Production control system

Abstract

To provide a production control system that can be built at low cost.SOLUTION: A production control system according to the present invention identifies a piece of equipment E in which an abnormality has occurred among multiple pieces of equipment E connected to each of multiple trunk lines D, and further identifies the products produced by the equipment E during the period in which the abnormality occurred, and includes: a power consumption information acquisition unit 31 that acquires power consumption on a trunk line basis; an operation information acquisition unit 32 that acquires operation information for each of the multiple pieces of equipment E; an abnormal equipment identification processing unit 34 that identifies a trunk line D in which the power abnormality has occurred and identifies equipment E in which the power consumption abnormality has occurred; a production control unit 11 that acquires product production information; and a product identification processing unit 37 that identifies the products produced by the equipment E during the period in which the power consumption abnormality occurred based on the power consumption information of the equipment E in which the power consumption abnormality has occurred and the production information of the product.SELECTED DRAWING: Figure 3

Description

Technical Field

[0001] The present invention relates to a production management system.

Background Art

[0002] Technologies for managing a plurality of facilities provided in a factory or a house based on their power consumption information are being applied. For example, Patent Document 1 discloses a technology for measuring the power consumption of a plurality of facilities. In this document, a technology is proposed in which a single power meter can measure the power consumption in a main line connected to a plurality of facilities in order to measure the power consumption of the plurality of facilities in a home. And in this technology, management of the facilities used in the home is executed based on the power consumption of the main line.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] Here, when a plurality of facilities are connected to a main line, there is also a technology for performing power measurement on the main line and executing energy management. However, since power measurement is performed on a main line basis, it is not possible to detect an abnormality in the power consumption of each facility. At this time, by providing a power meter for all facilities, it is possible to identify which facility has a power abnormality. However, there is a problem that a large amount of power meters need to be introduced, the system also becomes large, and the cost increases significantly.

[0005] The present invention has been made to solve such problems, and provides a production management system that can be constructed at low cost.

Means for Solving the Problems

[0006] The production management system according to the present invention is a production management system that identifies equipment in which an abnormality has occurred among a plurality of pieces of equipment connected to each of a plurality of main lines, and further identifies products produced by the equipment during the period in which the abnormality has occurred. The production management system includes a power consumption information acquisition unit that acquires power consumption in units of main lines, an operation information acquisition unit that acquires operation information for each of the plurality of pieces of equipment, and based on the power consumption acquired by the power consumption information acquisition unit, identifies a main line in which a power abnormality has occurred, and based on the power consumption of the identified main line and the operation information of the equipment acquired by the operation information acquisition unit, an abnormal equipment identification processing unit that identifies equipment in which an abnormality in power consumption has occurred, a production management unit that acquires production information of products, and a product identification processing unit that identifies products produced by the equipment during the period in which a power consumption abnormality has occurred based on the power consumption information of the equipment in which a power consumption abnormality has occurred and the production information of the products.

[0007] Here, the power consumption information includes time information of the period in which a power consumption abnormality has occurred and the power consumption of the equipment during the period, and the production information includes time information of the period in which the product is produced by the equipment and product identification information of the product. The product identification processing unit preferably identifies products produced by the equipment during the period in which a power consumption abnormality has occurred by associating the power consumption information and the production information using the time information as a linking key.

[0008] Further, the abnormal equipment identification processing unit compares the power consumption in units of the main lines acquired by the power consumption information acquisition unit with a predetermined power consumption threshold value for the corresponding main line, and when the acquired power consumption of the main line is equal to or higher than the upper limit of the corresponding threshold value, preferably identifies the equipment identified as being in operation by the operation information as the equipment in which an abnormality has occurred.

[0009] Further, the abnormal equipment identification processing unit compares the power consumption of each main line obtained by the power consumption information acquisition unit with a preset power consumption threshold value for the corresponding main line, and when the power consumption of the obtained main line is equal to or lower than the lower limit of the corresponding threshold value, it is preferable to identify the equipment specified as being stopped during operation based on the operation information as the equipment in which an abnormality has occurred.

