, inspection device 14, and main computer 16 can communicate with each other via network 17.

[0054] The main computer 16 has pre-configured settings for each device in the production line, such as storing information related to other devices configured before and after a device in a corresponding relationship with the device's inherent ID.

[0055] exist Figure 1 In the example shown, the main computer 16 stores the following information: a metering device 12 is configured in the metering process, a packaging device 13 is configured in the packaging process, and an inspection device 14 is configured in the inspection process.

[0056] In addition, when there are multiple devices in any process and each of them can communicate with the host computer 16, it can be configured to allow each device to be configured in series or in parallel.

[0057] The main computer 16 receives inspection information such as processing results, inspection results, and action history sent from various devices on the production line via the network 17, and stores it on the hard disk device for management.

[0058] The operation history of the devices mentioned here is not limited to the start and stop of operation of each device. For example, it includes the detection of the storage quantity of the supplied raw materials in the metering device 12 and the zeroing process of the metering mechanism (not shown), the temperature stabilization waiting of the heat sealing section in the packaging device 13 and the replacement of the paper roll of the packaging material, and the inherent operation information of each device in the inspection device 14, such as the detection of the loading of items, the output of inspection results, the reset process of the inspection mechanism (not shown), and the stabilization waiting period. This information is sent to the main computer 16 as inspection information.

[0059] In addition, the inspection information is assigned a device-specific ID, which can be set as identification information used to identify which inspection information was sent from which device in the data.

[0060] Furthermore, the host computer 16 may have a receiving time information appending mechanism that appends the received time information as a timestamp when receiving inspection information sent from each device. Thus, even if the inspection information from any one device does not contain time information, time information at approximately the same point in time is recorded in the host computer 16, thereby preventing functional limitations imposed by the control software on the device side. Moreover, even if there are discrepancies in the times set for each device, the impact is minimal.

[0061] The metering device 12 and the packaging device 13 send information related to the processing results of each device, namely the processing result information, to the main computer 16.

[0062] Metering device 12 receives and measures raw materials supplied from upstream supply devices (not shown), etc., and combines them in a manner that falls within a specified weight range, or sends the discharge time and the combined weight as the combined discharge result to the main computer 16.

[0063] The packaging device 13 sends the packaging result, such as packaging OK (meaning normal packaging) or packaging NG (meaning non-normal packaging) and the time of packaging completion, to the main computer 16.

[0064] The inspection device 14 sends the inspection result information, which is related to the inspection results, to the host computer 16.

[0065] The inspection device 14 sends the inspection results, such as "OK" or "NG", the time of completion, and the weight of the inspected products, to the main computer 16. The inspection device 14 may include a distribution device 14a that excludes NG products and products that have been packaged as NG from the packaging device 13 from the production line, thereby enabling the efficient discharge of only normal products in subsequent processes.

[0066] In this embodiment, the host computer 16 detects devices that are "not in an abnormal state, but are close to an abnormal state, i.e., have an abnormal trend" based on the processing result information and inspection result information received from each device, and outputs an alarm. The alarm is output as a message to a display device (not shown) connected to the host computer 16.

[0067] For example, when the processing quantity differs between adjacent devices, the host computer 16 determines that the product is not being accurately delivered between its devices.

[0068] The main computer 16 continuously monitors the inspection results in the inspection device 14. For example, if the weight inspection results in the inspection device 14 show a trend of increasing weight (i.e., although a defective product has not yet been produced, the raw material yield is deteriorating), or if there is a trend of decreasing weight (i.e., although a defective product has not yet been produced, there is a possibility of producing a low-weight NG product), it is determined that there is an abnormal trend in the measurement of the metering device 12. Alternatively, the determination can be made based on the condition that the measurement results in the metering device 12 are stable near the target weight.

[0069] Furthermore, if there is a difference between the measurement result in the measuring device 12 and the inspection result in the inspection device 14, and the measurement result in the measuring device 12 is close to the target weight, then it can be identified that the scale of the measuring device 12 has an abnormal trend.

[0070] For example, if the deviation of the inspection result value in the inspection device 14 is large, the main computer 16 determines that there is an abnormal trend in the packaging in the packaging device 13. Alternatively, the determination can be made based on the condition that the measurement result in the measuring device 12 becomes stable near the target weight.

