Operational status management system, operational status management device, program, and operational status management method

Abstract

To provide an operating status management system, an operating status management device, a program, and an operating status management method which allow for recognizing an influence on progress of manufacturing when a plurality of alerts have occurred in a manufacturing line.SOLUTION: An operating status management system 100 comprises a manufacturing device 130 which manufactures a product, an operating status management device 110 which acquires data from the manufacturing device, and a display device 120 which displays information acquired from the operating status management device. The operating status management device includes degradation coefficient storage means 112 in which relations between individual alert types of alerts and degradation coefficients indicative of influences on degradation in manufacturing efficiency are stored, and predictive operational efficiency calculation means 115 which calculates predictive operational efficiency based on alert occurrence information of the individual alert types received from the manufacturing device and the degradation coefficients of the individual alert types, and the display device displays predictive information based on the predictive operational efficiency.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present disclosure relates to an operation status management system, an operation status management device, a program, and an operation status management method. [Background technology]

[0002] Conventionally, various products are produced (manufactured) by various production lines installed in a factory. In a production line, production equipment that performs various processes is combined. In order to efficiently produce products using such a production line, techniques for managing the operation of the production line have been developed (for example, see Patent Document 1). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Patent No. 4846412 Summary of the Invention [Problem to be solved by the invention]

[0004] In production facilities that perform high-speed production, such as PET bottle aseptic filling lines, equipment stoppages result in significant production losses. Such production lines consist of multiple processes, and if a problem occurs during production, each process issues an alert and stops the process. Because production lines are large and complex, it is difficult to grasp the impact on production progress when multiple alerts are issued.

[0005] Therefore, an object of the present disclosure is to provide an operation status management system, an operation status management device, a program, and an operation status management method that are capable of understanding the impact on production progress when multiple alerts are issued on a production line. [Means for solving the problem]

[0006] In order to solve the above problems, the present disclosure provides: An operation status management system including a production device that produces a product, an operation status management device that acquires data from the production device, and a display device that displays information acquired from the operation status management device, The operation status management device a reduction coefficient storage means for storing a relationship between an alert for each alert type and a reduction coefficient that affects a reduction in production efficiency; a predicted operational efficiency calculation means for calculating a predicted operational efficiency based on alert occurrence information for each alert type received from the production device and the degradation coefficient for each alert type, The display device provides an operational status management system that displays predicted information based on the predicted operational efficiency.

[0007] In addition, in the operation status management system of the present disclosure, The operation status management device a production schedule storage means for storing production schedule information including the planned production quantity and production equipment capacity; The system further comprises a scheduled end time calculation means for calculating a scheduled end time using the predicted operating efficiency calculated by the predicted operating efficiency calculation means, the scheduled production quantity, and the production equipment capacity, The display device may display the estimated end time as the prediction information.

[0008] In addition, the operating status management system of the present disclosure includes: an operation record storage means for storing operation record information in which the occurrence result of an alert for each alert type and the operating efficiency of the production device are recorded in association with a manufacturing lot of the production target; The system may further include a reduction coefficient calculation means for calculating a reduction coefficient for an alert for each alert type by performing a simple regression analysis with reference to the operational performance information, using the operational efficiency as a response variable and the alert occurrence result as an explanatory variable.

[0009] In addition, in the operation status management system of the present disclosure, The reduction coefficient calculation means may calculate the reduction coefficient in association with one or more of the product type, liquid content, bottle shape, bottle capacity, cap type, and label material.

[0010] In addition, in this disclosure, An operation status management system including a production device that produces a product, an operation status management device that acquires data from the production device, and a display device that displays information acquired from the operation status management device, An operation status management device that acquires production information from a production device that produces a product and manages the operation status, a reduction coefficient storage means for storing a relationship between an alert for each alert type and a reduction coefficient that affects a reduction in production efficiency; An operation status management device is provided, which has a predicted operation efficiency calculation means that calculates a predicted operation efficiency based on alert occurrence information for each alert type received from the production device and the degradation coefficient for each alert type.

[0011] In addition, in this disclosure, Computer, a reduction coefficient storage means for storing a relationship between an alert for each alert type and a reduction coefficient that affects a reduction in production efficiency; a predicted operational efficiency calculation means for calculating a predicted operational efficiency based on alert occurrence information for each alert type received from the production equipment and the degradation coefficient for each alert type; We provide a program to function as a

[0012] In addition, in this disclosure, An operation status management method in which an operation status management device including a production schedule storage means for storing production schedule information and a reduction coefficient storage means for storing the relationship between alerts for each alert type and a reduction coefficient that affects a reduction in production efficiency manages an operation status, calculating a predicted operating efficiency based on alert occurrence information for each alert type received from the production device and the degradation coefficient for each alert type; Calculating an estimated end time using the predicted operation efficiency; The present invention provides an operational status management method having the above-mentioned steps. [Effects of the Invention]

