Design device, design method, and recording medium

Abstract

To provide change information applicable to a ladder program.SOLUTION: A design device changes a ladder program which performs a plurality of steps for causing cells taking charge of each of a series of processes in a line performing a series of processes to perform the processes on the basis of the resources constituting the cells. In the design device, a storage device includes operation information associating the steps with resource types indicative of the types of resources. A processor performs change identification processing, changed content identification processing, and output processing. The change identification processing identifies a change in the ladder program from the operation information on the basis of a change plan of the line. The changed content identification processing identifies the changed contents of the ladder program and generates change information of the ladder program on the basis of the change identified by the change identification processing. The output processing outputs change information generated by the changed content identification processing.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to a design apparatus, a design method, and a recording medium for generating data. [Background technology]

[0002] In the manufacturing industry, there is a demand for production formats that can manufacture a wide variety of products, and so there is a need for lines that can be flexibly reconfigured. In recent years, in order to respond to changes in the production environment such as natural disasters and epidemics, the flexibility of lines has become more important, such as restructuring production systems across multiple locations and switching from manual to automated equipment.

[0003] In order to reconstruct a production line in accordance with changes in the manufactured products, it is necessary to change not only the physical equipment that constitutes the line, but also the ladder programs that control the line equipment. As an existing method, a ladder program management device is disclosed in Patent Document 1.

[0004] The ladder program management device of Patent Document 1 comprises a ladder program storage area in which ladder programs for controlling each of a plurality of machines are stored, a database having ladder program history information in which identification information for identifying modifications that have already been made to the plurality of machines and correction programs required for the modifications are stored in correspondence with each other, and a database management unit for managing the database, and the database management unit comprises an identification information search unit that searches the ladder program history information for identification information corresponding to the modifications to be made to the machine to be modified, and a merging unit that extracts the correction program corresponding to the searched identification information from the ladder program history information and merges the correction program into the ladder program of the machine to be modified. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] JP 2018-88178 A Summary of the Invention [Problem to be solved by the invention]

[0006] The ladder program management device of Patent Document 1 takes past equipment change history and ladder program change history as input data, and has the function of automatically changing the ladder program for equipment changes that are the same as equipment changes that have been implemented in the past, but it cannot make equipment changes that have not been implemented in the past or change the allocation of work to equipment.

[0007] In addition, existing program management methods and resource / process data management methods such as BOP (Bill Of Process) manage multiple pieces of information required for investigating the scope of program changes, but the information does not have a corresponding relationship. Therefore, it is necessary for people to track the information, and the labor required to identify the scope of changes is large.

[0008] In addition, although there is a possibility that throughput can be improved by implementing proposed changes to accommodate production fluctuations, this requires work to change resources and check operation. Therefore, it is necessary to select the optimal plan based on both the number of work hours and the effect of improving throughput.

[0009] There is also ladder programming software that can create and manage ladder programs provided or sold by PLC (Programmable Logic Controller) manufacturers.Ladder programming software offers implementation support functions such as group development management functions that improve the efficiency of program implementation by multiple people when programming manually, and easy debugging by visualizing program sequences and line operations by performing signal processing between a line simulator and ladder program on a GUI.

[0010] Ladder programming software also has functions such as using templates that contain a certain number of signal control combinations to simplify the effort of entering code when programming, and managing parts of previously created programs as function blocks to increase reusability.

[0011] In terms of PLC-related design and implementation automation, products on the market include a function to automate the creation of a GUI that displays the parameters that a ladder program receives from equipment and the progress of a control sequence, as well as a function to automatically generate programs other than ladder programs for visualizing and monitoring energy efficiency such as equipment power consumption.

[0012] However, ladder programming software does not have the functionality to automatically design control sequences from process design information, etc. and automatically generate ladder programs. In other words, there is no functionality support for the labor-intensive part of considering and designing control sequences across each piece of equipment, which is considered by humans before or during implementation.

[0013] The present invention aims to provide modification information that can be applied to ladder programs. [Means for solving the problem]

[0014] A design device according to one aspect of the invention disclosed in this application has a processor that executes a program and a storage device that stores the program, and modifies a ladder program that executes a plurality of steps to cause a cell to perform a series of processes on a line where the series of processes are performed based on resources that constitute a cell responsible for each of the series of processes, wherein the storage device has operation information that associates the steps with resource types that indicate the types of the resources, and the processor executes a change location identification process that identifies change locations in the ladder program from the operation information based on a proposed change to the line, a change content identification process that identifies change contents of the ladder program based on the change locations identified by the change location identification process and generates change information for the ladder program, and an output process that outputs the change information generated by the change content identification process. Effect of the Invention

[0015] According to a representative embodiment of the present invention, it is possible to provide modification information applicable to a ladder program. Problems, configurations and effects other than those described above will become apparent from the following description of the embodiments. [Brief description of the drawings]

[0016] [Figure 1] FIG. 1 is an explanatory diagram showing an example of generating a ladder program for reading in a line. [Diagram 2] FIG. 2 is a block diagram showing an example of the hardware configuration of a computer. [Diagram 3] FIG. 3 is an explanatory diagram of an example of the contents stored in the DB. [Figure 4] FIG. 4 is an explanatory diagram illustrating an example of resource information. [Diagram 5] FIG. 5 is an explanatory diagram illustrating an example of the line configuration information. [Figure 6] FIG. 6 is an explanatory diagram showing an example of task allocation change information. [Figure 7] FIG. 7 is an explanatory diagram illustrating an example of the resource-specific operation information. [Figure 8] FIG. 8 is an explanatory diagram showing Example 1 of ladder program change information. [Figure 9] FIG. 9 is an explanatory diagram showing Example 2 of ladder program change information. [Figure 10] FIG. 10 is an explanatory diagram illustrating an example of resource-specific change operation time information. [Figure 11] FIG. 11 is an explanatory diagram illustrating an example of resource / operation-specific confirmation task time information. [Figure 12] FIG. 12 is an explanatory diagram illustrating an example of the work performance information. [Figure 13] FIG. 13 is an explanatory diagram illustrating an example of standard operation time information. [Figure 14] FIG. 14 is an explanatory diagram illustrating an example of the production fluctuation information. [Figure 15] FIG. 15 is an explanatory diagram illustrating an example of resource state information. [Figure 16] FIG. 16 is a flowchart showing an example of a design process procedure for a ladder program. [Figure 17] FIG. 17 is a flowchart illustrating a detailed example of the change part identification process (step S1601) illustrated in FIG. [Figure 18] FIG. 18 is a flowchart (first half) illustrating a detailed example of the change content identification process (step S1602) illustrated in FIG. [Figure 19] FIG. 19 is a flowchart (second half) illustrating an example of detailed processing steps of the change content identification process (step S1602) illustrated in FIG. [Figure 20] FIG. 20 is a flowchart illustrating a detailed example of the change operation time calculation process (step S1604) illustrated in FIG. [Figure 21] FIG. 21 is a flowchart illustrating an example of detailed processing steps of the confirmation task time calculation process (step S1605) illustrated in FIG. [Figure 22] FIG. 22 is a flowchart illustrating a detailed example of the process of calculating throughput for each modification plan (step S1606) illustrated in FIG. [Diagram 23] FIG. 23 is a flowchart illustrating an example of detailed processing steps of the no-change plan throughput calculation process (step S1608) illustrated in FIG. [Figure 24] FIG. 24 is a flowchart illustrating a detailed example of the throughput comparison evaluation process (step S1609) illustrated in FIG. [Diagram 25] FIG. 25 is an explanatory diagram showing an example of a comparative evaluation result display screen. [Figure 26] FIG. 26 is an explanatory diagram showing an example of the identification result display screen. [Figure 27] FIG. 27 is an explanatory diagram showing the relationship between the design device and the PLC programming software. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0017] <Example of generating a ladder program for reading on a line> Fig. 1 is an explanatory diagram showing an example of generating a ladder program for reading in a line. Line L, for example, performs product assembly work. Line L has a transport conveyor row B and one or more (for example, five in Fig. 1) cells Ca to Ce (when there is no need to distinguish between cells Ca to Ce, they will be simply referred to as cells C). Line L performs product assembly work in multiple processes that each cell C is responsible for.

[0018] Conveyor row B has a plurality of conveyors, which are arranged in series in the conveying direction.

[0019] Cell C is a station located between two conveyors constituting conveyor row B, and is provided with resources such as a worker W, a robot R, a dedicated machine for a specific task, and various other work equipment. The resources include the worker W, the robot R, the dedicated machine, and also incidental equipment such as the parts storage area 121 used by them, the robot hand of the robot R, the conveyor, and an input device for the switch for the worker W. The dedicated machine is, for example, a detector that irradiates X-rays on the transported item to detect the presence or absence of foreign matter.

[0020] A cell C in which a worker W is placed but a robot R is not placed is referred to as a human work cell. A cell C in which a robot R is placed but a worker W is not placed is referred to as a robot work cell. Although not shown, a cell C in which neither a worker W nor a robot R is placed but a dedicated machine is placed is referred to as a dedicated machine work cell.

[0021] In the following, "line configuration" refers to the type of cell C in line L (human work cell, robot work cell, dedicated machine work cell) and the group of resources that make up the inside of that cell C. The line configuration of line L is decided by the user of line L. Also, "task allocation" refers to assigning each task within the assembly work procedure to the main resources of cell C, such as worker W, robot R, or dedicated machine, such as "assigning them to be responsible for assembling a certain part" or "assigning them to be responsible for inspecting a certain part."

[0022] Here, a human work cell and a robot work cell will be described using the cell Cc as an example. Note that Fig. 1 shows that the cell Cc is changed from a human work cell to a robot work cell.

[0023] The human work cell has, as a resource group, a worker W, a work pallet 110, a front-end connecting conveyor 111, a back-end connecting conveyor 112, a conveyor controller 113, an arrival detection sensor 114, a camera 115, a camera controller 116, a transport button 117, an inspection button 118, a monitor 119, a PLC 120, and a part storage area 121. The arrival detection sensor 114, the camera 115, the camera controller 116, the transport button 117, the inspection button 118, and the monitor 119 are connected to the PLC 120 by a bus indicated by a thick black line.

[0024] The work pallet 110 is a container on which an object is placed. The front-end connecting conveyor 111 is a conveyor that conveys the work pallet 110 from the cell Cb. The back-end connecting conveyor 112 is a conveyor that conveys the work pallet 110 to the cell Cd.

[0025] The arrival detection sensor 114 detects that the work pallet 110 has arrived at a position between the front-end connecting conveyor 111 and the back-end connecting conveyor 112. The camera 115 captures an image of the transported object in the work pallet 110. The camera controller 116 controls the imaging timing and imaging conditions of the camera 115 under the control of the PLC 120.

[0026] The transport button 117 is an input device that, when pressed by the worker W, starts or stops the transport of the work pallet 110 on the front-process connecting conveyor 111 and the back-process connecting conveyor 112. The inspection button 118 is an input device that, when pressed by the worker W, starts or stops the inspection of the work pallet 110.

[0027] The monitor 119 displays the transported items in the work pallet 110 captured by the camera 115, and also displays instruction information for the worker W.

[0028] The PLC 120 is a controller that controls resources connected via a bus using a ladder program. The PLC 120 receives signals from input devices such as the arrival detection sensor 114, the camera 115, the transport button 117, and the inspection button 118, executes various processes according to the program, and controls output devices such as the conveyor controller 113, the camera controller 116, and the monitor 119.

[0029] The parts storage area 121 is a space in which parts to be assembled to the transported goods in the work pallet 110 are placed.

[0030] A specific description will now be given of the PLC 120. The PLC 120 executes parts kitting, camera inspection, and pallet transportation using a ladder program.