[0071] If the standard deviation of the weight detected by the inspection device 14 is greater than the specified value, and the measurement result in the measuring device 12 is within the specified range near the target weight, then it can be identified that there is an abnormal trend in the packaging device 13, such as biting or blockage in the forming mold.

[0072] Furthermore, by monitoring the trend of temperature and pressure drop in the heater of the packaging device 13, inspected items that have not yet reached the packaging defect stage and are being processed within the trend range can be excluded from the production line by the distribution device 14a within the subsequent inspection device 14, and the outflow of so-called potentially defective products can also be prevented. In this case, the packaging device 13 notifies the inspection device 14 of the information of the inspected items that need to be excluded from the production line. The packaging device 13 also sends trend monitoring information as processing result information to the main computer 16, and the main computer 16 outputs an alarm. Moreover, the distribution device 14a is not limited to being installed within the inspection device 14; it is self-evident that it can be installed independently of the inspection device 14. Furthermore, even production line devices other than the packaging device 13 can send the decline trend information of their own prescribed performance to the main computer 16 and the distribution device 14a, and perform the same processing.

[0073] In the host computer 16, for example, the current operating status can be displayed on a display device.

[0074] like Figure 2 As shown, the main computer 16 displays, for example, the production quantity, the number of qualified products, the number of defective products, the average value, the standard deviation, and the number of losses for each device from the start of production.

[0075] Production quantity refers to the quantity processed in each unit. Qualified quantity refers to the quantity of products processed in each unit and classified as qualified. Defective quantity refers to the quantity of products processed in each unit and classified as defective.

[0076] The average value is the average weight measured in measuring device 12 and inspection device 14. The standard deviation is the standard deviation of the weight measured in measuring device 12 and inspection device 14. The loss quantity is the value obtained by subtracting the production quantity in the adjacent upstream device from the production quantity in the current device.

[0077] For example, if the difference between the average value of the measuring device 12 and the average value of the inspection device 14 is above a specified threshold and the average value of the measuring device 12 is a small value, the main computer 16 displays a message: "The weighing value of the measuring device has a negative trend. Please check the scale."

[0078] For example, if the standard deviation of the inspection device 14 exceeds a specified threshold, the main computer 16 displays a message: "There is a possibility that the measured quantity cannot be accurately packaged due to blockage in the forming mold of the packaging device. Please check the forming mold section."

[0079] For example, if the number of losses in inspection device 14 exceeds a predetermined threshold, the main computer 16 displays a message: "Products cannot be accurately transported between the packaging device and the inspection device. Please check the transport path."

[0080] Thus, in the above embodiment, when an abnormal trend is detected in the metering device 12 or the packaging device 13 based on the inspection result information, the main computer 16 outputs an alarm.

[0081] Therefore, if an abnormal trend is detected in the metering device 12 or the packaging device 13 based on the inspection results, an alarm is output. Thus, it is possible to detect abnormal trends in the metering device 12 or the packaging device 13 and identify device malfunctions at an early stage.

[0082] Furthermore, when an abnormal trend is detected in the metering device 12 or the packaging device 13 based on the inspection results and processing results, the main computer 16 outputs an alarm.

[0083] Therefore, if an abnormal trend is detected in the metering device 12 or the packaging device 13 based on the inspection and processing results, an alarm is output. Thus, it is possible to detect abnormal trends in the metering device 12 or the packaging device 13 and identify device malfunctions at an early stage.

[0084] Furthermore, when the product weight defect information in the inspection results shows a trend of becoming defective due to excessive weight or a trend of becoming defective due to insufficient weight, the main computer 16 determines that the measuring device 12 has an abnormal trend.

[0085] Therefore, based on the inspection results, abnormal trends in the metering device 12 were detected, thus enabling early detection of device malfunctions.

[0086] Furthermore, if the standard deviation of the product weight in the inspection result information is greater than the specified value, and the weight in the processing result information of the measuring device 12 is within the specified range near the target weight, then the main computer 16 determines that there is an abnormal trend in the packaging device 13.

[0087] Therefore, based on the inspection and processing results, abnormal trends in the packaging device 13 were detected, thus enabling early detection of device malfunctions.

