Bottleneck process acquisition method of production line, control device and readable storage medium

Abstract

The invention relates to the technical field of automatic production lines, particularly provides a bottleneck process acquisition method of a production line, a control device and a readable storage medium, and aims to solve the problem of how to more accurately acquire bottleneck processes on the production line. In order to achieve the purpose, the number of machines passing through a front station of each procedure in each time period on the production line is obtained, the difference value of the number of machines in each time period of the adjacent procedures is obtained according to the number of machines in the adjacent procedures, and the bottleneck procedure of the production line is obtained according to the difference value of the number of machines. Through the configuration mode, the bottleneck process is checked through the machine number difference value of the adjacent processes, the mutual influence between the processes is considered, and the bottleneck process is determined based on the machine number difference value of the adjacent processes, so that the basic bottleneck influencing the production line efficiency can be effectively checked, and the basic reason causing congestion can be found; therefore, the troubleshooting process is more efficient and accurate, and the production efficiency of a production line can be better improved.

Description

Technical Field

[0001] The present invention relates to the technical field of automated production lines, and specifically provides a method for obtaining a bottleneck process of a production line, a control device, and a readable storage medium. Background Art

[0002] Factory production lines generally deploy RFID devices based on process locations. RFID devices are used to monitor passing machines in real time and report monitoring data to the server. Production lines that use digital twin technology can display the movement of machines on the production line in real time on the twin screen based on the reported data, thereby achieving the purpose of digital twins.

[0003] In the process of production line, there are often bottleneck processes, which leads to reduced production efficiency. Therefore, how to identify the bottleneck process is the key to improving production efficiency.

[0004] In the prior art, the tact time of each process is generally calculated at different time periods, and then the average value is taken, and the process with the larger average value is regarded as the bottleneck process. This method often lacks consideration of the mutual influence of the processes before and after the production line. Similar to the situation of traffic jam, the long waiting time of the current process does not mean that the current process is the cause of the congestion.

[0005] Accordingly, the art needs a new solution for obtaining the bottleneck process of a production line to solve the above problems. Summary of the invention

[0006] In order to overcome the above-mentioned defects, the present invention is proposed to provide a solution or at least partially solve the problem of how to more accurately obtain the bottleneck process on the production line.

[0007] In a first aspect, the present invention provides a method for obtaining a bottleneck process of a production line, the method comprising:

[0008] Obtain the number of machines passing through the front station of each process in each time period on the production line;

[0009] According to the number of machines in the adjacent process, obtaining the difference in the number of machines in each time period of the adjacent process;

[0010] The bottleneck process of the production line is obtained according to the difference in the number of machines.

[0011] In a technical solution of the method for obtaining the bottleneck process of the production line, the step of obtaining the bottleneck process of the production line according to the machine quantity difference includes:

[0012] Obtaining the beat fluctuation of the front station of each process in each time period of the production line;

[0013] When there is a beat fluctuation in at least one time period that is greater than a preset first quantity threshold, the bottleneck process of the production line is obtained according to the machine quantity difference in the time period corresponding to the beat fluctuation;

[0014] When the beat fluctuation in each time period is less than or equal to the first quantity threshold, the bottleneck process of the production line is obtained according to the difference in the number of machines in all time periods.

[0015] In a technical solution of the method for obtaining the bottleneck process of the above production line, obtaining the bottleneck process of the production line according to the difference in the number of machines in the time period corresponding to the beat fluctuation includes:

[0016] Obtaining the bottleneck station of the production line according to the difference in the number of machines of all preceding stations in the time period corresponding to the beat fluctuation;

[0017] According to the bottleneck station, the bottleneck process of the production line is obtained.

[0018] In a technical solution of the method for obtaining the bottleneck process of the above production line, obtaining the bottleneck process of the production line according to the difference in the number of machines in all time periods includes:

[0019] Sum the differences in the number of machines in all time periods of each front-end station to obtain the total difference of each front-end station;

[0020] The front workstation whose total difference is greater than a preset second quantity threshold is used as the bottleneck workstation of the production line;

[0021] According to the bottleneck station, the bottleneck process of the production line is obtained.

