Production management system, production management method

Abstract

To provide a production management system that is able to grasp a state of processing being performed by production equipment, while preventing an increase in the number of components.SOLUTION: A production management system includes: an operating state acquisition device that is disposed in production equipment or near the production equipment and has a detection unit for generating a first signal corresponding to start of processing performed by the production equipment and a second signal corresponding to stop of the processing, and a transmission unit for transmitting the first signal and the second signal; and a production management device that has a processing completion determination unit that uses the first signal and the second signal to determine whether the production equipment has completed the processing or not. The processing completion determination unit acquires a processing time from reception of the first signal to reception of the second signal; if the processing time is equal to or longer than a reference processing-time, the processing completion determination unit determines that the production equipment has completed the processing; if the acquired processing time is shorter than the reference processing-time, the processing completion determination unit integrates successive processing times; and if an integrated value of the successive processing times is equal to or longer than the reference processing time, the processing completion determination unit determines that the processing equipment has completed the processing.SELECTED DRAWING: Figure 7

Description

[Technical Field]

[0001] The present disclosure relates to a production management system and a production management method. [Background technology]

[0002] A production management system is known that detects a pulse signal output from a sensor each time an item to be processed is dispensed from production equipment, and measures the cycle time from the high position of the pulse signal to the high position of the next pulse signal (for example, Patent Document 1). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Publication No. 8-185204 Summary of the Invention [Problem to be solved by the invention]

[0004] Conventional technology can only measure the timing of the delivery of an item to be processed. Therefore, there is a problem in that it is not possible to grasp the status of processing by the production equipment, such as whether or not the production equipment stops from the time the production equipment starts processing a part until the item to be processed is delivered, and the number of times the equipment stops. To grasp the status of processing by the production equipment, a sensor for detecting the start of processing by the production equipment and a sensor for detecting the stop of processing can be further installed, but this increases the number of parts. Therefore, there has been a demand for technology that can grasp the status of processing by the production equipment while suppressing the increase in the number of parts. [Means for solving the problem]

[0005] The present disclosure can be realized in the following forms.

[0006] (1) According to one aspect of the present disclosure, a production management system for managing the production status of a production line is provided. The production management system includes: an operational status acquisition device that includes a detection unit disposed in or near production equipment included in the production line, the detection unit generating a first signal corresponding to the start of processing of a processing target by the production equipment and a second signal corresponding to the stop of the processing, and a transmission unit for transmitting the first and second signals; and a production management device that receives the first and second signals transmitted from the operational status acquisition device, the production management device including a processing completion determination unit that determines whether the production equipment has completed the processing using the first and second signals. The processing completion determination unit obtains the processing time from receiving the first signal to receiving the second signal, and determines that the production equipment has completed the processing if the obtained processing time is equal to or longer than a predetermined standard processing time. If the obtained processing time is shorter than the standard processing time, the processing completion determination unit further: intermittent Integrating the processing time, intermittent When the integrated value of the processing time is equal to or greater than the reference processing time, it is determined that the production equipment has completed the processing. According to this type of production management system, a single detection unit can be used to grasp the processing status of the production equipment, such as whether or not the production equipment has stopped processing, etc. Therefore, it is possible to grasp the processing status of the production equipment while suppressing an increase in the number of parts. (2) In the production management system of the above aspect, when the acquired processing time is equal to or longer than the reference processing time, the processing completion determination unit may further acquire the acquisition interval from the first signal to the second signal as a machine cycle time from when the production equipment starts the processing to when it completes it, and when the acquired processing time is shorter than the reference processing time, intermittent When the integrated value of the processing time is equal to or greater than the reference processing time, intermittent In the processing time, the time from when the first signal is first received to when the second signal is last received may be acquired as the machine cycle time. According to this type of production management system, the machine cycle time of the production equipment can be obtained by one detection unit. (3) In the production management system of the above aspect, when the acquired processing time is equal to or longer than the reference processing time, the processing completion determination unit further intermittent The acquisition interval of the first signal may be acquired as a cycle time from when the production equipment starts the processing until when the production equipment starts the next processing, and when the acquired processing time is less than the reference processing time, and further, intermittent When the integrated value of the processing time is equal to or greater than the reference processing time, intermittent During the processing time, after first receiving the first signal, intermittent The cycle time may be the time from when the integrated value of the processing time becomes equal to or greater than the reference processing time until when the first signal is received. According to this type of production management system, the cycle time of the production equipment can be obtained by one detection unit. (4) In the production management system of the above aspect, the processing completion determination unit may further determine that there is an abnormality in the cycle time when the acquired processing time is less than the reference processing time. According to this type of production management system, it is possible to determine an abnormality in the cycle time earlier than the calculation of the cycle time is completed. (5) In the production management system of the above aspect, the processing completion determination unit may determine that the manufacturing line is stopped if the interval time from when the production equipment completes the processing until when the production equipment starts the next processing exceeds a predetermined reference interval time. According to this type of production management system, a stoppage of the production line can be detected by a single detection unit. (6) In the production management system of the above form, when the processing completion determination unit determines that the production equipment has completed the processing, it may further count the total number of processing items for which the production equipment has completed the processing. According to this type of production management system, the production volume of the production equipment can be obtained by one detection unit. (7) In the production management system of the above aspect, when the acquired processing time is less than the reference processing time, the processing completion determination unit further intermittent The number of times that a stop time occurs during the processing time may be counted. According to this type of production management system, the number of times the production equipment has been stopped can be obtained by one detection unit. (8) In the production management system of the above aspect, the production equipment may have a display unit that indicates the operating status of the production equipment by light, and the detection unit may be an optical sensor attached to the display unit that acquires the operating status indicated by the display unit and generates the first signal and the second signal. According to this type of production management system, a general-purpose sensor can be used as the detection unit. The present disclosure can also be realized in various forms other than a production management system, such as an operation status acquisition device, a production management device, a production management method, a manufacturing line or production equipment, a control method for a production management system, a control method for an operation status acquisition device, a control method for a production management device, a computer program for realizing the control method, a non-transitory recording medium on which the computer program is recorded, etc. [Brief explanation of the drawings]

[0007] [Figure 1] 1 is a schematic configuration diagram showing a production management system according to a first embodiment of the present disclosure. [Figure 2] FIG. 2 is a block diagram showing the internal functional configuration of the production management device. [Figure 3] FIG. 2 is a block diagram showing the functional configuration of an operational status acquisition device. [Figure 4] FIG. 2 is an explanatory diagram showing an example of the arrangement of a first operational status acquisition device including an optical sensor as a detection unit. [Figure 5] FIG. 10 is an explanatory diagram illustrating a case where the operating status acquisition device is attached to production equipment and used. [Figure 6]4 is a flowchart showing a processing routine executed by a first operational status acquisition device. [Figure 7] 4 is a flowchart showing a processing routine executed by the production management device. [Figure 8] 4 is a first time chart showing the relationship between a detection signal from an operational status acquisition device and a processing routine by a processing completion determination unit. [Figure 9] 10 is a second time chart showing the relationship between a detection signal from the operational status acquisition device and a processing routine by the processing completion determination unit. [Figure 10] 10 is a third time chart showing the relationship between a detection signal from the operational status acquisition device and a processing routine by the processing completion determination unit. [Figure 11] FIG. 10 is an explanatory diagram showing an example of production status information displayed on the display device. [Figure 12] FIG. 4 is an explanatory diagram showing an example of detailed display of the operating status of the first production facility displayed on the display device. DETAILED DESCRIPTION OF THE INVENTION

[0008] A. First embodiment: FIG. 1 is a schematic configuration diagram showing a production management system 100 according to a first embodiment of the present disclosure. The production management system 100 includes a production management device 10 and operational status acquisition devices 20a and 20b. The production management device 10 cooperates with the operational status acquisition devices 20a and 20b to manage the production status of a first production line L1 and a second production line L2. The number of production lines is not limited to two, and may be one, or three or more.

