Analysis system for seat product production line

Abstract

To provide an analysis system capable of easily and more accurately grasping elements to be improved in terms of effective improvement of operating rate without requiring a complicated input work.SOLUTION: An analysis system 100 comprises: a time identification unit 125; an acquisition unit 126; a storage unit 143; and a stop time calculation unit 144. The time identification unit 125 identifies a stop time of a PTP machine. The acquisition unit 126 acquires stop factor device information and a stop reason, which are inputted. The storage unit 143 associates and stores the stop factor device information and the like acquired by the acquisition unit 126 with the stop time specified by the time specifying unit 125. The stop time calculation unit 144 calculates the stop time of the PTP machine caused by an extraction target element for each extraction target element based on the information stored in the storage unit 143 as the extraction target element by using the stop factor device information, the stop reason, or a combination thereof as the extraction target element. In the management display unit 141, the extraction target elements can be displayed in an order according to length of the calculated stop times.SELECTED DRAWING: Figure 7

Description

[Technical field]

[0001] The present invention relates to a system for analyzing a sheet product production line capable of manufacturing blister sheets containing contents and producing sheet products by processing the manufactured blister sheets. [Background technology]

[0002] A press-through pack (PTP) sheet is known as a blister sheet generally used in the fields of medicines, food, etc. A PTP sheet comprises a container film having a pocket portion in which contents such as tablets are stored, and a cover film attached to the container film so as to seal the opening side of the pocket portion.

[0003] Such PTP sheets are manufactured and subjected to various processes using a sheet product production line having a PTP machine and post-processing equipment. The PTP machine is a device for manufacturing PTP sheets. The PTP machine is equipped with a means for preheating a belt-shaped container film being conveyed, a means for forming a pocket portion in the preheated container film, a means for filling the pocket portion with contents, a means for attaching a cover film to the container film so as to seal the opening side of the pocket portion, and a means for punching out the belt-shaped PTP film consisting of the container film and the cover film into PTP sheet units.

[0004] The post-processing equipment is an equipment that performs various processes on the PTP sheets produced by the PTP machine. Examples of the post-processing equipment include a stacking machine that stacks PTP sheets, a banding machine that bands the stacked PTP sheets, a pillow bagging machine that packs PTP sheets, and a boxing machine (such as a cartoner or caser) that packs multiple PTP sheets into boxes. The sheet products obtained through the post-processing equipment (such as multiple boxed PTP sheets) are finally shipped.

[0005] In sheet product production lines such as those described above, there is a constant demand for improving the operating rate. To achieve this, it is necessary to accurately grasp the operating status of each type of production equipment constituting the production line.

[0006] In this regard, a technique is known as a conventional technique for providing an equipment operation status recording device that is equipped with a cause input key for inputting causes such as failures for each piece of production equipment (see, for example, Patent Document 1, etc.). In this technique, the cause input keys include a first stop cause input means for inputting a stop cause when the production equipment is stopped due to a human cause, and a second stop cause input means for inputting a stop cause when the production equipment is stopped due to a failure or the like. When the production equipment is stopped, a specific stop cause is input by the first or second stop cause input means, making it possible to specifically record the human stop cause, failure, etc. [Prior art documents] [Patent documents]

[0007] [Patent Document 1] Japanese Patent Application Publication No. 10-6190 Summary of the Invention [Problem to be solved by the invention]

[0008] Here, it is conceivable to apply the above-mentioned conventional technology to a sheet product production line in order to increase the productivity of sheet products. However, a sheet product production line is equipped with a PTP machine and a post-process device, and is composed of a plurality of pieces of production equipment. Therefore, if the above-mentioned conventional technology is applied to a sheet product production line, when the production line is stopped, data must be input to the equipment operation status recording device provided for each piece of production equipment, and the input work may require a great deal of time. In addition, since the cause of the stoppage is input and stored for each piece of production equipment, it becomes difficult to grasp which production equipment has a problem in terms of improving the operation rate.

[0009] Furthermore, in a sheet product production line, the processing speed of the post-processing device may be set sufficiently higher than the manufacturing speed of the PTP sheet by the PTP machine. In such a case, a short stop of the post-processing device may not have any effect on the operation rate of the sheet product production line. If such information that has no effect on the operation rate is input to the equipment operation status storage device, it may be difficult to understand the factors that affect the operation rate of the production line, in other words, the factors that need to be improved in order to increase the operation rate.

[0010] The present invention has been made in consideration of the above-mentioned circumstances, and an object of the present invention is to provide an analysis system for a sheet product production line that can more easily and accurately grasp factors that need to be improved in order to effectively increase the operating rate, without requiring complicated input work. [Means for solving the problem]

[0011] The following describes each of the means suitable for achieving the above object. Note that, as necessary, the specific effects of the corresponding means will be added.

[0012] Means 1. A pocket forming means for forming a pocket in a strip-shaped container film; a filling means for filling the pocket formed by the pocket forming means with a content; an attachment means for attaching a strip-shaped cover film to the container film so as to close the pocket portion of the container film having the contents filled in the pocket portion; a punching means for punching a strip-shaped blister film formed by attaching the cover film to the container film by the attaching means, thereby obtaining a blister sheet having contents filled in the pocket portions; and one or more post-processing devices provided downstream of the blister sheet manufacturing apparatus and performing a predetermined process on the manufactured blister sheet; An analysis system for a sheet product production line for producing a sheet product obtained by subjecting the manufactured blister sheet to the processing, comprising: while the sheet product production line is in operation to produce the sheet products, the number of blister sheets that can be processed by the post-processing device per unit time is set to be greater than the number of blister sheets that can be manufactured by the blister sheet manufacturing device per unit time, A time specifying means for specifying a stop time of the blister sheet manufacturing apparatus; an input means for inputting stoppage cause device information, which is information indicating a device that caused the stoppage of the blister sheet manufacturing device among the blister sheet manufacturing device and one or more of the post-process devices, and a reason for the stoppage, which is the reason for the stoppage (for example, an input device for manual input and / or a blister sheet manufacturing device for automatic input, etc.); an acquisition means for acquiring the stop cause device information and the stop reason input by the input means; a storage means for storing the stop cause device information and the stop reason acquired by the acquisition means in association with the stop time identified by the time identification means; a stop time calculation means for calculating a stop time of the blister sheet manufacturing apparatus caused by each of the extraction target elements based on the information stored in the storage means, the stop cause device information, the stop reason, or a combination of the stop cause device information and the stop reason being an extraction target element; a display means for displaying the extraction target elements in an order according to the magnitude of the stop time of the blister sheet manufacturing apparatus calculated by the stop time calculation means. death, a reason classification means for classifying the reasons for suspension into essential suspension reasons necessary for the production of the sheet product and reducible suspension reasons which are unnecessary for the production of the sheet product and can be reduced, the downtime calculation means is configured to be able to calculate a downtime of the blister sheet manufacturing apparatus related to the reducible downtime reason for each of the extraction target elements, the display means is configured to be able to display the extraction target elements in an order according to the magnitude of the stoppage time of the blister sheet manufacturing apparatus related to the reducible stoppage reason, an upper limit time storage means for storing an upper limit time allowed for a stop time of the blister sheet manufacturing apparatus related to the essential stop reason, The reason classification means is configured to classify the stop reason corresponding to the stop time exceeding the upper limit time among the stop times of the blister sheet manufacturing apparatus related to the essential stop reason into the reducible stop reason. 1. An analysis system for a sheet product production line comprising:

[0013] According to the above-mentioned means 1, when the sheet product production line is operating to produce sheet products, the number of blister sheets that can be processed by the post-processing device per unit time (maximum number of processes) is set to be greater than the number of blister sheets manufactured per unit time. In other words, the processing speed of the post-processing device is set to be greater than the manufacturing speed of the blister sheets. Therefore, the stop of the blister sheet manufacturing device directly affects the operating rate of the sheet product production line.

[0014] In addition, in the above-mentioned means 1, when a stop of the blister sheet manufacturing apparatus occurs, which directly affects the operating rate of the sheet product production line, the time specifying means specifies the stop time of the blister sheet manufacturing apparatus. Furthermore, the input means inputs stop cause device information, which is information indicating the device that caused the stop among the blister sheet manufacturing apparatus and one or more post-process devices, and the stop reason, which is the reason for the stop, and the acquisition means acquires this information. For example, if the stop of the blister sheet manufacturing apparatus is caused by the apparatus itself, "blister sheet manufacturing apparatus" is acquired as the stop cause device information, and if the stop of the blister sheet manufacturing apparatus is caused by one post-process device, "one post-process device" is acquired as the stop cause device information. In addition, the reason that caused the stop, such as "cleaning", "work jamming", or "break", is acquired as the stop reason. Then, in the storage means, the stop cause device information and the stop reason are associated with the stop time of the blister sheet manufacturing apparatus and stored.