[0010] Further, the abnormal equipment identification processing unit outputs the equipment identified as the equipment in which an abnormality has occurred, and further, acquires the power consumption individually measured for the equipment, and based on the power consumption of the equipment and the operation information, it is preferable to re-identify the equipment in which an abnormality in power consumption has occurred.

Advantages of the Invention

[0011] The present invention can provide a production management system that can be constructed at low cost.

Brief Description of the Drawings

[0012]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Modes for Carrying Out the Invention

[0013] In the previous application, Japanese Patent Application No. 2023-204898 (not published at the time of filing of this application), the inventor of the present application proposed an abnormal equipment identification system. The abnormal equipment identification system proposed in the previous application can identify equipment in which an abnormality has occurred among a plurality of equipment connected to each of a plurality of main lines. This application identifies the equipment in which an abnormality has occurred in the same manner as the previous application, and further identifies the products produced by the equipment in which an abnormality has occurred during the period in which the abnormality has occurred.

[0014] Embodiment 1 Hereinafter, with reference to the drawings, the production management system according to Embodiment 1 will be described.

[0015] <Configuration of Production Management System> First, with reference to FIG. 1, the configuration of the production management system according to Embodiment 1 will be described. FIG. 1 is a schematic diagram showing the configuration of the production management system according to Embodiment 1. The production management system 100 is a system that produces products by a plurality of equipment installed in, for example, a factory.

[0016] The production management system 100 includes a power consumption management device 1, an operation status management device 2, an abnormal equipment identification device 3, an IoT platform 4, a main line power meter 5, an equipment power meter 6, a main line distribution board 7, a distribution board 8, a production backbone system 9, a terminal 10, a production management department 11, a main line D, an equipment power line d, and a plurality of equipment E.

[0017] The power consumption management device 1 is a system that manages the power consumption of the equipment E in units of main lines that supply power to each equipment E. The power consumption management device 1 is connected to a plurality of main line power meters 5 and the IoT platform 4. The power consumption management device 1 acquires the power consumption of the main line D measured by the main line power meter 5 at a predetermined timing (typically constantly). Then, the power consumption management device 1 transmits the acquired power consumption of the main line D to the abnormal equipment identification device 3 via the IoT platform 4.

[0018] The operation status management device 2 is a system that manages operation information of multiple pieces of equipment E. The operation status management device 2 is also called an "andon panel," and is an electronic display panel that electronically displays operation information and work instructions for the equipment E. The operation status management device 2 is connected to multiple pieces of equipment E and an abnormal equipment identification device 3. The operation status management device 2 acquires operation information for the equipment E at predetermined times (typically, continuously). Next, the operation status management device 2 transmits the acquired operation information for the equipment E to the abnormal equipment identification device 3. The acquired operation information for the equipment E includes information indicating the operation status of the equipment E, such as whether the equipment E is operating, stopped, experiencing an abnormality or warning, or in an emergency stop. The operation status management device 2 outputs the operation information for the equipment E from an operation information notification unit, such as a display (not shown), so that the user can grasp the operation information for the equipment E.

[0019] The abnormal equipment identification device 3 is a system that identifies an equipment E in which an abnormality has occurred among multiple equipment E connected to multiple trunk lines D, and further identifies the products produced by the equipment E in which the abnormality occurred during the period in which the abnormality occurred. Here, the "production" in "products produced by equipment E" refers to various processes that equipment E performs on products on the product production line, and includes not only production in the narrow sense but also processes such as transportation, quality control, and monitoring.

[0020] The abnormal equipment identifying device 3 is connected to the operation status management device 2 and the IOT platform 4. The abnormal equipment identifying device 3 receives from the power consumption management device 1 power consumption information of the main line D acquired by the power consumption management device 1. The abnormal equipment identifying device 3 also receives from the operation status management device 2 operation information of equipment E acquired by the operation status management device 2. The abnormal equipment identifying device 3 also receives from the equipment power measuring device 6 the power consumption of equipment E measured by the equipment power measuring device 6 as power consumption information. Based on this received information, the abnormal equipment identifying device 3 executes processing to identify the main line D in which an abnormality in power consumption has occurred and the equipment E in which an abnormality in power consumption has occurred.