[0013] According to the present disclosure, when an alert is issued on a production line, it becomes possible to understand to what extent the alert will affect production efficiency. [Brief explanation of the drawings]

[0014] [Figure 1] FIG. 1 is a configuration diagram illustrating an operational status management system according to an embodiment of the present disclosure. [Figure 2] FIG. 1 is a diagram illustrating an operating status management device 110 according to an embodiment of the present disclosure. [Figure 3] FIG. 4 is a diagram showing an example of operation performance information stored in an operation performance storage means. [Figure 4] FIG. 10 is a diagram illustrating an example of a reduction coefficient that is not based on product information. [Figure 5] FIG. 10 is a diagram illustrating an example of a reduction coefficient for each product type. [Figure 6] FIG. 10 is a diagram showing an example of a reduction coefficient for each bottle shape. [Figure 7] FIG. 10 is a diagram showing an example of a reduction coefficient for each bottle capacity. [Figure 8] FIG. 4 is a diagram showing an example of production schedule information stored in a production schedule storage means. [Figure 9] FIG. 10 is a diagram showing product information including product types. [Figure 10] FIG. 2 is a diagram illustrating a hardware configuration of a display device 120. [Figure 11] 10 is a flowchart showing the processing operation of the operational status management system. [Figure 12] 10 is a diagram showing a display image on a display device 120. FIG. [Figure 13] FIG. 10 is a diagram showing an example of an alert in an aseptic filling line for PET bottles. DETAILED DESCRIPTION OF THE INVENTION

[0015] Preferred embodiments of the present disclosure will be described in detail below with reference to the drawings. <System configuration> FIG. 1 is a diagram illustrating an operational status management system using an operational status management device according to an embodiment of the present disclosure. In FIG. 1, reference numeral 100 denotes the operational status management system, 110 denotes the operational status management device, 120 denotes a display device, 130 denotes a production device, 140 denotes a gateway device, and 150 denotes a network. The operational status management device 110, the display device 120, and the gateway device 140 are connected to a network 150 such as the Internet and are capable of data communication with each other. The production device 130 is connected to the gateway device 140 so as to be able to communicate data with each other. The gateway device 140 transmits data such as production information received from the production device 130 to the operational status management device 110 via the network 150. The display device 120 accesses the operational status management device 110 via the network 150, receives data from the operational status management device 110, and displays the data.

[0016] In the example of FIG. 1, for the sake of convenience, only one display device 120 is shown. However, in reality, the operational status management device 110 is accessible from a large number of display devices 120 via the network 150. Also, in the example of FIG. 1, for the sake of convenience, three production devices 130 are shown. However, in reality, a production site usually has many more production devices 130 installed. The operational status management system 100 according to this embodiment is particularly useful when a production line comprises a large number of production devices and the entire production line has a complex configuration.

[0017] FIG. 2 is a diagram illustrating the details of the operational status management device 110. FIG. 2(a) is a hardware configuration diagram of the operational status management device 110. The operational status management device 110 can be realized by a general-purpose server computer. Specifically, as shown in FIG. 2, the hardware configuration of the operational status management device 110 includes a CPU (Central Processing Unit) 110a, a RAM (Random Access Memory) 110b, which is the computer's main memory, a large-capacity storage device 110c (e.g., a hard disk, flash memory, etc.) for storing programs and data executed by the CPU, an input I / F (interface) 110d for receiving input from input devices such as a keyboard and a mouse, a data input / output I / F (interface) 110e for data communication with an external device (e.g., a data storage medium), a display output I / F (interface) 110f for sending information to a display device (e.g., a liquid crystal display), and a communication unit 110g for network communication with other devices such as a display device 120 and a gateway device 140 via a network 150. These elements are connected to each other via a bus.

[0018] Fig. 2(b) is a functional block diagram of the operational status management device 110. In the hardware configuration shown in Fig. 2(a), the CPU 110a loads a program stored in the storage device 110c into the RAM 110b and executes it, thereby enabling the operational status management device 110 to function as each of the means shown in Fig. 2(b). As shown in Fig. 2(b), the operational status management device 110 has an operational record storage means 111, a reduction coefficient storage means 112, a production schedule storage means 113, a reduction coefficient calculation means 114, a predicted operating efficiency calculation means 115, and a scheduled end time calculation means 116.

[0019] The operation performance storage means 111 is a storage means that stores operation performance information. The operation performance information is information that compiles the operation performance of each production device 130 by product manufacturing lot. Therefore, the operation performance information is recorded in association with the manufacturing lot of the production target. FIG. 3 is a diagram showing an example of operation performance information stored in the operation performance storage means 111. As shown in FIG. 3, the operation performance storage means 111 stores, as operation performance information, the production start time, production end time, production time, product type, production device capacity (denoted as "device capacity" in the figure), production quantity, operating efficiency (operation performance), and the number of alerts generated for each alert type.