[0015] Furthermore, the stop time calculation means can calculate the stop time of the blister sheet manufacturing apparatus caused by the stop cause device information, the stop cause, or a combination of these as the extraction target elements based on the information stored in the storage means for each extraction target element. More specifically, when the stop cause device information is the extraction target element, the stop time caused by each device that caused the stop of the blister sheet manufacturing apparatus can be calculated. For example, when the devices that caused the stop are a "blister sheet manufacturing apparatus" and a "first post-process device", the stop time caused by the "blister sheet manufacturing apparatus" and the stop time caused by the "first post-process device" can be calculated. Furthermore, when the stop cause is the extraction target element, the stop time caused by each of these stop causes can be calculated for each of these stop causes. For example, when the stop causes are "cleaning" and "break", the stop time caused by "cleaning" and the stop time caused by "break" can be calculated. Furthermore, when the extraction target element is a combination of the stop cause information device and the stop cause, the stop time caused by each of these combinations can be calculated. For example, if the element to be extracted is a combination of "blister sheet manufacturing equipment" or "post-process equipment 1" with "cleaning" or "rest," a maximum of four (2 x 2) types of downtime can be calculated, including the downtime caused by the stoppage of the "blister sheet manufacturing equipment" due to "cleaning."

[0016] According to the above-mentioned means 1, the display means can display the extraction target elements in an order according to the length of the stoppage time calculated by the stoppage time calculation means. For example, when the stoppage cause equipment information is set as the extraction target element, if the stoppage time caused by the blister sheet manufacturing equipment is 30 minutes and the stoppage time caused by one post-process equipment is 10 minutes, the blister sheet manufacturing equipment and the one post-process equipment are displayed in this order. Therefore, it is possible to more easily and more accurately grasp the extraction target elements that cause a long stoppage time of the blister sheet manufacturing equipment, i.e., the elements that have a particular impact on the operating rate of the sheet product production line and that should particularly be improved in terms of effectively improving the operating rate.

[0017] Furthermore, according to the above-mentioned means 1, when a stoppage occurs in the sheet product production line, the information that needs to be manually input to the system is, at most, the stoppage cause device information and the reason for the stoppage (to be acquired by the acquisition means). Therefore, complicated input work is not required, and it is possible to improve the convenience of managing the sheet product production line.

[0019] Also, The event classification means can classify stop events into essential stop events that are necessary for the production of sheet products and cannot be reduced, and reducible stop events that are unnecessary for the production of sheet products and can be reduced. Examples of essential stop events include "cleaning," "rest," and "work for switching the type of blister sheet being manufactured (product switching work)." On the other hand, examples of reducible stop events include "work jam (e.g., jam of contents or blister sheets)" and "scrap full (container for storing scrap is full)."

[0020] Furthermore, the stop time calculation means can calculate the stop time of the blister sheet manufacturing apparatus related to the reducible stop reason for each extraction target element. More specifically, when the stop cause device information is set as the extraction target element, the stop time related to the reducible stop reason caused by each device that caused the stop of the blister sheet manufacturing apparatus can be calculated. For example, when the devices that caused the stop are the "blister sheet manufacturing apparatus" and the "first post-process device", the time related to the reducible stop reason out of the stop time caused by the "blister sheet manufacturing apparatus" and the time related to the reducible stop reason out of the stop time caused by the "first post-process device" can be calculated. Furthermore, when the stop reason is set as the extraction target element, the stop time caused by each of these reducible stop reasons can be calculated. For example, when the stop reasons are "cleaning", "work jam" and "scrap full", the stop times caused by the reducible stop reasons "work jam" and "scrap full" can be calculated. Furthermore, when the elements to be extracted are combinations of stop cause information devices and stop reasons, the stop time related to the reducible stop reasons caused by each combination can be calculated. For example, when the elements to be extracted are a combination of "blister sheet manufacturing equipment" or "1 post-process equipment" and "work jam" or "rest", the time related to "work jam" out of the stop time caused by "blister sheet manufacturing equipment" and the time related to "work jam" out of the stop time caused by "1 post-process equipment" can be calculated.

[0021] In addition, the above means 1According to the display means, the elements to be extracted can be displayed in order according to the length of the stoppage time related to the reducible stoppage reason. For example, in a case where the stoppage cause device information is set as the element to be extracted, if the time related to the reducible stoppage reason among the stoppage time caused by the blister sheet manufacturing device is 5 minutes and the time related to the reducible stoppage reason among the stoppage time caused by one post-process device is 10 minutes, the one post-process device and the blister sheet manufacturing device are displayed in this order. Therefore, it is possible to more easily and accurately grasp the elements to be extracted that cause a long stoppage time of the blister sheet manufacturing device and that are related to the reducible stoppage reason, i.e., the elements that should be improved in terms of effectively increasing the operating rate and whose improvement does not affect the production of sheet products (the elements are not necessarily required for the production of sheet products).

[0023] Also, The reason classification means can classify the stoppage reason corresponding to the stoppage time exceeding the upper limit time among the stoppage times of the blister sheet manufacturing apparatus related to the mandatory stoppage reason into a reducible stoppage reason. This makes it possible to treat the stoppage reason corresponding to the stoppage time (work time) exceeding the upper limit time as a reducible stoppage reason, for example, when the blister sheet manufacturing apparatus stops due to work such as product type changeover or regular maintenance (i.e., a mandatory stoppage reason) and the work is not completed within the upper limit time. Therefore, it is possible to more easily and more accurately grasp the elements that need to be improved in terms of effectively increasing the operating rate. Also, it is possible to more reliably prevent the elements that need to be improved from being overlooked.

[0024] means 2 . a pocket forming means for forming a pocket in a strip-shaped container film; a filling means for filling the pocket formed by the pocket forming means with a content; an attachment means for attaching a strip-shaped cover film to the container film so as to close the pocket portion of the container film having the contents filled in the pocket portion; a punching means for punching a strip-shaped blister film formed by attaching the cover film to the container film by the attaching means, thereby obtaining a blister sheet having contents filled in the pocket portions; and one or more post-processing devices provided downstream of the blister sheet manufacturing apparatus and performing a predetermined process on the manufactured blister sheet; An analysis system for a sheet product production line for producing a sheet product obtained by subjecting the manufactured blister sheet to the processing, comprising: while the sheet product production line is in operation to produce the sheet products, the number of blister sheets that can be processed by the post-processing device per unit time is set to be greater than the number of blister sheets that can be manufactured by the blister sheet manufacturing device per unit time, A time specifying means for specifying a stop time of the blister sheet manufacturing apparatus; an input means for inputting stoppage cause device information, which is information indicating a device that caused the stoppage of the blister sheet manufacturing apparatus among the blister sheet manufacturing apparatus and one or more of the post-process devices, and a stoppage reason, which is the reason for the stoppage; an acquisition means for acquiring the stop cause device information and the stop reason input by the input means; a storage means for storing the stop cause device information and the stop reason acquired by the acquisition means in association with the stop time identified by the time identification means; a stop time calculation means for calculating a stop time of the blister sheet manufacturing apparatus caused by each of the extraction target elements based on the information stored in the storage means, the stop cause device information, the stop reason, or a combination of the stop cause device information and the stop reason being an extraction target element; a display means capable of displaying the extraction target elements in an order according to the length of the stop time of the blister sheet manufacturing apparatus calculated by the stop time calculation means, a reason classification means for classifying the reasons for suspension into essential suspension reasons necessary for the production of the sheet product and reducible suspension reasons which are unnecessary for the production of the sheet product and can be reduced, the downtime calculation means is configured to be able to calculate a downtime of the blister sheet manufacturing apparatus related to the reducible downtime reason for each of the extraction target elements, the display means is configured to be able to display the extraction target elements in an order according to the magnitude of the stoppage time of the blister sheet manufacturing apparatus related to the reducible stoppage reason, an upper limit number storage means for storing an upper limit number of times allowed as the number of times the blister sheet manufacturing apparatus is stopped due to the essential stop reason; The reason classification means is configured to classify the essential stop reason corresponding to the number of times exceeding the upper limit number of times into the reducible stop reason. Rusi Analysis system for automotive product production lines.