[0021] Then, the abnormal equipment identification device 3 acquires the production information of the products produced by the equipment E in which abnormal power consumption has occurred, from the abnormal equipment identification device 3. Based on the power consumption information of the equipment E and the production information of the products received from the production management department 11, the abnormal equipment identification device 3 identifies the products produced by the equipment E in which abnormal power consumption has occurred during the period when the abnormal power consumption has occurred.

[0022] The IOT platform 4 is connected via a network to a plurality of IOT (Internet Of Things) devices inside and outside the factory, and receives and transmits various information. The IOT platform 4 receives, for example, the power consumption of each main line D acquired by the power consumption management device 1 and transmits it to the abnormal equipment identification device 3. Also, the IOT platform 4 receives the production information acquired by the production management department and transmits it to the abnormal equipment identification device 3.

[0023] The main line power meter 5 is connected to the main line D and the power consumption management device 1. The main line power meter 5 constantly measures the power consumption of the main line D and transmits the measured power consumption information to the power consumption management device 1.

[0024] The equipment power meter 6 is used to individually measure the power consumption of the equipment E. The equipment power meter 6 is not provided for each of the equipment E, but is a device held by the user to measure the power of each equipment E. The equipment power meter 6 includes, for example, an input terminal connected to the power terminal of the equipment E, a sensor that detects the power amount based on the electrical signal input from the input terminal, a storage unit that holds the detected power amount as data, and an output unit that outputs the power amount. The user holds the equipment power meter 6 and moves it to appropriately measure the power consumption of the equipment E. The equipment power meter 6 transmits the measured power consumption of the equipment E to the abnormal equipment identification device 3 by wireless or wired communication.

[0025] The main line distribution board 7 supplies power to the distribution board 8 via the main line D. Then, the distribution board 8 supplies power to the equipment E via the equipment power line d.

[0026] The production backbone system 9 is a system that manages, for example, production plan information of products and procurement information of members used in production. The production backbone system 9 transmits production plan information, procurement information, etc. to the production management department 11. The production plan information is information regarding the production plan of products, including facility identification information, product identification information, time information, and operator identification information. The time information includes the scheduled production start time and the scheduled production completion time for each product at each facility E.

[0027] The terminal 10 is a terminal such as a smartphone, a tablet, a mobile terminal, or a portable terminal. The terminal 10 notifies the user of the work instruction information received from the production management department 11. Based on the work instruction information received by the terminal 10, the user executes work such as the operation and management of the facility E. Then, the user inputs the work performance information into the terminal 10. Then, the terminal 10 transmits the work performance information input by the user to the production management department 11. The work performance information is information regarding the production performance by each facility E, including facility identification information, product identification information, time information, and operator identification information. The time information includes the actual work start time and the actual work completion time for each product at each facility E.

[0028] The production management department 11 manages the production plan information, procurement information, etc. received from the production backbone system 9, and the work performance information received from the terminal 10. In addition, the production management department 11 generates work instruction information based on the production plan information, procurement information, etc. received from the production backbone system 9. The production management department 11 transmits the generated work instruction information to the terminal 10 as appropriate. When the production management department 11 receives the facility identification information of the facility E from the abnormal facility identification device 3, it transmits the production plan information or work performance information associated with the received facility identification information to the abnormal facility identification device 3 as the production information of the product.

[0029] When production is stable, since production can proceed according to the production plan, the production management system can use the production plan information as the production information of the product. On the other hand, for example, in the case of an unstable production process or product prototype, process abnormalities and equipment failures are likely to occur, and it is difficult to proceed with production according to the production plan. Therefore, when it is difficult to proceed with production according to the production plan, it is preferable to use the work performance information as the production information of the product.

[0030] Next, with reference to FIG. 2, the configuration of the abnormal equipment identification device 3 will be described. FIG. 2 is a block diagram of the abnormal equipment identification device according to Embodiment 1. The abnormal equipment identification device 3 includes a power consumption information acquisition unit 31, an operation information acquisition unit 32, a power consumption abnormality detection unit 33, an abnormal equipment identification processing unit 34, a notification unit 35, a production information acquisition unit 36, a product identification processing unit 37, and a product information storage unit 38.