[0022] In a technical solution of the method for obtaining the bottleneck process of the production line, the bottleneck process of the production line is obtained according to the bottleneck station, including:

[0023] Obtaining the correspondence between the front stations and processes of the production line;

[0024] The bottleneck process is acquired according to the corresponding relationship and the bottleneck workstation.

[0025] In a technical solution of the method for obtaining the bottleneck process of the above production line, an RFID device is provided at the front end of each process of the production line;

[0026] The method further comprises obtaining the beat fluctuation of the preceding workstation of each process according to the following steps:

[0027] According to the RFID equipment corresponding to each process, the process rhythm of each process in each time period is obtained;

[0028] According to the process rhythm of each process, the rhythm fluctuation of the preceding workstation of each process is obtained.

[0029] In a technical solution of the bottleneck process acquisition method of the above production line, the process rhythm of each process in each time period is acquired according to the RFID device corresponding to each process, including:

[0030] According to each of the RFID devices, obtaining the time of passing through the machine of each of the RFID devices;

[0031] The process rhythm of each process is obtained according to the time difference between two adjacent RFID devices passing through the same machine.

[0032] In a technical solution of the bottleneck process acquisition method of the above production line, the process beat of each process is acquired according to the time difference between two adjacent RFID devices passing through the same machine, including:

[0033] The process rhythm of each process is obtained according to the shift schedule of the production line and the time difference.

[0034] In a second aspect, a control device is provided, which includes at least one processor and at least one storage device, wherein the storage device is suitable for storing multiple program codes, and the program codes are suitable for being loaded and run by the processor to execute the bottleneck process acquisition method of the production line described in any one of the technical solutions of the bottleneck process acquisition method of the above-mentioned production line.

[0035] In a third aspect, a computer-readable storage medium is provided, which stores a plurality of program codes, wherein the program codes are suitable for being loaded and run by a processor to execute the bottleneck process acquisition method for a production line described in any one of the technical solutions of the bottleneck process acquisition method for the above-mentioned production line.

[0036] The above one or more technical solutions of the present invention have at least one or more of the following Beneficial effects:

[0037] In the technical solution of the present invention, the present invention obtains the number of machines passing through the front station of each process in each time period on the production line, obtains the difference in the number of machines in each time period of the adjacent processes according to the number of machines in the adjacent processes, and obtains the bottleneck process of the production line according to the difference in the number of machines. Through the above configuration, the present invention checks the bottleneck process by the difference in the number of machines in the adjacent processes, taking into account the mutual influence between the processes, and determining the bottleneck process based on the difference in the number of machines in the adjacent processes can effectively check out the fundamental bottleneck that affects the efficiency of the production line, find the root cause of the congestion, make the checking process more efficient and accurate, and facilitate to better improve the production efficiency of the production line. BRIEF DESCRIPTION OF THE DRAWINGS

[0038] The disclosure of the present invention will become more easily understood with reference to the accompanying drawings. It is easy for those skilled in the art to understand that these drawings are only for illustrative purposes and are not intended to limit the scope of protection of the present invention. Among them:

[0039] Figure 1 is a schematic flow chart of main steps of a method for obtaining a bottleneck process of a production line according to an embodiment of the present invention;

[0040] Figure 2 is a schematic diagram of beat fluctuation according to an example of an embodiment of the present invention;

[0041] Figure 3 4 is a schematic diagram of machine quantity difference according to an example of an embodiment of the present invention. DETAILED DESCRIPTION

[0042] Some embodiments of the present invention are described below with reference to the accompanying drawings. It should be understood by those skilled in the art that these embodiments are only used to explain the technical principles of the present invention and are not intended to limit the protection scope of the present invention.

[0043] In the description of the present invention, "module" and "processor" may include hardware, software or a combination of the two. A module may include hardware circuits, various suitable sensors, communication ports, and memories, and may also include software parts, such as program codes, or a combination of software and hardware. The processor may be a central processing unit, a microprocessor, an image processor, a digital signal processor, or any other suitable processor. The processor has data and / or signal processing functions. The processor may be implemented in software, hardware, or a combination of the two. Non-temporary computer-readable storage media include any suitable medium that can store program codes, such as a magnetic disk, a hard disk, an optical disk, a flash memory, a read-only memory, a random access memory, and the like. The term "A and / or B" means all possible combinations of A and B, such as only A, only B, or A and B. The term "at least one A or B" or "at least one of A and B" has a similar meaning to "A and / or B", and may include only A, only B, or A and B. The singular terms "one" and "the" may also include plural forms.