[0025] The above means 2 According to the method, the reason classification means can classify the mandatory stop reasons that exceed the upper limit number of times into reducible stop reasons. As a result, for example, when the blister sheet manufacturing apparatus stops due to work such as product type changeover or regular maintenance (i.e., mandatory stop reasons), if the number of stop times due to that work within a certain period of time exceeds the upper limit number of times, the stop reason corresponding to the number of times exceeding the upper limit number of times can be treated as a reducible stop reason. Therefore, it is possible to more easily and accurately grasp the elements that need to be improved in terms of effectively increasing the operating rate. Also, it is possible to more reliably prevent elements that need to be improved from being overlooked.

[0026] means 3 The acquiring means is configured to acquire at least one of the stoppage cause device information and the stoppage reason based on a predetermined cause identification signal input from at least one of the blister sheet manufacturing device and the post-process device as the input means. 1 or 2 2. An analysis system for a sheet product production line according to claim 1 .

[0027] The above means 3According to the present invention, the acquisition means can acquire at least one of the stop cause device information and the stop reason based on a predetermined cause identification signal input from at least one of the blister sheet manufacturing device and the post-process device as the input means, thereby reducing the effort and errors caused by manually inputting the stop reason, etc., and more effectively improving the convenience of managing the sheet product production line.

[0028] means 4 An information processing device having at least the acquisition means, Means 1 to 4, characterized in that only the blister sheet manufacturing apparatus out of the blister sheet manufacturing apparatus and the post-processing apparatus is configured to be able to communicate with the information processing apparatus. 3 2. The analysis system for a sheet product production line according to claim 1 .

[0029] The above means 4 According to the method, of the blister sheet manufacturing apparatus and the post-processing apparatus, only the blister sheet manufacturing apparatus is capable of communicating with an information processing device having an acquisition means, etc. Therefore, compared to a case where the post-processing apparatus is similarly capable of communicating, the system can be further simplified and the costs associated with the manufacturing and maintenance of the system can be effectively reduced. Note that, for example, a signal related to the stoppage of the blister sheet manufacturing apparatus (the above-mentioned means) is transmitted between the blister sheet manufacturing apparatus and the information processing device. 3 Signals such as a signal to identify the cause of the problem are communicated. [Brief description of the drawings]

[0030] [Figure 1] 1 is a block diagram showing a schematic configuration of a sheet product production line and an analysis system. [Diagram 2] FIG. 2 is a perspective view showing a PTP sheet. [Diagram 3] FIG. 2 is a partially enlarged cross-sectional view of the PTP sheet. [Figure 4] FIG. 1 is a schematic diagram showing a general configuration of a PTP machine. [Diagram 5]FIG. 1 is a schematic perspective view showing a sheet product and a bundle of sheets obtained in the production process thereof. [Figure 6] FIG. 2 is an explanatory diagram for simply explaining signals transmitted and received between devices, and the operation of the main tablet PC when receiving a signal. [Figure 7] FIG. 1 is a block diagram showing a schematic configuration of an analysis system. [Figure 8] FIG. 13 is a diagram illustrating an example of an upper limit time to be stored. [Figure 9] 11A and 11B are diagrams illustrating an example of stored stop time, stop cause device information, and the like. [Figure 10] FIG. 13 is a diagram showing an example of an excess response input screen. [Figure 11] FIG. 13 is a diagram showing an example of a basic screen. [Figure 12] FIG. 13 is a diagram showing an example of a stop information input screen. [Figure 13] FIG. 13 is a diagram showing an example of a condition designation screen. [Figure 14] FIG. 13 is a diagram illustrating an example of information arranged in order of downtime related to reducible downtime reasons in a case where downtime cause device information is set as an element to be extracted. [Figure 15] FIG. 13 is a diagram showing an example of information displayed when a reason for suspension is set as an extraction target element. [Figure 16] 13 is a diagram showing an example of information displayed when a combination of stop cause device information and a stop reason is set as an extraction target element. FIG. [Figure 17] 13 is a diagram showing an example of information arranged in order of stoppage time related to a mandatory stoppage reason when stoppage cause device information is set as an extraction target element. FIG. [Figure 18] FIG. 11 is a block diagram showing a schematic configuration of a main tablet PC having an upper limit number storage unit in another embodiment. [Figure 19] FIG. 13 is a diagram illustrating an example of an upper limit number of times that is stored. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0031] An embodiment will be described below with reference to the drawings. As shown in Fig. 1, an analysis system 100 in this embodiment is applied to a sheet product production line 200 for manufacturing a PTP sheet 1 (see Fig. 2) as a blister sheet and for producing a sheet product 9 (see Fig. 5) by subjecting the manufactured PTP sheet 1 to a predetermined process. Prior to describing the analysis system 100, the PTP sheet 1 and the sheet product production line 200 (hereinafter simply referred to as "production line 200") will be described.

[0032] First, we will explain the PTP sheet 1. As shown in Figures 2 and 3, the PTP sheet 1 has a container film 3 with multiple pockets 2, and a cover film 4 attached to the container film 3 so as to cover the pockets 2.

[0033] The container film 3 is made of a transparent thermoplastic resin material such as PP (polypropylene) or PVC (polyvinyl chloride), while the cover film 4 is made of an opaque material (such as aluminum foil) on whose surface a sealant made of polypropylene resin or the like is provided.

[0034] Each pocket 2 contains one tablet 5 as the "contents." Note that the materials of the films 3 and 4, the number and positions of the pockets 2, the contents contained in the pockets 2, etc. are not limited to those described above and may be changed as appropriate.

[0035] Next, the production line 200 will be described. As shown in Fig. 1, the production line 200 includes, in order from the upstream side, a PTP machine 10, a stacking machine 51, a banding machine 52, a pillow machine 53, and a boxing machine 54. In this embodiment, the PTP machine 10 constitutes a "blister sheet manufacturing apparatus." In addition, the stacking machine 51, the banding machine 52, the pillow machine 53, and the boxing machine 54 each constitute a "post-process apparatus."

[0036] The PTP machine 10, the stacking machine 51, the banding machine 52, the pillow machine 53, and the boxing machine 54 are connected to each other directly or via a conveyor. If necessary, the conveyor may have a buffer function for storing various works such as the PTP sheet 1 and the sheet bundle 7 described later.

[0037] Furthermore, the PTP machine 10 is disposed in the first chamber R1 of the first chamber R1 and the second chamber R2 separated by a predetermined wall. On the other hand, the stacking machine 51, the banding machine 52, the pillow machine 53 and the boxing machine 54 are disposed in the second chamber R2.

[0038] Next, the configuration of the PTP machine 10 will be described in more detail. As shown in Fig. 4, a raw roll 11 formed by winding a strip-shaped container film 3 is provided on the most upstream side of the PTP machine 10, and the container film 3 sent out from this is transported through a predetermined path. The PTP machine 10 includes, from the upstream side along the transport path of the container film 3, an automatic film splicing device 12, a preheating device 15, a pocket forming device 16, a filling device 21, an inspection device 22, a sealing device 25, a slit forming device 33, a marking device 34, and a sheet punching device 37. In this embodiment, the pocket forming device 16 constitutes the "pocket forming means", and similarly, the filling device 21 constitutes the "filling means", the sealing device 25 constitutes the "attaching means", and the sheet punching device 37 constitutes the "punching means".

[0039] When the container film 3 of the original roll 11 is consumed, the automatic film splicing device 12 automatically connects the end of the container film 3 to the beginning end of the container film 3 of a pre-set spare original roll 11 (not shown).

[0040] The preheating device 15 preheats the container film 3. The pocket forming device 16 forms the pocket 2 in the preheated container film 3 using a predetermined mold or the like.

[0041] The filling device 21 includes a cylindrical chute that stores the tablets 5 lined up in a row, and a shutter (both not shown) that can open and close the outlet of the chute, and fills the tablets 5 into the pockets 2 by opening the shutter at a predetermined timing. The filling device 21 may also include an adsorption drum (not shown) that can adsorb the tablets 5, and fill the tablets 5 into the pockets 2 by releasing the adsorption.

[0042] The inspection device 22 mainly inspects for tablet defects, such as whether the tablets 5 are securely filled in each pocket portion 2, whether there are any abnormalities in the tablets 5, and whether there is any foreign matter mixed into the pocket portion 2.