[0031] The power consumption information acquisition unit 31 receives, from the power consumption management device 1 via the IOT platform 4, the power consumption of the main line D acquired by the power consumption management device 1 and stores it in a storage unit (not shown). Further, the power consumption information acquisition unit 31 receives, from the equipment power measuring device 6, the power consumption of the equipment E acquired by the equipment power measuring device 6 and the equipment identification information, and stores them in a storage unit (not shown). Furthermore, the power consumption information acquisition unit 31 stores, in a storage unit (not shown), the time information during the period when an abnormality in the power consumption input from the power consumption abnormality detection unit 33 occurs. The power consumption information acquisition unit 31 outputs the stored these information to the notification unit 35. When a command is input from the abnormal equipment identification processing unit 34, the power consumption information acquisition unit 31 outputs, as power consumption information, the power consumption of the equipment E specified by the abnormal equipment identification processing unit 34, the equipment identification information, and the time information during the period when an abnormality in the power consumption occurs, to the product information storage unit 38.

[0032] The operation information acquisition unit 32 receives, from the operation status management device 2, the operation information of the equipment E acquired by the operation status management device 2 and stores it in a storage unit (not shown). The operation information acquisition unit 32 outputs the stored operation information of the equipment E to the notification unit 35.

[0033] The power consumption abnormality detection unit 33 detects an abnormality in the power consumption based on the power consumption of the main line D stored in the power consumption information acquisition unit 31, and identifies the main line D in which the power consumption abnormality has occurred. The power consumption abnormality detection unit 33 outputs the information (identification information) of the identified main line D to the notification unit 35. Further, the power consumption abnormality detection unit 33 outputs the time information of the period during which the power consumption abnormality has occurred to the power consumption information acquisition unit 31.

[0034] The abnormal equipment identification processing unit 34 primarily identifies the equipment E in which the power consumption abnormality has occurred based on the power consumption of the main line D acquired by the power consumption information acquisition unit 31 from the power consumption management device 1 and the operation information of the equipment E acquired by the operation information acquisition unit 32 from the operation status management device 2. Further, the abnormal equipment identification processing unit 34 secondarily identifies, that is, re-identifies the equipment E in which the power consumption abnormality has occurred based on the power consumption of the equipment E acquired from the equipment power measuring instrument 6 and the operation information of the equipment E acquired from the operation information acquisition unit 32. These identification and re-identification processes will be described in detail later. The abnormal equipment identification processing unit 34 outputs the equipment identification information of the identified and re-identified equipment E to the notification unit 35 and the production information acquisition unit 36. Further, the abnormal equipment identification processing unit 34 outputs an instruction to output the power consumption of the identified and re-identified equipment E, the equipment identification number, and the time information of the period during which the power consumption abnormality has occurred as power consumption information to the product information storage unit 38 to the power consumption information acquisition unit 31.

[0035] The notification unit 35 outputs the information input from the power consumption information acquisition unit 31, the operation information acquisition unit 32, the power consumption abnormality detection unit 33, the abnormal equipment identification processing unit 34, and the product identification processing unit 37 so that the user can grasp it.

[0036] The production information acquisition unit 36 acquires the production information of the product from the production management unit 11. First, the production information acquisition unit 36 transmits the equipment identification information of the equipment E in which the abnormal power consumption has occurred, which is input from the abnormal equipment identification processing unit 34, to the production management unit 11. Then, the production management unit 11 transmits the production plan information or work performance information associated with the received equipment identification information to the abnormal equipment identification device 3 as the production information of the product. The production information acquisition unit 36 outputs the production information of the product received from the production management unit 11 to the product information storage unit 38.

[0037] The product identification processing unit 37 identifies the product produced by the equipment E in which the abnormal power consumption has occurred during the period when the abnormal power consumption has occurred, based on the power consumption information of the equipment E in which the abnormal power consumption has occurred and the production information of the product. The power consumption information of the equipment E includes the equipment identification information of the equipment E identified and re-identified as having an abnormal power consumption, the power consumption, and the time information of the period when the abnormal power consumption has occurred. The production information of the product includes the time information of the period when the product is produced by the equipment E identified and re-identified as having an abnormal power consumption, and the product identification information of the product.