[0009] The production lines L1, L2 include production equipment 31-36 and a conveying mechanism 41. The production equipment 31-36 are arranged on the conveying mechanism 41. The conveying mechanism 41 conveys items to be processed by the production equipment 31-36 (hereinafter also referred to as "items to be processed"), such as parts and workpieces, flowing through the production lines L1, L2. In this disclosure, "processing" means performing a specific task on a product, such as machining. The conveying mechanism 41 includes, for example, a belt conveyor, a conveyor that moves on a predetermined track, and the like.

[0010] The production equipment 31-36 is, for example, equipment such as metal processing machines, welding machines, resin molding machines, coating machines, hot forging machines, finished product recovery machines, and processed parts supply machines. The production equipment 31-36 is equipped with a programmable logic controller (PLC) for executing production processing and processing on the products to be processed, and various sensors connected to the PLC, such as photoelectric sensors and area sensors. The various sensors are arranged in advance when the production lines L1, L2 and the production equipment 31-36 are installed and positioned in order to operate the production lines L1, L2 and the production equipment 31-36.

[0011] 1, the first production line L1 is provided with a first production facility 31, a second production facility 32, and a third production facility 33. The second production line L2 is provided with a fourth production facility 34, a fifth production facility 35, and a sixth production facility 36.

[0012] The operational status acquisition devices 20a, 20b are retrofitted to the production equipment 31, 34. In the present disclosure, "retrofitted" means that they are not attached to or incorporated in the production equipment at the time of installation and placement of the production equipment, are not connected to the PLC that controls the operation of the production equipment, and are attached or placed on the production equipment independently of the operation and control of the production equipment. The operational status acquisition devices 20a, 20b may be retrofitted and placed near the production equipment 31, 34. In the example of FIG. 1, the first operational status acquisition device 20a is attached to the first production equipment 31, and the second operational status acquisition device 20b is attached to the fourth production equipment 34.

[0013] As shown in FIG. 1, the production management device 10 and the operation status acquisition devices 20a and 20b can transmit and receive data to each other via wireless communication. For example, the production management device 10 transmits generated production status information to the terminal devices PD1 and PD2 via wireless communication in response to a request from the terminal devices PD1 and PD2. The production status information refers to information related to the operation status of the production equipment. The production status information includes, for example, the operation time of the production equipment, the number of production units, the output per unit time, the cycle time availability rate (%), the cycle time (hereinafter also referred to as "cycle time CT"), the machine cycle time (hereinafter also referred to as "machine cycle time MCT"), the processing time, the stop time, the interval time, the delay time, and the like.

[0014] Operating time refers to the cumulative time that a production facility is operating after it has been started. Production volume refers to the total number of items processed by the production facility. The number of items that can be processed by the production facility at one time is also referred to as the "processing volume." In this embodiment, the number of items processed by the first production facility 31 is 1. Output per unit time refers to the number of items processed per unit time, such as one hour. Cycle time availability refers to the percentage of time during which the production facility is normally executing processing relative to a predetermined set time. The set time can be set using a specified unit time, such as one hour, operating time, or running time. Processing time refers to the time during which the production facility is processing items. Stoppage time refers to the period during which the production facility is stopped from processing items from the time the production facility starts processing the items until the processing is completed. Stoppage time is not included in processing time. Downtime includes, for example, the time from when production equipment stops processing a target item due to an abnormality until it resumes, as well as periods of temporary downtime, such as when operators perform recovery or maintenance on the production equipment. Interval time refers to the time from when production equipment completes processing a target item until it starts the next processing. Interval time is also called the "interval period." Delay time refers to the delay in actual processing time compared to the planned processing time. Machine cycle time (MCT) refers to the time required for production equipment to process a target item per cycle, and refers to the time from when processing a target item begins until that processing is completed. Machine cycle time (MCT) is the sum of processing time and downtime, and approximately equals processing time when no downtime occurs. Cycle time (CT) refers to the time from when production equipment starts processing a target item until it starts processing the next target item. Cycle time (CT) approximately equals the sum of machine cycle time (MCT) and interval time.

[0015] The production management device 10 may be located within the factory as a local server, or may be located outside the factory as a remote server. When the production management device 10 is installed as a remote server, detection signals from the added operational status acquisition devices 20a, 20b and production status information to the terminal devices PD1, PD2 and the local computer are transmitted and received by the production management device 10 via wireless access points within the factory and a network such as an intranet or the Internet. As will be described later, the detection signals from the operational status acquisition devices 20a, 20b include a first signal corresponding to the start of processing of the target items by the production equipment 31, 34, and a second signal corresponding to the stop of processing of the target items by the production equipment 31, 34.

[0016] 2 is a block diagram showing the internal functional configuration of the production management device 10. The production management device 10 comprises a central processing unit (CPU) 11, a storage device 12, a transmission / reception unit 13, a display device 14, an input device 15, and a timer 16 for measuring time, which are interconnected via a bus 17 so as to be able to communicate with each other. The CPU 11, the storage device 12, and the transmission / reception unit 13 are capable of bidirectional communication with each other. The production management device 10 is a device different from the PLC that controls the operation of the production equipment 31-36, and the operation of the production equipment 31-36 is controlled by the PLC even when the production management device 10 is not used.

[0017] The CPU 11 functions as a processing completion determination unit 110 by executing various programs stored in the storage device 12. The processing completion determination unit 110 determines whether the production equipment has completed processing, for example, using a first signal and a second signal transmitted from the operation status acquisition devices 20a and 20b. The storage device 12 is, for example, a RAM, a ROM, a hard disk drive (HDD), a solid state drive (SSD), or the like. The HDD, SSD, or ROM stores various programs for realizing the functions provided in this embodiment. The various programs read from the HDD or ROM are expanded on the RAM and executed by the CPU 11. The generated production status information, etc., is stored in a readable / writable area of ​​the storage device 12. Specifically, it is provided with a processing time memory unit 120 that stores the acquired processing time and the integrated value of the processing time, a cycle time memory unit 121 that stores the acquired cycle time CT, a machine cycle time memory unit 122 that stores the acquired machine cycle time MCT, a production number memory unit 124 that stores the counting results of the production number, a stop time memory unit 125 that stores the acquired stop time and the integrated value of the stop time, a stop count memory unit 126 that stores the counting results of the number of stops, and a standard processing time memory unit 128 that stores a predetermined standard processing time.