[0043] The sealing device 25 includes a heating roll 25a having a heating function and a film feed roll 25b for continuously transporting the container film 3, and attaches the cover film 4 to the container film 3 so as to close the pocket portion 2. More specifically, the cover film 4 is guided to the heating roll 25a, and the container film 3 and the cover film 4 pass between the two rolls 25a and 25b in a heated and pressed state, thereby attaching the cover film 4 to the container film 3. By attaching the cover film 4 to the container film 3, a belt-shaped PTP film 6 in which tablets 5 are accommodated in each pocket portion 2 is manufactured. In this embodiment, the PTP film 6 constitutes a "blister film."

[0044] The slit forming device 33 forms a separation slit at a predetermined position in the PTP film 6. The marking device 34 marks a predetermined position (e.g., a tag portion) of the PTP film 6. Note that the separation slit and marking are not shown in FIG.

[0045] The sheet punching device 37 has the function of punching out the outer edge of the PTP film 6 into individual PTP sheets 1, that is, of cutting the PTP sheets 1 from the PTP film 6.

[0046] The PTP sheet 1 obtained by the sheet punching device 37 is transported by the conveyor 39 to the accumulator 51. Meanwhile, the scrap portion of the PTP film 6 remaining after punching is cut to a predetermined size by the cutting device 41 and stored in the scrap hopper 43.

[0047] In the PTP machine 10, the conveying mode of the container film 3 and the PTP film 6 is changed to continuous conveying or intermittent conveying as appropriate to accommodate the various processes performed by the various devices described above. In order to prevent slackening of the container film 3, etc. due to such changes in the conveying mode, tension rolls are provided at predetermined positions in the conveying path of the container film 3, etc., to keep the tension of the container film 3, etc. within a certain range.

[0048] The PTP machine 10 also includes a control device 45 and a communication device 46. The control device 45 is configured by a computer system equipped with a CPU, RAM, ROM, storage medium, etc., and the storage medium stores programs and parameters for controlling the operation of the device. The control device 45 controls the start, stop, operation timing, operation speed, heating temperature, heating time, applied pressure, etc. of each device (pocket forming device 16, filling device 21, sealing device 25, sheet punching device 37, etc.) that constitutes the PTP machine 10 based on the stored programs and parameters.

[0049] The control device 45 also manages the operating status of each device constituting the PTP machine 10, and if an abnormality occurs in the operating status causing a problem in the production of the PTP sheet 1, it stops the operation of each device, thereby stopping the operation of the PTP machine 10. Furthermore, the control device 45 also stops the operation of the PTP machine 10 when a stop command, which will be described later, is input from the stacking machine 51. Of course, the control device 45 also stops the operation of the PTP machine 10 when a stop operation is performed by an operator of the production line 200 or the like.

[0050] The communication device 46 is a device that is responsible for wireless communication between the PTP device 10 (particularly the control device 45) and the analysis system 100 (particularly the main tablet PC 111 described later).

[0051] In this embodiment, when the PTP device 10 starts (resumes) operation, in other words, when the PTP device 10 ends its shutdown, a shutdown end signal and a shutdown end time signal indicating the time when the shutdown ended are transmitted from the PTP device 10 (control device 45) to the analysis system 100 (main tablet PC 111) via the communication device 46 (see FIG. 6). The time is acquired from a clock function provided in the control device 45. The time includes not only hour and minute information, but also date information.

[0052] Furthermore, when the operation of the PTP machine 10 stops due to an abnormality in the operating state of the PTP machine 10 itself, a first abnormality stop signal, a stop start time signal indicating the time of the stop, and a cause identification signal are transmitted from the PTP machine 10 (control device 45) to the analysis system 100 (main tablet PC 111) via the communication device 46 (see FIG. 6). The cause identification signal includes the stop cause device information and the reason for the stop.

[0053] Here, the stoppage cause device information is information indicating the device that has caused the PTP machine 10 to stop among the PTP machine 10 and the multiple post-process devices (the stacking machine 51, the banding machine 52, the pillow machine 53, and the boxing machine 54). The reason for the stoppage is the reason for the stoppage of the PTP machine 10. The stoppage cause device information may be information indicating both the PTP machine 10 and the post-process devices. However, if the operation of the PTP machine 10 has stopped due to an abnormality in the operating condition of the PTP machine 10 itself, the device indicated by the stoppage cause device information included in the cause identification signal will be only the PTP machine 10.

[0054] In addition, when the operation of the PTP machine 10 stops due to a stop command input from the stacking machine 51, which will be described later, the PTP machine 10 (control device 45) transmits a second abnormality stop signal, a stop start time, and a signal for identifying the cause of the cause to the analysis system 100 (main tablet PC 111) via the communication device 46 (see FIG. 6). This signal for identifying the cause of the cause is set based on an alarm signal, which will be described later, transmitted from the stacking machine 51. This signal for identifying the cause of ...

[0055] Furthermore, when the operation of the PTP machine 10 is stopped by an operation of an operator or the like, a normal stop signal and a stop start time signal are transmitted from the PTP machine 10 (control device 45) to the analysis system 100 (main tablet PC 111) via the communication device 46 (see Figure 6).

[0056] Returning to FIG. 1, the stacking machine 51, the banding machine 52, the pillow machine 53 and the boxing machine 54 will be described.

[0057] The stacking machine 51 stacks the manufactured PTP sheets 1 in units of a predetermined number, and then passes the stacked PTP sheets 1 to a banding machine 52 which is responsible for the next process.

[0058] The banding machine 52 bands the stacked PTP sheets 1 with a predetermined band 7a, and delivers the resulting bundle of sheets 7 (see FIG. 5) to the pillow machine 53 which is in charge of the next process.

[0059] The pillow machine 53 packs a plurality of sheet bundles 7 into bags, and delivers the resulting sheet storage bags 8 (see FIG. 5) to a boxing machine 54 in charge of the next process.

[0060] The boxing machine 54 performs a boxing process on a plurality of sheet storage bags 8, thereby producing a sheet product 9 in which a plurality of PTP sheets 1 are boxed. The sheet products 9 are bundled together in multiple units as necessary and then finally shipped.

[0061] In this embodiment, the stacking machine 51, banding machine 52, pillow machine 53, and cartoning machine 54 output a stop command and an alarm signal to the device immediately upstream when an abnormality in the device prevents the continuation of processing. The device to which the stop command is input outputs the input stop command and alarm signal to the device immediately upstream and stops operating. The stop command is ultimately input to the PTP machine 10 (control device 45), and the PTP machine 10 to which the stop command is input stops operating.

[0062] In this embodiment, when the production line 200 is operating to produce the sheet products 9, the number of PTP sheets 1 that can be processed per unit time by the post-processing devices (the stacking machine 51, the banding machine 52, the pillow machine 53, and the boxing machine 54) is greater than the number of PTP sheets 1 that can be manufactured per unit time by the PTP machine 10. That is, the processing speed of the post-processing devices is greater than the manufacturing speed of the PTP sheets 1. Therefore, the stoppage of the PTP machine 10 directly affects the operation rate of the production line 200. On the other hand, even if the post-processing devices (such as the stacking machine 51) stop, if the stoppage time is short, the delay in processing can be sufficiently made up for after the operation is resumed. Therefore, the stoppage of the post-processing devices may not affect the operation rate of the production line 200.

[0063] Next, the analysis system 100 will be described. The analysis system 100 stores various data related to the stop of the PTP device 10, and provides information for analysis based on this data to an administrator, etc. In this embodiment, the analysis system 100 includes a main tablet PC 111, a sub-tablet PC 112, and an administrative PC 113, each of which includes a CPU, RAM, ROM, a storage medium, etc. Each of the tablet PCs 111, 112 includes a touch panel and is portable.

[0064] The main tablet PC 111 is arranged in the second room R2, assuming that it will be used in the second room R2. On the other hand, the sub-tablet PC 112 is arranged in the first room R1, assuming that it will be used in the first room R1. Of course, the arrangement and use locations of the tablet PCs 111, 112 are not limited to these. In this embodiment, the main tablet PC 111 constitutes an "information processing device."

[0065] 7, the main tablet PC 111 includes a main display unit 121, a main input unit 122, an upper limit time storage unit 123, a stop information receiving unit 124, a time identifying unit 125, an acquisition unit 126, a storage unit 127, a reason classification unit 128, and a main display control unit 129. The functions of the stop information receiving unit 124, the time identifying unit 125, the acquisition unit 126, the reason classification unit 128, and the main display control unit 129 are realized by various hardware such as the CPU, ROM, and RAM, and predetermined software stored in a storage medium. In this embodiment, the upper limit time storage unit 123 constitutes the "upper limit time storage means", and similarly, the time identifying unit 125 constitutes the "time identifying means", the acquisition unit 126 constitutes the "acquisition means", and the reason classification unit 128 constitutes the "reason classification means".