[0031] Parts kitting is a work process in which parts are assembled onto the transported goods on the work pallet 110. When the arrival detection sensor 114 detects the arrival of the work pallet 110, the detection signal is input to the PLC 120. When the detection signal from the arrival detection sensor 114 is input, the PLC 120 outputs a transport stop signal to the conveyor controller 113. When the conveyor controller 113 receives the transport stop signal from the PLC 120, it stops driving the post-process connecting conveyor 112. This stops the transport of the work pallet 110.

[0032] Furthermore, when a detection signal is input from the arrival detection sensor 114, the PLC 120 displays work instructions for parts kitting on the monitor 119. The worker W takes out a part from the parts storage area 121 and assembles it on the transported item. When the assembly of the part is completed, the worker W presses the inspection button 118, and a press signal is output to the PLC 120. This completes the parts kitting.

[0033] The camera inspection is a work process in which the transported object kitted with parts is inspected by the camera 115. When a press signal of the inspection button 118 is input, the PLC 120 outputs a control start signal to the camera controller 116. The camera 115 captures an image of the transported object kitted with parts according to the imaging timing and imaging conditions set in advance in the camera controller 116.

[0034] When a control start signal is input from PLC 120, camera controller 116 starts controlling image capture by camera 115 and performs an inspection as to whether or not parts kitting has been performed correctly based on image data of the parts-kitted transported goods captured by camera 115. When the inspection is completed, camera controller 116 outputs the inspection result and an inspection completion signal to PLC 120. When the inspection result and inspection completion signal are input, PLC 120 causes monitor 119 to display the inspection result.

[0035] Pallet transport is a work process in which the work pallet 110 on which the transported items that have completed part kitting and camera inspection are placed is transported to the downstream cell Cd. When the worker W presses the transport button 117, the press signal is output to the PLC 120. When the press signal of the transport button 117 is input, the PLC 120 outputs a transport start signal to the conveyor controller 113. When the conveyor controller 113 receives the transport start signal from the PLC 120, it starts driving the downstream process connecting conveyor 112. As a result, the work pallet 110 is transported to the downstream cell Cd.

[0036] Next, the robot work cell will be explained. Explanation of the parts common to the human work cell will be omitted.

[0037] The robot work cell has, as a resource group, a robot R, a work pallet 110, a front-end connecting conveyor 111, a back-end connecting conveyor 112, a conveyor controller 113, an arrival detection sensor 114, a camera 115, a camera controller 116, a transport button 117, an inspection button 118, a monitor 119, a parts storage area 121, a PLC 130, and a robot controller 131. The arrival detection sensor 114, the camera 115, the camera controller 116, the transport button 117, the inspection button 118, the monitor 119, and the robot controller 131 are connected to the PLC 130 by a bus indicated by a thick black line.

[0038] The robot R is a work machine that performs part kitting in place of the worker W. The robot R takes out a part from the part storage area 121 and assembles it on a conveyed object in the work pallet 110. The robot controller 131 controls the robot R according to instructions from the PLC 130.

[0039] The PLC 130 is a controller that controls resources connected via a bus using a ladder program. The ladder program in the PLC 130 is, for example, a ladder program that is a modified version of the ladder program in the PLC 120 for a human work cell for a robot work cell, and the configuration other than the ladder program is the same as that of the PLC 120.

[0040] The PLC 130 receives signals from input devices such as the arrival detection sensor 114 and the camera 115, executes various processes according to programs, and controls output devices such as the conveyor controller 113, the camera controller 116, and the robot controller 131.

[0041] The PLC 130 will be described in detail. The PLC 130 executes parts kitting, camera inspection, and pallet transport using a ladder program. Parts kitting is a work process in which parts are assembled onto the transported items on the work pallet 110. When the arrival detection sensor 114 detects the arrival of the work pallet 110, the detection signal is input to the PLC 130.

[0042] When the PLC 130 receives a detection signal from the arrival detection sensor 114, it outputs a transport stop signal to the conveyor controller 113. When the conveyor controller 113 receives the transport stop signal from the PLC 130, it stops driving the post-process connecting conveyor 112. This stops the transport of the work pallet 110.

[0043] Furthermore, when a detection signal is input from the arrival detection sensor 114, the PLC 130 outputs a part kitting work instruction signal to the robot controller 131. When the work instruction signal is input from the PLC 130, the robot controller 131 controls the part kitting by the robot R. When the part kitting by the robot R is completed, the robot controller 131 outputs a part kitting work completion signal to the PLC 130.

[0044] The camera inspection is a work process in which the transported goods on which parts have been kitted are inspected by the camera 115. When a work completion signal for parts kitting is input, the PLC 130 outputs a control start signal to the camera controller 116. The camera 115 captures an image of the transported goods on which parts have been kitted according to the imaging timing and imaging conditions set in advance in the camera controller 116.

[0045] When a control start signal is input from PLC 120, camera controller 116 starts controlling image capture by camera 115 and performs an inspection as to whether or not parts kitting has been performed correctly based on image data of the parts-kitted transported goods captured by camera 115. When the inspection is completed, camera controller 116 outputs an inspection completion signal to PLC 130.

[0046] Pallet transport is a work process in which the work pallet 110 on which the transported items have been subjected to part kitting and camera inspection is placed is transported to the downstream cell Cd. When an inspection completion signal is input, the PLC 130 outputs a transport start signal to the conveyor controller 113. When the transport start signal is input, the conveyor controller 113 starts driving the downstream process connecting conveyor 112. This causes the work pallet 110 to be transported to the downstream cell Cd.

[0047] Since there is no worker W in the robot work cell, the transport button 117 and the inspection button 118 are not pressed, and there is no need to display information on the monitor 119.

[0048] The dedicated machine work cell has a cell configuration in which the robot R and the robot controller 131 are removed from the robot work cell. In addition, when the dedicated machine work cell is, for example, a cell for detecting foreign objects in transported goods, the camera 115 becomes an X-ray exposure device that irradiates X-rays, and the camera controller 116 becomes an X-ray exposure controller that controls the X-ray exposure device.

[0049] Next, the change from a ladder program for a human work cell to a ladder program for a robot work cell will be described. A design device 100 can access a database (hereinafter, DB) 101. The design device 100 generates a read ladder program 102 using information in DB 101. The read ladder program 102 is a ladder program for a robot work cell that has been changed from the ladder program for a human work cell and is to be read into a writing device 103.

[0050] The writing device 103 is a computer in which PLC programming software is implemented. Normally, in the writing device 103, a person uses a coding function in the PLC programming software to consider the changes from the human work cell to the robot work cell and inputs the changes while coding. The writing device 103 debugs the coded ladder program using a debugging function and writes it to the PLC.

[0051] In contrast, in this embodiment, the writing device 103 reads the read ladder program 102 generated by the design device 100, debugs the read ladder program 102 using the debug function, and writes it to the PLC 130, eliminating the need for coding in the writing device 103.

[0052] In the above example, the change from a human work cell to a robot work cell has been described, but the change from a robot work cell to a human work cell may also be performed. In addition, although a dedicated machine work cell is not illustrated, the same applies to the change between a human work cell and a dedicated machine work cell, and the change between a robot work cell and a dedicated machine work cell.

[0053] <Example of computer hardware configuration> FIG. 2 is a block diagram showing an example of a hardware configuration of a computer (design device 100, writing device 103, PLCs 120 and 130). The computer 200 has a processor 201, a storage device 202, an input device 203, an output device 204, and a communication interface (communication IF) 205. The processor 201, the storage device 202, the input device 203, the output device 204, and the communication IF 205 are connected by a bus 206. The processor 201 controls the computer 200. The storage device 202 is a working area for the processor 201. The storage device 202 is a non-transient or temporary recording medium that stores various programs and data. Examples of the storage device 202 include a ROM (Read Only Memory), a RAM (Random Access Memory), a HDD (Hard Disk Drive), and a flash memory. The input device 203 inputs data. The input device 203 may be, for example, a keyboard, a mouse, a touch panel, a numeric keypad, a scanner, a microphone, or a sensor. The output device 204 outputs data. The output device 204 may be, for example, a display, a printer, or a speaker. The communication IF 205 connects to a network and transmits and receives data.

[0054] <db101> 3 is an explanatory diagram showing an example of the contents stored in DB 101. DB 101 has resource information 301, line configuration change information 302, work assignment change information 303, resource-specific operation information 304, ladder program change information 305, resource-specific changed work time information 306, confirmation work time information 307, work performance information 308, standard work time information 309, production fluctuation information 310, and resource status information 311.

[0055] [Resource Information 301] 4 is an explanatory diagram showing an example of resource information 301. The resource information 301 is information related to resources constituting a line L. The resource information 301 includes a resource type name table 400 and a resource name table 410. The resource type name table 400 has fields of a resource type ID 401 and a resource type name 402. One resource type is identified by a combination of values ​​of each field in the same row.

[0056] The resource type indicates the type of resource, such as the worker W, robot R, and dedicated machine as described above, as well as the work pallet 110 contained in cell C, the front-end connecting conveyor 111, the back-end connecting conveyor 112, the conveyor controller 113, the arrival detection sensor 114, the camera 115, the camera controller 116, the transport button 117, the inspection button 118, the monitor 119, and the PLCs 120 and 130.

[0057] Resource type ID 401 is identification information that uniquely identifies a resource type. Hereinafter, xxx with a value of "zzz" for xxxIDyyy ("xxx" is the name that identifies the attribute of the ID, and "yyy" is the ID code) may be expressed as "xxx#zzz." For example, if the value of resource type ID 401 is "1000," it becomes resource type #1000.

[0058] The resource type name 402 is the name of the resource type. The resource name table 410 has the following fields: resource ID 411, resource type ID 401, and resource name 412. One resource is identified by a combination of values ​​in each field in the same row. The resource ID 411 is identification information that uniquely identifies a resource. The resource name 412 is the name of the resource.

[0059] The resource information 301 may also include information that can identify specifications such as the cost, weight capacity, and introduction time for each resource type.

[0060] [Line configuration change information 302] 5 is an explanatory diagram showing an example of line configuration change information 302. Line configuration change information 302 is information related to resource changes constituting line L. Line configuration change information 302 has fields including pre-change cell ID 501, pre-change resource ID 502, post-change cell ID 503, post-change resource ID 504, and change type 505. One resource change is specified by a combination of values ​​of each field in the same row.

[0061] Pre-change cell ID 501 is a cell ID before a resource that configures line L is changed. The cell ID is identification information that uniquely identifies cell C.

[0062] The pre-change resource ID 502 is the resource ID 401 of the resource that is the change target before the resource that configures the line L is changed.

[0063] The post-change cell ID 503 is the cell ID of the resource constituting the line L after the change.

[0064] The post-change resource ID 504 is the resource ID 401 of the resource to be changed after the resource constituting the line L is changed.

[0065] The change type 505 indicates the type of change to the resources constituting the line L. Specifically, for example, the change type 505 includes resource replacement, resource deletion, resource addition, and "-" indicating no change. The change type 505 is recorded by the person who selects the line change or by a program that automatically sets the line change when the line configuration is changed.

[0066] Resource replacement refers to replacing a resource specified by a pre-change resource ID 502 with a resource specified by a post-change resource ID 504 .

[0067] Resource deletion indicates that the resource identified by pre-change resource ID 502 is deleted from cell C identified by pre-change cell ID. When change type 505 is resource deletion, post-change cell ID 503 and post-change resource ID 504 are set to “-”, indicating that they have not been changed.

[0068] Resource addition indicates that a resource specified by post-change resource ID 504 is added to cell C specified by the pre-change cell ID. When change type 505 is resource addition, pre-change cell ID 501 and pre-change resource ID 502 are set to “-”, indicating that they have not been changed.

