Method for calculating target unit consumption value of rolling and packing workshop and method for carrying out real-time monitoring by utilizing target unit consumption value

Abstract

The invention relates to a calculation method for calculating a target unit consumption value of a rolling and packing workshop and a method for performing real-time monitoring by using the calculation method, and belongs to the technical field of rolling and packing workshop production process monitoring. According to the method, the yield and consumption data of the unit in the production process are recorded in real time, the target unit consumption value is adopted to carry out real-time quantitative index evaluation on the yield and consumption data, the evaluation result is pushed to an operator and a production manager in real time, and when the evaluation result exceeds the early warning range, alarm information can be sent in real time, so that the production efficiency is improved. A basis is provided for operators to adjust equipment parameters in real time, and the corresponding equipment parameters are adjusted, so that the lean production level of the whole equipment is improved.

Description

Technical Field

[0001] The present invention relates to the technical field of production process monitoring and control in a wrapping workshop, in particular to a method for calculating a target unit consumption value and a method for real-time monitoring using the same. Background Art

[0002] Real-time statistical analysis of production consumption by each unit in the wrapping workshop is a routine operation during the wrapping process. Real-time production and consumption analysis and alarms can alert operators and provide feedback on equipment control and parameter adjustments, thereby improving quality and reducing consumption. However, due to the existence of units with varying production efficiencies, producing different products, operated by different personnel, and varying equipment maintenance status, it is difficult to conduct a horizontal comparative analysis of actual production and consumption across units, nor is it easy to conduct a unified quantitative analysis and evaluation of the operators of each unit. Furthermore, production and consumption analysis is typically performed after production is completed, without the support of real-time production and consumption statistical analysis methods, and thus cannot provide useful feedback and alarms to operators during the production process. Summary of the Invention

[0003] The technical problem to be solved by the present invention is to address the shortcomings of the existing technology and propose a method for calculating the target unit consumption value and a method for real-time monitoring using the same. By real-time recording of the output and consumption data of the unit during the production process, the target unit consumption value is used to perform real-time quantitative unified indicator evaluation on the output and consumption data of all units within the entire workshop. When the actual output-consumption ratio is greater than the target unit consumption value, it is pushed to the operator and production management personnel in real time, providing a basis for the operator to adjust the equipment parameters in real time.

[0004] To solve the above technical problems, the present invention proposes a method for calculating a target unit consumption value and a method for real-time monitoring using the same. The method for calculating the target unit consumption value is as follows: Step 1: Determine the weight value of each unit: Count the output and consumption of all production units in the wrapping workshop and the actual output-consumption ratio R of similar products produced in the last three months, and count the actual output-consumption ratio of all batches of similar products produced within three months.

[0005] The use of data from the last three months is based on experience in production process data statistics. Generally, production and consumption statistics within the last three months can ensure relatively stable statistical results even with a small amount of abnormal consumption.

[0006] Classify similar units according to their production efficiency, service life, and equipment maintenance status, and thus derive the model weight value A, service life weight value B, and maintenance status weight value C: Determine the model weight value A of each unit: take the average output-consumption ratio of similar models as the model standard value, the standard weight value = 1. When the average output-consumption ratio of a unit is lower than 10% of the standard value of the output-consumption ratio of similar models, A = model standard weight value - 0.1 = 0.9; when the average output-consumption ratio of a unit is higher than 10% of the standard value, A = model standard weight value + 0.1 = 1.1.

[0007] The addition or subtraction of 0.1 to the standard weight value is based on the inventor's long-term experience and statistical data from production line work. The average output-to-consumption ratio for similar models is calculated by analyzing the output and consumption data of similar models over the past three months. The standard value for each model has a small dynamic range and is relatively stable.

[0008] Determine the service life weight, B, for each unit: The average output-to-consumption ratio for units with the same service life (over 3 years, less than 5 years) is used as the standard service life value. The standard service life weight is 1. When the standard service life value is less than 3 years, B = the standard service life weight - 0.05 = 0.95; when the standard service life value is more than 3 years, B = the standard service life weight + 0.05 = 1.05. In a wrapping production workshop, wrapping equipment typically has a service life of around 20 years, with a maintenance cycle every five years. The average output-to-consumption ratio over a five-year period objectively reflects the service life of the wrapping equipment. The addition or subtraction of 0.05 to the standard service life weight is based on statistical experience and data from the inventor's long-term experience in production lines.