[0066] The main display unit 121 is configured by the touch panel and displays various information. The information displayed on the main display unit 121 is controlled by a main display control unit 129.

[0067] The main input unit 122 is configured by the touch panel, and is used to input information to the main tablet PC 111 .

[0068] The upper limit time storage unit 123 is configured by the storage medium and stores an upper limit time. The upper limit time refers to the maximum time permitted as the stop time of the PTP machine 10 due to a mandatory stop reason described later. The upper limit time can be changed using the main input unit 122. In this embodiment, the upper limit time storage unit 123 stores an upper limit time per unit time (for example, per day) for each stop reason (particularly a mandatory stop reason described later) (see FIG. 8).

[0069] The stop information receiving unit 124 receives information related to the stop of the PTP machine 10 from the PTP machine 10. In this embodiment, the stop information receiving unit 124 can receive, as information related to the stop of the PTP machine 10, a stop end signal, a first abnormal stop signal, a second abnormal stop signal, a normal stop signal, a stop end time signal, a stop start time signal, and a cause identification signal from the PTP machine 10.

[0070] The time identifying unit 125 identifies the stop time of the PTP device 10, that is, the time when the stop of the PTP device 10 starts (stop start time) and the time when the stop of the PTP device 10 ends (stop end time).

[0071] More specifically, when the stop information receiving unit 124 receives a stop end time signal, the time identifying unit 125 identifies the stop end time of the PTP device 10 based on the signal. On the other hand, when the stop information receiving unit 124 receives a stop start time signal, the time identifying unit 125 identifies the stop start time of the PTP device 10 based on the signal.

[0072] The acquisition unit 126 acquires the stop cause device information and the stop reason based on input from the PTP machine 10 (particularly the control device 45), the main input unit 122, and the sub-input unit 132 described later. The stop reason includes a mandatory stop reason and a reducible stop reason.

[0073] The essential stoppage reason refers to a reason necessary for the production of the sheet product 9. Examples of the essential stoppage reason include "cleaning," "break," "production changeover," "lot changeover," "regular maintenance," "production preparation," and "waiting for production instructions."

[0074] For example, "production changeover" refers to the work of changing the product type of PTP sheet 1 being manufactured, and "lot changeover" refers to the work of changing the lot number of the PTP sheet 1 or the sheet product 9. Furthermore, "production preparation" refers to various preparatory work required for the production of the sheet product 9, and "waiting for production instructions" refers to the state of waiting for an instruction to start production from a manager or the like after preparatory work, etc.

[0075] The reducible stoppage reasons refer to stoppage reasons that are unnecessary for the production of the sheet product 9 and can be reduced. Examples of the reducible stoppage reasons include "workpiece jamming," "material splicing failure," "scrap full," "cylinder operation abnormality," "seal temperature abnormality," "slitter adjustment," "inspection device adjustment," and "product condition accuracy check."

[0076] "Work jam" means that the work such as the PTP sheet 1, the sheet bundle 7, the sheet storage bag 8, etc. is jammed in the conveying path and cannot be conveyed downstream. "Material splicing failure" means that the automatic film splicing device 12 fails to splice the container film 3. "Scrap full" means that the scrap stored in the scrap hopper 43 exceeds the limit. "Cylinder operation abnormality" means that an abnormality has occurred related to the cylinder for operating a specific device (e.g., the heating roll 25a, etc.) in the PTP machine 10. "Sealing temperature abnormality" means that an abnormality has occurred in the heating temperature of the films 3, 4 by the sealing device 25. These abnormalities can be automatically detected by a sensor (not shown) or the like. When such an abnormality is detected, the operation of the PTP machine 10 is automatically stopped by the control device 45.

[0077] Furthermore, "slitter adjustment" refers to adjustment work for the slit forming device 33. "inspection device adjustment" refers to adjustment work for the inspection conditions in the inspection device 22. "checking the product condition accuracy" refers to work in which an operator or the like checks the condition of the manufactured PTP sheet 1 and sheet product 9. When performing these tasks, the operation of the PTP machine 10 may be stopped by the operator or the like.

[0078] Returning to the description of the acquisition unit 126, when the stop information receiving unit 124 receives a cause-of-cause identification signal, the acquisition unit 126 acquires the stop cause device information and the cause of stop based on the cause-of-cause identification signal.

[0079] On the other hand, when the stop information receiving unit 124 receives a normal stop signal, the acquiring unit 126 acquires the stop cause device information and the stop reason input by each of the input units 122, 132, using a stop information input screen 151 described later. The stop information input screen 151 and the input of information using it will be described later.

[0080] The storage unit 127 is configured by the storage medium, and stores various information. When the acquisition unit 126 acquires information on the device causing the stoppage, the storage unit 127 stores the information acquired by the acquisition unit 126 (device causing the stoppage and the reason for the stoppage) in association with the stoppage time (start time of the stoppage and end time of the stoppage) identified by the time identification unit 125 (see FIG. 9). In other words, when the PTP machine 10 stops, the storage unit 127 stores information indicating the device causing the stoppage, the reason for the stoppage, and the stoppage time (start time of the stoppage and end time of the stoppage) in association with each other. Furthermore, when information is input using the administrator input field 151b described later, this information is also stored in association with each other. More precisely, this information is stored in a specified file in the storage unit 127. The reason classification unit 128 classifies the stop reason into a mandatory stop reason or the reducible stop reason, and stores the classification result in the storage unit 127.

[0081] To describe the classification of stop reasons in detail, when a stop reason or the like is stored in the storage unit 127, the reason classification unit 128 basically classifies the stop reason into a mandatory stop reason or a reducible stop reason using a predetermined data table pre-stored in the storage unit 127 or the like. The data table has information for determining, for each stop reason, whether the stop reason is a mandatory stop reason or a reducible stop reason.

[0082] However, the event classification unit 128 calculates each stop time (for example, the total stop time for one day) of the PTP machine 10 related to each mandatory stop event from the stop time (stop start time and stop end time) of the PTP machine 10 at a predetermined timing (for example, a predetermined time). Then, the event classification unit 128 compares the stop time related to the calculated mandatory stop time with the upper limit time for the mandatory stop event (stored in the upper limit time storage unit 123), and if the stop time exceeds the upper limit time, classifies the mandatory stop event related to the exceeded stop time as a reducible stop event. For example, a stop event called "product type switching" is basically classified as a mandatory stop event, but when the stop time related to "product type switching" exceeds the upper limit time due to the time required for the work, etc., the "product type switching" related to the exceeded stop time is classified as a reducible stop event (see the bottom row of FIG. 9).

[0083] Furthermore, the reason classification unit 128 changes the reason for the stoppage related to the exceeded stoppage time as necessary. For example, the reason classification unit 128 changes the reason for the stoppage from "product type change" to "product type change excess" and stores the change in the storage unit 127 (see the bottom row of FIG. 9).

[0084] Furthermore, as described above, when a stoppage reason that is basically classified as a mandatory stoppage reason is classified as a reducible stoppage reason, an excess response input screen 152 (see FIG. 10) can be displayed on the main display unit 121 by display control by the main display control unit 129. This excess response input screen 152 is used to input stoppage cause device information that indicates the device that caused the exceeding of the stoppage time.

[0085] When the stop cause equipment information related to the reason for the stop is input using this excess response input screen 152, the input information is stored in the storage unit 127. For example, if the stop time related to "product type switching" exceeds the upper limit time and the exceeding is caused by the "pillow machine", the information "pillow machine" is input and stored as the stop cause equipment information (see the bottom row of FIG. 9).

[0086] The main display control unit 129 controls the information displayed on the main display unit 121. The main display control unit 129 normally causes the main display unit 121 to display a basic screen 153, as shown in FIG.

[0087] The basic screen 153 displays the stop time of the PTP machine 10, the device that caused the PTP machine 10 to stop (stopping device), the reason for stopping the PTP machine 10, and the classification of the stop reason (mandatory stop reason or reducible stop reason) based on the information stored in the storage unit 127. In this embodiment, various information such as the stopping device is set to be arranged in order of the stop time. Of course, the information displayed on the basic screen 153 and its arrangement order may be changed as appropriate.

[0088] Furthermore, when the stop information receiving unit 124 receives a normal stop signal, the main display control unit 129 is able to display a stop information input screen 151 on the main display unit 121 as shown in FIG.