[0069] There is one or more pieces of line configuration change information 302. Since the line configuration after change is specified by the line configuration change information 302, it is possible to calculate the cycle time and throughput of line L using the throughput by changed plan and the throughput of the no-change plan described below. In addition, since the line configuration change information 302 specifies the changed parts of the line configuration (changed cell ID 503 and changed resource ID 504), it is possible to specify the changed parts of the ladder program and it becomes possible to calculate the change work time.

[0070] [Work Allocation Change Information 303] 6 is an explanatory diagram showing an example of the work assignment change information 303. The work assignment change information 303 is information regarding changes in work assignment to resources that make up line L. The work assignment change information 303 has an assigned work ID 601, a pre-change resource ID 502, and a post-change resource ID 504 as fields.

[0071] A resource change in one work assignment is specified by the values ​​of the assigned work ID 601, pre-change resource ID 502, and post-change resource ID 504 in the same row.

[0072] The assigned work ID 601 is identification information that uniquely identifies the work assigned as a work assignment. As described above, "work assignment" means assigning each work in an assembly work procedure to a worker W, a robot R, or a dedicated machine, which is the main resource of cell C, such as "assigning them to assemble a certain part" or "assigning them to inspect a certain part."

[0073] Here, the assigned work corresponds to a resource, not to a cell C constituting a line L. For example, assume that two "medium robots" exist as resources in a pre-change cell C#5 of the line configuration change information 302 (for example, pre-change resource 2002_3 of entry 513 and pre-change resource 2002_4 of entry 514 in FIG. 5).

[0074] In this case, pre-change resource #2002_3 is assigned to entry 613 of assigned work #9 in work assignment change information 303, and pre-change resource #2002_4 is assigned to entry 614 of assigned work #10. That is, it is shown that assigned work #9 and #10 are performed for each of resources #2002_3 and #2002_4 in one cell C#5.

[0075] There is one or more pieces of work assignment change information 303. One change plan is a combination of one piece of line configuration change information 302 (FIG. 5) and one piece of work change information 303 (FIG. 6). Therefore, if the number of pieces of line configuration change information 302 (FIG. 5) is M (an integer greater than or equal to 1) and the number of pieces of work change information 303 (FIG. 6) is N (an integer greater than or equal to 1), the total number of change plans is M×N.

[0076] [Resource-specific operation information 304] 7 is an explanatory diagram showing an example of resource-specific operation information 304. Resource-specific operation information 304 is information showing details of steps of a ladder program showing the work performed by a resource in cell C. Resource-specific operation information 304 has fields including step ID 701, step name 702, output port 703, input port 704, instruction command 705, process name 706, work performing resource type name 707, resource type ID 708, auxiliary resource type name 709, and work performing resource specific operation applicable 710. A step related to detailed process operations is specified by a combination of values ​​of each field in the same row.

[0077] Step ID 701 is identification information that uniquely identifies a step executed in a ladder program that details the processes performed by resources. The same step ID 701 may be registered in multiple entries. For example, step #500, step name 702 "Instruction to start conveyor", represents the action of starting a conveyor, but there are two entries. This is because the work execution resource type names 707 are different ("Worker" and "Robot").

[0078] Specifically, for example, if the task execution resource type name 707 is a "worker", a switch is pressed, and if it is a "small robot" or an "add-on robot", a signal is sent. In addition, the output port 703 and input port 704 to the PLC 120 also change.

[0079] The step name 702 is the name of the step identified by the step ID 701 .

[0080] The output port 703 is a port number of the PLC 120 to which an output signal for executing an operation in the step specified by the step ID 701 is output.

[0081] The input port 704 is a port number of the PLC 120 to which a detection signal or a completion signal in the step identified by the step ID 701 is input.

[0082] The instruction command 705 is a command that indicates a signal processing method for the step identified by the step ID 701. In the instruction command 705, "OUT" is a process that turns on the output port 703 of the PLC in order to send an ON / OFF signal to a control device connected to the PLC.

[0083] "AND" is a ladder program logical expression for determining whether equipment operation is complete using multiple signals in response to the ON / OFF signal of the sensor received from the PLC input port 704. For example, if the process proceeds to the next step when both input port X1 and input port X2 are ON, the logical expression step would be "X1 AND X2."

[0084] The process name 706 is the name of the process that the resource performs in the step identified by the step ID 701. Although not shown in the figure, the process name may be associated with the cell ID of the cell C that performs the process. For example, line L performs four processes of kitting → visual inspection → assembly → transportation as product assembly work. Specifically, for example, cell C#1 performs kitting, cell C#2 performs visual inspection, cell C#3 performs assembly, and cell C#4 performs transportation.

[0085] The task execution resource type name 707 is the resource type name 402 of the resource type that executes the process in the step identified by the step ID 701 .

[0086] The resource type ID 708 is the resource type ID 401 that corresponds to the operation execution resource type name 707 .

[0087] The auxiliary resource type name 709 is the resource type name 402 of the auxiliary resource used when the resource specified by the task execution resource type name 707 executes the step specified by the step ID 701 .

[0088] The work performing resource specific operation applicability 710 indicates whether or not the work performing resource specific operation applies. "○" indicates that the operation applies, and "×" indicates that the operation does not apply. The work performing resource specific operation is a specific operation that is performed only in the process of the process name 706 by the work performing resource specified by the work performing resource type name 707.

[0089] [Ladder program change information 305] Fig. 8 is an explanatory diagram showing Example 1 of ladder program change information 305. Fig. 9 is an explanatory diagram showing Example 2 of ladder program change information 305. Ladder program change information 305 is information regarding changes to a ladder program for each resource step that defines the ladder program steps that detail the process and the detailed process operations and resources that correspond to each step, and describes the changes made to each step of the ladder program.

[0090] The ladder program change information 305 has the following fields: assigned task ID 601, step ID 701, step change type 801, step change content type 802, pre-change I / O port 803, post-change I / O port 804, instruction command 705, proposed change ID 805, and throughput 806. By combining the values ​​of each field in the same row, ladder program change information for each combination of assigned task ID 601 and step ID 701 is specified.

[0091] The combinations of the assigned task ID 601 and the step ID 701 are set in advance so as to cover all steps in the resource-specific operation information 304 (FIG. 7).

[0092] The step change type 801 indicates the type of change to the step identified by the step ID 701. Specifically, for example, the step change type 801 includes change types such as "delete step," "replacement step," "step removed from work assignment," and "step immediately before work assignment." "-" indicates no change.

[0093] A "delete step" is a step in which a resource should be deleted.

[0094] A "replacement step" is a step in which resource replacement should be performed. For a replacement step, the output port 703 and the input port 704 need to be edited.

[0095] A "removal of work assignment step" is a step within a process performed by a resource that is to be removed from the work assignment.

[0096] The "step immediately preceding a work assignment" is the step of the work assignment immediately preceding the step to be added to cell C in which there is another resource that is assigned in place of a resource that has been unassigned from the work assignment.

[0097] The step change type 802 is the type of change, such as "addition" or "deletion" of the step identified by the step ID 701, or "value change" of an input / output signal.

[0098] The pre-change input / output port 803 is the pre-change output port 703 or input port 704 of the step identified by the step ID 701 .

[0099] The post-change input / output port 804 is the post-change output port 703 or input port 704 of the step identified by the step ID 701 .

[0100] The change proposal ID 805 is identification information that uniquely identifies a change proposal. The change proposal is a proposal for changing the line configuration or the work assignment that is the target of the change to the ladder program.

[0101] The throughput 806 is the number of products produced per given period in the change plan identified by the change plan ID 805 .

[0102] Note that ladder program change information 305 (FIG. 9) is generated for each change plan. Therefore, change plan ID 805 and throughput 806 are stored in only one entry of ladder program change information 305 (FIG. 9) (the first entry in FIG. 9).

[0103] [Resource-specific change work time information 306] 10 is an explanatory diagram showing an example of resource-specific change work time information 306. Resource-specific change work time information 306 is information related to the time required for change work by resource (change work time). Resource-specific change work time information 306 has the following fields: resource ID 401, addition work time 1001, and removal work time 1002. The change work time by resource is specified by the combination of values ​​in each field in the same row.

[0104] The addition operation time 1001 is the operation time for adding the resource specified by the resource type ID 401 to the line L. The removal operation time 1002 is the operation time for removing the resource specified by the resource type ID 401 from the line L.

[0105] [Verification work time information 307] 11 is an explanatory diagram showing an example of the confirmation work time information 307. The confirmation work time information 307 is information related to the confirmation work time of a step for each resource. The confirmation work time information 307 has a resource ID 401, a step ID 701, and a confirmation work time 1101 as fields.

[0106] The confirmation operation time 1101 is the operation time for the resource type specified by the resource type ID 401 to confirm the operation of the step specified by the step ID 701 .

[0107] [Work performance information 308] 12 is an explanatory diagram showing an example of work performance information 308. Work performance information 308 is information related to past production performance. Work performance information 308 has the following fields: product ID 1201, part ID 1202, cell ID 1203, resource type ID 401, step ID 701, resource ID 411, date and time 1205, start time 1206, and end time 1207. Past production performance is identified by the combination of values ​​of each field in the same row.

[0108] The product ID 1201 is identification information that uniquely identifies a product. The part ID 1202 is identification information that uniquely identifies a part. The cell ID 1203 is identification information that uniquely identifies a cell C.

[0109] Date and time 1205 is, for example, the date and time when a part identified by part ID 1202 is assembled in cell C identified by cell ID 1203 in the production of a product identified by product ID 1201. Start time 1206 is the time when the process in charge of cell C identified by cell ID 1203 started. End time 1207 is the time when the process in charge of cell C identified by cell ID 1203 ended.

[0110] [Standard work time information 309] 13 is an explanatory diagram showing an example of the standard operation time information 309. The standard operation time information 3090 is information related to the standard operation time of a process by resource. The standard operation time information 309 has the following fields: resource type ID 401, step ID 701, standard operation time 1301, and average operation time 1302.

[0111] The standard operation time 1301 is the standard operation time when the resource type specified by the resource type ID 401 performs the step specified by the step ID 701 .

[0112] The average operation time 1302 is the average value of the actual operation time when the resource type specified by the resource type ID 401 executes the step specified by the step ID 701 .

[0113] [Production Fluctuation Information 310] FIG. 14 is an explanatory diagram showing an example of production fluctuation information 310. The production fluctuation information 310 is information on the location and state of production fluctuation currently occurring on line L. A production fluctuation refers to a fluctuation in production due to a breakdown or work delay, or an event of this nature. The production fluctuation information 310 has the following fields: production fluctuation occurring resource ID 1401, production fluctuation occurring cell ID 1402, fluctuation type 1403, detection time 1404, and fluctuation resolution time 1405. The location and state of the production fluctuation are identified by the combination of values ​​in each field in the same row.

[0114] The production change occurring resource ID 1401 is the resource ID 411 in which the production change occurred. The production change occurring cell ID 1402 is the cell ID 1203 of the cell C in charge of the process in which the resource specified by the production change occurring resource I 1401 is performing the work.

[0115] The fluctuation type 1403 is the type of fluctuation occurring in the resource identified by the production fluctuation occurring resource ID 1401. Specifically, the fluctuation types 1403 include, for example, "breakdown," "absence," and "work delay."

[0116] The detection time 1404 is the time when a production fluctuation is detected in the resource identified by the production fluctuation occurring resource ID 1401. The fluctuation resolution time 1405 is the scheduled time when the production fluctuation that occurred in the resource identified by the production fluctuation occurring resource ID 1401 will be resolved. The fluctuation resolution time 1405 is, for example, the time when the shift of the worker W changes or the expected time when an equipment failure will be restored.