[0018] The transmitter-receiver 13 receives a first signal and a second signal via wireless communication from the operational status acquisition devices 20a, 20b that are attached to the production equipment 31, 34 on the production lines L1, L2 or that are located near the production equipment 31, 34. The transmitter-receiver 13 transmits various execution commands to the operational status acquisition devices 20a, 20b. The transmitter-receiver 13 may further transmit production status information to the terminal devices PD1, PD2, and may receive command signals from the terminal devices PD1, PD2 that request the execution of various processes.

[0019] The transmitter-receiver 13 can acquire the first signal and the second signal from the operational status acquisition devices 20a and 20b without being connected to the operational status acquisition devices 20a and 20b by wire. This configuration allows the production management system 100 of this embodiment to be introduced into an existing factory using a simple method of retrofitting or disposing the operational status acquisition devices 20a and 20b on the production equipment 31 and 34. For example, if the transmitter-receiver 13 is an input / output interface (I / F) with wireless communication capabilities, the transmitter-receiver 13 may receive wireless radio waves from the operational status acquisition devices 20a and 20b via a wireless repeater (access point) (not shown) installed in the factory. Alternatively, the transmitter-receiver 13 itself may be located in a location where it can receive wireless radio waves from the operational status acquisition devices 20a and 20b as a wireless access point. Alternatively, the transmitter-receiver 13 may be connected to the wireless repeater by wire. The wireless communication can be realized, for example, by a wireless connection through a wireless local network (LAN) conforming to the IEEE802.11 standard or wireless communication using Bluetooth (registered trademark).

[0020] The display device 14 is a display for displaying production status information such as the process details when operating the production management system 100, the cycle time CT, and the machine cycle time MCT. The display device 14 may be provided separately from the production management device 10. For example, if the production management device 10 is a remote server and is provided to generate production status information, the display device 14 may not be provided. The input device 15 is a device used to enter input into the production management system 100. The input device 15 is, for example, a keyboard or a mouse. The input device 15 may also be a touch panel provided on the screen of the display device 14.

[0021] FIG. 3 is a block diagram showing the functional configuration of the operational status acquisition devices 20a and 20b. In FIG. 3, the first operational status acquisition device 20a is used as an example for explanation, but the second operational status acquisition device 20b has a similar configuration. The operational status acquisition devices 20a and 20b are attached or disposed on the production lines L1 and L2 or production equipment as retrofits. The first operational status acquisition device 20a includes a detection unit 25a, a first transmission / reception unit 21a, a second transmission / reception unit 22a, and a controller 23a. The detection unit 25a, the first transmission / reception unit 21a, and the second transmission / reception unit 22a are communicably connected to the controller 23a.

[0022] The detection unit 25a is a variety of sensors that are attached to the first production facility 31 or arranged in the vicinity of the first production facility 31. The detection unit 25a is a sensor that is different from existing sensors connected to a programmable logic controller (PLC). The detection unit 25a may be provided integrally with the first operational status acquisition device 20a or may be separate from the first operational status acquisition device 20a. If the detection unit 25a is separate from the first operational status acquisition device 20a, it is connected to the first operational status acquisition device 20a via a signal line. The detection unit 25a may be a detection unit that includes only a detection element and outputs an analog signal, or may be a detection unit that includes a detection element and a circuit that converts a signal output from the detection element into a digital signal and outputs the digital signal.

[0023] The sensors used as the detection unit 25a include optical sensors, sound sensors, heat sensors, current sensors, distance sensors, air pressure sensors, acceleration sensors, rotational speed sensors, humidity sensors, magnetic sensors, and pressure sensors. Each sensor is used to detect the operating status of the production equipment. In this embodiment, the operating status refers to the status during processing by the production equipment. The operating status includes the start and stop of processing of items to be processed on the manufacturing line and in the production equipment. The operating status may also include operations and manipulations related to processing, as well as the start, execution, stop, and completion status of the operation and manipulation.

[0024] The detection unit 25a detects the start of processing of the object to be processed by the first production facility 31 and the stop of processing of the object to be processed by the first production facility 31, and generates a pulse signal. For example, the detection unit 25a generates a pulse signal that rises (ON) from a reference state when it detects the start of processing by the first production facility 31, and falls (OFF) from the ON state when it detects the stop of processing by the first production facility 31. The generated pulse signal is output to the controller 23a. The detection unit 25a may generate a pulse signal that falls (OFF) from the ON state to the reference state when it detects the start of processing by the first production facility 31, and rises (ON) from the reference state when it detects the stop of processing by the first production facility 31.

[0025] The controller 23a includes a central processing unit (CPU) and a storage device (not shown). The controller 23a generates a first signal and a second signal, each having an identifier identifiable by the production management device 10, using the pulse signal received from the detection unit 25a. The controller 23a outputs the first signal and the second signal to the first transmission / reception unit 21a and the second transmission / reception unit 22a, respectively. In this embodiment, the controller 23a detects the rising edge (ON) of the pulse signal received from the detection unit 25a, generates a first signal, and outputs the first signal to the first transmission / reception unit 21a. The controller 23a generates a second signal and outputs the second signal to the second transmission / reception unit 22a when it detects the falling edge (OFF) of the pulse signal received from the detection unit 25a. In addition, if the detection unit 25a generates a pulse signal that falls (OFF) from the ON state to the reference state when it detects the start of processing by the first production equipment 31, and generates a pulse signal that rises (ON) from the reference state when it detects the stop of processing by the first production equipment 31, the controller 23a may generate a first signal and output it to the first transmission / reception unit 21a when it detects the falling edge of the pulse signal, and generate a second signal and output it to the second transmission / reception unit 22a when it detects the rising edge of the pulse signal. Instead of the controller 23a, the detector 25a may generate the first signal and the second signal and output them to the controller 23a. When the signal input from the detector 25a is an analog signal, the controller 23a converts the signal into a digital signal that is High (1) in active-high logic or Low (1) in active-low logic when the signal value is equal to or greater than a predetermined value, less than a specified value, or within an arbitrary range, and transmits the first signal and the second signal to the production management device 10.

[0026] The first transceiver 21a and the second transceiver 22a function as transmitters that transmit a first signal and a second signal to the production management device 10 via wireless communication in accordance with an arbitrary communication protocol. More specifically, the first transceiver 21a functions as a first transmitter that transmits a first signal to the production management device 10, and the second transceiver 22a functions as a second transmitter that transmits a second signal to the production management device 10. The first transceiver 21a and the second transceiver 22a may generate the first signal and the second signal in accordance with a command from the controller 23a that receives a pulse signal from the detector 25a. The first transceiver 21a and the second transceiver 22a may receive an execution command from the production management device 10.