[0038] The product identification processing unit 37 associates the power consumption information and the production information stored in the product information storage unit 38 with the time information as the linking key. Then, the product identification information of the product produced by the equipment E in which the abnormal power consumption has occurred during the period when the abnormal power consumption has occurred can be obtained. In other words, the product produced by the equipment E in which the abnormal power consumption has occurred during the period when the abnormal power consumption has occurred can be identified. Further, the identification information of the identified product is output to the notification unit 35.

[0039] <Production management method> The production management method by the production management system according to the first embodiment will be described. FIG. 3 is a flowchart of the production management system according to the first embodiment.

[0040] First, the power consumption information acquisition unit 31 acquires the power consumption of each main line D from the power consumption management device 1 via the IOT platform 4 and stores it in a storage unit (not shown) (step S101). Next, the power consumption abnormality detection unit 33 detects an abnormality in the power consumption of the main line D acquired and stored by the power consumption information acquisition unit 31, and identifies the main line D in which the power consumption abnormality has occurred (step S102). The method for detecting the power consumption abnormality will be described in detail later.

[0041] Next, the operation information acquisition unit 32 acquires the operation information of the facility E from the operation status management device 2 and stores it in a storage unit (not shown) (step S103). Next, the abnormal facility identification processing unit 34 identifies the facility E in which the power consumption abnormality has occurred (step S104). Based on the power consumption of the main line D identified as having an abnormality in step S102 and the operation information of the facility E connected to the main line D, the abnormal facility identification processing unit 34 identifies the facility E in which the power consumption abnormality has occurred. The method for identifying the facility E in which the power consumption abnormality has occurred in step S104 will be described in detail later.

[0042] Next, the power consumption individually measured for the facility identified in step S104 is acquired (step S105). After identifying the facility E in which the power consumption abnormality has occurred, the user individually measures the power consumption of the identified facility E using the facility power meter 6. The power consumption information acquisition unit 31 receives and stores the power consumption of the facility E and the facility identification information acquired by the facility power meter 6 from the facility power meter 6.

[0043] Next, the abnormal equipment identification processing unit 34 re-identifies the equipment E in which abnormal power consumption has occurred (step S106). Based on the operation information of the equipment E connected to the main line D identified as having an abnormality in step S102 and the power consumption of the equipment E identified as the equipment in which the abnormality has occurred, received from the equipment power meter 6 in step S105, the abnormal equipment identification processing unit 34 re-identifies the equipment E in which abnormal power consumption has occurred. Next, the abnormal equipment identification processing unit 34 outputs an instruction to output the power consumption of the re-identified equipment E, the equipment identification number, and the time information during the period when the abnormal power consumption has occurred as power consumption information to the product information storage unit 38 to the power consumption information acquisition unit 31. Then, the abnormal equipment identification processing unit 34 outputs the equipment identification information of the equipment E in which abnormal power consumption has occurred to the production information acquisition unit 36.

[0044] If there are multiple pieces of equipment E identified in step S104, there may be equipment E whose cause of abnormality is not power consumption. Therefore, in step S105, by individually measuring the power consumption of the equipment E, the equipment E whose cause of abnormality is due to power consumption is re-identified. Thus, if, for example, there is only one piece of equipment E identified in step S104 and it can be determined that the cause of the abnormality of the identified equipment E is due to power consumption, re-identification is unnecessary and step S106 may not be executed.

[0045] If step S106 is not executed, in step S104, the abnormal equipment identification processing unit 34 outputs the equipment identification information of the equipment E in which abnormal power consumption has occurred to the production information acquisition unit 36. Also, in step S105, the abnormal equipment identification processing unit 34 outputs an instruction to output the power consumption of the identified equipment E, the equipment identification number, and the time information during the period when the abnormal power consumption has occurred as power consumption information to the product information storage unit 38 to the power consumption information acquisition unit 31.