[0044] See attached Figure 1 , Figure 1 FIG. 1 is a flow chart showing the main steps of a method for obtaining a bottleneck process of a production line according to an embodiment of the present invention. Figure 1 As shown, the method for obtaining the bottleneck process of a production line in the embodiment of the present invention mainly includes the following steps S101 to S103.

[0045] Step S101: Obtain the number of machines passing through the front station of each process in each time period on the production line.

[0046] In this embodiment, the number of machines passing through the preceding station of each process in each time period on the production line can be obtained. Wherein, a process on the production line can correspond to one or more stations. The first station of each process can be used as the preceding station of the process.

[0047] In one implementation, the number of machines passing through the front station of each process in each time period may be obtained by means of data statistics.

[0048] In one implementation, the time period may be half an hour.

[0049] Step S102: According to the number of machines in adjacent processes, obtain the difference in the number of machines in each time period of adjacent processes.

[0050] In this embodiment, the difference in the number of machines at adjacent workstations in each time period may be obtained according to the number of machines at adjacent workstations.

[0051] In one implementation, the number of machines that have undergone adjacent processes in the same time period may be subtracted to obtain a machine number difference.

[0052] Step S103: Obtain the bottleneck process of the production line according to the difference in the number of machines.

[0053] In this embodiment, the bottleneck process of the production line can be determined according to the difference in the number of machines.

[0054] Based on the above steps S101 to S103, the embodiment of the present invention obtains the number of machines passing through the front station of each process in each time period on the production line, obtains the difference in the number of machines in each time period of the adjacent processes according to the number of machines in the adjacent processes, and obtains the bottleneck process of the production line according to the difference in the number of machines. Through the above configuration, the embodiment of the present invention checks the bottleneck process by the difference in the number of machines in the adjacent processes, taking into account the mutual influence between the processes, and determining the bottleneck process based on the difference in the number of machines in the adjacent processes can effectively check out the fundamental bottleneck that affects the efficiency of the production line, find the root cause of the congestion, make the checking process more efficient and accurate, and facilitate better improvement of the production efficiency of the production line.

[0055] The step S103 is further described below.

[0056] In one implementation of the embodiment of the present invention, step S103 may further include the following steps S1031 to S1033:

[0057] Step S1031: Obtain the beat fluctuation of the preceding workstation of each process in each time period of the production line.

[0058] In this embodiment, the beat fluctuation of the preceding workstation of each process in each time period on the production line can be obtained, wherein the beat fluctuation is the change of the beat of the process in the current time period compared with the previous time period.

[0059] In one embodiment, each process of the production line is provided with an RFID (Radio Frequency Identification) device at the front end, and the beat fluctuation can be obtained according to the following steps S201 and S202:

[0060] Step S201: According to the RFID device corresponding to each process, the process rhythm of each process in each time period is obtained.

[0061] In this embodiment, step S201 may further include step S2011 and step S2012:

[0062] Step S2011: According to each RFID device, the time of the machine passing through each RFID device is obtained.

[0063] Step S2012: Obtain the process rhythm of each process based on the time difference between two adjacent RFID devices passing through the same machine.

[0064] In this embodiment, a device relationship between a process and an RFID device can be established, and the RFID device can be used to collect statistics on the data of the machines passing through it. The time difference of the same machine passing through adjacent RFID devices is calculated as the beat of each machine, so that the process beat can be calculated more accurately, avoiding the problem of inaccurate time difference scanned by the RFID device before and after the machine passes due to the difficulty in determining the boundary of the RFID device scanning area.

[0065] In one implementation, the process rhythm of each process may be obtained based on the production line's shift schedule and time difference.

[0066] In this embodiment, according to the shift schedule of the production line, abnormal data such as rest time in the calculated time difference can be removed to obtain a more accurate process rhythm.

[0067] Step S202: According to the process rhythm of each process, the rhythm fluctuation of the preceding workstation of each process is obtained.

[0068] In this embodiment, the beat fluctuation of the preceding workstation of each process can be obtained according to the process beat of each process.