[0027] 4 is an explanatory diagram showing an example of the arrangement of a first operational status acquisition device 20a equipped with an optical sensor as the detection unit 25a. The first operational status acquisition device 20a is provided in the first production facility 31 of the first manufacturing line L1. A housing 310 that houses a PLC is disposed adjacent to the first production facility 31. The housing 310 is provided with a signal tower 40 that indicates the operational status of the first production facility 31 with three-colored signal lights. The signal lights are an example of a display unit that indicates the operational status of the first production facility 31. The operational status indicated by the signal tower 40 is, for example, green for processing, yellow for processing stopped, and red for abnormal stop.

[0028] The optical sensor serving as the detector 25a may be a photoelectric conversion element, such as a photodiode or phototransistor, capable of detecting whether a signal light is on or off. The detector 25a is attached, for example, to the light-emitting surface of a green signal light on the signal tower 40. By attaching the detector 25a to the signal tower 40, it is possible to easily detect the start or stop of processing of the target item by the first production facility 31, as indicated by the signal tower 40. The detector 25a detects the start of processing by the first production facility 31 when the green signal light is on, and detects the stop of processing by the first production facility 31 when the green signal light is off. When the start of processing by the first production facility 31 is detected, the controller 23a generates a first signal using the pulse waveform from the detector 25a and outputs the first signal to the first transceiver 21a. When the stop of processing by the first production facility 31 is detected, the controller 23a generates a second signal using the pulse waveform from the detector 25a and outputs the second signal to the second transceiver 22a. The detector 25a may generate a first signal and a second signal and output them to the controller 23a. The detector 25a may output a current corresponding to the amount of received light to the controller 23a. In this case, when the amount of received light is equal to or greater than a predetermined amount, the controller 23a generates a pulse waveform as the first signal, and when the amount of received light is less than the predetermined amount, the controller 23a generates a pulse waveform as the second signal.

[0029] 5 is an explanatory diagram illustrating a case where an operating status acquisition device is attached to production equipment for use. A second operating status acquisition device 20b is attached to the fourth production equipment 34. The first transceiver 21b, the second transceiver 22b, and the controller 23b are attached near an opening / closing door 341 provided on the fourth production equipment 34. The opening / closing door 341 is closed when the fourth production equipment 34 starts processing the items to be processed, and is opened when the fourth production equipment 34 stops processing the items to be processed and when processing is completed.

[0030] The second operational status acquisition device 20b includes a magnetic sensor serving as a detection unit 25b. The detection unit 25b detects the movement of the door 341 as information indicating the operational status of the fourth production equipment 34. In this embodiment, the detection unit 25b detects the opening and closing of the door 341 using a change in magnetic force caused by a change in distance from a magnet 342 attached to the fourth production equipment 34, and can detect the start and stop of processing of the items to be processed based on the opening and closing of the door 341.

[0031] When the controller 23b detects that processing by the fourth production equipment 34 has started, it generates a first signal using the pulse waveform from the detection unit 25b and outputs it to the first transceiver unit 21b, and when the controller 23b detects that processing by the fourth production equipment 34 has stopped, it generates a second signal using the pulse waveform from the detection unit 25b and outputs it to the second transceiver unit 22b.

[0032] 6 is a flowchart showing a processing routine executed by the first operational status acquisition device 20a. This flow can be repeatedly executed from the time the first operational status acquisition device 20a is started until the operation of the first operational status acquisition device 20a is terminated. Note that the second operational status acquisition device 20b can also execute the same processing.

[0033] In step S200, the first operational status acquisition device 20a checks whether a pulse signal has been input from the detection unit 25a. If a pulse signal has not been input from the detection unit 25a (S200: NO), the controller 23a waits for the input of a pulse signal.

[0034] When the controller 23a receives a pulse signal from the detector 25a (step S200: Yes), the controller 23a detects a rising edge (ON) or a falling edge (OFF) of the detected pulse signal (step S210). In this embodiment, when the controller 23a detects a rising edge (ON) of the pulse signal (S210: YES), the controller 23a generates a first signal indicating the start of processing of the object by the first production facility 31 and outputs it to the first transmitter / receiver 21a, and the first transmitter / receiver 21a transmits the acquired first signal to the production management device 10 (step S211). When the controller 23a detects a falling edge (OFF) of the pulse signal (S210: NO), the controller 23a outputs a second signal corresponding to the stop of processing of the object by the production facility to the second transmitter / receiver 22a, and the second transmitter / receiver 22a transmits the acquired second signal to the production management device 10 (step S212).

[0035] FIG. 7 is a flowchart showing a processing routine executed by the production management device 10. This flow can be repeatedly executed from the time the production management device 10 is started until the operation of the production management device 10 is terminated. When this flow starts, the production management device 10 waits for reception of a detection signal and starts timing using the timer 16. Note that this flow may also be started when the production management device 10 receives a first signal. In the following explanation, the first operational status acquisition device 20a installed in the first production equipment 31 on the first production line L1 will be used as an example, but the same applies to the second operational status acquisition device 20b installed in the fourth production equipment 34 on the second production line L2.

[0036] In step S10, the processing completion determination unit 110 receives a first signal from the first operational status acquisition device 20a via wireless communication at the transmitter-receiver 13. The received first signal is stored in the storage device 12. In step S20, the processing completion determination unit 110 waits for reception of a second signal from the first operational status acquisition device 20a. When the processing completion determination unit 110 receives the second signal via wireless communication at the transmitter-receiver 13 (S20: YES), the processing completion determination unit 110 proceeds to step S30.

[0037] In step S30, the processing completion determination unit 110 calculates the processing time Tk and the integrated value ATk of the processing time Tk. The processing time Tk is the time during which the first production equipment 31 processes the item to be processed, and corresponds to the period from when the first signal is received to when the second signal is received. The processing completion determination unit 110 acquires the time from when the first signal is received to when the second signal is received as the processing time Tk. The processing completion determination unit 110 further accumulates the acquired processing time Tk by the integrated value ATk of the processing time Tk stored in the processing time memory unit 120, stores the accumulated value in the processing time memory unit 120, and updates the integrated value ATk.

[0038] In step S40, the processing completion determination unit 110 compares the integrated value ATk of the processing time Tk with the reference processing time Ts. The reference processing time Ts is stored in the reference processing time storage unit 128 as a predetermined arbitrary set value. The reference processing time Ts is set using the time required for the first production equipment 31 to successfully complete processing of the items to be processed. The reference processing time Ts can be set in advance using, for example, the shortest processing time in the first production equipment 31, the average processing time in the first production equipment 31, or the upper limit of the processing time in the first production equipment 31.