[0020] Operational performance information is managed by production lot for each produced product. Furthermore, the operational performance information is managed in chronological order, with the production lots listed in order of earliest start. In the example of FIG. 3, the same product type, product c, is produced in a different production lot. FIG. 3 shows an example in which products a, b, and d are each produced once, and product c is produced twice in different production lots. A production device 130 corresponds to each product type. The production device capacity is the number of units that can be produced per unit time. In FIG. 3, the production device capacity indicates the number of units of the corresponding product type that each production device 130 can produce. Here, the production device capacity is shown as the number of units of the corresponding product type that can be produced per minute. For example, the example of FIG. 3 indicates that the production device 130 corresponding to product type a has the capacity to produce a maximum of 606 units of product type a per minute.

[0021] In Figure 3, the production start time and production end time indicate the production start time and production end time for the corresponding manufacturing lot. Production time is the time during production, and indicates the elapsed time from the production start time to the production end time. The production quantity is the number of products actually produced during that production time. Operational efficiency is the ratio of the production quantity to the number that would be produced if production were made using the maximum capacity of the production equipment.

[0022] In the example of FIG. 3, the number of occurrences (occurrence count) of each of four alerts, Alert A to Alert D, is displayed as the number of occurrences for each alert type. Note that although the number of alert occurrences is used here as an example of alert occurrence information indicating the degree of alert occurrence, the alert occurrence time, alert occurrence rate, etc. may also be used as alert occurrence information. The alert occurrence time is the total time during which an alert has occurred. The alert occurrence rate is the number of times an alert has occurred per unit time.

[0023] Using the top row of Figure 3 as an example, this shows that the production equipment capacity of production equipment 130 producing product type a is 606 units per minute. It also shows that production took place over 24.48 hours, from the production start time of "2020 / 12 / 1 18:12" to the production end time of "2020 / 12 / 2 18:29," and that 837,114 units of product type a were produced. It also shows that between the production start time of "2020 / 12 / 1 18:12" and the production end time of "2020 / 12 / 2 18:29," alert A occurred 10 times, alert B occurred 20 times, alert C occurred 14 times, and alert D occurred 1 time. It also shows that the operating efficiency was 94.8%.

[0024] The reduction coefficient storage means 112 is a storage means that stores reduction coefficient information. The reduction coefficient information is a coefficient that indicates the degree to which each alert reduces production efficiency. Naturally, the impact on production efficiency varies depending on the malfunction that the alert is directed to. Therefore, the reduction coefficient also varies depending on the alert type. Figure 4 is a diagram showing an example of a reduction coefficient that is not based on product information. As shown in Figure 4, the reduction coefficient storage means 112 stores a reduction coefficient associated with each alert type. The reduction coefficient is not particularly limited as long as it is a numerical value that indicates the degree of reduction, and various values ​​can be used. In this embodiment, a reduction rate that indicates the ratio of reduction in operating efficiency is used as the reduction coefficient. In this embodiment, the reduction rate is a negative value.

[0025] The reduction coefficients shown in Figure 4 are reduction coefficients that do not depend on product information, but reduction coefficients managed by product information may also be used. For example, reduction coefficients for each type of product information, such as product type, bottle shape, and bottle capacity, may be used. Figures 5, 6, and 7 are diagrams showing reduction coefficients for each type of product, bottle shape, and bottle capacity, respectively. As shown in Figures 5, 6, and 7, even for alerts of the same type, the reduction coefficients differ depending on the type of product produced, bottle shape, bottle capacity, etc.

[0026] The production schedule storage means 113 is a storage means that stores production schedule information including the planned production quantity and production equipment capacity. Fig. 8 is a diagram showing an example of production schedule information stored in the production schedule storage means 113. As shown in Fig. 8, the production schedule information includes the product number, the product type to be produced, the production equipment capacity (denoted as "equipment capacity" in the figure), and the planned production quantity. For example, the first line in Fig. 8 indicates that "100,000 units" of product type a are planned to be produced by production equipment 130 with a production equipment capacity of "606 (units / min)."

[0027] The "product type" used in the production schedule information of FIG. 8 can be accompanied by product information such as bottle shape, labeler type, bottle capacity, whether acidic or neutral, liquid contents, cap type, and label material. FIG. 9 is a diagram showing an example of product information. In the example of FIG. 9, the product type information includes bottle shape, labeler type, bottle capacity, whether acidic or neutral, liquid contents, cap type, and label material. This type of product information can be stored in a predetermined storage area within the storage device 110c. The product information may include attributes other than those shown in FIG. 9.

[0028] The reduction coefficient calculation means 114 is a means for calculating a reduction coefficient for each alert by referring to the operation performance information stored in the operation performance storage means 111. Specifically, a simple regression analysis is performed for each objective variable, with the operation efficiency as the objective variable and the alerts of each alert type as the explanatory variables. As the simple regression analysis, for example, the least squares method can be used. This simple regression analysis calculates a p-value (reliability) and a slope for each alert. Then, this slope is used as the reduction coefficient. In this way, the reduction coefficient calculation means 114 calculates a reduction coefficient for each alert.