[0088] Furthermore, the packaging device 13 sends information on the decreasing trend of its own heater temperature and pressure as processing result information to the main computer 16, and sends information on products that are being processed in the range of the decreasing trend to the distribution device 14a located after its own device, so as to exclude the product from the production line. When an abnormal trend is detected in the packaging device 13 based on the processing result information, the main computer 16 outputs an alarm.

[0089] Therefore, it is possible to detect abnormal trends in the packaging device 13 and identify malfunctions in the packaging device 13 at an early stage. Moreover, it is possible to effectively remove potentially defective products from the production line.

[0090] [Variation Example]

[0091] Hereinafter, a production management system according to a modified example of the present invention will be described with reference to the accompanying drawings. This production management system uses the processing result information output by the production line device and the inspection result information output by the inspection device, and is further equipped with the function of being able to determine where the loss occurred in the production line, which was previously impossible to determine.

[0092] exist Figure 1 In the present invention, the production management system 1 according to the modified example of the present invention manages the production line, which receives raw materials such as food and beverages manufactured and processed in the upstream manufacturing process, collects and packages them into products in a specified weight in the metering and packaging process, and inspects the weight of the products, foreign matter contamination, and packaging status in the inspection process.

[0093] The production line is configured to include a metering device 12, a packaging device 13, and an inspection device 14 that perform different processes. Typically, these devices are arranged in a series, with conveyor mechanisms such as belt conveyors positioned between upstream and downstream processes and between devices within each process. The metering device 12 and the packaging device 13 are also referred to as production line equipment.

[0094] In addition, such as Figure 1 As shown, the arrangement is not limited to the adjacent arrangement of the devices (12-14). For example, the raw material supply device (not shown) to the packaging device 13 may be arranged adjacently in the raw material area where the raw materials are processed before packaging, and the inspection device 14 and the case packer (not shown) may be arranged adjacently in the product area where the products are processed after packaging. The two areas are connected by a conveying mechanism consisting of a belt conveyor and a chute.

[0095] The metering device 12 collects or combines the supplied raw materials in a manner that constitutes a predetermined weight and discharges them into the packaging device 13.

[0096] The metering device 12 may have a combined metering mechanism that temporarily stores the received raw materials in a storage container, distributes them into multiple metering containers in a specified amount, and performs combined calculations on the metering values ​​obtained from each metering container to discharge raw materials within a specified weight range.

[0097] The packaging device 13 uses packaging material to package a predetermined weight of raw materials discharged from the metering device 12 and discharges them to the inspection device 14. The packaging device 13 can, for example, detect the amount of packaging material used from the start of the production line to the present.

[0098] The inspection device 14 inspects the weight of the packaged products discharged from the packaging device 13 for foreign matter contamination, and discharges the packaged products that pass the inspection without any abnormalities and are determined to be qualified products.

[0099] The main computer 16 consists of a computer unit equipped with a CPU (Central Processing Unit), RAM (Random Access Memory), ROM (Read Only Memory), hard disk drive, and input / output ports (not shown).

[0100] Measuring device 12, packaging device 13, inspection device 14, and main computer 16 are connected to network 17. Measuring device 12, packaging device 13, inspection device 14, and main computer 16 can communicate with each other via network 17.

[0101] The host computer 16 has pre-configured the configurations of each device on the production line, and stores information related to other devices configured before and after a device in a corresponding association with the device's inherent ID.

[0102] exist Figure 1 In the example shown, the main computer 16 stores the following information: a metering device 12 is configured in the metering process, a packaging device 13 is configured in the packaging process, and an inspection device 14 is configured in the inspection process.

[0103] In addition, when there are multiple devices in any process and each of them can communicate with the host computer 16, it can be configured to allow each device to be configured in series or in parallel.

[0104] The main computer 16 receives inspection results, action history and other inspection information sent from each device on the production line via the network 17, and stores them on the hard disk device for management.