[0039] In step S40, if the integrated value ATk of the processing time Tk is less than the standard processing time Ts (S40: NO), the processing completion determination unit 110 determines that the first production equipment 31 has not completed processing the item to be processed, and proceeds to step S50. Examples of cases in which the integrated value ATk is less than the standard processing time Ts include when the first production equipment 31 stops abnormally, when the first production equipment 31 receives a stop operation from an operator, and when the first production equipment 31 receives a second signal due to being temporarily stopped before processing by the first production equipment 31 is completed.

[0040] In step S50, the processing completion determination unit 110 counts the number of stops and starts timing the stop time. The "number of stops" refers to the number of times a stop time occurred before the first production equipment 31 completed processing of the item to be processed. The processing completion determination unit 110 adds 1 to the cumulative value of the number of stops stored in the stop count memory unit 126, stores the result in the stop count memory unit 126, and updates the count result of the number of stops.

[0041] In step S60, the processing completion determination unit 110 waits for reception of a first signal. When the transmitter / receiver 13 receives the first signal (S60: YES), the process proceeds to step S70. In step S70, the processing completion determination unit 110 calculates the stop time Tm and an integrated value ATm of the stop time Tm. The stop time Tm is the period during which the first production equipment 31 stops processing the items to be processed, and in this flow, it corresponds to the period from when the second signal is received in step S20 to when the first signal is received in step S60. The processing completion determination unit 110 acquires the time from when the second signal is received to when the first signal is received as the stop time Tm. The processing completion determination unit 110 integrates the acquired stop time Tm with the integrated value ATm of the stop time Tm stored in the stop time memory unit 125, stores the integrated value ATm in the stop time memory unit 125, and updates the integrated value ATm.

[0042] In step S80, the process completion determination unit 110 determines that there is an abnormality in the cycle time CT. This setting is based on the fact that it is possible to predict that the cycle time CT will be delayed compared to the normal cycle time CT when the stop time Tm occurs. However, this is not limited to this example. For example, the presence or absence of an abnormality in the cycle time CT may be determined based on the result of comparing the sum of the integrated value ATk of the process time Tk and the integrated value ATm of the stop time Tm with a predetermined threshold. Alternatively, it may be determined that there is an abnormality in the cycle time CT when the stop time Tm or the integrated value ATm of the stop time Tm is longer than the predetermined threshold. If the process completion determination unit 110 determines that there is an abnormality in the cycle time CT, it stores the determination result in the storage device 12 and returns to step S20.

[0043] In step S40, if the integrated value ATk of the processing time Tk is equal to or greater than the standard processing time Ts (S40: YES), the processing completion determination unit 110 determines that the first production equipment 31 has completed processing the item to be processed, and proceeds to step S100. "If the integrated value ATk is equal to or greater than the standard processing time Ts" includes, for example, two cases: one where a stop time Tm does not occur, and one where a stop time Tm occurs, as in the following (1) and (2). (1) When the downtime Tm does not occur and the processing time Tk is equal to or greater than the standard processing time Ts (2) When a stop time Tm occurs and the integrated value ATk of the processing time Tk is equal to or greater than the reference processing time Ts (1) corresponds to the case where the first production equipment 31 normally completes the processing without stopping during processing. In other words, it corresponds to the case where the processing of step S100 is performed without performing the processing of steps S50 to S80. In this case, the integrated value ATk and the processing time Tk are equal to each other. (2) corresponds to the case where the first production equipment 31 stops during processing, multiple processing times Tk occur, and the integrated value ATk becomes equal to or greater than the standard processing time Ts. In this case, since the time required for processing by the first production equipment 31 has elapsed, it can be predicted that the first production equipment 31 has completed processing the items to be processed.

[0044] In step S100, the processing completion determination unit 110 acquires the machine cycle time MCT from when the first production equipment 31 starts processing until when it completes it. The processing completion determination unit 110 acquires the machine cycle time MCT using a calculation method depending on whether or not a stop time Tm has occurred. If a stop time Tm has not occurred, the processing completion determination unit 110 acquires the processing time Tk as the machine cycle time MCT. Specifically, the processing completion determination unit 110 acquires the acquisition interval from when the first signal is received in step S10 to when the second signal is received in step S20 as the machine cycle time MCT.

[0045] When a stop time Tm occurs, i.e., intermittentWhen the integrated value ATk of the processing time Tk becomes equal to or greater than the reference processing time Ts, the processing completion determination unit 110 intermittent In the processing time Tk, the time from when the first signal is first received to when the second signal is last received is acquired as the machine cycle time MCT. intermittent The case where the integrated value ATk of the processing time Tk becomes equal to or longer than the reference processing time Ts corresponds to the case where the processing of step S100 is executed after the processing of steps S50 to S80 has been executed at least once. In this case, the machine cycle time MCT includes the stop time Tm and is approximately equal to the sum of the integrated value ATk of the processing time Tk and the integrated value ATm of the stop time Tm. The processing completion determination unit 110 stores the acquired machine cycle time MCT in the machine cycle time storage unit 122.

[0046] In step S110, the processing completion determination unit 110 counts the total number of processing items that have been processed by the first production facility 31, i.e., the production number. The processing completion determination unit 110 adds the production number stored in the production number storage unit 124 to the processing number of the first production facility 31 (1 in this embodiment), stores the result in the production number storage unit 124, and updates the count result of the production number.

[0047] In step S120, the processing completion determination unit 110 compares the interval time Ti with a predetermined reference interval time Tr. The interval time Ti is the time from when the first production equipment 31 completes processing of the processing target item to when the first production equipment 31 starts the next processing.

[0048] The reference interval time Tr is used to determine whether or not there is an abnormality in the interval time Ti. When the interval time Ti exceeds the reference interval time Tr, this corresponds to when the interval time Ti is delayed relative to normal. The reference interval time Tr can be set in advance using, for example, the shortest value, average value, or upper limit value of the interval time Ti, as well as the time required for so-called setup change by the first production equipment 31, or a time longer than these times.

[0049] The interval time Ti may exceed the reference interval time Tr when the processing by the production facilities 31 to 33 cannot be performed normally, for example, when the second production facility 32 or the third production facility 33 downstream of the first production facility 31 stops abnormally, causing the first production facility 31 to be unable to deliver the products to be processed to the second production facility 32, or when the first production facility 31 cannot start processing due to an abnormal stop of the first production facility 31. A case where the processing by the production facilities 31 to 33 cannot be performed normally corresponds to a case where the first manufacturing line L1 including the first production facility 31 is stopped.

[0050] In this embodiment, if the elapsed time since the last time the second signal was received exceeds the reference interval time Tr, the processing completion determination unit 110 determines that the interval time Ti has exceeded the reference interval time Tr (S120: YES) and proceeds to step S160. That is, before receiving the first signal and calculating the interval time Ti in step S130, the processing completion determination unit 110 determines that the interval time Ti has exceeded the reference interval time Tr. This makes it possible to determine whether the first production line L1 has stopped without waiting for the first signal to be received. However, the processing completion determination unit 110 may also receive the first signal in step S130, acquire the interval time Ti, and compare the acquired interval time Ti with a predetermined reference interval time Tr.