[0029] The predicted operation efficiency calculation means 115 calculates the predicted operation efficiency based on the degradation coefficient calculated by the degradation coefficient calculation means 114. Specifically, the predicted operation efficiency calculation means 115 executes processing in accordance with the following [Equation 1] to calculate the predicted operation efficiency.

[0030] [Formula 1] Predicted operational efficiency = 1 + (number of occurrences of alert A × α) + (number of occurrences of alert B × β) + (number of occurrences of alert C × γ) + + (number of occurrences of alert Z × ζ)

[0031] In [Formula 1], α, β, γ, and ζ are reduction coefficients corresponding to each alert. In the above [Formula 1], the reduction coefficients α, β, γ, and ζ indicate the reduction coefficients for alerts A, B, C, and Z, respectively. In this embodiment, the reduction coefficients are calculated as the reduction rate at which driving efficiency decreases. Therefore, the reduction coefficients take negative values. Therefore, the more the number of occurrences of each alert increases, the more the predicted driving efficiency decreases. In the above [Formula 1], when no alerts have occurred, the predicted driving efficiency is at its maximum, ie, 1.

[0032] The scheduled end time calculation means 116 calculates the predicted operation efficiency using the predicted operation efficiency calculated by the predicted operation efficiency calculation means 115. Specifically, the scheduled end time calculation means 116 executes processing according to the following [Equation 2] to calculate the scheduled end time.

[0033] [Formula 2] Estimated end time= Current time + (Planned production volume - Current production volume) / (Production equipment capacity x Predicted operating efficiency)

[0034] In [Formula 2], the planned production quantity is the planned production quantity of the product being produced. The current production quantity is the quantity that has been produced up to that point. The equipment capacity is the equipment capacity of the production equipment that is currently in production. As shown in [Formula 2], the planned completion time is calculated by subtracting the current production quantity from the planned production quantity, dividing the result by the product of the equipment capacity multiplied by the predicted operating efficiency, and adding the result to the current time.

[0035] The operating status management device 110 also performs various processes not included in the above-described means by having the CPU 110a load a program stored in the storage device 110c into the RAM 110b and execute the program. The operating status management device 110 may be physically realized by a single computer or multiple computers. It may also be realized as a cloud system distributed across multiple computers on the network 150.

[0036] The display device 120 is a terminal device that displays information stored and managed by the operational status management device 110. Fig. 10 is a hardware configuration diagram of the display device 120. The display device 120 is realized by, for example, a general-purpose computer with browser software installed.

[0037] As shown in FIG. 10, the display device 120 includes a CPU (Central Processing Unit) 120a, a RAM (Random Access Memory) 120b as the main memory, a non-volatile storage device 120c (e.g., flash memory, etc.) for storing programs and data executed by the CPU 120a, an instruction input unit 120d such as a keyboard or touch panel, a data input / output I / F (interface) 120e for data communication with an external device (data storage medium, etc.), a display unit (liquid crystal display, etc.) 120f, and a communication unit 120g for network communication with other computers such as the operating status management device 110 via a network 150, all of which are connected to each other via a bus.

[0038] The display device 120 may be any device that includes a CPU processing unit and has a display function, an information processing function, a network communication function, etc., and may be a general-purpose device such as a laptop PC, a tablet, or a smartphone. In this embodiment, the display device 120 includes a web browser and uses the web browser to access the operational status management device 110, which has a function as a web server. This allows the display device 120 to obtain and display information managed by the operational status management device 110.

[0039] The production devices 130 are facilities for producing a predetermined variety of products. Each production device 130 is equipped with a PLC (programmable logic controller), various sensors, and a communication device, and acquires production information and transmits it to the gateway device 140.

[0040] The gateway device 140 aggregates production information acquired from multiple production devices 130. Then, the aggregated production information is transmitted to the operation status management device 110 via the network 150. The timing of transmitting the production information to the operation status management device 110 may be periodically (for example, every 5 minutes) or may be transmitted in real time upon receipt from each production device 130. Note that the production devices 130 may be directly connected to the network 150 and transmit the production information directly to the operation status management device 110 without going through the gateway device 140.

[0041] <Collecting operational performance information> Next, we will explain how operation information is collected in the operation status management system shown in Fig. 1. As shown in Fig. 1, the production equipment 130 is capable of transmitting data to the operation status management device 110 via the gateway device 140 and the network 150. Therefore, in the production equipment 130, the production information detected by an attached sensor or the like is transmitted to the operation status management device 110 by an attached PLC. The operation status management device 110 stores the collected production information in operation record storage means 111.

[0042] Regarding the production start time and production end time, the production device 130 transmits information indicating the start and end of production and the time, and the operation status management device 110 stores the acquired time information as the production start time and production end time.