[0105] The operation history of the devices mentioned here is not limited to the start and stop of operation of each device. For example, it includes the detection of excessive or insufficient supply of raw materials from upstream processes in the supply device 11, the detection of the opening of the cover that accompanies the stop of operation, and the detection of the passage of raw materials discharged by the supply device; the detection of the storage of supplied raw materials in the metering device 12 and the zeroing process of the metering mechanism (not shown); the temperature stabilization waiting of the heat sealing section in the packaging device 13 and the replacement of the paper roll of packaging material; and the inherent operation information of each device, such as the detection of the loading of items in the inspection device 14, the output of inspection results, the reset process of the inspection mechanism (not shown), and the stabilization waiting period. These are sent to the main computer 16 as event data.

[0106] In addition, the event data is assigned a device-specific ID, which can be set as identification information to identify which event data was sent from which device.

[0107] Furthermore, the host computer 16 may have a receiving time information appending mechanism that appends the received time information as a timestamp when receiving event data sent from each device. Thus, even if the event data from any one device does not contain time information, time information at approximately the same time point is recorded in the host computer 16, thereby enabling it to be configured without being limited by the functionality of the control software on the device side. Moreover, even if there is a discrepancy in the time settings for each device, the impact is minimal.

[0108] Measuring device 12, packaging device 13 and inspection device 14 send information related to the processing results of each device, namely device result information (referring to processing result information and inspection result information), to main computer 16.

[0109] Measuring device 12 receives and measures the supplied raw materials, assembles them in a manner that falls within a specified weight range, or sends the assembly discharge result, including the discharge time and the weight of the assembly, as processing result information to host computer 16.

[0110] The packaging device 13 sends the packaging result information, including whether the packaging is OK (meaning normal packaging) or NG (meaning non-normal packaging), the time of completion of packaging, and the amount of packaging materials used, to the main computer 16 as the packaging result information.

[0111] The inspection device 14 sends the inspection result, including whether the inspection is OK or NG, the time of completion of the inspection, and the weight of the inspection result, to the main computer 16 as inspection result information. The inspection device 14 may include a distribution device (14a) to exclude products that are NG and products that have been packaged as NG from the packaging device 13 from the production line, thereby enabling only normal products to be effectively discharged to the subsequent case packer.

[0112] In this embodiment, the main computer 16 calculates the profit margin based on the device result information received from each device, and based on the raw material quantity and production plan quantity set before the start of production line operation, the deviation from the production plan quantity, and the occurrence of raw material or packaging material losses, and based on the cost price of raw materials and packaging materials and the shipment amount of the transaction amount, for example, displayed on a display device (not shown) of the main computer 16.

[0113] At this time, the main computer 16 converts the numerical value representing the amount of raw materials from the device result information received from each device into a common unit (e.g., kg).

[0114] Here, the loss of raw materials and packaging materials refers to the loss and waste of raw materials and packaging materials that did not become qualified products during the operation of the production line. This includes raw materials and packaging materials of products spilled during transportation between devices; raw materials and packaging materials of products determined to be defective in inspection device 14; and packaging materials that were not used in packaging device 13 due to adjustments, etc.

[0115] For example, the main computer 16, as the current production schedule, can... Figure 3 The image shown is displayed on the monitor device.

[0116] exist Figure 3 In this context, "raw materials" refers to the quality of the supplied raw materials, and "pre-planned production quantity" refers to the planned number of units to be produced from the raw materials.

[0117] "Metered production quantity" is the number of items combined and discharged in metering device 12, calculated from the combined discharge results of metering device 12. "Total mass" is the sum of the masses combined and discharged in metering device 12, calculated from the combined discharge results of metering device 12, that is, the total mass of raw materials actually collected and discharged in the metered value of raw materials measured in order to collect and combine them within a specified weight range.

[0118] In addition, the specified weight range used in the measuring device 12 is usually set in grams (g), but the "total mass" is converted in kilograms (kg).

[0119] "Packaging production quantity" refers to the number of packages discharged from packaging device 13, calculated from the packaging results of packaging device 13. "Packaging material usage amount" refers to the amount of packaging material used in packaging within packaging device 13 from the start of production line operation to the present, calculated from the packaging results of packaging device 13.

[0120] When the packaging result of the packaging device 13 does not include the amount of packaging material used for packaging, the amount of packaging material can be calculated by multiplying the number of packaged items by the amount of packaging material for each item, or by receiving a pulse signal corresponding to the feed amount of packaging material from the packaging device 13 and counting the number of pulses.