[0009] The number of repairs for similar models is used as the standard value for maintenance, with a standard weight value of 1. When the unit has undergone more than one medium repair or less than three major repairs, C = standard weight value + 0.05 = 1.05; when the unit has undergone three or more major repairs, C = standard weight value + 0.1 = 1.1; when the standard value for maintenance is 10% higher than the standard value, C = standard weight value - 0.05 = 0.95; when the standard value for maintenance is 10% lower than the standard value, C = standard weight value + 0.05 = 1.05. The addition or subtraction of 0.05 to the standard weight value is the result of the inventor's long-term work on the production line and statistical experience. This indicator only determines whether the unit has undergone major repairs or medium repairs, and general minor repairs are not included. Medium repairs and major repairs are only carried out when the unit has a more serious equipment failure, and are not common.

[0010] Step 2: Determine the target unit consumption value of the unit: Based on A, B, and C obtained in step 1, further calculate the target unit consumption value of the unit: U=AT*(A+B+C). Among them, U is the target unit consumption value of the unit, AT is the average target unit consumption value of similar units, A is the weight value of the model, B is the weight value of the service life, and C is the weight value of the maintenance status; Step 3: Determine the product weight: The average output-to-consumption ratio of different products produced by the same machine model is used as the target unit consumption standard value. The standard weight value for a single product is 1. When the output-to-consumption ratio of the corresponding product produced by this machine model is less than 10% of the standard value for the single product, D = standard weight value - 0.05 = 0.95, where D is the product weight value. When the output-to-consumption ratio is more than 10% of the standard value, D = standard weight value + 0.05 = 1.05, where D is the product weight value. The addition or subtraction of 0.05 to the standard weight value is based on the inventor's long-term experience and statistical data from production line work.

[0011] The average output-consumption ratio of different products produced by the same model is calculated by collecting the output-consumption data of the same product produced by the same model in the last three months.

[0012] Step 4: Determine the target unit consumption value of the product: further calculate the target unit consumption value of the product based on D obtained in step 3: P=SP*D, Among them, P is the target unit consumption value of the product, SP is the target unit consumption standard value of the product, and D is the product weight value; Step 5: Determine the target unit consumption value for the wrapping workshop: Based on the U and P values ​​obtained in Steps 2 and 4, further calculate the target unit consumption value for the wrapping workshop: T = U + P + 0.1R. Multiplying the output-consumption ratio by 0.1 is a statistical calculation based on empirical data from the inventor's long-term experience working on the production line.

[0013] Among them, T is the target unit consumption value of the wrapping workshop, U is the target unit consumption value of the unit, P is the target unit consumption value of the product, and R is the statistical production-consumption ratio for 3 months.

[0014] A method for real-time monitoring of the unit using the target unit consumption value obtained above, presetting the target unit consumption value of the wrapping workshop, and recording the output and consumption data of the unit during the production process in real time. When the actual output-consumption ratio is greater than 20% of the target unit consumption value of the wrapping workshop (the warning range can be adjusted according to actual needs), an alarm message is sent and a statistical analysis report is generated.

[0015] Because production and consumption vary across units with different production efficiencies, products, personnel, and equipment status, it's difficult to conduct a unified quantitative analysis and evaluation of production and consumption across each unit. This technology uses target unit consumption as the basis for a unified evaluation of each unit, enabling a unified quantitative analysis of production and consumption across units, personnel, and products.

[0016] The present invention records the output and consumption data of the unit in the production process in real time, uses the target unit consumption value to perform real-time quantitative index evaluation on the output and consumption data, and pushes the evaluation results to operators and production managers in real time. When the warning range is exceeded, an alarm message can be sent in real time, providing a basis for operators to adjust the equipment parameters in real time, and adjust the corresponding equipment parameters, thereby improving the overall lean production level of the equipment. DETAILED DESCRIPTION

[0017] The specific embodiments of the present invention are described in further detail below. The technologies or products not specified in the examples are all existing technologies or conventional products that can be purchased.