[0043] For the product type, information on the product type obtained from the production equipment 130 is stored. For the production equipment capacity, a table is provided in which values ​​calculated from past performance are recorded for each product type, and when a product type is identified, it is automatically stored as part of the operation performance information. For the production quantity, a detection sensor installed on the production equipment 130 detects the produced products and sends this information to the operation status management device 110. The operation status management device 110 then counts the obtained information and sets it as the production quantity. The value counted up to the end of production becomes the actual production quantity. The operation status management device 110 stores the actual production quantity in association with the corresponding product type.

[0044] Regarding alerts, each time an alert is generated by each alert generating means, the PLC installed in the production equipment 130 transmits the alert type and the fact that an alert has been generated to the operation status management device 110 via the gateway device 140. The operation status management device 110 then counts the acquired information on alert generation for each alert type. Then, at the end of production, the number of alerts generated up to that point for each alert type is stored in association with the corresponding product type.

[0045] In this way, various pieces of information from the production start time to the production end time are sent from each production device 130 to the operation status management device 110, and the operation status information is accumulated in the operation performance storage means 111. When production ends and the production end time is determined, the operation status management device 110 calculates the production time from the difference between the production start time and the production end time. Furthermore, the operation status management device 110 calculates the operation efficiency (operation performance) by dividing the number of productions by the value obtained by multiplying the production time by the operation status management device capacity. In the example of Figure 3, the operation efficiency is converted to a percentage and recorded in % units.

[0046] <Calculation of the reduction coefficient> When production for a certain production lot is completed, the reduction coefficient calculation means 114 in the operation status management device 110 calculates the reduction coefficient of each alert for each alert type. The reduction coefficient is a coefficient that indicates the degree to which each alert reduces production efficiency. The reduction coefficient takes a negative value. Specifically, the reduction coefficient calculation means 114 performs a simple regression analysis using the operating efficiency and the number of alerts for each alert from the operation performance information such as that shown in FIG. 3, and calculates the p-value and slope for each alert.

[0047] The calculated p-value represents the reliability of the numerical value. If the p-value is not sufficiently small, the reliability of the data is low. Therefore, a predetermined threshold is set, and data with a p-value greater than this threshold is excluded from the adopted data. Therefore, if the p-value is greater than the threshold, the reduction coefficient is not calculated and the reduction coefficient is set to 0. In this manner, each calculated reduction coefficient is stored in the reduction coefficient storage means 112 as reduction coefficient information. The reduction coefficient calculation means 114 can calculate a reduction coefficient independent of product information, as shown in FIG. 4. Alternatively, as shown in FIGS. 5, 6, and 7, reduction coefficients may be calculated for each product type, bottle shape, and bottle capacity. Furthermore, reduction coefficients may be calculated for other attributes, which are attribute information shown in the product information of FIG. 9. For example, the reduction coefficient calculation means 114 may calculate a reduction coefficient by associating information on the labeler type, acidic / neutral, liquid contents, cap type, and label material with one or more of the bottle shape, labeler type, bottle capacity, acidic / neutral, liquid contents, cap type, and label material.

[0048] <Calculating the estimated end time> As described above, the reduction coefficient is calculated using the latest operational performance information, and the reduction coefficient for each alert stored in the reduction coefficient storage means 112 is always updated to the latest one. In the operational status management system according to this embodiment, the predicted operational efficiency and estimated completion time are calculated as prediction information when a product is produced. The operational status is managed by obtaining the prediction information in this manner. For this purpose, production schedule information for the product to be produced is prepared in the production schedule storage means 113. As described above, the production schedule information is as shown in FIG. 8.

[0049] 11 is a flowchart showing an operation status management method according to this embodiment. When production is started by the production device 130 with the reduction coefficient information and production schedule information prepared, the production device 130 transmits production information to the operation status management device 110, as in the case described above. The operation status management device 110 acquires production information from the production device 130, as in the case described above (step S1). The received production information is accumulated in the operation record storage means 111. The production volume is received at any time, so it increases over time. In addition, the number of alerts is received each time an alert is generated, so the number of alerts stored in the operation record storage means 111 also increases.

[0050] The predicted operational efficiency calculation means 115 calculates the predicted operational efficiency at a predetermined timing while the production equipment 130 is in operation (step S2). The predetermined timing can be set to various timings, such as when a predetermined unit time has elapsed or when an alert is received. When the predetermined timing arrives, the predicted operational efficiency calculation means 115 calculates the predicted operational efficiency. Specifically, the predicted operational efficiency calculation means 115 executes processing in accordance with the following [Equation 1] to calculate the predicted operational efficiency.