[0121] In addition, the amount of packaging material used in the packaging of each product is usually set in millimeters (mm), but the "amount of packaging material used" is converted in meters (m).

[0122] "Number of qualified products" is the number of products set as qualified products in the inspection device 14, calculated from the inspection results of the inspection device 14. "Total mass of qualified products" is the total mass of products set as qualified products in the inspection device 14, calculated from the inspection results of the inspection device 14, and is the sum of the measured values ​​used in over- or under-inspection.

[0123] "Number of Defective Products" is the number of products designated as defective in the inspection device 14, calculated from the inspection results of the inspection device 14. "Total Mass of Defective Products" is the total mass of products designated as defective in the inspection device 14, calculated from the inspection results of the inspection device 14, and is the sum of the measured values ​​used in over- or under-inspection.

[0124] In addition, the values ​​used in over- or under-inspection of each product are usually set in grams (g), but the "total mass of qualified products" is converted in kilograms (kg).

[0125] "Raw material loss" refers to the amount of raw materials lost since the production line started operating, indicating the status of raw material loss.

[0126] "Before metering" refers to the amount of raw materials lost between the supply device 11 and the metering device 12, calculated by subtracting "total mass" from "raw materials".

[0127] "Before inspection" refers to the amount of raw materials lost between the packaging device 13 and the inspection device 14, calculated by subtracting the "total mass of qualified products" and the "total mass of defective products" from the "total mass". In other words, "before inspection" is the amount of raw materials lost between the packaging device 13 and the inspection device 14.

[0128] "Inspection item" refers to the amount of raw material lost in the inspection device 14, which is the value of "total defective product mass".

[0129] "Raw material loss" is calculated by adding up all the losses "before measurement", "before inspection" and "inspection items".

[0130] "Packaging material loss" refers to the amount of raw materials lost since the production line started operating, indicating the status of packaging material loss.

[0131] "Inspection item" refers to the amount of packaging material lost in the inspection device 14, which is calculated by multiplying the "number of defective items" by the amount of packaging material used in one product, for example, 0.2m.

[0132] "Before inspection" is the amount of packaging material lost between the packaging device 13 and the inspection device 14, calculated by multiplying the value of "packaging production quantity" by the amount of packaging material used in one product. In other words, "before inspection" is the amount of packaging material lost between the packaging device 13 and the inspection device 14.

[0133] "Before packaging" refers to the amount of packaging material lost in the packaging device 13, which is calculated by subtracting the value of "packaging production quantity" multiplied by the amount of packaging material used in a product from "amount of packaging material used".

[0134] "Packing material loss" is calculated by adding up all losses: "before packaging materials", "before inspection" and "inspected items".

[0135] "Profit margin" is a preliminary estimate calculated based on the assumed shipment amount multiplied by the pre-set unit price information of the "quantity of qualified products"; the assumed original cost of raw materials and packaging materials used; and the assumed profit calculated based on the assumed expenses corresponding to the production line's operating time. The assumed original cost can be calculated based on the production plan or based on actual production performance corresponding to the production progress.

[0136] In addition to the “profit margin” shown in the diagram, information such as production progress rate stored in the main computer 16 can be combined, or project names and formulas can be set so that various indicators can be calculated using other information set for input, so that appropriate indicators in the measurement, packaging and inspection processes can be grasped according to the production progress.

[0137] As another indicator, the loss amount can be displayed as the profit that would have been obtained from the market price of the product that could not be shipped as a product due to "raw material loss". In this case, the loss amount per 1 kg of "raw material loss" is pre-calculated in the main computer 16 based on the amount of raw materials for each product and the average profit of each product.

[0138] The main computer 16, for example, calculates the current production progress results. When the values ​​of "raw material loss" and "packaging material loss" exceed the specified threshold or the profit margin is lower than the specified threshold, it can display an alarm message on the display device or change the display mode such as color to emphasize the display.

[0139] Furthermore, the main computer 16, for example, can serve as a current production progress curve, and can display, for example, Figure 4The image shown is displayed on the monitor device.

[0140] In this variation, "raw material loss" is expressed in kilograms (kg) and "packaging material loss" is expressed in meters (m). However, it can be converted to other quantities for the convenience of production management. For example, it can be converted to a value in "roles" by dividing the packaging material loss by the length of each roll and output.