[0069] In one implementation, the beat fluctuation can be obtained by calculating the mean and variance according to the process beat of each process.

[0070] Step S1032: When there is at least one time period in which the beat fluctuation is greater than a preset first quantity threshold, the bottleneck process of the production line is obtained according to the difference in the number of machines in the time period corresponding to the beat fluctuation.

[0071] In this embodiment, if there is a time period with large beat fluctuations, the bottleneck process of the production line can be determined according to the difference in the number of machines in the corresponding time period. Those skilled in the art can set the value of the first quantity threshold according to the needs of actual applications.

[0072] In one implementation, step S1032 may further include the following steps S10321 and S10322:

[0073] Step S10321: Obtain the bottleneck station of the production line according to the difference in the number of machines of all the preceding stations in the time period corresponding to the beat fluctuation.

[0074] Step S10322: Obtain the bottleneck process of the production line according to the bottleneck station.

[0075] In this embodiment, the preceding workstations with a large machine quantity difference (such as greater than a preset third quantity threshold) in the period of large beat fluctuation can be used as bottleneck workstations, and the bottleneck process is obtained according to the corresponding relationship between the workstations and the processes. Those skilled in the art can set the value of the third quantity threshold according to the needs of actual applications.

[0076] Step S1033: When the beat fluctuation in each time period is less than or equal to the first quantity threshold, the bottleneck process of the production line is obtained according to the difference in the number of machines in all time periods.

[0077] In this embodiment, if the beat fluctuation in each time period is small (less than the first quantity threshold), the bottleneck process can be obtained by total screening, that is, the difference in the number of machines in all time periods is counted to obtain the bottleneck process of the production line.

[0078] In one implementation, step S1033 may include the following steps S10331 to S10333:

[0079] Step S10331: sum up the differences in the number of machines in all time periods of each front station to obtain the total difference of each front station.

[0080] Step S10332: The front workstation whose total difference is greater than a preset second quantity threshold is regarded as the bottleneck workstation of the production line.

[0081] Step S10333: Obtain the bottleneck process of the production line according to the bottleneck station.

[0082] In this embodiment, the machine quantity differences of each front-end workstation in all time periods can be summed up to obtain the total difference of each front-end workstation, and the total difference can be compared with the second quantity threshold. If it is greater than the second quantity threshold, the front-end workstation can be considered as a bottleneck workstation, and the bottleneck process of the production line can be obtained based on the correspondence between the process and the workstation.

[0083] In one implementation, the machine data of the machines on the production line acquired by the RFID device can be reported to the server in real time, so that the movement of the machines on the production line can be displayed in real time through the digital twin large screen, thereby achieving the purpose of the digital twin.

[0084] As an example, as shown in Table 1, the number of machines, average cycle time and machine number difference of the preceding station of each process can be counted. The station number in the table is the preceding station of the process.

[0085] Table 1 Process Statistics Workstation No. time Number of machines Average beat Machine quantity difference 14 2023 / 5 / 106:00 70 25.33 0 18 2023 / 5 / 106:00 70 25.33 0 19 2023 / 5 / 106:00 70 25.3 0 20 2023 / 5 / 106:00 70 25.31 0 14 2023 / 5 / 106:30 68 26.31 0 18 2023 / 5 / 106:30 68 26.31 0 19 2023 / 5 / 106:30 68 26.46 1 20 2023 / 5 / 106:30 69 26 0

[0086] For example, the difference in the number of machines at station number 14 is the difference between the number of machines at station number 18 and the number of machines at station number 14. The larger the difference in the number of machines, the slower the current station and the faster the next station.

[0087] See attached Figure 2 , Figure 2 FIG. 1 is a schematic diagram of a beat fluctuation according to an example of an embodiment of the present invention. Figure 2 As shown, the beat fluctuation of each preceding workstation can be calculated, thereby obtaining the time period with large beat fluctuation.

[0088] See attached Figure 3 , Figure 3 FIG. 1 is a schematic diagram of machine quantity difference according to an example of an embodiment of the present invention. Figure 3 As shown in the figure, the difference in the number of machines in all time periods of each front station can be counted. When there is a time period with large beat fluctuations, Figure 3 , find the front station with the largest machine quantity difference in the corresponding time period to obtain the bottleneck station, and then obtain the bottleneck process based on the bottleneck station. If the beat fluctuations throughout the day are very small, you can apply the total investigation method, that is, obtain the sum of the machine quantity differences of each front station throughout the day, and determine the bottleneck process based on the sum of the machine quantity differences throughout the day.