[0018] Example 1: The method for calculating the target unit consumption value of the roll workshop is as follows: Step 1, determine the unit weight value: statistics are collected on the production and consumption of all production units in the wrapping workshop and the actual production and consumption ratio R of similar products produced in the past three months. The actual production and consumption ratio of the ZJ17 model in the production of Furong King (hard) in the past three months is also counted. The use of data from the past three months is based on the experience of production process data statistics. Generally, the production and consumption statistics in the past three months can ensure that the statistical results are relatively stable even with a small amount of abnormal consumption. Classify similar units according to their production efficiency, service life, and equipment maintenance status, and thus derive the model weight value A, service life weight value B, and maintenance status weight value C respectively: The average output-to-consumption ratio of the 52JJ01 unit is 0.75 (this value is obtained through statistical calculation, total waste smoke volume kg / total output kg). It has been in use for 4 years with no major maintenance record.

[0019] The average output-consumption ratio of the ZJ17 model is 0.75 (this value is obtained through statistical calculation, total waste smoke volume kg / total output kg), which is taken as the standard value of the model, and the standard weight value = 1.

[0020] The average output-to-consumption ratio of the ZJ17 model after 5 years of use is 0.75 (this value is obtained through statistical calculation, total waste smoke volume kg / total output kg), which is taken as the standard value of the service life, and the standard weight value = 1.

[0021] The number of repairs for 52JJ01 is set to 0 (actual number of repairs counted), which is counted as the standard value for repair and maintenance, and the standard weight value = 1.

[0022] Step 2: Determine the target unit consumption value of 52JJ01 unit: Based on A, B, and C obtained in step 1, further calculate the target unit consumption value of the unit: U = AT* (A + B + C) = AT* (1 + 1 + 1) = 0.75*3 = 2.25 Among them, U is the target unit consumption value of the unit, AT is the average target unit consumption value of similar units, A is the weight value of the model, B is the weight value of the service life, and C is the weight value of the maintenance status; Step 3, determine the product weight value: take the average output-consumption ratio of Furongwang (hard) products produced by ZJ17 unit as 0.7810, which is calculated as the product target unit consumption standard value, and the standard weight value = 1.

[0023] Step 4, determine the target unit consumption value of the product: further calculate the target unit consumption value of the product based on D obtained in step 3: P=SP*D=0.7810*1=0.7810.

[0024] Among them, P is the target unit consumption value of the product, SP is the target unit consumption standard value of the product, and D is the product weight value; Step 5, determine the target unit consumption value of the wrapping workshop: further calculate the target unit consumption value of the wrapping workshop based on U and P obtained in steps 2 and 4: T=U+P+0.1R=2.25+0.7810+0.1*0.75=3.106 Among them, T is the target unit consumption value of the wrapping workshop, U is the target unit consumption value of the unit, P is the target unit consumption value of the product, and R is the statistical production-consumption ratio for 3 months.

[0025] The target unit consumption value is used for real-time monitoring of the unit. The target unit consumption value is preset, and the output and consumption data of the unit during the production process are recorded in real time. When the actual output-consumption ratio is greater than 20% of the target unit consumption value, an alarm message is sent and a statistical analysis report is generated.

[0026] Example 2: The method for calculating the target unit consumption value of the roll workshop is as follows: Step 1, determine the unit weight value: statistically analyze the production and consumption of all production units in the wrapping workshop and the actual production and consumption ratio R of similar products produced in the past three months, and calculate the actual production and consumption ratio of the ZJ19 model in the production of Furong King (hard) within three months. The use of data from the past three months is based on the experience of production process data statistics. Generally, the production and consumption statistics in the past three months can ensure that the statistical results are relatively stable even with a small amount of abnormal consumption. Classify similar units according to their production efficiency, service life, and equipment maintenance status, and thus derive the model weight value A, service life weight value B, and maintenance status weight value C respectively: The average output-to-consumption ratio of the 52JJ16 unit is 0.76 (this value is obtained through statistical calculation, total waste smoke volume kg / total output kg). It has been in use for 8 years with no major maintenance record.

[0027] The average output-consumption ratio of the ZJ19 model is 0.70 (this value is obtained through statistical calculation, total waste smoke volume kg / total output kg), which is taken as the standard value of the model, and the standard weight value = 1.