[0117] In the production fluctuation information 310, the entry in the first row indicates that the production fluctuation occurrence resource ID 1401 value “2001_3” (small robot Z) was detected to have broken down at detection time 1404 (2020 / 3 / 18 9:20) and is scheduled to be resolved at fluctuation resolution time 1405 (2020 / 3 / 18 9:55).

[0118] [Resource status information 311] 15 is an explanatory diagram showing an example of resource status information 311. The resource status information 311 is information related to the status of a resource. The resource status information 311 has the following fields: resource ID 411, resource name 412, resource status 1501, worker shift start time 1502, worker shift end time 1503, and scheduled recovery time from equipment failure 1504. The status of a resource is specified by a combination of values ​​of each field in the same row.

[0119] The resource status 1501 is the status of the resource specified by the resource ID 411. The status may be, for example, "normal," "absent," "delay," or "failure."

[0120] The worker shift start time 1502 is the shift start time of the worker W in the case where the resource specified by the production change occurring resource ID 1401 is the worker W.

[0121] The worker shift end time 1503 is the shift end time of the worker W when the resource specified by the production change occurrence resource ID 1401 is the worker W.

[0122] The equipment failure planned recovery time 1504 is the planned recovery time of the equipment in the case where the resource specified by the production fluctuation occurrence resource ID 1401 is a failure of the equipment.

[0123] In the resource status information 311, for example, for "Worker C" identified by resource #1000_3, the value of resource status 1501 is "Delayed", so it can be seen that Worker C's work is delayed and Worker C is working between worker shift start time 1502 (2020 / 3 / 20 9:00) and worker shift end time 1503 (2020 / 3 / 18 17:00).

[0124] <Ladder program design process> Fig. 16 is a flowchart showing an example of a design process procedure for a ladder program. The design device 100 executes a change location specification process (step S1601). Specifically, for example, the design device 100 updates the ladder program change information 305 (Fig. 8) based on the resource information 301 (Fig. 4), the line configuration change information 302 (Fig. 5) or the work assignment change information 303 (Fig. 6), and the resource-specific operation information 304 (Fig. 7). That is, a column of the step change type 801 is added to the ladder program change information 305 (Fig. 8). The details of the change location specification process (step S1601) will be described later with reference to Fig. 17.

[0125] By reading all of the line configuration change information 302 (FIG. 5) and the work assignment change information 303 (FIG. 6), the total number of change proposals is identified as M×N. For example, if the number in the line configuration change information 302 (FIG. 5) is "3" and the number in the work assignment change information 303 (FIG. 6) is "4", the total number of change proposals is "12".

[0126] Next, the design device 100 executes a change content identification process (step S1602). Specifically, for example, the design device 100 updates the ladder program change information 305 ( FIG. 8 ) based on the line configuration change information 302, the work assignment change information 303, and the resource-specific operation information 304. That is, for the combination of the target assigned work ID 601 and step ID 701, columns of step change content type 802, pre-change I / O port 803, post-change I / O port 804, instruction command 705, and change proposal ID 805 are added (see FIG. 9 ).

[0127] This automatically identifies the changes to be made to the ladder program in accordance with the proposed changes. This reduces the amount of work required to change the ladder program. The details of the change identification process (step S1602) will be described later with reference to FIGS. 18 and 19.

[0128] If steps S1601 and S1602 have been completed for all change proposals (step S1603: Yes), the design device 100 proceeds to step S1604. If an unprocessed change proposal exists (step S1603: No), the design device 100 returns to step S1601.

[0129] On the other hand, when the specification of the change range of all change proposals has been completed (step S1603: Yes), the design device 100 executes a change work time calculation process (step S1604) for the change proposals for which the change work time has not been calculated. Specifically, for example, the design device 100 calculates the change work time when changing the line in accordance with the line configuration change information 302, based on the line configuration change information 302 and the resource-specific change work time information 306.

[0130] This makes it possible to evaluate each proposed change as a measure against production fluctuations from the viewpoint of production efficiency, taking into account the change work time such as adding or removing physical resources. Details of the change work time calculation process (step S1604) will be described later with reference to FIG. 20.

[0131] Next, the design device 100 executes a confirmation work time calculation process (step S1605) for change proposals for which the change work time has been calculated but the confirmation work time has not been calculated. Specifically, for example, the design device 100 calculates the confirmation work time of the ladder program changed to match the change proposal based on the resource status information 311, the production fluctuation information 310, and the work result information 308. This makes it possible to evaluate each change proposal as a measure against production fluctuation from the viewpoint of production efficiency that also takes into account the operation confirmation work time. Details of the confirmation work time calculation process (step S1605) will be described later with reference to FIG. 21.

[0132] Next, the design device 100 executes a change plan-specific throughput calculation process (step S1606) for a change plan for which the change work time and confirmation work time have been calculated but the throughput has not been calculated. Specifically, for example, the design device 100 calculates the throughput based on the resource status information 311, the production fluctuation information 310, the work result information 308, and the standard work time information 309. That is, a column for the throughput 806 is added for the combination of the target assigned work ID 601 or step ID 701 (see FIG. 9). Details of the change plan-specific throughput calculation process (step S1606) will be described later with reference to FIG. 22.

[0133] The design device 100 judges whether the calculation of the change work time, confirmation work time, and throughput for all change plans has been completed (step S1607). If the calculation of the change work time, confirmation work time, and throughput for all change plans has not been completed (step S1607: No), the design device 100 executes steps S1604 to S1606 for the change plans for which the calculation of the change work time, confirmation work time, and throughput has not been completed.

[0134] On the other hand, when the calculation of the change work time, confirmation work time, and throughput for all change plans is completed (step S1607: Yes), the design device 100 executes a no-change plan throughput calculation process (step S1608). Specifically, for example, the design device 100 calculates the throughput when no changes are made (the throughput of the no-change plan) based on the resource status information 311, the production fluctuation information 310, and the work performance information 308. This allows the plan of not making any changes to be evaluated from the viewpoint of production efficiency as a measure against production fluctuations. Details of the no-change plan throughput calculation process (step S1608) will be described later with reference to FIG. 23.

[0135] Next, the design device 100 executes a throughput comparison evaluation process (step S1609). Specifically, for example, the design device 100 compares and evaluates the throughput of the changed plan and the throughput of the no-change plan, and selects the optimal plan with the maximum throughput based on the evaluation result. As a result, the optimal plan with the maximum throughput is automatically identified from one or more changed plans or no-change plans, so that the user can quickly identify the plan to be implemented when a production change occurs. Details of the throughput comparison evaluation process (step S1609) will be described later with reference to FIG. 24.

[0136] Then, the design device 100 outputs the results of steps S1604 to S1606, S1608, and S1610 (step S1610). Specifically, for example, the design device 100 may display the results on a display, which is an example of the output device 204, or may transmit the results to another computer via the communication IF 205 through a network such as the Internet, a LAN (Local Area Network), or a WAN (Wide Area Network).

[0137] Finally, the design device 100 generates a modified ladder program by applying the optimal plan to the ladder program before the modification (step S1611).

[0138] This completes the series of processes of the design apparatus 100. Details of each process of steps S1601, S1602, S1604 to S1606, S1608, and S1609 will now be specifically described.

[0139] [Changed part identification process (step S1601)] FIG. 17 is a flowchart illustrating a detailed example of the change part identification process (step S1601) illustrated in FIG.

[0140] (Step S1701) First, the design device 100 reads a combination (one change proposal) of unselected line configuration change information 302 (Figure 5) and work assignment change information 303 (Figure 6), resource-specific operation information 304 (Figure 7), and ladder program change information 305 (Figure 8).

[0141] (Step S1702: Identifying the deletion step) Next, based on the line configuration change information 302 (FIG. 5), the design device 100 identifies, from the resource-specific operation information 304 (FIG. 7), the steps (hereinafter, steps to be deleted) that are handled by the work performing resources to be deleted in the line configuration change information 302 (FIG. 5).

[0142] Specifically, for example, in entry 510 in line configuration change information 302 (FIG. 5), the value of pre-change cell ID 501 is "2," the value of pre-change resource ID 502 is "2005_1" (add-on robot), and the values ​​of post-change cell ID 503 and post-change resource ID are both "-." Therefore, this resource #2005_1 (add-on robot) is identified as having been removed from pre-change cell C#2.

[0143] The value of the resource type ID 401 of the work performing resource 2005_1 (add-on robot) of the entry 510 is "2005" with reference to the resource information 301 of Fig. 4. Therefore, the design device 100 identifies the entries 711 and 712 with the step ID 701 values ​​"10004" and "503" including the resource type #2005 of the resource #2005_1 (add-on robot) in the resource-specific operation information 304 of Fig. 7 as candidates for deletion steps.

[0144] Then, the design device 100 identifies an entry whose step ID 701 matches the deletion step candidate in the ladder program change information 305 (FIG. 8), and determines that step ID 701 as the step to be deleted.

[0145] Specifically, for example, the step IDs 701 of the deletion step candidates are “10004” of the entry 711 and “503” of the entry 712 .

[0146] Of these, "503" exists in entry 811 of ladder program change information 305 (FIG. 8). Therefore, step #503 is identified as the step to be deleted.

[0147] (Step S1703: Identifying replacement steps) Next, based on the line configuration change information 302 (FIG. 5) and the ladder program change information 305 (FIG. 8), the design device 100 identifies, from the resource-specific operation information 304 (FIG. 7), the operation step (hereinafter, the replacement step) that is in charge of the work performing resource to be replaced in the line configuration change information 302 (FIG. 5).

[0148] Specifically, for example, in entry 511 in line configuration change information 302 (FIG. 5), the value of pre-change cell ID 501 is “1”, the value of pre-change resource ID 502 is “1000_1”, the value of post-change cell ID 503 is “1”, and the value of post-change resource ID 504 is “2004_1.” Therefore, entry 511 specifies that resource #1000_1 in pre-change cell C#1 has been replaced with resource #2004_1.

[0149] The work performing resource #1000_1 is identified by the value of the pre-change resource ID 502 of the entry 511. The value of the resource type ID 401 is "1000" with reference to the resource information 301 (FIG. 4). Therefore, the design device 100 identifies the entries 713 to 718 of the step ID 701 values ​​"713" to "718" including the resource type #1000 of the work performing resource #1000_1 in the resource-specific operation information 304 (FIG. 7) as replacement step candidates.

[0150] Also, in entry 512 in line configuration change information 302 (FIG. 5), the value of pre-change cell ID 501 is "3," the value of pre-change resource ID 502 is "2002_1," the value of post-change cell ID 503 is "3," and the value of post-change resource ID 504 is "1000_2." Therefore, entry 512 specifies that resource #2002_1 in pre-change cell C#3 has been replaced with resource #1000_2.

[0151] Also, in entry 515 in line configuration change information 302 (FIG. 5), the value of pre-change cell ID 501 is “4”, the value of pre-change resource ID 502 is “2002_2”, the value of post-change cell ID 503 is “4”, and the value of post-change resource ID 504 is “2003_1.” Therefore, entry 515 specifies that resource #2002_2 in pre-change cell C#4 has been replaced with resource #2003_1.

[0152] The work performing resource #2002_1 is identified by the value of the pre-change resource ID 502 of the entry 512. The value of the resource type ID 401 is "2002" when referring to the resource information 301 (FIG. 4). Therefore, the design device 100 identifies the entries 719, 720, and 721 with the step ID 701 values ​​"10021," "10022," and "10023" in which the resource type 2002 is the work performing resource #2002_1 in the resource-specific operation information 304 (FIG. 7) as replacement step candidates.