[0051] [Formula 1] Predicted operational efficiency = 1 + (number of occurrences of alert A × α) + (number of occurrences of alert B × β) + (number of occurrences of alert C × γ) + + (number of occurrences of alert Z × ζ)

[0052] To execute the process according to the above [Formula 1], the predicted operational efficiency calculation means 115 acquires the number of occurrences of each alert from the start of production to the present. The predicted operational efficiency calculation means 115 also acquires the reduction coefficient of each alert for each alert type from the reduction coefficient storage means 112. Then, using the number of occurrences and reduction coefficient of each alert, the process according to the above [Formula 1] is executed to calculate the predicted operational efficiency.

[0053] After the predicted operation efficiency is calculated, the estimated end time calculation means 116 calculates the estimated end time using the predicted operation efficiency (step S3). Specifically, the estimated end time calculation means 116 executes a process according to the following [Equation 2] to calculate the estimated end time.

[0054] [Formula 2] Estimated end time= Current time + (Planned production volume - Current production volume) / (Production equipment capacity x Predicted operating efficiency)

[0055] The estimated end time calculation means 116 acquires information on the current time, planned production quantity, current production quantity, production equipment capacity, and predicted operating efficiency to execute the process according to [Equation 2] above. The current time is acquired from the internal clock of the computer that implements the operation status management device 110. The planned production quantity is acquired from the production plan information. The current production quantity is the production quantity received from the production equipment 130 and updated as needed. The production equipment capacity can be acquired and used as the production equipment capacity recorded in the operation information. The predicted operating efficiency is the current predicted operating efficiency calculated by the predicted operating efficiency calculation means 115. Then, using each acquired information, the process according to [Equation 2] above is executed to calculate the estimated end time.

[0056] The operational status management device 110 calculates the predicted operational efficiency and the scheduled end time as prediction information whenever necessary while the production equipment 130 is in operation. The calculated values ​​are stored together with the calculation time, and are transmitted in response to a request from the display device 120. The display device 120 then displays the obtained prediction information (step S4). FIG. 12 is a diagram showing a display image on the display device 120.

[0057] An arrow pointing from top to bottom is shown on the left side of Fig. 12. This arrow indicates the progression of time, with the further down the arrow goes, the more time has advanced. In the example of Fig. 12, alert A occurs at a certain time after production starts, and then alerts D and H occur. Three screens G1 to G3 are shown on the right side of Fig. 12. Screens G1 to G3 correspond to the progression of time on the left side of Fig. 12. As shown on screens G1 to G3 in Fig. 12, during production, four items are displayed on the display device 120: scheduled finish time, operating results, predicted operating efficiency, and alerts.

[0058] As the scheduled end time, the scheduled end time calculated by the scheduled end time calculation means 116 is displayed. As the operating performance, the details of the operating efficiency from the start of the current production to the present time are displayed. As the predicted operating efficiency, the current predicted operating efficiency calculated by the predicted operating efficiency calculation means 115 is displayed. As the alerts, all alerts that have occurred up to that point and caused a decrease in the predicted operating efficiency are displayed with the most recent alert at the top. The most recent alert is then displayed at the top. The scheduled end time and predicted operating efficiency are both predicted information based on the predicted operating efficiency. It is not necessary to display the scheduled end time, and it is also possible to display only the predicted operating efficiency as it is, as predicted information based on the predicted operating efficiency.

[0059] After production starts, but before alert A is generated, the display device 120 displays the content shown in screen G1 in FIG. 12. At the time screen G1 is displayed, no alert has been generated since production started. Therefore, the predicted operating efficiency calculated by the process according to the above [Formula 1] is 1. When converted to a percentage, the predicted operating efficiency is "100%." ​​Using this predicted operating efficiency of "100%," the current time, the planned production quantity, the current production quantity, and the production equipment capacity in the operation information, the estimated end time calculation means 116 executes the process according to the above [Formula 2]. In this way, the estimated end time calculation means 116 calculates the estimated end time. Screen G1 shows an example in which 17:00 is calculated as the estimated end time.

[0060] After alert A has occurred 10 times, the content shown on screen G2 in FIG. 12 is displayed. Because alert A has occurred 10 times at the time screen G2 is displayed, the value of the predicted operational efficiency calculated by the process according to the above [Formula 1] is less than 1. Screen G2 in FIG. 12 converts this to a percentage and displays the predicted operational efficiency as "97%." Using this predicted operational efficiency of "97%," the current time, the planned production quantity, the current production quantity, and the production equipment capacity in the operation information, the estimated end time calculation means 116 executes the process according to the above [Formula 2]. In this way, the estimated end time calculation means 116 calculates the estimated end time.

[0061] Screen G2 in FIG. 12 displays the calculated scheduled end time of 17:05. As the predicted operation efficiency decreases, the value of the predicted end time calculated by the above [Formula 2] increases. In other words, the predicted end time is delayed. In screen G1 in FIG. 12, the predicted operation efficiency was "100%," so the scheduled end time was 17:00. However, in screen G2 in FIG. 12, the predicted operation efficiency is "97%, so the scheduled end time is 17:05, which is five minutes late. This means that alert A has occurred 10 times, and the operational status management device 110 has estimated (calculated) a new scheduled end time.