[0028] The average output-to-consumption ratio of the ZJ19 model over five years of use is 0.70 (this value is calculated statistically: total waste smoke (kg) / total output (kg). This is used as the standard value for the service life, with a standard weight of 1. For this model, which has been in use for eight years, the weight is 1.05.

[0029] The number of repairs of 52JJ16 is set as 0 (actual number of repairs counted), which is counted as the standard value of maintenance, and the standard weight value = 1.

[0030] Step 2: Determine the target unit power consumption of the 52JJ10 unit: Based on A, B, and C obtained in step 1, further calculate the target unit power consumption of the unit: U = AT* (A + B + C) = AT* (1 + 1.05 + 1) = 0.76*3 = 2.318 Among them, U is the target unit consumption value of the unit, AT is the average target unit consumption value of similar units, A is the weight value of the model, B is the weight value of the service life, and C is the weight value of the maintenance status; Step 3, determine the product weight value: take the average output-consumption ratio of Furongwang (hard) products produced by ZJ19 unit as 0.70, which is calculated as the product target unit consumption standard value, and the standard weight value = 1.

[0031] Step 4: Determine the target unit consumption value of the product: Further calculate the target unit consumption value of the product based on D obtained in step 3: P=SP*D=0.70*1=0.70 Among them, P is the target unit consumption value of the product, SP is the target unit consumption standard value of the product, and D is the product weight value; Step 5, determine the target unit consumption value of the wrapping workshop: further calculate the target unit consumption value of the wrapping workshop based on U and P obtained in steps 2 and 4: T=U+P+0.1R=2.318+0.70+0.1*0.7=3.088 Among them, T is the target unit consumption value of the wrapping workshop, U is the target unit consumption value of the unit, P is the target unit consumption value of the product, and R is the statistical production-consumption ratio for 3 months.

[0032] The target unit consumption value is used for real-time monitoring of the unit. The target unit consumption value is preset, and the output and consumption data of the unit during the production process are recorded in real time. When the actual output-consumption ratio is greater than 20% of the target unit consumption value, an alarm message is sent and a statistical analysis report is generated.

[0033] Example 3: The method for calculating the target unit consumption value of the coil workshop is as follows: Step 1, determine the unit weight value: statistically analyze the production and consumption of all production units in the wrapping workshop and the actual production and consumption ratio R of similar products produced in the past three months, and calculate the actual production and consumption ratio of ZJ19 in the production of Furongwang (hard) in three months. The use of data from the past three months is based on the experience of production process data statistics. Generally, the production and consumption statistics in the past three months can ensure that the statistical results are relatively stable even with a small amount of abnormal consumption. Classify similar units according to their production efficiency, service life, and equipment maintenance status, and thus derive the model weight value A, service life weight value B, and maintenance status weight value C respectively: The average output-consumption ratio of 52JJ20 is 0.70, which is obtained through statistical calculation (total waste smoke volume kg / total output kg). It has been in use for 4 years with no major repair records.

[0034] The average output-consumption ratio of the ZJ19 model is 0.70 (this value is obtained through statistical calculation, total waste smoke volume kg / total output kg), which is taken as the standard value of the model, and the standard weight value = 1.

[0035] The average output-to-consumption ratio of the ZJ19 model over five years of use is 0.70 (this value is statistically calculated: total waste smoke (kg) / total output (kg),) and is used as the standard value for service life, with a standard weight of 1. This model has been in use for four years, so the weight is 1.0.

[0036] The number of repairs of 52JJ16 is set as 0 (actual number of repairs counted), which is counted as the standard value of maintenance, and the standard weight value = 1.

[0037] Step 2: Determine the target unit power consumption of the 52JJ10 unit: Based on A, B, and C obtained in step 1, further calculate the target unit power consumption of the unit: U = AT* (A + B + C) = AT* (1 + 1.0 + 1) = 0.7*3 = 2.1 Among them, U is the target unit consumption value of the unit, AT is the average target unit consumption value of similar units, A is the weight value of the model, B is the weight value of the service life, and C is the weight value of the maintenance status; Step 3, determine the product weight value: take the average output-consumption ratio of Furongwang (hard) products produced by ZJ19 unit as 0.70, which is calculated as the product target unit consumption standard value, and the standard weight value = 1.