[0153] Furthermore, the work performing resource #2002_2 is identified by the value of the pre-change resource ID 502 of the entry 515. The value of the resource type ID 401 is "2002" when referring to the resource information 301 (FIG. 4). Therefore, the design device 100 identifies the entries 719, 720, and 721 with the step ID 701 values ​​"10021," "10022," and "10023" in which the resource type #2002 is the work performing resource #2002_2 in the resource-specific operation information 304 (FIG. 7) as replacement step candidates.

[0154] Then, the design device 100 identifies an entry whose step ID 701 matches the replacement step candidate in the ladder program change information 305 (FIG. 8), and determines that step ID 701 as the replacement step.

[0155] Specifically, for example, the step IDs 701 of the replacement step candidates are “10001” for entry 713, “10004” for entry 714, “10007” for entry 715, “10021” for entry 716, “10022” for entry 717, “10021” for entry 719, “10022” for entry 720, and “10023” for entry 721.

[0156] Of these, "10001" exists in entry 812 of ladder program change information 305 (FIG. 8), "10021" exists in entry 813 of ladder program change information 305 (FIG. 8), "10022" exists in entry 814 of ladder program change information 305 (FIG. 8), and "10023" exists in entry 815 of ladder program change information 305 (FIG. 8). Therefore, steps #10001, #10021, #10022, and #10023 are identified as replacement steps.

[0157] (Step S1704: Identifying the work allocation exclusion step) Next, based on the work assignment change information 303 (Figure 6) and the ladder program change information 305 (Figure 8), the design device 100 identifies from the resource-specific operation information 304 (Figure 7) the operation step (hereinafter referred to as the work assignment removal step) that is handled by the work performing resource or the auxiliary resource from which the work assignment in the work assignment change information 303 (Figure 6) is to be removed.

[0158] Specifically, for example, in assigned task #5 identified by entry 611 of task assignment change information 303 (FIG. 6), pre-change resource #2002_1 has been changed to post-change resource #1000_1. With reference to pre-change cell ID 501 of line configuration change information 302 (FIG. 5), the cell C to which pre-change resource #2002_1 belongs is cell C#3, and the cell C to which post-change resource #1000_1 belongs is cell C#1. Therefore, pre-change resource #2002_1 is identified as a resource excluded from the task assignment of assigned task #5 in cell C#3.

[0159] The value of pre-change resource ID 502 of assigned task #5 identifies task performing resource #2002_1, which is the pre-change resource. With reference to resource information 301 (FIG. 4), the value of resource type ID 401 is "2002". Therefore, in resource-specific operation information 304 (FIG. 7), the design device 100 identifies entries 719, 720, and 721 with step ID 701 values ​​"10021," "10022," and "10023," which include the value "2002" of resource type ID 708 of task performing resource #2002_1, as candidates for steps to be removed from task allocation.

[0160] Similarly, in assigned task #7 identified by entry 611 of task assignment change information 303 (FIG. 6), pre-change resource #2002_1 has been changed to post-change resource #2005_1. Referring to pre-change cell ID 501 of line configuration change information 302 (FIG. 5), the cell C to which pre-change resource #2002_1 belongs is cell C#3, and the cell C to which post-change resource #2005_1 belongs is cell C#2. Therefore, resource #2002_1 is identified as the resource that has been removed from the task assignment of assigned task #5 in cell C#3.

[0161] The work performing resource #2002_1 is identified by the value of the pre-change resource ID 502 of the assigned work #7. The value of the resource type ID 401 is "2002" when referring to the resource information 301 (FIG. 4). Therefore, the design device 100 identifies the entries 719, 720, and 721 of the step ID 701 values ​​"10021," "10022," and "10023" including the resource type ID 708 value "2002" of the work performing resource #2002_1 in the resource-specific operation information 304 (FIG. 7) as candidates for steps to be removed from work allocation.

[0162] Then, the design device 100 identifies an entry whose step ID 701 matches the work allocation removal step candidate in the ladder program change information 305 (FIG. 8), and determines that step ID 701 as the work allocation removal step.

[0163] Specifically, for example, the step IDs 701 of the work allocation removal step candidates are "10021" of entry 719, "10022" of entry 720, and "10023" of entry 721. Of these, "10021" exists in entry 813 of ladder program change information 305 (FIG. 8), "10022" exists in entry 814 of ladder program change information 305 (FIG. 8), and "10023" exists in entry 815 of ladder program change information 305 (FIG. 8). Therefore, steps #10021, #10022, and #10023 are identified as work allocation removal steps.

[0164] (Step S1705: Identifying the step immediately before task allocation) Next, based on the line configuration change information 302 (FIG. 5) and the ladder program change information 305 (FIG. 8), the design device 100 identifies from the resource-specific operation information 304 (FIG. 7) the step of the operation to be performed immediately before the work assignment to be added by the change in the work assignment change information 303 (FIG. 6) (hereinafter, the step immediately before the work assignment) (step S1705).

[0165] Specifically, for example, assigned task #5 identified by entry 611 of task assignment change information 303 (FIG. 6) has been changed from pre-change resource #2002_1 to post-change resource #1000_1 in line configuration change information 302 (FIG. 5).

[0166] Therefore, a step to be executed in assigned work #5 must be added to the operation sequence of cell C#2 in which changed resource #1000_1 exists in line configuration change information 302 (FIG. 5). That is, the step immediately before the step of the work performed by changed resource #1000_1 instead of pre-change resource #2002_1 in assigned work #5 is the last step #10022 executed in the previous assigned work #4. Therefore, step #10022 is identified as the step immediately before the work assignment.

[0167] (Step S1706) Next, the design device 100 registers each of the steps identified as the change points in the ladder program (deletion step, replacement step, work assignment removal step, and step immediately before work assignment) as step change types 801 in the ladder program change information 305, as shown in Figure 9.

[0168] Specifically, for example, the design device 100 writes "delete step" in the step change type 801 of entry 811 of the ladder program change information 305 (FIG. 9). The design device 100 also writes "replacement step" in the step change type 801 of entries 812, 813, 814, and 816 of the ladder program change information 305 (FIG. 9). The design device 100 also writes "step removed from work allocation" in the step change type 801 of entries 813, 814, and 816 of the ladder program change information 305 (FIG. 9). The design device 100 also writes "step immediately before work allocation" in the step change type 801 of entry 814 of the ladder program change information 305 (FIG. 9). After this, the process proceeds to the change content identification process (step S1602).

[0169] [Change content identification process (step S1602)] FIG. 18 is a flowchart (first half) illustrating a detailed example of the change content identification process (step S1602) illustrated in FIG.

[0170] (Step S1801) The design device 100 reads line configuration change information 302 (FIG. 5), work allocation change information 303 (FIG. 6), resource-specific operation information 304 (FIG. 7), and ladder program change information 305 (FIG. 9) updated in the change location identification process (step S1601).

[0171] (Step S1802: Designation of steps to be deleted) The design device 100 designates, as a step to be deleted, a step in the ladder program change information 305 (FIG. 9) corresponding to the task assignment to be deleted in the task assignment change information 303 (FIG. 6) that has been identified as a task assignment exclusion step.

[0172] Specifically, for example, assigned task ID #5 in ladder program change information 305 (FIG. 9) is identified as a step to be excluded from task assignment by step change type 801. This step #10023 becomes the step to be deleted. Therefore, design device 100 writes "delete" in step change content type 802 of entry 815 in ladder program change information 305 (FIG. 9).

[0173] (Step S1803: Specify step to be added 1) Next, the design device 100 identifies a first operation step to be added from the resource-specific operation information 304 (FIG. 7) for the work assignment to be added in the work assignment change information 303 (FIG. 6). Step S1803 is a process of allocating work to cell C constituting line L without changing resources. The design device 100 designates the first operation step to be added in the ladder program change information 305 as the step to be added after the step immediately before the work assignment identified in step S1705.

[0174] For example, in entry 611 of the work assignment change information 303 (FIG. 6), assigned work #5 was assigned to pre-change resource #2002_1, but due to the work assignment change, this has been changed to post-change resource #1000_1 (worker A). Therefore, it is necessary to add a step for performing assigned work #5 to the operation sequence in cell C in which post-change resource #1000_1 exists.

[0175] The step immediately before the addition is identified as the step immediately before the task assignment (step S1705). In step S1803, the design device 100 adds a step (first additional operation step) #10023 in which the changed resource type #1000 (worker W) performs the assigned task #5 as a step to be added to the row after the step immediately before the task assignment in the ladder program change information 305 (FIG. 9).

[0176] Specifically, for example, in the resource-specific operation information 304 (FIG. 7), the entry 722 is a changed resource type #1000 and a step (first added operation step) #10023. The design device 100 identifies "Y33" which is the output port 703 of the entry 722 and "OUT" which is the instruction command 705. Then, the design device 100 adds the step (first added operation step) #10023 as an entry 900 in the ladder program change information 305 (FIG. 9). Then, the design device 100 stores "Y33", which is the output port 703 of the entry 722, in the changed input / output port 804 of the step (first added operation step) #10023 in the entry 900, and stores "OUT", the instruction command 705 of the entry 722, in the instruction command 705.

[0177] Furthermore, the design device 100 writes "addition" into the step change content type 802 of the entry 900 of the ladder program change information 305 (FIG. 9).

[0178] (Step S1804: Designation of steps to be deleted) Next, the design device 100 designates, as steps to be deleted, the steps in the ladder program change information 305 that are handled by the resources to be deleted in the line configuration change information 302 (FIG. 5) identified as the steps to be deleted.

[0179] 9, for assigned task #3, step #503 is identified as the deletion step from step change type 801. As a result, step #503 becomes the step to be deleted. Therefore, the design device 100 writes "delete" into step change content type 802 of entry 811 indicating step #503 in ladder program change information 305 (FIG. 9).

[0180] (Step S1805: Specify step to be added 2) Next, the design device 100 identifies a second added operation step from the resource-specific operation information 304 after the immediately preceding step of the operation assignment identified in step S1705 for the added resource and the operation assigned to the added resource in the line configuration change information 302 (FIG. 5). Step S1805 shows a process in which the operation changes due to the physical insertion of a resource into cell C. The design device 100 designates the second added operation step in the ladder program change information 305 as the step to be added.

[0181] For example, in entry 516 of line configuration change information 302 (FIG. 5), resource #2005_1 (add-on robot) has been removed from cell C#2 (entry 510) and added to cell C#3. The added resource #2005_1 is then assigned to assigned task #7 in task assignment change information 303 (FIG. 6) (entry 612). Therefore, resource #2005_1 is the added resource, and assigned task #7 in entry 612 is the task assigned to the added resource.

[0182] The immediately preceding step of task assignment identified in step S1705 is step #10022 as described above. In the resource-specific operation information 304 (FIG. 7), the design device 100 adds a step whose resource type is performing assignment task #7 as a second added operation step after the immediately preceding step #10022 of task assignment immediately prior to the step of assignment task #7, which is an assignment task to an added resource. Therefore, the design device 100 writes "add" in the step change content type 802 of the entry 900 indicating step #503 in the ladder program change information 305 (FIG. 9). Then, the process proceeds to step S1901 in FIG. 19.

[0183] In step S1805, if the same step has been added to the ladder program change information 305 in step S1803, it is not specified as the second added operation step.

[0184] FIG. 19 is a flowchart (second half) illustrating an example of detailed processing steps of the change content identification process (step S1602) illustrated in FIG.

[0185] (Step S1901) The design device 100 determines whether or not the number of operation steps of the work handled by a resource before and after the change is different for a replacement resource for which the change content type 802 in the line configuration change information 302 (FIG. 5) is unspecified, based on the resource-specific operation information 304 (FIG. 7). A replacement resource for which the change content type 802 in the line configuration change information 302 (FIG. 5) is unspecified is a resource for which the resource replacement is specified as a "replacement step" in the change location specification process (step S1601) (step change type 801 is "replacement step"), but the change content type 802 has not yet been specified in the change content specification process (step S1602).