[0062] After alert D has occurred 20 times and alert H has occurred 8 times, the content shown in screen G3 in FIG. 12 is displayed. After screen G2 is displayed, alert D has occurred 20 times and alert H has occurred 8 times by the time screen G3 is displayed. As described above, the most recent alert is displayed at the top of the screen of the display device 120. In this example, alert A has occurred 10 times, alert D has occurred 20 times, and alert H has occurred 8 times. Therefore, screen G3 displays, from the top, alert H 8 times, alert D 20 times, and alert A 10 times. At this point, the predicted operation efficiency calculation means 115 calculates a new predicted operation efficiency by performing processing in accordance with the above [Formula 1] using alerts A, D, and H that have occurred so far and their respective occurrence counts. Suppose the new predicted operation efficiency calculated by performing processing in accordance with the above [Formula 1] is 0.8. In this case, screen G2 in FIG. 12 converts this to a percentage and displays the predicted operation efficiency as "80%." Using this predicted operating efficiency of "80% (0.8)", the current time, the planned production quantity, the current production quantity, and the production equipment capacity in the operation information, the estimated end time calculation means 116 executes processing according to the above [Equation 2]. In this way, the estimated end time calculation means 116 calculates the estimated end time.

[0063] The calculated scheduled end time of 17:30 is displayed on screen G3 in Fig. 12. On screen G2 in Fig. 12, the predicted operation efficiency was 97%, so the scheduled end time was 17:05, but on screen G3 in Fig. 12, the predicted operation efficiency is 80%, so the scheduled end time is 17:30, which is a further delay of 25 minutes. This means that the operational status management device 110 has estimated (calculated) a new scheduled end time because alert D has occurred 20 times and alert H has occurred 8 times.

[0064] As described above, the operational status management system 100 according to this embodiment includes production equipment 130 that produces products, an operational status management device 110 that acquires data from the production equipment 130, and a display device that displays the information acquired from the operational status management device. The operational status management device 110 includes reduction coefficient storage means 112 that stores the relationship between alerts for each alert type and reduction coefficients that affect reduction in production efficiency, and predicted operational efficiency calculation means 115 that calculates predicted operational efficiency based on alert occurrence information for each alert type received from the production equipment 130 and the reduction coefficient for each alert type. The display device 120 displays prediction information based on the predicted operational efficiency, so that when an alert is generated on the production line, it becomes possible to understand to what extent production efficiency will be affected.

[0065] Furthermore, in the operation status management system 100 according to this embodiment, the operation status management device 110 further has a production schedule storage means 113 that stores production schedule information including the planned production quantity and production equipment capacity, and a planned end time calculation means that calculates the planned end time using the predicted operating efficiency calculated by the predicted operating efficiency calculation means 115, the planned production quantity, and the production equipment capacity, and the display device 120 displays the planned end time as predicted information. Therefore, if an alert occurs and the initial end time is delayed, it becomes possible to know the planned end time, making it easier to adjust the schedule for subsequent processes.

[0066] The operational status management system according to this embodiment further includes an operational performance storage means 111 that stores operational performance information that records the alert occurrence results for each alert type and the operational efficiency of production equipment in association with the production lot of the production target. It also includes a reduction coefficient calculation means 114 that references the operational performance information, performs a simple regression analysis using the operational efficiency as the objective variable and the alert occurrence results as the explanatory variable, and calculates a reduction coefficient for each alert type. This allows the system to maintain an up-to-date relationship between the alert type and production delays, which is useful for accurately calculating predicted operational efficiency and scheduled completion times. The reduction coefficient calculation means 114 may also calculate a reduction coefficient in association with one or more of the product type, liquid contents, bottle shape, bottle capacity, cap type, and label material. In this case, using a reduction coefficient specialized for each attribute allows for more accurate calculation of predicted operational efficiency and scheduled completion times.

[0067] The operational status management system according to the present disclosure can be applied to any production device in the production process that is equipped with a means for detecting the status of the production device and issuing an alert. Therefore, it can be applied to a variety of products and production devices, regardless of the type of product or the type of production device that produces the product.

[0068] For example, the operational status management system according to the present disclosure can be applied to an aseptic filling line for PET (polyethylene terephthalate) bottles. When applied to an aseptic filling line for PET bottles, production equipment includes equipment for performing a blending and liquid treatment process, a filling and molding process, and a packaging process. These pieces of equipment are equipped with PLCs, and information detected in the production process is sent to a predicted operational efficiency calculation device via a gateway device.