[0141] In this modified example, if an inspection item other than over- or under-inspection is deemed NG in the inspection device 14, the weight value measured for over- or under-inspection can be used to calculate the "total defective product weight". However, in the inspection device 14, sometimes the weight cannot be measured for some reason.

[0142] As an example where the weight cannot be measured in the inspection device 14, the result may exceed the measurement range. In this case, the inspection result includes "OVF" (overflow) indicating that the upper limit of the measurement range has been exceeded. The main computer 16 replaces the "OVF" included in the inspection result with the maximum value of the measurement range of the pre-set inspection device 14, and then sums them into the "number of defective products" and "total mass of defective products," respectively. The difference from the actual weight is called error, but it is within the allowable range in terms of total raw material loss.

[0143] As another example of why the weight cannot be measured in inspection device 14, the so-called "two-load" situation can be cited. Two-load refers to two products being brought in at short intervals, making it impossible to accurately measure the weight of each. Such two-load situations will not be judged as non-compliant and transferred for re-inspection, therefore they do not match either the "number of qualified products" or the "number of defective products," and thus neither the "total weight of qualified products" nor the "total weight of defective products" can be calculated. Figure 3 The project uses "raw material loss" and "packaging material loss" as "before inspection" to represent the losses.

[0144] As described above, for exceptions whose weight cannot be determined in the inspection device 14, management rules can be set according to the regulations for each production line, and different processing based on the host computer 16 can be performed by the inspection device 14 based on the range that can be detected or identified according to the information contained in the inspection results. Thus, the functionality of the inspection device 14 can also be improved.

[0145] Furthermore, not limited to the inspection device 14, for exceptions generated in the metering device 12 and the packaging device 13, management rules can be set according to the regulations of each production line, and different processing based on the main computer 16 can be carried out within an identifiable range, thereby also being able to cope with the functional enhancement of the metering device 12 and the packaging device 13.

[0146] Regarding Figure 3 As shown in the output, the main computer 16 can add or omit items through operations from a keyboard (not shown) in a manner corresponding to the management rules specified for each production line.

[0147] Furthermore, regarding such Figure 3 The output shown indicates that the host computer 16 can change the display mode, such as color and layout, by operating the keyboard (not shown) to correspond to the configuration of the production line or to highlight the items that need to be managed.

[0148] Furthermore, the main computer 16 can aggregate progress information from multiple production lines onto a single screen for output. In this case, it can aggregate information such as... Figure 3 The output is set to output specific items from the items shown.

[0149] This makes it easy to identify an increase in packaging material usage or a decrease in production quantity and the number of qualified products.

[0150] Thus, in the above-described variation, the metering device 12, the packaging device 13, and the inspection device 14 send device result information containing the content set in their own devices to the main computer 16. Based on the received device result information, the main computer 16 outputs the loss status in the production line, in addition to detecting abnormal trends in the production line devices.

[0151] Therefore, based on the device result information from the metering device 12, packaging device 13, and inspection device 14, the status of losses occurring in the production line is output. Thus, it is possible to determine where losses occurred in the production line and to identify areas for improvement to reduce losses.

[0152] Furthermore, the metering device 12, the packaging device 13, and the inspection device 14 send information indicating the number of products processed by their respective devices as device result information to the main computer 16. The main computer 16 calculates the number of products lost between the devices based on the received device result information and outputs the result.

[0153] Therefore, based on the number of processed products from the metering device 12, packaging device 13, and inspection device 14, the number of products lost between the devices is calculated and output. Thus, it is possible to determine where the loss occurred in the production line and identify areas for improvement to reduce the loss.

[0154] Furthermore, when the number of product losses exceeds the specified threshold, the main computer 16 outputs an alarm.

[0155] Therefore, when the number of product losses exceeds a specified threshold, an alarm is triggered. This allows for early identification of situations where losses exceed the threshold, enabling improvements to be made to reduce losses.

[0156] Embodiments of the present invention have been disclosed, but it will be apparent to those skilled in the art that additional modifications can be made without departing from the scope of the invention. Of course, all such modifications and equivalents are included within the scope of this technical solution.