[0186] At the start of the change part identification process (step S1602), the change content type 802 is unspecified for step #10001 of assigned task #1 and step #10021 of assigned task #4, which have step change type 801 of "replacement step" in ladder program change information 305. The replacement resources that perform the operations of these steps #10001 and #10021 correspond to replacement resources whose change content type 802 is unspecified.

[0187] An example of determining whether the number of operation steps of the work assigned to the resource before and after the change is different from the resource-specific operation information 304 (Fig. 7) will be described. For example, in the case of a flow in which a worker W instructs the camera inspection machine process for kitting inspection in a cell C where kitting is performed, and transitions to the conveyor transport work upon completion, the worker W performs the kitting work based on the kitting instruction display (step #10001 of entry 713), presses the inspection start switch (step #10004 of entry 714), the camera controller executes the inspection program (step #10005), the camera controller outputs a signal indicating that the inspection is complete (step #10006), and outputs an inspection completion report to the worker W on the monitor (step #10007), and the worker W, seeing this, presses the conveyor transport switch (step #500 of entry 718).

[0188] When changing resources from worker W to a robot, for example, as in assigned task #11 in ladder program change information 305 (Figure 9), when the inspection completion signal is output in step #10006, the conveyor in step #500 of assigned task #12 is started, and one step specific to worker W, that is, outputting a completion report on the monitor for worker W in step #10007 of assigned task #11, is deleted.

[0189] In this way, the number of steps varies depending on the resource even for the same task of camera inspection. The following steps S1902 and S1903 are executed taking into consideration the difference in the number of steps due to the resource-specific operation.

[0190] If the number of steps is different (step S1901: Yes), a step needs to be added or deleted, so the process proceeds to step S1902. If the number of steps is the same (step S1902: No), no step needs to be added or deleted, but the output port 703 or input port 704 needs to be changed, so the process proceeds to step S1904.

[0191] (Step S1902) When proceeding to step S1902, the design device 100 designates, for the work handled by the replacement resource, the steps of the operations unique to the pre-change resource as steps to be deleted based on the resource-specific operation information 304 (FIG. 7).

[0192] For example, assigned task #1 of step #10001 in ladder program change information 305 (FIG. 9) is a part where the resource has been changed from resource #1000_8 (human) to resource 2004_1 (robot) as shown in task assignment change information 303 (FIG. 5).

[0193] When the parts pallets are transported by a conveyor and kitting is started by a human, a step specific to the worker W, "displaying the kitting start command on the monitor", is required. Conversely, when switching from the worker W to a robot, the above step specific to the worker W becomes unnecessary.

[0194] Therefore, step #10001 of entry 713 in resource-specific operation information 304 (FIG. 7) corresponding to this step is designated to be deleted from the ladder program. Accordingly, step change content type 802 for step #10001 of assigned work #1 in ladder program change information 305 (FIG. 9) becomes "delete."

[0195] (Step S1903) Next, the design device 100 designates, for the work handled by the replacement resource, a step of an operation specific to the changed resource as a step to be added based on the resource-specific operation information 304 (FIG. 7).

[0196] For example, when replacing resource #1000_1 (worker) and worker W issues an instruction to carry out conveyor transport, a unique action of worker W, namely, "push a switch to execute," is required. Therefore, a corresponding step is added to entry 718 (step #500, work execution resource type name 707 "worker," resource type ID 708 value "1000") of resource-specific action information 304 (FIG. 7).

[0197] (Step S1904) Next, the design device 100 identifies the pre-change I / O port 803, the post-change I / O port 804, and the instruction command 705 from the resource-specific operation information 304 (FIG. 7) for the work handled by the replacement resource in the line configuration change information 302 (FIG. 5) (a resource identified by the pre-change resource ID 502 whose change type 505 is “resource replacement”).

[0198] Specifically, for example, the design device 100 identifies the output port 703 or the input port 704 of the step handled by the replaced resource in the line configuration change information 302 (Figure 5) (a resource identified by a pre-change resource ID 502 whose change type 505 is "resource replacement") as the pre-change input / output port 803.

[0199] For example, the change type 505 of the entry 512 of the line configuration change information 302 (FIG. 5) is “resource replacement.” The resource identified by the pre-change resource ID 502 of this entry 512 is resource #2002_1, and its resource type ID is “2002” (medium-sized robot).

[0200] According to the task assignment change information 303 (FIG. 6), the tasks assigned to the resource #2002_1 before the change are assigned tasks #5, #6, and #7. According to the ladder program change information 305 (FIG. 9), the steps corresponding to the assigned tasks #5 and #6 are steps #10023 and #10012 (step ID 701 corresponding to the assigned task #7 is not shown). The design device 100 refers to the resource-specific operation information 304 (FIG. 7), and identifies the output port 703 and input port 704 of steps #10023 and #10012, whose resource type ID 708 is "2002" (medium-sized robot), as the input / output port before the change 803.

[0201] Specifically, for example, the output port 703 "Y15" of #10012 of the entry 724 is identified as the pre-change I / O port 803, and the output port 703 "D14" of #10023 of the entry 721 is identified as the pre-change I / O port 803.

[0202] Furthermore, the design device 100 specifies the output port 703 or the input port 704 when the modified resource (the resource specified by the modified resource ID 504) is used as the modified input / output port 804.

[0203] For example, the change type 505 of the entry 512 of the line configuration change information 302 (FIG. 5) is “resource replacement”. The resource identified by the changed resource ID 504 of this entry 512 is the resource #1000_2, and its resource type ID is “1000” (worker). The assigned work assigned to the changed resource #1000_2 is the assigned work #6 of the entry 615 according to the work assignment change information 303 (FIG. 6). The step corresponding to this assigned work #6 is the step #10012 of the entry 816 according to the ladder program change information 305 (FIG. 9). The design device 100 refers to the resource-specific operation information 304 (FIG. 7) and identifies the output port 703 and the input port 704 of the step #10012, whose resource type ID 708 is “1000”, as the changed input / output port 803.

[0204] Specifically, for example, the output port 703 "Y102" of the entry 723 #10012 is identified as the pre-change I / O port 803.

[0205] The design device 100 identifies an instruction command 705 of the same entry as the output port 703 or input port 704 of the step handled by the changed resource (resource identified by the changed resource ID 504) from the resource-specific operation information 304 (FIG. 7).

[0206] The design device 100 saves the identified pre-change I / O port 803, post-change I / O port 804, and instruction command 705 in the entry for the step in ladder program change information 305 (FIG. 9) (the pre-change I / O port 803, post-change I / O port 804, and instruction command 705 in the entry for the resource currently being processed in step S1904 and its step ID 701 in ladder program change information 305 (FIG. 9)), and sets the step change content type 802 to "value change." This designates the step as one in which a value is changed.

[0207] For example, when the operating resources are swapped, as in entry 816 for assigned task #6 and step #10012 in ladder program change information 305 (Figure 9) (an entry whose step change type 801 is "swapped step"), the output port 703 and input port 704 of PLC 120 are also changed.

[0208] Therefore, the design device 100 specifies "Y15" as the pre-change I / O port 803 in the ladder program change information 305 (FIG. 9), and specifies "Y102" as the post-change I / O port 804. Therefore, in the ladder program change information 305 (FIG. 9), the step change content type 802 of the step is set to "value change", and the pre-change I / O port 803 "Y15" is changed to the post-change I / O port 804 "Y102".

[0209] (Step S1905) Next, the design device 100 judges whether or not the identification of change contents of all replaced resources in the line configuration change information 302 (FIG. 5) has been completed. If not completed (step S1905: No), the process returns to step S1901, and the design device 100 executes steps S1901 to S1904 for the replaced resources whose change contents have not been identified. On the other hand, if the identification of change contents of all replaced resources has been completed (step S1905: Yes), the process proceeds to step S1906.

[0210] (Step S1906) Next, the design device 100 assigns a unique change plan ID 805 to the change plan currently being processed and stores it in the ladder program change information 305 (FIG. 9). In the example of FIG. 9, "6" is stored as the change plan ID 805. Then, the process proceeds to step S1603.

[0211] In this way, in the change content identification process (step S1602), the design device 100 identifies the change content for the step to be changed, such as adding a new step, or changing only the output port 703 or the input port 704 without changing the step itself. The design device 100 updates the ladder program change information 305 (FIG. 8) as shown in FIG. 9 based on the identified change content.

[0212] [Change work time calculation process (step S1604)] FIG. 20 is a flowchart illustrating a detailed example of the change operation time calculation process (step S1604) illustrated in FIG.

[0213] (Step S2001) The design device 100 reads the line configuration change information 302 (FIG. 5) and the resource-specific change work time information 306 (FIG. 10).

[0214] (Step S2002) The design device 100 identifies the resource name and the change work time in the resource-specific change work time information 306 (Figure 10) corresponding to the change type for each resource to be changed (pre-change resource identified by pre-change resource ID 502) of the change proposal to be calculated in the line configuration change information 302 (Figure 5).

[0215] For example, in the line configuration change information 302 (FIG. 5), the pre-change resource #2002_1 (medium robot P) of the pre-change cell #3 belongs to the resource type #2002 (medium robot) (see resource information 301 (FIG. 4)).

[0216] In the line configuration change information 302 (FIG. 5), the pre-change resource #2002_1 (medium-sized robot P) of the pre-change cell #3 is changed to the post-change resource #1000_2 (worker B). The post-change resource #1000_2 (worker B) belongs to the resource type #1000 (worker) (see resource information 301 (FIG. 4)).

[0217] Referring to the resource-specific changed work time information 306 (FIG. 10), the removal work time 1002 of resource type #2002 (medium robot) before the change is "20" minutes, and the addition work time 1001 of resource type #1000 (worker) after the change is "5" minutes. In other words, it is specified that it takes 20 minutes to remove resource #2002_1 (medium robot P) before the change, and 5 minutes to add resource #1000_2 (worker B) after the change.

[0218] (Step S2003) The design device 100 calculates the sum of the addition work time 1001 and the removal work time 1002 identified in step S2002 using the resource-specific change work time information 306 (FIG. 10) as the change work time of the change proposal.

[0219] For example, in the above example, the design device 100 calculates 25 minutes as the sum of the removal work time 1002 of the resource type #2002 (medium robot) before the change of "20" minutes and the additional work time 1001 of the resource type #1000 (worker) after the change of "5" minutes. Note that if there are additional work times 1001 and removal work times 1002 other than "20" minutes and "5", they are added.

[0220] As a result, the design device 100 ends the change operation time calculation process (step S1604), and proceeds to the confirmation operation time calculation process (step S1605).

[0221] [Confirmation work time calculation process (step S1605)] FIG. 21 is a flowchart illustrating an example of detailed processing steps of the confirmation task time calculation process (step S1605) illustrated in FIG.

[0222] (Step S2101) The design device 100 acquires ladder program change information 305 (FIG. 9) and confirmation work time information 307 (FIG. 11).

[0223] (Step S2102) The design device 100 specifies the corresponding confirmation work time 1101 for each combination of an added step or an in-step value change target step of the calculation target change plan and a resource that executes that step in the ladder program change information 305 (FIG. 9).

[0224] For example, in order for resource type #2002 (medium robot) to perform step #10001, it is necessary to repeatedly confirm that the operation of resource type #2002 (medium robot) is performed safely and without error several times to ensure that the operation is successful. The confirmation operation time information 307 (FIG. 11) specifies that the confirmation operation time 1101 will take "15" minutes (see entry 1111).

[0225] (Step S2103) The design device 100 calculates the sum (total confirmation work time) of the confirmation work times 1101 for each combination in step S2102.

[0226] As a result, the design device 100 ends the confirmation work time calculation process (step S1605), and proceeds to the change plan-specific throughput calculation process (step S1606).