[0046] Next, the power consumption information acquisition unit 31 stores the power consumption information of the equipment E specified and re-specified by the abnormal equipment identification processing unit 34 in the product information storage unit 38 (step S107). The power consumption information acquisition unit 31 outputs the power consumption of the equipment E specified and re-specified by the abnormal equipment identification processing unit 34, the equipment identification information, and the time information of the period during which the power consumption abnormality occurred to the product information storage unit 38 as power consumption information.

[0047] Next, the production information acquisition unit 36 acquires the production information of the product from the production management unit 11 and stores the production information of the product in the product information storage unit 38 (step S108). The production information acquisition unit 36 transmits the equipment identification information of the equipment E in which the power consumption abnormality occurred, which is input from the abnormal equipment identification processing unit 34, to the production management unit 11. Then, the production management unit 11 transmits the production plan information or work performance information associated with the received equipment identification information to the abnormal equipment identification device 3 as the production information of the product. The production information acquisition unit 36 outputs the production information of the product received from the production management unit 11 to the product information storage unit 38.

[0048] Finally, the product identification processing unit 37 identifies the products produced by the equipment E in which the power consumption abnormality occurred during the period in which the power consumption abnormality occurred, based on the power consumption information of the equipment E in which the power consumption abnormality occurred and the production information of the product (step S109). The power consumption information of the equipment E includes the equipment identification information of the equipment E specified and re-specified as having the power consumption abnormality, the power consumption, and the time information of the period during which the power consumption abnormality occurred. The production information of the product includes the time information of the period during which the product is produced by the equipment E specified and re-specified as having the power consumption abnormality, and the product identification information of the product.

[0049] The product identification processing unit 37 associates the power consumption information and the production information stored in the product information storage unit 38 using the time information as a linking key. Then, the product identification information of the products produced by the equipment E in which the power consumption abnormality occurred during the period in which the power consumption abnormality occurred can be obtained. In other words, the products produced by the equipment E in which the power consumption abnormality occurred during the period in which the power consumption abnormality occurred can be identified.

[0050] In these steps, the received power consumption, operation information, the identified and re-identified information of the equipment E, the identification information of the products produced by the equipment E where the power consumption anomaly occurred during the period when the power consumption anomaly occurred, etc. are appropriately output to the notification unit 35 so that the user can grasp them.

[0051] <Method for Detecting Power Consumption Anomaly in Main Line> Referring to FIG. 4, a method (step S102) for detecting an anomaly in the power consumption of the main line D in the power consumption anomaly detection unit 33 will be described. FIG. 4 is a flowchart of a method for detecting a power consumption anomaly in the main line according to Embodiment 1.

[0052] The power consumption anomaly detection unit 33 detects an anomaly in the power consumption of the main line D based on the power consumption of the main line D stored in the power consumption information acquisition unit 31 in step S101. Specifically, the user determines in advance a threshold value of the power consumption in the main line D that serves as a criterion for determining an anomaly in the power consumption and sets it in the power consumption anomaly detection unit 33. In a typical example, the threshold value includes information on the upper limit value and the lower limit value of the power consumption determined to be normal. The power consumption anomaly detection unit 33 compares the power consumption of the main line D stored in the power consumption information acquisition unit 31 with the predetermined threshold value of the power consumption for the corresponding main line D (step S201).

[0053] If the power consumption of the main line D stored in the power consumption information acquisition unit 31 in step S101 is equal to or greater than the upper limit of the threshold value, or equal to or less than the lower limit, the power consumption anomaly detection unit 33 determines that an anomaly in the power consumption of the main line D has occurred (step S202). Then, the abnormal equipment identification device 3 executes step S103. On the other hand, if the power consumption of the main line D stored in the power consumption information acquisition unit 31 in step S101 is less than the upper limit of the threshold value and exceeds the lower limit, the power consumption anomaly detection unit 33 determines that the power consumption of the main line D is normal. When the power consumption of the main line D is determined to be normal, the abnormal equipment identification device 3 does not execute step S103.