[0038] Step 4: Determine the target unit consumption value of the product: Further calculate the target unit consumption value of the product based on D obtained in step 3: P=SP*D=0.70*1=0.70 Among them, P is the target unit consumption value of the product, SP is the target unit consumption standard value of the product, and D is the product weight value; Step 5, determine the target unit consumption value of the wrapping workshop: further calculate the target unit consumption value of the wrapping workshop based on U and P obtained in steps 2 and 4: T=U+P+0.1R=2.1+0.70+0.1*0.7=2.87 Among them, T is the target unit consumption value of the wrapping workshop, U is the target unit consumption value of the unit, P is the target unit consumption value of the product, and R is the statistical production-consumption ratio for 3 months.

[0039] The target unit consumption value is used for real-time monitoring of the unit. The target unit consumption value is preset, and the output and consumption data of the unit during the production process are recorded in real time. When the actual output-consumption ratio is greater than 20% of the target unit consumption value, an alarm message is sent and a statistical analysis report is generated.

[0040] The above describes the technical content of the present invention, but the scope of protection of the present invention is not limited to the said content. Within the scope of knowledge possessed by ordinary technicians in this field, various changes can be made to the technical content of the present invention without departing from the purpose of the present invention. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of the present invention should be included in the scope of protection of the present invention.

Claims

1. A method for calculating the target unit consumption value of a wrapping workshop, characterized in that: The method comprises: Step 1, determine the unit weight value: count the production and consumption of all production units in the wrapping workshop and the actual production and consumption ratio R of similar products produced in the last three months, count the actual production and consumption ratio of all batches of similar products produced within three months, and classify similar units according to production efficiency, service life, and equipment maintenance and repair status, so as to obtain the model weight value A, service life weight value B, and maintenance and repair status weight value C respectively: The average value of the output-consumption ratio of similar models is taken as the model standard value, and the standard weight value = 1. When the model standard value is 10% lower than the standard value, A = 0.9; when the model standard value is 10% higher than the standard value, A = 1.1; The average value of the production-consumption ratio of the same service life is taken as the standard value of the service life, and the standard weight value = 1. When the standard value of the service life is lower than the standard life of 3 years, B = 0.95; when the standard value of the service life is higher than the standard life of 3 years, B = 1.05; The number of repairs of the same type of aircraft is used as the standard value for maintenance, and the standard weight value = 1. When more than one medium repair or less than three major repairs have been carried out, C = 1.05; when more than three major repairs have been carried out, C = 1.1; when the standard value for maintenance is higher than the standard value by 10%, C = standard weight value - 0.05; when the standard value for maintenance is lower than the standard value by 10%, C = 1.05; Step 2, determine the unit target consumption value: According to A, B, C obtained in step 1, further calculate the unit target consumption value: U = AT * (A + B + C), Among them, U is the target unit consumption value of the unit, AT is the average target unit consumption of similar units, A is the weight value of the model, B is the weight value of the service life, and C is the weight value of the maintenance status; Step 3, determine the product weight value: take the average value of the output-consumption ratio of different products produced by the same model as the product target unit consumption standard value, and mark the single product standard weight value = 1. When the output-consumption ratio of the corresponding product produced by the model is lower than 10% of the single product standard value, D = 0.95, and D is the product weight value; when the output-consumption ratio of the corresponding product produced by the model is higher than 10% of the single product standard value, D = 1.05, and D is the product weight value; Step 4, determine the product target unit consumption value: further calculate the product target unit consumption value based on D obtained in step 3: P = SP * D, Among them, P is the target unit consumption value of the product, SP is the target unit consumption standard value of the product, and D is the product weight value; Step 5, determine the target unit consumption value of the wrapping workshop: further calculate the target unit consumption value of the wrapping workshop based on U and P obtained in steps 2 and 4: T=U+P+0.1R, Among them, T is the target unit consumption value of the wrapping workshop, U is the target unit consumption value of the unit, P is the target unit consumption value of the product, and R is the statistical production-consumption ratio for 3 months.

2. A method for real-time monitoring of a unit using the target unit consumption value obtained in claim 1, characterized in that: The target unit consumption value is preset, and the output and consumption data of the unit during the production process are recorded in real time. When the actual output-consumption ratio is greater than 20% of the target unit consumption value, an alarm message is sent and a statistical analysis report is generated.