[0227] [Throughput calculation process for each change plan (step S1606)] FIG. 22 is a flowchart illustrating a detailed example of the process of calculating throughput for each modification plan (step S1606) illustrated in FIG.

[0228] (Step S2201) The design device 100 acquires line configuration change information 302 (FIG. 5), work performance information 308 (FIG. 12), standard work time information 309 (FIG. 13), change work time for each change plan calculated by the change work time calculation process (step S1604) (FIG. 20), and total confirmation work time for each change plan calculated by the confirmation work time calculation process (step S1605) (FIG. 21).

[0229] (Step S2202) The design device 100 refers to the work result information 308 (FIG. 12) and calculates the current average work time for each production resource / cell C in an arbitrary period. Specifically, for example, the design device 100 calculates the actual work time by subtracting the start time 1206 from the end time 1207 for each entry of the same cell ID 1203, calculates the sum, and divides the sum by the number of entries of the same cell ID 1203, thereby calculating the average work time for that cell ID 1203.

[0230] For example, in the work result information 308 (FIG. 12), for cell C#1 with cell ID 1203 of "1", there are two entries (the entry in the first row and the entry in the fifth row) within the arbitrary period. For the entry in the first row, the actual work time obtained by subtracting start time 1206 from end time 1207 is 40 (seconds), and for the entry in the fifth row, the actual work time obtained by subtracting start time 1206 from end time 1207 is 50 (seconds). Therefore, the total actual work time is 90 (seconds), which, when divided by the number of entries "2", gives the average work time of cell C#1 as 45 (seconds).

[0231] The design device 100 similarly calculates the average work time for the cells C#2 to C#4 other than the cell C#1.

[0232] Similarly, the design device 100 can calculate the average work time for each entry with the same resource ID 411 by calculating the actual work time by subtracting the start time 1206 from the end time 1207, calculating the sum, and dividing the sum by the number of entries with the same resource ID 411.

[0233] For example, in the work result information 308 (FIG. 12), for resource #2004_1 with resource ID 411 "2004_1", there are two entries (the entry in the first row and the entry in the fifth row) within the arbitrary period. For the entry in the first row, the actual work time obtained by subtracting the start time 1206 from the end time 1207 is 40 (seconds), and for the entry in the fifth row, the actual work time obtained by subtracting the start time 1206 from the end time 1207 is 50 (seconds). Therefore, the total actual work time is 90 (seconds), which, when divided by the number of entries "2", gives an average work time of resource #2004_1 of 45 (seconds).

[0234] The design device 100 similarly calculates the average work time for the other resources #1001_1, #1000_2, and #2003_1 other than the resource #2004_1.

[0235] (Step S2203) The design device 100 calculates the cycle time (hereinafter referred to as CT) of each process using the line configuration change information 302 (FIG. 5) and the current average operation time 1302 for each resource / cell C (for a new resource / operation assignment combination (a certain operation assigned to a certain resource) whose average operation time 1302 does not include the most recent average operation time 1302, the standard operation time 1301), and calculates the longest CT within the line L as the changed line CT (changed line CT).

[0236] Specifically, when a process that a certain cell C is responsible for is composed of multiple steps (identified by step ID 701), the design device 100 obtains the average work time 1302 (or standard work time 1301) for each step ID 701 from the standard work time information 309 (Figure 13).

[0237] For example, in the case of kitting performed by cell C#1, referring to the resource-specific operation information 304 (FIG. 7), steps #10001 to 10003 are performed. For step #10001, the design device 100 acquires the value “6” of the average work time 1302 of the entry 1311 and the value “28” of the average work time 1302 of the entry 1321.

[0238] Similarly, for step #10002, the design device 100 obtains the value "11" of the average work time 1302 in the entry 1312 and the value "11" of the average work time 1302 in the entry 1322. Similarly, the design device 100 obtains the value "10" of the average work time 1302 in the entry 1312 and the value "5" of the average work time 1302 in the entry 1322 for step #10003.

[0239] When multiple average work time 1302 values ​​are obtained for the same step ID 701, the design device 100 calculates a statistical value. The statistical value may be a maximum value, a minimum value, or an average value. When the statistical value is the maximum value, the design device 100 calculates the average work time 1302 value "28" for step #10001, the average work time 1302 value "11" for step #10002, and the average work time 1302 value "10" for step #10003.

[0240] The design device 100 calculates the sum of the calculated values ​​of average work time 1302 for each step ID 701. In the case of steps #10001 to #10003, the design device 100 sets the statistical value to the maximum value, so adds the average work time 1302 value of step #10001, "28," the average work time 1302 value of step #10002, "11," and the average work time 1302 value of step #10003, "10," to calculate "49" as the CT of cell C#1.

[0241] The design device 100 similarly calculates the CT for the other cells C other than the cell C#1. Then, the design device 100 determines the longest CT among the CTs of the cells C as the post-change line CT.

[0242] (Step S2204) The design device 100 calculates a first throughput for an arbitrary period from the current time based on the change work time for each change plan (FIG. 20) and the total confirmation work time for each change plan (FIG. 21) acquired in step S2201 and the post-change line CT calculated in step S2203. For example, the first throughput TP1 is calculated for each change plan by the following formula (1).

[0243] TP1 = any period from the current time - change work time for each change plan - (total confirmation work time for each change plan / post-change line CT) (1)

[0244] The arbitrary period in the above formula (1) may be set according to the period for which it is desired to evaluate the first throughput TP1, such as one day or one week.

[0245] Then, the design device 100 registers the first throughput TP1 of the change plan in the throughput 806 of the entry identified by the change plan ID 805 in the ladder program change information 305. As a result, the design device 100 ends the change plan-specific throughput calculation process (step S1606) and proceeds to step S1607.

[0246] [No change plan throughput calculation process (step S1608)] FIG. 23 is a flowchart illustrating an example of detailed processing steps of the no-change plan throughput calculation process (step S1608) illustrated in FIG.

[0247] (Step S2301) The design device 100 reads the work result information 308 (FIG. 12), the production fluctuation information 310 (FIG. 14), and the resource status information 311 (FIG. 15).

[0248] (Step S2302) The design device 100 calculates the average cycle time (normal line CT) of the bottleneck process when no production fluctuation occurs, using the time before the fluctuation occurs in the production fluctuation information 310 (FIG. 14) and the work result information 308 (FIG. 12). Here, the detection time 1404 in the production fluctuation information 310 (FIG. 14) indicates the time of the fluctuation occurrence in the production fluctuation information 310 (FIG. 14). Moreover, the time when no production fluctuation occurs from the time before the fluctuation occurs is an arbitrary period during which no production fluctuation occurs before the oldest detection time 1404 in all processes in the line L.

[0249] The cycle time is calculated, for example, by taking the average value of (work completion time-work start time) for each product, but the design device 100 calculates the average value of (work completion time-work start time) for each product at the bottleneck process (the process with the longest CT in line L) within the above-mentioned arbitrary period before the production fluctuation as the average cycle time of line L.

[0250] The work start time is the latest start time 1206 within the above-mentioned arbitrary period before the production change in the work result information 308. The work completion time is the latest end time 1207 within the above-mentioned arbitrary period before the production change in the work result information 308.

[0251] For example, in the work performance information 308 (FIG. 12), for cell C#1, the work time for product #08ABA01 of production resource #180 is calculated as "40" seconds, which is the difference between the start time 1206 "8:05:40" and the end time 1207 "8:06:20". The work time for product #08ABA01 of production resource #181 is calculated as "50" seconds, which is the difference between the start time 1206 "8:08:30" and the end time 1207 "8:09:20". In this way, the design device 100 calculates the average of the work times (40 seconds, 50 seconds, ...) calculated in an arbitrary period (for example, from 8:00 to 10:00) as the average cycle time (normal line CT) of cell C#1.

[0252] Similarly, for cells C#2, C#3, and C#4, the design device 100 calculates the average cycle time (normal line CT) of cells C#2, C#3, and C#4. The design device 100 determines the process performed by cell C, which has the longest normal line CT among cells C#1 to C#4, as the bottleneck process, and determines the longest normal line CT as the average cycle time (normal line CT) of the bottleneck process when no production fluctuation occurs.

[0253] (Step S2304) The design device 100 calculates a fluctuation recovery time required for the ongoing production fluctuation to be resolved based on the production fluctuation information 310 (FIG. 14) and the resource state information 311 (FIG. 15).

[0254] For example, in the case of a slowdown in work speed or absence due to differences in worker skill levels, the design device 100 calculates the difference between the worker shift end time 1503 and the current time as the fluctuation recovery time indicating the time until the ongoing production fluctuation is resolved.

[0255] Also, for example, in the case of equipment failure (fluctuation type 1403 is "failure"), the design device 100 calculates the difference between the fluctuation resolution time 1405 in the production fluctuation information 310 (FIG. 14) and the current time as the fluctuation recovery time indicating the time until the ongoing production fluctuation is resolved.

[0256] (Step S2305) The design device 100 calculates the second throughput of the line L for an arbitrary period based on the normal line CT calculated in step S2302, the fluctuating line CT calculated in step S2303, and the fluctuation recovery time calculated in step S2304.

[0257] For example, the second throughput TP2 is calculated by the following formula (2).

[0258] TP2 = {(any period from the current time - fluctuation recovery time) / normal line CT} - (fluctuation recovery time / fluctuation line CT) (2)

[0259] As a result, the design device 100 ends the no-change plan throughput calculation process (step S1608), and proceeds to the throughput comparison evaluation process (step S1609).

[0260] [Throughput comparison evaluation process (step S1609)] FIG. 24 is a flowchart illustrating a detailed example of the throughput comparison evaluation process (step S1609) illustrated in FIG.

[0261] (Step S2401) The design device 100 reads the ladder program change information 305 (FIG. 9).

[0262] (Step S2402) The design device 100 compares the first throughputs TP1 stored in the throughput 806 for each change plan stored in the change plan ID 805 of the ladder program change information 305 (FIG. 9), and selects the plan with the maximum first throughput TP1.

[0263] For example, from the ladder program change information 305 (FIG. 9), change plan #6 for assigned work #1 is identified, and its first throughput 806 is identified as "500." Since only ladder program change information 305 (FIG. 9) for change plan #6 exists in FIG. 9, change plan #6 is selected as the plan that maximizes the first throughput TP1.

[0264] (Step S2403) The design device 100 outputs the entry selected in step S2402 from the ladder program change information 305 (FIG. 9) as a selected change plan, whereby the design device 100 ends the change throughput comparison and evaluation process (step S1609).

[0265] <Comparative evaluation result display screen> 25 is an explanatory diagram showing an example of a comparative evaluation result display screen. The comparative evaluation result display screen 2500 has an optimal plan display area 2501 and a production efficiency evaluation result display area 2502. In the optimal plan display area 2501, the change plan ID 805 of the change plan selected in the throughput comparative evaluation process (step S1609), the throughput 806 (first throughput TP1), the change work time (calculated in the change work time calculation process (step S1604)), the confirmation work time (calculated in the confirmation work time calculation process (step S1605)), and the number of change steps are displayed as the optimal plan.

[0266] The number of changed steps is the number of steps in the ladder program change information 305 (FIG. 9) that have a value in the step change type 801. In the example of FIG. 9, the number is “7” for steps #10001, #503, #10012, #10021, #10022, #10023, and #10007.

[0267] The production efficiency evaluation result display area 2502 displays the change plan ID 805, throughput 806 (first throughput TP1, second throughput TP2 for the no-change plan), change work time (calculated in the change work time calculation process (step S1604)), confirmation work time (calculated in the confirmation work time calculation process (step S1605)), and number of change steps as the optimal plan for each change plan and no-change plan.