[0089] The stop information input screen 151 is provided with a number of stop information input buttons 151a for inputting stop cause device information and the reason for the stop, an administrator input field 151b for inputting the administrator's name etc., a free input button 151c for an operator etc. to freely input information, and a status display field 151d.

[0090] The stop information input button 151a is arranged in each frame corresponding to the PTP machine 10, the stacking machine 51, "all", etc., and is provided with a letter or the like to indicate the reason for the stop. Incidentally, "all" means the entire PTP machine 10, the stacking machine 51, the banding machine 52, the pillow machine 53, and the boxing machine 54. For example, when the PTP machine 10 stops due to "cleaning", the button labeled "cleaning" located in the "all" frame is operated on the main tablet PC 111, whereby "all" is input as the stop cause device information and "cleaning" is input as the reason for the stop.

[0091] The manager input field 151b is a field for inputting information for identifying a manager, an operator, etc. of the production line 200. After information such as a name is input in this field, the stop information input button 151a is operated, whereby information on the manager, the operator, etc. is input to the main tablet PC 111 together with information on the device causing the stop and the reason for the stop.

[0092] The free input button 151c is a button for calling a file for entering information such as details about the cause of the PTP machine 10 being stopped and the measures taken to resume operation. This file stores the stopped device information and the like saved in the storage unit 127 in association with each other. By inputting information into this file, the input information can be stored in association with the stopped device information and the like.

[0093] The status display field 151d displays the status of the PTP machine 10, whether or not the stop cause device information has been input using the stop information input button 151a, etc. For example, if the PTP machine 10 is in operation, "In production" is displayed. Also, if the stop cause device information, etc. has not been input, "No selection" is displayed.

[0094] Furthermore, even when the stop information receiving unit 124 receives a first abnormality stop signal or a second abnormality stop signal, the main display control unit 129 causes the main display unit 121 to display the stop information input screen 151. In this case, however, the stop information input screen 151 is adjusted so that the stop cause device information and the stop reason cannot be input using the stop information input button 151a.

[0095] Furthermore, as described above, when a stop reason that is basically classified as a mandatory stop reason is classified as a reducible stop reason, the main display control unit 129 is capable of displaying an excess response input screen 152 (see Figure 10) on the main display unit 121.

[0096] The excess response input screen 152 is provided with an equipment input field 152a for inputting information on the equipment causing the stoppage, and an input decision button 152b. In the equipment input field 152a, "PTP machine", "stacking machine", "banding machine", "pillow machine", "boxing machine" or "all" can be selected. After selecting an equipment in the equipment input field 152a, the input decision button 152b is finally operated to input the equipment causing the stoppage information.

[0097] Next, the sub-tablet PC 112 will be described. As shown in Fig. 7, the sub-tablet PC 112 includes a sub-display unit 131, a sub-input unit 132, and a sub-display control unit 133. Note that these functions are realized by various hardware and software, similar to the main tablet PC 111. The sub-tablet PC 112 is configured to be capable of wireless communication with the main tablet PC 111.

[0098] The sub-display unit 131 is configured with a touch panel and displays various information. In this embodiment, the sub-display unit 131 is controlled by the sub-display control unit 133 to display information similar to that displayed on the main display unit 121 (for example, a stop information input screen 151, etc.).

[0099] The sub-input unit 132 is configured with a touch panel, and is used to input information to the sub-tablet PC 112. In this embodiment, the information input by the sub-input unit 132 is treated in the same manner as the information input by the main input unit 122. Therefore, for example, when the stop cause device information and the stop reason are input by the sub-input unit 132 using the stop information input screen 151 displayed on the sub-display unit 131, these pieces of information are transmitted from the sub-tablet PC 112 to the main tablet PC 111. The transmitted stop cause device information and the like are acquired by the acquisition unit 126 and then stored in the storage unit 127. In this embodiment, the "input means" is configured by the input units 122, 132 for inputting the stop cause device information and the stop reason, and the PTP machine 10 (particularly the control device 45) for inputting the cause identification signal including the stop cause device information and the stop reason.

[0100] The sub-display control unit 133 controls the display on the sub-display unit 131 based on information related to display control sent from the main tablet PC 111 to the sub-tablet PC 112 .

[0101] Next, the management PC 113 will be described. The management PC 113 is used by a manager of the production line 200 to check and analyze information collected by the analysis system 100. The management PC 113 includes a management display unit 141, a management input unit 142, a storage unit 143, a stop time calculation unit 144, and a management display control unit 145. The management PC 113 is configured to be capable of wireless communication with the main tablet PC 111. In this embodiment, the management display unit 141 constitutes the "display means" and the stop time calculation unit 144 constitutes the "stop time calculation means".

[0102] The management display unit 141 is configured with, for example, a liquid crystal display, and displays various information such as information stored in the storage unit 143 .

[0103] The administration input unit 142 is composed of, for example, a keyboard, a mouse, and the like, and is used to input information to the administration PC 113 .

[0104] The storage unit 143 stores information having the same content as the information held by the storage unit 127 of the main tablet PC 111. In this embodiment, when storing information in the storage unit 127, information having the same content as the information is transmitted from the main tablet PC 111 to the management PC 113. Then, the transmitted information is stored in the storage unit 143, so that the storage unit 143 basically stores information having the same content as the information held by the storage unit 127. In this embodiment, the storage unit 143 constitutes a "storage means."

[0105] The stop time calculation unit 144 calculates the stop time of the PTP machine 10 caused by the extraction target element (for example, the total stop time for one day) based on the information stored in the storage unit 143 (see FIG. 9 ) with the stop cause device information, the stop cause, or a combination of the stop cause device information and the stop cause as the extraction target element. For example, when the stop cause device information is the extraction target element, the stop time calculation unit 144 can calculate the stop time of the PTP machine 10 caused by these devices for each of the PTP machine 10, the stacking machine 51, the banding machine 52, the pillow machine 53, and the packing machine 54. Note that it may be possible to calculate the stop time for a certain period of time designated by the administrator, etc., as such a stop time.

[0106] In addition, the stoppage time calculation unit 144 can calculate the stoppage time related to the mandatory stoppage reason and the stoppage time related to the reducible stoppage reason for each extraction target element. For example, when the stoppage cause device information is the extraction target element, the stoppage time calculation unit 144 can calculate the stoppage time related to the mandatory stoppage reason and the stoppage time related to the reducible stoppage reason for each of the PTP machine 10, the stacking machine 51, the banding machine 52, the pillow machine 53, and the packing machine 54, out of the stoppage time of the PTP machine 10 caused by these devices.

[0107] The management display control unit 145 controls the information displayed on the management display unit 141. The management display control unit 145 is capable of displaying a condition specification screen 154 on the management display unit 141, as shown in FIG.

[0108] The condition specification screen 154 is used for displaying the extraction target elements and the stop time corresponding to the extraction target elements calculated by the stop time calculation unit 144 on the management display unit 141. The condition specification screen 154 is provided with, for example, an element specification field 154a for specifying the extraction target elements, a reason selection field 154b for selecting the type of stop reason, and an input decision button 154c.

[0109] In the element specification field 154a, an element to be extracted can be selected. As described above, the elements to be extracted are the stop cause device information, the stop cause, or the combination of the stop cause device information and the stop cause, and there are three kinds in total.

[0110] In the reason selection field 154b, the type of the stop reason can be selected. The selectable types of the stop reason are a mandatory stop reason, a reducible stop reason, or both of these reasons.

[0111] Finally, by operating the input decision button 154c, the information selected in each of the fields 154a, 154b is input to the management PC 113, and the stoppage time calculation unit 144 calculates the stoppage time of the PTP machine 10 based on that information.

[0112] Then, the management display control unit 145 causes the management display unit 141 to display the extraction target elements and the stop times in order according to the magnitude of the calculated stop times.

[0113] For example, when the "stop cause device" is selected in the element designation field 154a and the "reducible stop reason" is selected in the reason selection field 154b, the input decision button 154c is operated, and the stop time calculation unit 144 calculates the stop time related to the reducible stop reason out of the stop time of the PTP machine 10 caused by these devices for each of the PTP machine 10, the stacking machine 51, the banding machine 52, the pillow machine 53, and the packing machine 54. Then, the management display control unit 145 displays the PTP machine 10, the stacking machine 51, the banding machine 52, the pillow machine 53, and the packing machine 54 (i.e., the extraction target elements) and each stop time of the PTP machine 10 related to these devices on the management display unit 141 in order according to the magnitude of the calculated stop time, as shown in FIG.