[0051] In step S160, the processing completion determination unit 110 determines that the first production line L1 including the first production equipment 31 has stopped, and ends the processing. The processing completion determination unit 110 may further notify the stoppage of the first production line L1.

[0052] In step S130, the processing completion determination unit 110 waits for reception of a first signal from the first operational status acquisition device 20a. In this embodiment, if the first signal is received before the reference interval time Tr (S130: YES), the process proceeds to step S140, where the processing completion determination unit 110 acquires the cycle time CT. In the example of FIG. 7, the processing completion determination unit 110 acquires the cycle time CT as the period from the time when the first signal is first received, i.e., the time when the first signal is received in step S10, to the time when the next first signal is received after the last second signal is received, i.e., the time when the first signal is received in step S130. The cycle time CT may be calculated by multiplying the machine cycle time MCT by the interval time Ti, or by multiplying the sum of the processing time Tk or the integrated value ATk, the stop time Tm or the integrated value ATm by the interval time Ti. Once the cycle time CT is acquired, the process proceeds to step S150, where the processing completion determination unit 110 resets the integrated value ATk of the processing time Tk stored in the processing time memory unit 120 of the storage device 12 and the integrated value ATm of the stop time Tm stored in the stop time memory unit 125, and completes this flow.

[0053] The processing routine executed by the production management device 10 will be described with reference to Figures 8 to 10. Figure 8 is a first time chart showing the relationship between the detection signal from the operational status acquisition device 20a and the processing routine by the processing completion determination unit 110. In Figures 8 to 10, the horizontal axis is the time axis, and the vertical axis schematically shows the timing of generation of the ON signal and OFF signal by the detection unit 25a.

[0054] The time chart shown in Fig. 8 is an example of a time chart in which the first production equipment 31 completes processing normally without stopping during processing. No downtime Tm occurs, and the integrated value ATk and the processing time Tk are equal. In the example of Fig. 8, the processing time Tk is longer than the reference processing time Ts.

[0055] 8, at time T1, the detection unit 25a detects the start of processing by the first production equipment 31, and the controller 23a generates a first signal as an ON signal that rises from a reference state. At time T2, which is a reference processing time Ts after time T1, the detection unit 25a detects the stop of processing by the first production equipment 31, and generates a second signal as an OFF signal that falls from the ON state. At time T3, which is an interval time Ti after time T2, the first production equipment 31 starts processing the next item to be processed, and the detection unit 25a generates a first signal.

[0056] 8, the period from when the first signal is received at time T1 to when the second signal is received at time T2, i.e., the processing time Tk, is equal to or greater than the reference processing time Ts. Therefore, the processing completion determination unit 110 determines that the integrated value ATk of the processing time Tk is equal to or greater than the reference processing time Ts, acquires the processing time Tk as the machine cycle time MCT, and integrates the production quantity.

[0057] 8, the elapsed time from time T2 to time T3, i.e., the interval time Ti, is less than the reference interval time Tr. Therefore, the processing completion determination unit 110 acquires the time from time T1 when the first signal is first detected to time T3 when the first signal is next detected as the cycle time CT.

[0058] Fig. 9 is a second time chart showing the relationship between the detection signals from the operational status acquisition devices 20a and 20b and the processing routine by the processing completion determination unit 110. The time chart shown in Fig. 9 is an example of a time chart in which the integrated value ATk becomes equal to or greater than the reference processing time Ts after the first production equipment 31 has stopped (n-1) times during processing, where n is a natural number equal to or greater than 2.

[0059] 9, the processing time Tk1 from when the first signal is received at time T10 to when the second signal is received at time T11 is less than the reference processing time Ts. Therefore, the processing completion determination unit 110 increments the number of stops stored in the stop count storage unit 126 by 1 and waits for detection of the first signal. When the first signal is detected at time T12, the processing completion determination unit 110 acquires the time from time T11 to time T12 as the stop time Tm1.

[0060] Next, the processing completion determination unit 110 acquires the time from time T12 to time T13, when the second signal is next detected, as processing time Tk2. The processing completion determination unit 110 also calculates an integrated value ATk by integrating processing time Tk1 with processing time Tk2. In the example of FIG. 9, at time T13, the integrated value ATk is less than the reference processing time Ts. Therefore, the processing completion determination unit 110 further integrates the number of stops by 1 and waits for detection of the first signal.

[0061] 9, the first production equipment 31 has been stopped (n-1) times. When a first signal is detected at time T14 and a second signal is detected at time T15, the processing completion determination unit 110 acquires the time from time T14 to time T15 as the processing time Tkn. Note that from processing time Tk1 to processing time Tkn, intermittent At time T15, intermittent The processing completion determination unit 110 determines whether the integrated value ATk of the processing times Tk1 to Tkn is equal to or greater than the reference processing time Ts. intermittent In the processing times Tk1 to Tkn, the time from the time T10 when the first signal is first received to the time T15 when the second signal is last received is acquired as the machine cycle time MCT. In the example of Fig. 9, the number of stops stored in the stop count storage unit 126 is (n-1).

[0062] The interval time Ti from time T15 to time T16 when the next process starts is less than the reference interval time Tr. Therefore, the process completion determination unit 110 acquires the time from time T1 when the first signal is first detected to time T16 when the second signal is last received and the next first signal is detected as the cycle time CT.

[0063] For example, if the production management system 100 has multiple sensors, including one that detects the start of processing of the items by the first production facility 31 and another that detects the completion of processing, it can detect the start and completion of processing by the first production facility 31. However, in this case, it may not be possible to detect a temporary stop of processing by the first production facility 31. Also, for example, in a case where a signal tower 40 indicates that processing of the items is in progress or has stopped, but does not indicate whether processing of the items is complete, the detection unit may not be able to detect whether processing of the items is complete simply by detecting whether the signal tower 40's signal light is on or off. In the production management system 100 of this embodiment, the processing completion determination unit 110 determines whether the processing time Tk per processing has reached the reference processing time Ts, thereby detecting whether the signal tower 40's signal light is on or off, thereby determining whether processing of the first production facility 31 is complete. Furthermore, if the processing time Tk per processing has not reached the standard processing time Ts, a stoppage during processing of the first production equipment 31 can be detected, and by determining whether the integrated value ATk of the processing time Tk has reached the standard processing time Ts, it can be determined whether processing of the first production equipment 31 has been completed.

[0064] FIG. 10 is a third time chart showing the relationship between the detection signals from the operational status acquisition devices 20a and 20b and the processing routine by the processing completion determination unit 110. As shown in FIG. 10, the first production equipment 31 completes processing from time T20 to time T21 without stopping during the processing. At time T22, the elapsed time from time T21 exceeds the reference interval time Tr. At time T22, the processing completion determination unit 110 determines that the interval time Ti has exceeded the reference interval time Tr because the elapsed time from time T21, when the second signal was last received, exceeds the reference interval time Tr. The processing completion determination unit 110 determines that the first production line L1, including the first production equipment 31, has stopped, and ends the processing.