[0268] The user can refer to the optimal plan display area 2501 and the production efficiency evaluation result display area 2502 to confirm the optimal change plan to be executed, or to confirm the evaluation results of the production efficiency of each change plan and the plan without changes, and consider which change plan should be executed.

[0269] <Specific result display screen> 26 is an explanatory diagram showing an example of a specification result display screen 2600. A specification result display screen 2600 displays the specification results of the ladder program change locations and change contents in the ladder program change information 305 (FIG. 9).

[0270] The identification result display screen 2600 has a plan selection pull-down 2601, a ladder program change range display area 2602, and a production efficiency display area 2603. The plan selection pull-down 2601 is a pull-down for selecting a changed plan or a no-change plan by a user operation. For the selected plan, the ladder program change range display area 2602 displays the ladder program change range, and the production efficiency display area 2603 displays production efficiency information.

[0271] The ladder program change range display area 2602 displays the change range of the ladder program for the selected plan selected in the plan selection pull-down 2601. Specifically, for example, the ladder program change range display area 2602 displays the step ID 701, step change type 801, pre-change input / output port 803, post-change input / output port 804, and program command (instruction command 705) for each change location of the selected plan selected in the plan selection pull-down 2601.

[0272] The production efficiency display area 2603 displays production efficiency information of the selected plan selected in the plan selection pull-down 2601. Specifically, for example, the production efficiency display area 2603 displays the throughput 806 (first throughput TP1 for the changed plan, and second throughput TP2 for the no-change plan), change work time (calculated in the change work time calculation process (step S1604)), confirmation work time (calculated in the confirmation work time calculation process (step S1605)), and number of change steps for the selected plan selected in the plan selection pull-down 2601. The user can check the ladder program change range and production efficiency of the plan to be executed.

[0273] According to the embodiment described above, it is possible to reduce the man-hours required to specify the range of changes to be made to the ladder program, and to reduce the line downtime. In addition, it is possible to specify the proposed change that maximizes the throughput. As a result, it is possible to suppress a decrease in throughput when production fluctuates.

[0274] In addition, to create ladder programs, manual programming was done using PLC programming software sold by PLC manufacturers and the coding function of the software. In addition to the coding function, this PLC programming software also has a debug function that sends pseudo signals to the created program to check the program's operation, and a write function that sends the program to the PLC.

[0275] The design device 100 automates the coding function of this PLC programming software. This makes it possible to reduce the amount of work that would previously have been done by a person while referring to multiple pieces of information when coding. In addition, the design device 100 may generate a ladder program modified according to the program change range identified by the design device 100, and by loading the modified ladder program into each company's PLC programming software, it becomes possible to debug and write it into the PLC.

[0276] <Relationship between design device 100 and PLC programming software> Fig. 27 is an explanatory diagram showing the relationship between the design device 100 and the PLC programming software. Fig. 27 shows the relationship between the design device 100 and the PLC programming software as a process flow from creating a ladder program to writing to the PLC. First, the design device 100 outputs a ladder program 2700 written in a format for reading a ladder program or a ladder program designated by each PLC programming software as an external file according to the process of the above-mentioned embodiment.

[0277] Specifically, in step S1611, the design device 100 refers to the ladder program change information 305 (FIG. 9), updates the ladder program, and outputs the updated ladder program 2700. For example, the design device 100 refers to the ladder program change information 305 (FIG. 9), and deletes steps #10001, #503, #10023, and #10007 from the ladder program.

[0278] Furthermore, the design device 100 refers to the ladder program change information 305 (FIG. 9), changes the input / output port of step #10021 from "D12" to "Y31", and updates the instruction command 705 to "OUT".

[0279] Furthermore, the design device 100 refers to the ladder program change information 305 (FIG. 9), changes the input / output port of step #10022 from "D13" to "Y32", and updates the instruction command 705 to "OUT".

[0280] Furthermore, the design device 100 refers to the ladder program change information 305 (FIG. 9), changes the input / output port of step #10012 from "D15" to "Y102", and updates the instruction command 705 to "OUT".

[0281] Furthermore, the design device 100 refers to the ladder program change information 305 (FIG. 9) and adds step S#10023, in which the post-change input / output port 804 is "Y33" and the instruction command 705 is "OUT", immediately after step S#10022.

[0282] Next, a ladder program 2700 is input to the PLC programming software 2701 by a read function 2702 that reads a program file outside the PLC programming software 2701. This eliminates the need for a person to manually create the ladder program 2700 using a coding function 2703, as was previously the case.

[0283] A debug function 2704 of the PLC programming software 2701 debugs the ladder program 2700 , and a write function 2705 to the PLC 130 writes the debugged ladder program 2700 to the PLC 130 .

[0284] When outputting this ladder program 2700 to the reading function 2702, from a quality standpoint, the design device 100 displays the comparison evaluation result display screen 2500 and the specific result display screen 2600, thereby making visible information that makes it possible to suppress a decrease in throughput during production fluctuations.

[0285] As described above, the design device 100 of this embodiment automatically identifies the ladder program change range (change locations and change contents) of the proposed change to the configuration and work assignment of line L. Therefore, change information applicable to the ladder program can be automatically generated, and the man-hours for range identification work and the downtime of line L can be reduced.

[0286] Moreover, according to the design device 100 of this embodiment, the proposed changes can be quantified by calculating the throughput for the change information of the proposed changes. Therefore, when there are multiple proposed changes, it becomes easy to identify the optimal proposed change. In particular, by making it possible to identify the proposed change with the maximum throughput, it is possible to prevent a decrease in throughput during production fluctuations. Moreover, by comparing the throughput with that of the no-change plan, it is easy to identify whether the plan before or after the change is optimal.

[0287] Furthermore, by automatically modifying the ladder program by applying the modification information, it is possible to improve the efficiency of designing the ladder program.

[0288] The present invention is not limited to the above-described embodiments, and includes various modified examples and equivalent configurations within the spirit of the appended claims. For example, the above-described embodiments have been described in detail to clearly explain the present invention, and the present invention is not necessarily limited to those having all of the configurations described. Also, a part of the configuration of one embodiment may be replaced with a configuration of another embodiment. Also, a configuration of another embodiment may be added to a configuration of one embodiment. Also, a part of the configuration of each embodiment may be added, deleted, or replaced with another configuration.

[0289] In addition, each of the above-mentioned configurations, functions, processing units, processing means, etc. may be realized in hardware, for example by designing some or all of them as an integrated circuit, or may be realized in software by a processor interpreting and executing a program that realizes each function.

[0290] Information such as programs, tables, files, etc. that realize each function can be stored in a storage device such as a memory, a hard disk, or an SSD (Solid State Drive), or in a recording medium such as an IC (Integrated Circuit) card, an SD card, or a DVD (Digital Versatile Disc).

[0291] In addition, the control lines and information lines shown are those considered necessary for the explanation, and do not necessarily show all the control lines and information lines necessary for implementation. In reality, it can be considered that almost all components are connected to each other. [Explanation of symbols]

[0292] 100 Design equipment 301 Resource Information 302 Line configuration change information 303 Work Allocation Change Information 304 Resource specific operation information 305 Ladder program change information 306 Resource-specific change work time information 307 Confirmation work time information 308 Work performance information 309 Standard work time information 310 Production Fluctuation Information 311 Resource Status Information

Claims

1. A design device comprising: a processor for executing a program; and a storage device for storing the program; the design device modifies a ladder program that executes a plurality of steps for causing a cell to perform a series of processes on a line where the series of processes are performed, based on resources constituting the cell that is responsible for each of the series of processes; the storage device has operation information that associates the step with a resource type that indicates a type of the resource; The processor: a change part identification process for identifying a change part in the ladder program from the operation information based on the change proposal in the line; a change content identification process for identifying changes to the ladder program based on the changes identified by the change content identification process and generating change information for the ladder program; an output process for outputting the change information generated by the change content identification process; A design device characterized by executing the above.

2. 2. The design device according to claim 1, In the change portion identification process, when a first resource that performs the process in the cell is deleted in the change plan, the processor identifies a first step in the operation information that corresponds to a first resource type to which the first resource belongs as a change portion indicating that the first step is a deleted step. A design device characterized by:

3. 2. The design device according to claim 1, In the change portion identification process, when a first resource that performs the process in the cell is changed to a second resource in the change plan, the processor identifies a first step that corresponds to a first resource type to which the first resource belongs in the operation information as a change portion that indicates a replacement step. A design device characterized by:

4. 2. The design device according to claim 1, In the change part identification process, when a first resource in a first cell to which an operation corresponding to a first step among the plurality of steps is assigned is changed to a second resource in a second cell in the change proposal, the processor identifies the first step corresponding to a first resource type to which the first resource belongs in the operation information as a change part indicating that the first step is a step to be excluded from the assignment of the operation, and identifies a second step executed immediately before the first step as a change part indicating that the second step is a step immediately before the operation is assigned in the second cell. A design device characterized by:

5. 3. The design device according to claim 2, In the change content identification process, the processor generates the change information by determining the first step as a step to be deleted. A design device characterized by:

6. 3. The design device according to claim 2, In the change content identification process, when the first resource is replaced with a second resource in the change plan, the processor determines the first step as a step to be deleted, and identifies a second step handled by the second resource from the change plan and determines the second step as a step to be added, thereby generating the change information. A design device characterized by:

7. 3. The design device according to claim 2, In the change content identification process, when the first step is handled by a second resource different from the first resource, the processor generates the change information by changing information about the second step handled by the second resource to information about the first step. A design device characterized by:

8. 5. The design device according to claim 4, In the change content identification process, the processor determines the first step as a step to be deleted, identifies a third step that is in charge of the second resource that performs the work from the operation information, and determines the third step as a step to be added after the second step, thereby generating the change information. A design device characterized by:

9. 2. The design device according to claim 1, The processor: Executing a calculation process to calculate a first throughput for the modification plan based on the modification information; In the output process, the processor outputs the first throughput calculated in the calculation process. A design device characterized by:

10. 10. The design device according to claim 9, In the calculation process, the processor calculates the first throughput based on a change operation time related to the change proposal and a confirmation operation time related to the change proposal. A design device characterized by:

11. 10. The design device according to claim 9, In the output process, the processor outputs the first throughput and a second throughput in a case where the change according to the change proposal is not made. A design device characterized by:

12. 2. The design device according to claim 1, The processor: a generation process for generating a modified ladder program by applying the change information to the ladder program; A design device characterized by executing the above.

13. A design method executed by a design device having a processor that executes a program and a storage device that stores the program, the design device changing a ladder program that executes a plurality of steps to cause a cell to perform a series of processes on a line that performs the series of processes based on resources that constitute the cell that is responsible for each of the series of processes, the storage device has operation information that associates the step with a resource type that indicates a type of the resource; The processor: a change part identification process for identifying a change part in the ladder program from the operation information based on the change proposal of the line; a change content identification process for identifying changes to the ladder program based on the changes identified by the change content identification process and generating change information for the ladder program; an output process for outputting the change information generated by the change content identification process; A design method comprising:

14. A computer-readable non-transitory recording medium having recorded thereon a design program for causing a processor to execute a design for changing a ladder program that executes a plurality of steps for causing a cell to perform a series of processes on a line that performs the series of processes based on resources constituting the cell that is responsible for each of the series of processes, the processor is capable of accessing operation information that associates the step with a resource type that indicates a type of the resource; the processor, a change part identification process for identifying a change part in the ladder program from the operation information based on the change proposal of the line; a change content identification process for identifying changes to the ladder program based on the changes identified by the change content identification process and generating change information for the ladder program; an output process for outputting the change information generated by the change content identification process; A computer-readable non-transitory recording medium having recorded thereon a design program for causing a computer to execute the above.

Images