[0089] It should be pointed out that although the various steps in the above embodiments are described in a specific order, those skilled in the art can understand that in order to achieve the effects of the present invention, different steps do not have to be performed in such an order. They can be performed simultaneously (in parallel) or in other orders. These changes are within the scope of protection of the present invention.

[0090] It is understood by those skilled in the art that the present invention implements all or part of the processes in the method of the above embodiment, and can also be completed by instructing the relevant hardware through a computer program, and the computer program can be stored in a computer-readable storage medium, and the computer program can implement the steps of the above-mentioned various method embodiments when executed by the processor. Among them, the computer program includes computer program code, and the computer program code can be in source code form, object code form, executable file or some intermediate form. The computer-readable storage medium may include: any entity or device, medium, U disk, mobile hard disk, disk, optical disk, computer memory, read-only memory, random access memory, electric carrier signal, telecommunication signal and software distribution medium that can carry the computer program code. It should be noted that the content contained in the computer-readable storage medium can be appropriately increased or decreased according to the requirements of legislation and patent practice in the jurisdiction. For example, in some jurisdictions, according to legislation and patent practice, computer-readable storage media do not include electric carrier signals and telecommunication signals.

[0091] Furthermore, the present invention also provides a control device. In an embodiment of a control device according to the present invention, the control device includes a processor and a storage device, the storage device can be configured to store a program for executing the bottleneck process acquisition method of the production line of the above method embodiment, and the processor can be configured to execute the program in the storage device, which includes but is not limited to the program for executing the bottleneck process acquisition method of the production line of the above method embodiment. For ease of explanation, only the parts related to the embodiment of the present invention are shown. For specific technical details not disclosed, please refer to the method part of the embodiment of the present invention. The control device can be a control device device formed by various electronic devices.

[0092] In the embodiment of the present invention, the control device may be a control device device formed by various electronic devices. In some possible implementations, the control device may include multiple storage devices and multiple processors. The program for executing the bottleneck process acquisition method of the production line of the above method embodiment can be divided into multiple subprograms, and each subprogram can be loaded and run by the processor to execute different steps of the bottleneck process acquisition method of the production line of the above method embodiment. Specifically, each subprogram can be stored in different storage devices, and each processor can be configured to execute the program in one or more storage devices to jointly implement the bottleneck process acquisition method of the production line of the above method embodiment, that is, each processor executes different steps of the bottleneck process acquisition method of the production line of the above method embodiment to jointly implement the bottleneck process acquisition method of the production line of the above method embodiment.

[0093] The above-mentioned multiple processors may be processors deployed on the same device. For example, the above-mentioned control device may be a high-performance device composed of multiple processors, and the above-mentioned multiple processors may be processors configured on the high-performance device. In addition, the above-mentioned multiple processors may also be processors deployed on different devices. For example, the above-mentioned control device may be a server cluster, and the above-mentioned multiple processors may be processors on different servers in the server cluster.

[0094] Furthermore, the present invention also provides a computer-readable storage medium. In a computer-readable storage medium embodiment according to the present invention, the computer-readable storage medium can be configured to store a program for executing the bottleneck process acquisition method of the production line of the above method embodiment, and the program can be loaded and run by the processor to implement the bottleneck process acquisition method of the above production line. For ease of explanation, only the parts related to the embodiment of the present invention are shown. For specific technical details not disclosed, please refer to the method part of the embodiment of the present invention. The computer-readable storage medium can be a storage device formed by various electronic devices. Optionally, the computer-readable storage medium in the embodiment of the present invention is a non-temporary computer-readable storage medium.

[0095] Further, it should be understood that since the setting of each module is only for illustrating the functional units of the device of the present invention, the physical devices corresponding to these modules may be the processor itself, or a part of the software in the processor, a part of the hardware, or a part of the combination of software and hardware. Therefore, the number of each module in the figure is only schematic.