[0065] FIG. 11 is an explanatory diagram illustrating an example of production status information displayed on the display device 14. In the example of FIG. 11, the following information is displayed: the time T0 when the first signal was first input after the production line was started; the number of stoppages of the production lines L1 and L2; production efficiency (%); the number of abnormalities in the cycle time CT of each of the production equipment 31-36 arranged on the production lines L1 and L2; the total number of stoppages; and the total number of line stoppages. The "Number of Line Stoppages" field displays the number of times the processing completion determination unit 110 determined that the first production line L1, including the first production equipment 31, was stopped. In this embodiment, a detail display button B1 is provided to display more detailed information about the production line and production equipment items. This information may be displayed on the display units of the terminal devices PD1 and PD2 instead of the display device 14 provided in the production management device 10. When the detail display button B1 is operated, the screen of the display device 14 switches to a detailed display.

[0066] FIG. 12 is an explanatory diagram showing an example of a detailed display of the operating status of the first production equipment 31 displayed on the display device 14. As shown in FIG. 12, the detailed display after the detailed display button B1 is operated displays, in order of reception, details of the cycle time CT, the interval period as the interval time Ti, the machine cycle time MCT, the processing time, the stop time, the number of stop times, and the delay time for a predetermined number of times (10 times in the illustrated example). The delay time refers to the time by which the actual value of the cycle time CT is delayed relative to a preset target cycle time. The "Processing Time" field shown in FIG. 12 displays the integrated value ATk of the processing time Tk, and the "Stop Time" field displays the integrated value ATm of the stop time Tm. The "Number of Stops" field displays the integrated value of the number of stop times stored in the stop count memory unit 126. Note that "Processing time" may further display a breakdown of the integrated value ATk of the processing time Tk, such as the processing times Tk1 to Tkn shown in Fig. 9, and "Stoppage time" may display a breakdown of the integrated value ATm of the stoppage time Tm, such as the stoppage times Tm1 to Tm(n-1) shown in Fig. 9. According to the production management system 100 of this embodiment, it is possible to grasp in detail whether or not there is an abnormality in the operating status of each of the production lines L1, L2 and the production equipment 31 to 36, which can contribute to identifying the cause of low cycle time availability.

[0067] As described above, the production management system 100 of this embodiment includes an operational status acquisition device 20a having a detection unit 25a disposed in the first production equipment 31 included in the first manufacturing line L1, the detection unit 25a generating a first signal and a second signal, and a detection unit 13 for transmitting the first signal and the second signal, and a production management device 10 receiving the first and second signals from the operational status acquisition device 20a and having a processing completion determination unit 110 that determines whether the production equipment 31 has completed processing using the first and second signals. The processing completion determination unit 110 obtains a processing time Tk from the time the first signal is received to the time the second signal is received, and determines that the first production equipment 31 has completed processing if the obtained processing time Tk is equal to or greater than a predetermined standard processing time Ts. If the calculated processing time Tk is less than the standard processing time Ts, intermittent The first production equipment 31 is determined to have completed processing when the integrated value ATk of the processing time Tk is equal to or greater than the reference processing time Ts. According to the production management system 100 of this embodiment, the single detection unit 25a that generates the first and second signals can grasp the processing status of the production equipment, such as the presence or absence and number of stops from when the first production equipment 31 starts processing a part until the product is dispensed. Furthermore, the processing completion determination unit 110 can determine whether the processing by the first production equipment 31 has been completed by determining whether the processing time Tk per process has reached the reference processing time Ts. Even if the processing time Tk per process has not reached the reference processing time Ts, it can also determine whether the processing by the first production equipment 31 has been completed by determining whether the integrated value ATk of the processing time Tk has reached the reference processing time Ts. Therefore, the processing status of the production equipment can be grasped while suppressing an increase in the number of parts.

[0068] According to the production management system 100 of this embodiment, when the acquired processing time Tk is equal to or greater than the reference processing time Ts, the processing completion determination unit 110 further acquires the acquisition interval from the first signal to the second signal as the machine cycle time MCT. When the processing time Tk is less than the reference processing time Ts, intermittent When the integrated value ATk of the processing times Tk1 to Tkn becomes equal to or greater than the reference processing time Ts, intermittent During the processing times Tk1 to Tkn, the time from when the first signal is first received to when the second signal is last received is obtained as the machine cycle time MCT. Therefore, the machine cycle time MCT of the first production facility 31 can be obtained by one detection unit 25a.

[0069] According to the production management system 100 of this embodiment, when the acquired processing time Tk is equal to or greater than the reference processing time, the processing completion determination unit 110 further intermittent The processing completion determination unit 110 determines whether the processing time Tk is less than the reference processing time Ts and determines whether the processing time Tk is less than the reference processing time Ts. intermittentWhen the integrated value ATk of the processing times Tk1 to Tkn becomes equal to or greater than the reference processing time Ts, intermittent During the processing times Tk1 to Tkn, the time from when the first signal is first received intermittent The cycle time CT is obtained from the time when the integrated value ATk of the processing times Tk1 to Tkn becomes equal to or greater than the reference processing time Ts until the time when the first signal is received. Therefore, the cycle time CT of the first production equipment 31 can be obtained by one detection unit 25a.

[0070] According to the production management system 100 of this embodiment, when the processing time Tk is less than the reference processing time Ts, the processing completion determination unit 110 further determines that there is an abnormality in the cycle time CT. Therefore, it is possible to determine that there is an abnormality in the cycle time CT earlier than the calculation of the cycle time CT is completed.

[0071] According to the production management system 100 of this embodiment, the processing completion determination unit 110 determines that the first production line L1 is stopped when the interval time Ti from when the first production equipment 31 completes processing to when the first production equipment 31 starts the next processing exceeds a predetermined reference interval time Tr. Therefore, a stop of the entire first production line L1 can be detected by a single detection unit 25a.

[0072] According to the production management system 100 of this embodiment, when the processing completion determination unit 110 determines that the first production facility 31 has completed processing, it further counts the total number of processing items that have been processed by the first production facility 31. Therefore, the number of products produced by the first production facility 31 can be obtained by one detection unit 25a.

[0073] According to the production management system 100 of this embodiment, the processing completion determination unit 110 further intermittent The number of times that the first production equipment 31 stops during the machine cycle time MCT is counted. Therefore, the number of times that the first production equipment 31 stops during the machine cycle time MCT can be obtained by one detection unit 25a.

[0074] According to the production management system 100 of this embodiment, the first production facility 31 is equipped with a signal tower 40 having a signal light that functions as a display unit that uses light to indicate the operating status of the first production facility 31. The detection unit 25a is an optical sensor that is attached to the display unit, acquires the operating status indicated by the display unit, and generates a first signal and a second signal. Therefore, a general-purpose sensor can be used as the detection unit 25a.