[0114] Also, for example, when the "stop reason" is selected in the element designation field 154a and the "reducible stop reason" is selected in the reason selection field 154b, the stop time calculation unit 144 calculates the stop time related to the reducible stop reason among the stop times of the PTP machine 10 caused by these stop reasons for each stop reason. Then, the management display control unit 145 displays each stop reason and each stop time of the PTP machine 10 related to the stop reason on the management display unit 141 in order according to the magnitude of the calculated stop times, as shown in FIG.

[0115] Furthermore, for example, when the input decision button 154c is operated with "stop cause device + stop reason" selected in the element specification field 154a and "reducible stop reason" selected in the reason selection field 154b, the stop time calculation unit 144 calculates the stop time related to the reducible stop reason out of the stop time of the PTP machine 10 caused by each combination of the stop cause device information and the stop reason. Then, the management display control unit 145 displays the combination of the stop cause device information and the stop reason and each stop time of the PTP machine 10 related to the combination on the management display unit 141 in order according to the magnitude of the calculated stop time, as shown in FIG.

[0116] Also, for example, when the "stop cause equipment" is selected in the element designation field 154a and the "mandatory stop reason" is selected in the reason selection field 154b, the stop time related to the mandatory stop reason out of the stop time of the PTP machine 10 caused by these equipment is calculated for each of the PTP machine 10, the stacking machine 51, the banding machine 52, the pillow machine 53, and the packing machine 54. Then, for example, as shown in Fig. 17, the stop cause equipment information and the like are displayed in the management display unit 141 in order according to the magnitude of the calculated stop time.

[0117] As described above in detail, according to this embodiment, it is possible to more easily and accurately grasp the extraction target elements that lengthen the downtime of the PTP machine 10, i.e., the elements that have a particular impact on the operating rate of the production line 200 and that particularly need to be improved in terms of effectively increasing the operating rate.

[0118] Furthermore, when the production line 200 is stopped, the information that needs to be manually input to the analysis system 100 is, at most, the stoppage cause device information and the reason for the stoppage (to be acquired by the acquisition unit 126). Therefore, complicated input work is not required, and the convenience of managing the production line 200 can be improved.

[0119] In addition, the cause classification unit 128 can classify the stoppage reasons into mandatory stoppage reasons and reducible stoppage reasons. Then, the management display unit 141 can display the extraction target elements in order of the stoppage times related to the reducible stoppage reasons. Therefore, it is possible to more easily and accurately grasp the extraction target elements that cause a long stoppage time of the PTP machine 10 and that are related to the reducible stoppage reasons, that is, the elements that should be improved in terms of effectively improving the operating rate and whose improvement does not affect the production of the sheet products 9 (the elements are not necessarily required for the production of the sheet products 9).

[0120] Furthermore, the cause classification unit 128 can classify the stop cause corresponding to the stop time exceeding the upper limit time among the stop times of the PTP machine 10 related to the mandatory stop cause into a reducible stop cause. As a result, for example, when the PTP machine 10 stops due to work such as product type changeover or regular maintenance (i.e., a mandatory stop cause), if the work is not completed within the upper limit time, it is possible to treat the stop cause corresponding to the stop time (work time) exceeding the upper limit time as a reducible stop cause. Therefore, it is possible to more easily and more accurately grasp the elements to be improved in terms of effectively improving the operating rate. In addition, it is possible to more reliably prevent the elements to be improved from being overlooked.

[0121] In addition, the acquisition unit 126 can acquire the stop cause device information and the reason for the stop based on the cause identification signal input from the PTP machine 10 (control device 45) as the "input means." Therefore, the labor and mistakes caused by manually inputting the reason for the stop can be reduced, and the convenience of managing the production line 200 can be improved more effectively.

[0122] Furthermore, among the PTP machine 10 and the post-processing devices, only the PTP machine 10 is capable of communicating with the main tablet PC 111. Therefore, compared with a case in which the post-processing devices are similarly capable of communicating, the analysis system 100 can be further simplified, and the costs associated with the manufacture, maintenance, etc. of the analysis system 100 can be effectively reduced.

[0123] The present invention is not limited to the above-described embodiment, and may be implemented as follows: Of course, other applications and modifications not exemplified below are also possible.

[0124] (a) In the above embodiment, the reason classification unit 128 compares the stop time of the PTP machine 10 related to the mandatory stop reason with the upper limit time for that stop reason stored in the upper limit time memory unit 123, and if the stop time exceeds the upper limit time, classifies the stop reason corresponding to the exceeded stop time as a reducible stop reason.

[0125] On the other hand, the cause classification unit 128 may be capable of classifying, among the mandatory stop reasons, a stop reason corresponding to a number of times exceeding the upper limit number stored in the upper limit number storage unit 123a (see FIG. 18) into a reducible stop reason. In the upper limit number storage unit 123a, an upper limit number of times per unit time (for example, per day) that is permitted as the number of stops of the PTP machine 10 related to the mandatory stop reason is set for each stop reason (particularly, the mandatory stop reason) (see FIG. 19). In this example, the upper limit number storage unit 123a constitutes the "upper limit number storage means". By configuring the cause classification unit 128 in this way, if the upper limit number of times corresponding to "excessive variety" is set to, for example, 1 time in the upper limit number storage unit 123a, when the PTP machine 10 stops three times in one day due to "product type switching", the "product type switching" corresponding to the second and third times will be classified as a reducible stop reason. Therefore, it is possible to more easily and more accurately grasp the elements that should be improved in terms of effectively improving the operating rate. It is also possible to more reliably prevent elements that need improvement from being overlooked.

[0126] The reason classification unit 128 may be capable of classifying a mandatory stop reason into a reducible stop reason by using both the upper limit time and the upper limit number of times.

[0127] (b) In the above embodiment, the acquisition unit 126 is configured to automatically acquire the stop cause device information and the reason for the stop based on the cause identification signal when the PTP machine 10 stops due to an abnormality in the PTP machine 10, the post-process device (accumulator 51), etc. In contrast, when the PTP machine 10 stops due to an abnormality in the PTP machine 10, the post-process device (accumulator 51), etc., an operator or the like may input the stop cause device information, etc. into the main tablet PC 111 using the input units 122, 132, and the acquisition unit 126 may acquire the stop cause device information, etc. based on the input.

[0128] (c) In the above embodiment, an example is given in which two tablet PCs 111 and 112 are provided, but one tablet PC or three or more tablet PCs may be provided. When only one tablet PC is provided, this one tablet PC may be configured to function as the main tablet PC 111 in the above embodiment. When three or more tablet PCs are provided, one tablet PC may be configured to function as the main tablet PC 111 and the other tablet PCs may be configured to function as the sub-tablet PC 112.

[0129] Of course, a computer other than a tablet PC (such as a notebook computer) may also be used.

[0130] (d) In the above embodiment, the reason classification unit 128 and the upper limit time storage unit 123 are provided in the main tablet PC 111, but they may be provided in the management PC 113. In other words, a function for classifying reasons for suspension may be provided in the management PC 113. In this case, classification of reasons for suspension is performed on the information stored in the storage unit 143.

[0131] Furthermore, the management PC 113 may be installed in a remote location away from where the production line 200 is installed.

[0132] (e) In the above embodiment, the PTP machine 10 and the main tablet PC 111 are configured to be able to communicate with each other, and when the PTP machine 10 stops due to an abnormality in a subsequent process device (such as the accumulator 51), various signals are transmitted from the PTP machine 10 to the main tablet PC 111, not from the subsequent process device. In contrast, a communication device may be provided in the subsequent process device to enable communication between the subsequent process device and the main tablet PC 111, and when the PTP machine 10 stops due to an abnormality in the subsequent process device, various signals (such as a signal for identifying the cause) may be transmitted directly from the subsequent process device to the main tablet PC 111.

[0133] (f) In the above embodiment, the banding machine 52, the pillow machine 53, and the cartoning machine 54 are configured to send stop commands to the devices immediately upstream of them, but they may also send stop commands directly to the PTP machine 10. In this case, the PTP machine 10 may be configured to stop post-process devices other than the post-process device that sent the stop command.

[0134] (g) In the above embodiment, the stacking machine 51, banding machine 52, pillow machine 53 and box packing machine 54 are given as post-processing equipment, however, the post-processing equipment is not limited to these and may be changed as appropriate.

[0135] (h) A function may be provided to automatically embed information stored in the storage units 127, 143 at appropriate positions in written data such as various documents and reports, thereby assisting in the creation of the written data. It is preferable that the written data be displayable using a general-purpose application such as a browser or spreadsheet software.