[0157] Symbol Explanation

[0158] 1-Production management system, 12-Metering device (production line device for metering process), 13-Packaging device (production line device for packaging process), 14-Inspection device (device for inspection process), 14a-Distribution device, 16-Main computer, 17-Network.

Claims

1. A production management system for managing production lines that produce products, the production management system comprising: Production line equipment; Inspection equipment, together with the production line equipment, constitutes the production line and is located downstream of the production line equipment; and The main computer is configured to communicate with the production line equipment and the inspection equipment. The inspection device sends its inspection results to the main computer. The production line device sends its processing results to the main computer. When the inspection result information and / or the processing result information satisfies a prescribed condition, the host computer determines that there is an abnormal trend in the production line device, and outputs an alarm, wherein, When the production line equipment exhibits an abnormal trend, the production line equipment is in a state close to an abnormal condition. The production line device includes a measuring device for measuring the weight of the product and a packaging device for packaging the product. If the standard deviation of the product weight in the inspection result information is greater than a specified value, and the weight in the processing result information from the measuring device is within a specified range near the target weight, then the main computer determines that the packaging device has an abnormal trend.

2. The production management system according to claim 1, wherein, When the weight of the product in the inspection results is undesirably too heavy or too light, the main computer determines that the measuring device has an abnormal trend.

3. The production management system according to claim 1, wherein, The packaging device sends information on the decreasing trend of its own heater temperature and / or pressure as a processing result to the main computer, and sends information on products processed within the range of this decreasing trend to a downstream distribution device to exclude those products from the production line. When the processing result information detects a downward trend that is an abnormal trend of the packaging device, the main computer outputs an alarm.

4. The production management system according to any one of claims 1-3, further comprising a display device, When an abnormal trend is determined to exist in the production line device, the host computer displays the abnormal trend in the display device.

5. The production management system according to claim 1, wherein, The host computer outputs the loss status in the production line based on the received processing result information and / or inspection result information, i.e., device result information.

6. The production management system according to claim 5, wherein, The production line device and / or the inspection device will send information indicating the number of products processed by their own devices as device result information to the main computer. The host computer calculates and outputs the number of products lost between multiple production line devices or the number of products lost between the production line device and the inspection device based on the received device result information.

7. The production management system according to claim 5, further comprising a display device, The host computer displays the loss status of the production line on the display device.

8. The production management system according to claim 6, wherein, When the number of products lost exceeds a specified threshold, the main computer outputs an alarm.

9. The production management system according to claim 8, further comprising a display device. The host computer will display the alarm message on the display device.

10. A production management system for managing production lines that produce products, the production management system comprising: Production line equipment, constituting the production line; and The host computer is configured to communicate with the production line equipment. The production line device includes a packaging unit that sends information on the decreasing trend of its own heater temperature and / or pressure as processing result information to the main computer. It also sends information on products processed within the decreasing trend range that have not yet reached the packaging defect stage to a downstream distribution unit, so as to exclude these products from the production line. When the falling trend as the abnormal trend of the packaging apparatus is detected based on the processing result information, the host computer outputs an alarm, wherein When the production line device exhibits an abnormal trend, it is in a state close to an abnormal condition.

11. The production management system according to claim 10, further comprising a display device, When an abnormal trend is determined to exist in the production line device, the host computer displays the abnormal trend in the display device.

12. A storage medium storing a production management program for a production management system, the production management system comprising a production line for producing products, a production line assembly, an inspection device constituting the production line together with the production line assembly and located downstream of the production line assembly, and a main computer configured to communicate with the production line assembly and the inspection device, wherein the inspection device sends its inspection result information to the main computer, and the production line assembly sends its processing result information to the main computer, the storage medium storing a production management program for enabling the main computer to perform the following functions: When the inspection result information and / or the processing result information satisfies a prescribed condition, it is determined that there is an abnormal trend in the production line device, and an alarm is output, wherein When the production line equipment exhibits an abnormal trend, the production line equipment is in a state close to an abnormal condition. The production line device includes a measuring device for measuring the weight of the product and a packaging device for packaging the product. If the standard deviation of the product weight in the inspection result information is greater than a specified value, and the weight in the processing result information from the measuring device is within a specified range near the target weight, then the main computer determines that the packaging device has an abnormal trend.

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