[0054] <Method for Identifying Equipment with Abnormal Power Consumption> Referring to FIG. 5, a method (step S104) for identifying equipment with abnormal power consumption in the abnormal equipment identification processing unit 34 will be described. FIG. 5 is a flowchart of a method for identifying equipment with abnormal power consumption according to Embodiment 1.

[0055] Based on the power consumption of the main line D stored in the power consumption information acquisition unit 31 in step S101 and the operation information of the equipment E stored in the operation information acquisition unit 32 in step S103, the abnormal equipment identification processing unit 34 identifies the equipment E with abnormal power consumption among the equipment E connected to the main line D with abnormal power consumption.

[0056] First, the abnormal equipment identification processing unit 34 compares the power consumption of the main line D stored in the power consumption information acquisition unit 31 with a predetermined power consumption threshold value for the corresponding main line D (step S401). The power consumption threshold value in this step S401 is the same as the power consumption threshold value used in step S201. Also, this step S401 is a step after it is determined in step S202 that abnormal power consumption has occurred in the main line D. Therefore, it is a prerequisite that the acquired power consumption of the main line D is equal to or higher than the upper limit of the threshold value, or equal to or lower than the lower limit.

[0057] In step S401, when the power consumption of the main line D is equal to or higher than the upper limit of the threshold value, the abnormal equipment identification processing unit 34 extracts the operating equipment E connected to the main line D where the abnormal power consumption has occurred, based on the operating information of the equipment E stored in the operation information acquisition unit 32 in step S103 (step S402). Next, in the same manner as step S402, the abnormal equipment identification processing unit 34 extracts the equipment E where an abnormality or warning has occurred and that is connected to the main line D where the power abnormality has occurred, based on the operating information of the equipment E stored in the operation information acquisition unit 32 in step S103 (step S403). Next, the abnormal equipment identification processing unit 34 extracts the equipment E extracted in both steps S402 and S403 (step S404). Then, the equipment E extracted in step S404 is output to the notification unit 35 as the equipment E where an abnormality has occurred. The order of steps S402 and S403 may be reversed.

[0058] On the other hand, in step S401, when the power consumption of the main line D is equal to or lower than the lower limit of the threshold value, the abnormal equipment identification processing unit 34 extracts the equipment E that has stopped operating or has stopped abnormally and that is connected to the main line D where the power abnormality has occurred, based on the operating information of the equipment E stored in the operation information acquisition unit 32 in step S103 (step S405). Then, the abnormal equipment identification processing unit 34 outputs the equipment E extracted in step S405 to the notification unit 35 as the equipment E where an abnormality has occurred.

[0059] The state of the equipment E identified as abnormal in steps S404 and S405 can be estimated as follows. Since the equipment E identified in step S404 has a power consumption equal to or higher than the upper limit of the threshold value detected in the main line D, it is estimated that an equipment abnormality has occurred due to, for example, a cycle time overrun. On the other hand, since the equipment E identified in step S405 has a power consumption equal to or lower than the lower limit of the threshold value detected in the main line D, it is estimated that a sudden abnormal stop or a stop in operation has occurred.

[0060] Note that the present invention is not limited to the above-described embodiments, and can be appropriately modified without departing from the spirit thereof.

[0061] In the first embodiment, the abnormal equipment identification device 3 identifies the products produced by the equipment E in which the abnormality occurred during the period when the abnormality occurred, but is not limited thereto. For example, the IOT platform 4, the production management department 11, etc. may identify the products produced by the equipment E in which the abnormality occurred during the period when the abnormality occurred.

[0062] As an application example of the present invention, for example, carbon footprint countermeasures can be cited. In order to calculate the CO2 emission per product, it is necessary to obtain the power consumption per equipment unit and divide it by the number of products produced by the equipment to calculate the power consumption per product. In the present invention, the products produced by the equipment E in which the power consumption abnormality occurred during the period when the power consumption abnormality occurred are identified. Therefore, for example, by dividing the power consumption during the period when the power consumption abnormality occurred by the number of identified products, the power consumption per product during the period when the power consumption abnormality occurred can be calculated.