[0096] Those skilled in the art will appreciate that the modules in the device can be adaptively split or merged. Such splitting or merging of specific modules will not cause the technical solution to deviate from the principle of the present invention, and therefore, the technical solutions after splitting or merging will fall within the protection scope of the present invention.

[0097] So far, the technical solutions of the present invention have been described in conjunction with the preferred embodiments shown in the accompanying drawings. However, it is easy for those skilled in the art to understand that the protection scope of the present invention is obviously not limited to these specific embodiments. Without departing from the principle of the present invention, those skilled in the art can make equivalent changes or substitutions to the relevant technical features, and the technical solutions after these changes or substitutions will fall within the protection scope of the present invention.

Claims

1. A method for obtaining the bottleneck process of a production line, characterized in that: The method comprises: Obtain the number of machines passing through the front station of each process in each time period on the production line; According to the number of machines in the adjacent process, obtaining the difference in the number of machines in each time period of the adjacent process; The bottleneck process of the production line is obtained according to the difference in the number of machines.

2. The method for obtaining the bottleneck process of a production line according to claim 1, characterized in that: The step of obtaining the bottleneck process of the production line according to the machine quantity difference comprises: Obtaining the beat fluctuation of the front station of each process in each time period of the production line; When there is a beat fluctuation in at least one time period that is greater than a preset first quantity threshold, the bottleneck process of the production line is obtained according to the machine quantity difference in the time period corresponding to the beat fluctuation; When the beat fluctuation in each time period is less than or equal to the first quantity threshold, the bottleneck process of the production line is obtained according to the difference in the number of machines in all time periods.

3. The method for obtaining the bottleneck process of a production line according to claim 2, characterized in that: The step of obtaining the bottleneck process of the production line according to the difference in the number of machines in the time period corresponding to the beat fluctuation includes: Obtaining the bottleneck station of the production line according to the difference in the number of machines of all preceding stations in the time period corresponding to the beat fluctuation; According to the bottleneck station, the bottleneck process of the production line is obtained.

4. The method for obtaining the bottleneck process of a production line according to claim 2, characterized in that: The step of obtaining the bottleneck process of the production line according to the machine quantity difference in all time periods includes: Sum the differences in the number of machines in all time periods of each front-end station to obtain the total difference of each front-end station; The front workstation whose total difference is greater than a preset second quantity threshold is used as the bottleneck workstation of the production line; According to the bottleneck station, the bottleneck process of the production line is obtained.

5. The method for obtaining the bottleneck process of a production line according to claim 3 or 4, characterized in that: The step of obtaining the bottleneck process of the production line according to the bottleneck station includes: Obtaining the correspondence between the front stations and processes of the production line; The bottleneck process is acquired according to the corresponding relationship and the bottleneck workstation.

6. The method for obtaining the bottleneck process of a production line according to claim 2, characterized in that: Each process front end of the production line is equipped with RFID equipment; The method further comprises obtaining the beat fluctuation of the preceding workstation of each process according to the following steps: According to the RFID equipment corresponding to each process, the process rhythm of each process in each time period is obtained; According to the process rhythm of each process, the rhythm fluctuation of the preceding workstation of each process is obtained.

7. The method for obtaining the bottleneck process of a production line according to claim 6, characterized in that: The step of obtaining the process rhythm of each process in each time period according to the RFID device corresponding to each process includes: According to each of the RFID devices, obtaining the time of passing through the machine of each of the RFID devices; The process rhythm of each process is obtained according to the time difference between two adjacent RFID devices passing through the same machine.

8. The method for obtaining the bottleneck process of a production line according to claim 7, characterized in that: The step of obtaining the process beat of each process according to the time difference between two adjacent RFID devices passing through the same machine includes: The process rhythm of each process is obtained according to the shift schedule of the production line and the time difference.

9. A control device, comprising at least one processor and at least one storage device, wherein the storage device is suitable for storing a plurality of program codes, characterized in that: The program code is suitable for being loaded and run by the processor to execute the bottleneck process acquisition method of the production line according to any one of claims 1 to 8.

10. A computer-readable storage medium storing a plurality of program codes, characterized in that: The program code is suitable for being loaded and run by a processor to execute the bottleneck process acquisition method for a production line according to any one of claims 1 to 8.

Images