[0075] B. Other Embodiments: (B1) In the above embodiment, the production management system 100 is provided with the operational status acquisition devices 20a and 20b in the first production equipment 31 and the fourth production equipment 34 of the two production lines L1 and L2. However, the operational status acquisition devices 20a and 20b may be provided in any of the production equipment 31 to 36.

[0076] (B2) In the above embodiment, an example was shown in which only the detection unit 25a functions as the detection unit. However, the detection unit may be realized by the detection unit 25a and the controller 23a. The controller 23a may store the pulse signal received from the detection unit 25a in a storage device, and may execute a process of transmitting the first signal and the second signal to the production management device 10 in response to an execution command received from the production management device 10.

[0077] (B3) In the above embodiment, the production management device 10 and the operation status acquisition devices 20a, 20b communicate by wireless communication, but they may also communicate by wired communication. For example, if a wired local area network (LAN) connection port is provided near the production equipment 31-36, the connection port can be used to eliminate the need for new wiring, and the production management system 100 according to the first embodiment can be easily introduced in the same way as wireless communication.

[0078] (B4) In the above embodiment, the operating status detection devices 20a to 20f are not connected to a PLC, but are attached to the production equipment 31 to 36 as a retrofit. In contrast, the operating status detection devices 20a to 20f may be connected to a PLC without being attached as a retrofit. In this case, for example, the detection unit 25a is connected to the PLC. In the operating status detection devices 20a to 20f, the transmission / reception unit 13 as an acquisition unit receives a command signal output from the PLC to control the operation of the equipment, and acquires the start timing and stop timing of processing by the equipment based on the received command signal from the PLC.

[0079] The control unit and the method described herein may be implemented by a special-purpose computer configured by configuring a processor and memory programmed to perform one or more functions embodied in a computer program. Alternatively, the control unit and the method described herein may be implemented by a special-purpose computer configured by configuring a processor with one or more dedicated hardware logic circuits. Alternatively, the control unit and the method described herein may be implemented by one or more special-purpose computers configured by combining a processor and memory programmed to perform one or more functions with a processor configured with one or more hardware logic circuits. Furthermore, the computer program may be stored as instructions executed by a computer on a computer-readable non-transitory tangible storage medium.

[0080] The present disclosure is not limited to the above-described embodiments and can be realized in various configurations without departing from the spirit thereof. For example, the technical features in the embodiments corresponding to the technical features in each aspect described in the Summary of the Invention section can be appropriately replaced or combined to solve some or all of the above-described problems or achieve some or all of the above-described effects. Furthermore, if a technical feature is not described as essential in this specification, it can be appropriately deleted. [Explanation of symbols]

[0081] 10...production management device, 11...CPU, 12...storage device, 13...transmission / reception unit, 14...display device, 15...input device, 16...timer, 17...bus, 20a...first operation status acquisition device, 20b...second operation status acquisition device, 21a, 21b...first transmission / reception unit, 22a, 22b...second transmission / reception unit, 23a, 23b...controller, 25a, 25b...detection unit, 31...first production equipment, 32...second production equipment, 33...third production equipment, 34...fourth production equipment, 35...fifth production equipment, 36...sixth production equipment Equipment, 40... signal tower, 41... conveying mechanism, 100... production management system, 110... processing completion determination unit, 120... processing time memory unit, 121... cycle time memory unit, 122... machine cycle time memory unit, 124... production quantity memory unit, 125... stop time memory unit, 126... stop count memory unit, 128... reference processing time memory unit, 310... housing, 341... opening and closing door, 342... magnet, B1... detail display button, L1... first production line, L2... second production line, PD1, PD2... terminal device

Claims

1. A production management system for managing the production status of a production line, an operational status acquisition device having a detection unit disposed in or near a production facility included in the manufacturing line, the detection unit generating a first signal corresponding to the start of processing of the target item by the production facility and a second signal corresponding to the stop of the processing, and a transmission unit for transmitting the first signal and the second signal; a production management device that receives the first signal and the second signal transmitted from the operation status acquisition device, the production management device having a processing completion determination unit that determines whether or not the production equipment has completed the processing using the first signal and the second signal; The processing completion determination unit acquiring a processing time from receiving the first signal to receiving the second signal; If the acquired processing time is equal to or longer than a predetermined reference processing time, it is determined that the production equipment has completed the processing; If the acquired processing time is less than the reference processing time, the processing time is further integrated, and if the integrated value of the processing time is equal to or greater than the reference processing time, it is determined that the production equipment has completed the processing. Production management system.

2. The production management system according to claim 1, When the acquired processing time is equal to or longer than the reference processing time, the processing completion determination unit further acquires an acquisition interval from the first signal to the second signal as a machine cycle time from when the production equipment starts the processing to when it completes the processing, When the acquired processing time is less than the reference processing time and when the integrated value of the intermittent processing time is equal to or greater than the reference processing time, the time from when the first signal is first received to when the second signal is last received is acquired as the machine cycle time. Production management system.

3. The production management system according to claim 1 or 2, When the acquired processing time is equal to or longer than the reference processing time, the processing completion determination unit further acquires an interval between acquisition of the intermittent first signal as a cycle time from when the production equipment starts the processing to when the production equipment starts the next processing, When the acquired processing time is shorter than the reference processing time and further when an integrated value of the intermittent processing time is equal to or greater than the reference processing time, the cycle time is acquired as the period from when the first signal is first received during the intermittent processing time until when the first signal is received after the integrated value of the intermittent processing time is equal to or greater than the reference processing time. Production management system.

4. The production management system according to claim 3, When the acquired processing time is less than the reference processing time, the processing completion determination unit further determines that there is an abnormality in the cycle time. Production management system.

5. The production management system according to any one of claims 1 to 4, the processing completion determination unit determines that the manufacturing line is stopped when an interval time from when the production equipment completes the processing until when the production equipment starts the next processing exceeds a predetermined reference interval time. Production management system.

6. The production management system according to any one of claims 1 to 5, When the processing completion determination unit determines that the production equipment has completed the processing, it further counts the total number of processing target items that have been processed by the production equipment. Production management system.

7. The production management system according to any one of claims 1 to 6, When the acquired processing time is less than the reference processing time, the processing completion determination unit further counts the number of times a stop period occurs between the intermittent processing times. Production management system.

8. The production management system according to any one of claims 1 to 7, the production equipment has a display unit that indicates the operating status of the production equipment by light, the detection unit is an optical sensor attached to the display unit, acquires the operating state indicated by the display unit, and generates the first signal and the second signal; Production management system.

9. A production management method for managing the production status of a production line, comprising: a detection unit that is installed later on production equipment included in the manufacturing line or in the vicinity of the production equipment, for detecting the start and stop of processing of the processing target by the production equipment; determining that the production equipment has completed the processing when a processing time from when the start of the processing is detected to when the stop of the processing is detected is equal to or longer than a predetermined reference processing time; If the processing time is less than the reference processing time, the processing time of the intermittent processing is further integrated, and if the integrated value of the intermittent processing time is equal to or greater than the reference processing time, it is determined that the production equipment has completed the processing. Production management methods.

Images