[0063] In addition, the present disclosure can also be realized by causing a CPU (Central Processing Unit) to execute part or all of the processing of the abnormal equipment identification device 3 as an abnormal equipment identification program.

[0064] The above program can be stored using various types of non-transitory computer readable media and supplied to a computer. Non-transitory computer readable media include various types of tangible storage media. Non-transitory computer readable media include, for example, magnetic recording media, magneto-optical recording media, CD-ROM (Read Only Memory), CD-R, CD-R / W, and semiconductor memory. Magnetic recording media include, for example, flexible disks, magnetic tapes, hard disk drives, etc. Magneto-optical recording media include, for example, magneto-optical disks. Semiconductor memory includes, for example, mask ROM, PROM (Programmable ROM), EPROM (Erasable PROM), flash ROM, RAM (Random Access Memory), etc. Also, the program may be supplied to the computer by various types of transitory computer readable media. Examples of transitory computer readable media include electrical signals, optical signals, and electromagnetic waves. Transitory computer readable media can supply the program to the computer via wired communication paths such as electric wires and optical fibers, or wireless communication paths.

Explanation of Signs

[0065] 1 Power consumption management device 2 Operating status management device 3 Abnormal equipment identification device 4 IOT platform 5 Trunk power meter 6 Equipment power meter 7 Main distribution board 8 Distribution board 9 Production backbone system 10 Terminal 11 Production management department 31 Power consumption information acquisition unit 32 Operating information acquisition unit 33 Power consumption abnormality detection unit 34 Abnormal Equipment Specific Processing Unit 35 Notification Unit 36 Production Information Acquisition Unit 37 Product Specific Processing Unit 38 Product Information Storage Unit 100 Production Management System D Trunk Line d Equipment Power Line E Equipment

Claims

1. A production management system that identifies equipment in which an abnormality has occurred among a plurality of pieces of equipment connected to each of a plurality of main lines, and further identifies products produced by the equipment during the period in which the abnormality has occurred, comprising: a power consumption information acquisition unit that acquires power consumption in units of main lines; an operation information acquisition unit that acquires operation information for each of the plurality of pieces of equipment; an abnormal equipment identification processing unit that identifies a main line in which a power abnormality has occurred based on the power consumption acquired by the power consumption information acquisition unit, and identifies equipment in which a power consumption abnormality has occurred based on the power consumption of the identified main line and the operation information of the equipment acquired by the operation information acquisition unit; a production management unit that acquires production information of products; a product identification processing unit that identifies products produced by the equipment during the period in which a power consumption abnormality has occurred based on the power consumption information and the production information of the equipment in which the power consumption abnormality has occurred; and a production management system.

2. The power consumption information includes time information of a period in which a power consumption abnormality has occurred and the power consumption of the equipment during the period, the production information includes time information of a period in which the product is produced by the equipment and product identification information of the product, respectively, and the product identification processing unit identifies products produced by the equipment during the period in which a power consumption abnormality has occurred by associating the power consumption information and the production information using the time information as an association key. The production management system according to claim 1.

3. The abnormal equipment identification processing unit: compares the power consumption in units of main lines acquired by the power consumption information acquisition unit with a power consumption threshold value predetermined for the corresponding main line, and when the power consumption of the acquired main line is equal to or higher than the upper limit of the corresponding threshold value, identifies the equipment identified as being in operation based on the operation information as the equipment in which an abnormality has occurred. The production management system according to claim 2.

4. The abnormal equipment identification processing unit: compares the power consumption in units of main lines acquired by the power consumption information acquisition unit with a power consumption threshold value predetermined for the corresponding main line, and when the power consumption of the acquired main line is equal to or lower than the lower limit of the corresponding threshold value, identifies the equipment identified as being in a stopped state based on the operation information as the equipment in which an abnormality has occurred. The production management system according to claim 2.

5. The abnormal equipment identification processing unit: outputs the equipment identified as the equipment in which an abnormality has occurred. Furthermore, obtain the power consumption measured individually for the equipment, and re-identify the equipment in which an abnormality in power consumption has occurred based on the power consumption of the equipment and the operation information. The production management system according to claim 3 or 4.

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