[0136] (i) In the above embodiment, only one stop reason corresponds to one stop time (stop start time and stop end time), but multiple stop reasons may be configured to correspond to one stop time. For example, if the stop start time is 16:00 and the stop end time is 16:50, one stop reason may correspond to 16:00 to 16:30, and other stop reasons may be configured to correspond to 16:30 to 16:50.

[0137] (j) In the above embodiment, only the management PC 113 has the function of displaying the extraction target elements and the like in order according to the length of the stop time, but the tablet PCs 111 and 112 may also have this function.

[0138] (k) In the above embodiment, various tables (e.g., the tables in Figs. 14 to 17) are used to display the stop cause device information in order of the stop time, but the display format of the information can be changed as appropriate. For example, the stop cause device information may be displayed using a graph or the like.

[0139] (l) In the above embodiment, the acquisition unit 126 is configured to acquire both the stop cause device information and the stop reason based on the cause identification signal, but it may be configured to acquire only one of them.

[0140] (m) In the above embodiment, the PTP sheet 1 is given as the blister sheet, but the technical concept of the present invention may be applied to blister sheets other than the PTP sheet 1.

[0141] (n) In the above embodiment, the stop information input screen 151 is configured not to be displayed while the PTP machine 10 is in operation, but the screen 151 may be displayed so that the stop cause device information and the reason for the stop cannot be input using the stop information input button 151a.

[0142] (o) In the above embodiment, when the stop information receiving unit 124 receives the first abnormal stop signal or the second abnormal stop signal, the stop cause device information and the stop reason cannot be input using the stop information input button 151a, but the stop information input button 151a may be made available for input of the stop cause device information and the stop reason. In this case, for example, after the stop information receiving unit 124 receives the first abnormal stop signal or the second abnormal stop signal and the production line 200 stops, it becomes easy to record when "cleaning" or "rest" is performed without restarting the production line 200 (for example, before restarting the production line 200). [Explanation of symbols]

[0143] 1... PTP sheet (blister sheet), 2... pocket portion, 3... container film, 9... sheet product, 10... PTP machine (blister sheet manufacturing device, input means), 16... pocket portion forming device (pocket portion forming means), 21... filling device (filling means), 25... sealing device (attaching means), 37... sheet punching device (punching means), 51... accumulating machine (post-process device), 52... banding machine (post-process device), 53... pillow machine (post-process device), 54... boxing machine (post-process device), 100... analysis system system, 111...main tablet PC (information processing device), 122...main input section (input means), 123...upper limit time memory section (upper limit time memory section), 123a...upper limit number memory section (upper limit number memory section), 125...time determination section (time determination means), 126...acquisition section (acquisition means), 132...sub-input section (input means), 141...management display section (display means), 143...memory section (memory means), 144...stop time calculation section (stop time calculation means), 200...sheet product production line.

Claims

1. a pocket forming means for forming a pocket in a strip-shaped container film; a filling means for filling the pocket formed by the pocket forming means with a content; an attachment means for attaching a strip-shaped cover film to the container film so as to close the pocket portion of the container film having the contents filled in the pocket portion; a punching means for punching the strip-shaped blister film formed by attaching the cover film to the container film by the attaching means, thereby obtaining a blister sheet having contents filled in the pocket portions; and one or more post-processing devices provided downstream of the blister sheet manufacturing apparatus and performing a predetermined process on the manufactured blister sheet; An analysis system for a sheet product production line for producing a sheet product obtained by subjecting the manufactured blister sheet to the processing, comprising: while the sheet product production line is in operation to produce the sheet products, the number of blister sheets that can be processed by the post-processing device per unit time is set to be greater than the number of blister sheets that can be manufactured by the blister sheet manufacturing device per unit time, A time specifying means for specifying a stop time of the blister sheet manufacturing apparatus; an input means for inputting stoppage cause device information, which is information indicating a device that caused the stoppage of the blister sheet manufacturing apparatus among the blister sheet manufacturing apparatus and one or more of the post-process devices, and a stoppage reason, which is the reason for the stoppage; an acquisition means for acquiring the stop cause device information and the stop reason input by the input means; a storage means for storing the stop cause device information and the stop reason acquired by the acquisition means, and the stop time identified by the time identification means in association with each other; a stop time calculation means for calculating a stop time of the blister sheet manufacturing apparatus caused by each of the extraction target elements based on the information stored in the storage means, the stop cause device information, the stop reason, or a combination of the stop cause device information and the stop reason being an extraction target element; a display means for displaying the extraction target elements in an order according to the length of the stop time of the blister sheet manufacturing apparatus calculated by the stop time calculation means, a reason classification means for classifying the reasons for suspension into essential suspension reasons necessary for the production of the sheet product and reducible suspension reasons which are unnecessary for the production of the sheet product and can be reduced, the downtime calculation means is configured to be able to calculate a downtime of the blister sheet manufacturing apparatus related to the reducible downtime reason for each of the extraction target elements, the display means is configured to be able to display the extraction target elements in an order according to the magnitude of the stoppage time of the blister sheet manufacturing apparatus related to the reducible stoppage reason, an upper limit time storage means for storing an upper limit time allowed for a stop time of the blister sheet manufacturing apparatus related to the essential stop reason, The analysis system for a sheet product production line is characterized in that the reason classification means is configured to be able to classify a stop reason corresponding to a stop time exceeding the upper limit time among the stop times of the blister sheet manufacturing apparatus related to the mandatory stop reasons, into the reducible stop reasons.

2. a pocket forming means for forming a pocket in a strip-shaped container film; a filling means for filling the pocket formed by the pocket forming means with a content; an attachment means for attaching a strip-shaped cover film to the container film so as to close the pocket portion of the container film having the contents filled in the pocket portion; a punching means for punching the strip-shaped blister film formed by attaching the cover film to the container film by the attaching means, thereby obtaining a blister sheet having contents filled in the pocket portions; and one or more post-processing devices provided downstream of the blister sheet manufacturing apparatus and performing a predetermined process on the manufactured blister sheet; An analysis system for a sheet product production line for producing a sheet product obtained by subjecting the manufactured blister sheet to the processing, comprising: while the sheet product production line is in operation to produce the sheet products, the number of blister sheets that can be processed by the post-processing device per unit time is set to be greater than the number of blister sheets that can be manufactured by the blister sheet manufacturing device per unit time, A time specifying means for specifying a stop time of the blister sheet manufacturing apparatus; an input means for inputting stoppage cause device information, which is information indicating a device that caused the stoppage of the blister sheet manufacturing apparatus among the blister sheet manufacturing apparatus and one or more of the post-process devices, and a stoppage reason, which is the reason for the stoppage; an acquisition means for acquiring the stop cause device information and the stop reason input by the input means; a storage means for storing the stop cause device information and the stop reason acquired by the acquisition means in association with the stop time identified by the time identification means; a stop time calculation means for calculating a stop time of the blister sheet manufacturing apparatus caused by each of the extraction target elements based on the information stored in the storage means, the stop cause device information, the stop reason, or a combination of the stop cause device information and the stop reason being an extraction target element; a display means capable of displaying the extraction target elements in an order according to the length of the stop time of the blister sheet manufacturing apparatus calculated by the stop time calculation means, a reason classification means for classifying the reasons for suspension into essential suspension reasons necessary for the production of the sheet product and reducible suspension reasons which are unnecessary for the production of the sheet product and can be reduced, the downtime calculation means is configured to be able to calculate a downtime of the blister sheet manufacturing apparatus related to the reducible downtime reason for each of the extraction target elements, the display means is configured to be able to display the extraction target elements in an order according to the magnitude of the stoppage time of the blister sheet manufacturing apparatus related to the reducible stoppage reason, an upper limit number storage means for storing an upper limit number of times allowed as the number of times the blister sheet manufacturing apparatus is stopped due to the essential stop reason; The analysis system for a sheet product production line, wherein the reason classification means is configured to classify, among the mandatory stop reasons, a stop reason that corresponds to a number of times exceeding the upper limit number of times, into the reducible stop reasons.

3. The analysis system for a sheet product production line as described in claim 1 or 2, characterized in that the acquisition means is configured to acquire at least one of the stop cause equipment information and the stop reason based on a predetermined cause identification signal input from at least one of the blister sheet manufacturing apparatus and the post-process apparatus as the input means.

4. An information processing device having at least the acquisition means, 4. The analysis system for a sheet product production line according to claim 1, wherein only the blister sheet manufacturing apparatus of the blister sheet manufacturing apparatus and the post-processing apparatus is configured to be able to communicate with the information processing apparatus.

Images