[0069] FIG. 13 is a diagram showing an example of an alert in a PET bottle aseptic filling line. Because alerts for the entire production line are aggregated, there are a variety of alerts, as shown in FIG. 13. The urgency of each alert varies depending on the alert type (alert name). In FIG. 13, the urgency is expressed in order of increasing urgency with ◎, ○, and △. This urgency is determined by the worker's perception and does not necessarily correspond to the degree of production delay. In the operation status management system according to this embodiment, the alert reduction coefficient is accurately set based on actual results, making it possible to calculate predicted operating efficiency and estimated completion times that cannot be fully grasped by the worker's perception.

[0070] While the preferred embodiments of the present disclosure have been described above, the present disclosure is not limited to the above embodiments and various modifications are possible. For example, in the above embodiments, the predicted driving efficiency and the scheduled end time are received from the predicted driving efficiency calculation device via a network and displayed on a display device, but they may also be displayed on a display device directly connected to a display output I / F of the predicted driving efficiency calculation device.

[0071] In the above embodiment, the predicted driving efficiency calculation device calculates the predicted driving efficiency and the scheduled end time, and the display device displays them. However, it is also possible to calculate and display only the predicted driving efficiency without calculating and displaying the scheduled end time. This is because, even if the scheduled end time is unknown, knowing the predicted driving efficiency makes it possible to estimate a certain amount of time delay. [Explanation of symbols]

[0072] 100···Operation status management system 110 Operation status management device 110a...CPU(Central Processing Unit) 110b...RAM(Random Access Memory) 110c...Storage device 110d···Input I / F 110e Data input / output interface 110f...Display output I / F 110g...Communication Department 111... Operational performance storage means 112... Reduction coefficient storage means 113 Production schedule storage means 114... Reduction coefficient calculation method 115...Predicted operation efficiency calculation means 116... Scheduled end time calculation means 120...Display device 130 Production Equipment 140 Gateway device 150···Network

Claims

1. An operation status management system including a production device that produces a product, an operation status management device that acquires data from the production device, and a display device that displays information acquired from the operation status management device, The operation status management device a reduction coefficient storage means for storing a relationship between an alert for each alert type and a reduction coefficient that affects a reduction in production efficiency; a predicted operational efficiency calculation means for calculating a predicted operational efficiency based on alert occurrence information for each alert type received from the production device and the degradation coefficient for each alert type, the display device displays prediction information based on the predicted driving efficiency, an operation record storage means for storing operation record information in which the occurrence result of an alert for each alert type and the operating efficiency of the production device are recorded in association with a manufacturing lot of the production target; a reduction coefficient calculation means for calculating a reduction coefficient for an alert of each alert type by performing a simple regression analysis with reference to the operational performance information and using the operational efficiency as a response variable and the alert occurrence result as an explanatory variable; An operation status management system further comprising:

2. The operation status management device a production schedule storage means for storing production schedule information including the planned production quantity and production equipment capacity; The system further comprises a scheduled end time calculation means for calculating a scheduled end time using the predicted operating efficiency calculated by the predicted operating efficiency calculation means, the scheduled production quantity, and the production equipment capacity, The operating status management system according to claim 1 , wherein the display device displays the scheduled end time as the predicted information.

3. 3. The operating status management system according to claim 1, wherein the reduction coefficient calculation means calculates the reduction coefficient in association with one or more of the product type, liquid contents, bottle shape, bottle capacity, cap type, and label material.

4. An operation status management device that acquires production information from production equipment that produces products and manages operation statuses, a reduction coefficient storage means for storing a relationship between an alert for each alert type and a reduction coefficient that affects a reduction in production efficiency; a predicted operational efficiency calculation means for calculating a predicted operational efficiency based on alert occurrence information for each alert type received from the production device and the degradation coefficient for each alert type; an operation record storage means for storing operation record information in which the occurrence result of an alert for each alert type and the operating efficiency of the production device are recorded in association with a manufacturing lot of the production target; an operational status management device having a reduction coefficient calculation means for calculating a reduction coefficient for an alert for each alert type by referring to the operational performance information and performing a simple regression analysis using the operational efficiency as a target variable and the alert occurrence result as an explanatory variable.

5. Computer, a reduction coefficient storage means for storing a relationship between an alert for each alert type and a reduction coefficient that affects a reduction in production efficiency; a predicted operational efficiency calculation means for calculating a predicted operational efficiency based on alert occurrence information for each alert type received from the production equipment and the degradation coefficient for each alert type; an operation record storage means for storing operation record information in which the occurrence result of an alert for each alert type and the operating efficiency of the production equipment are recorded in association with the production lot of the production target; a reduction coefficient calculation means for calculating a reduction coefficient for an alert of each alert type by performing a simple regression analysis with reference to the operational performance information and using the operational efficiency as a response variable and the alert occurrence result as an explanatory variable; A program to function as a

6. An operation status management method in which an operation status management device including a production schedule storage means for storing production schedule information and a reduction coefficient storage means for storing the relationship between alerts for each alert type and a reduction coefficient that affects a reduction in production efficiency manages operation status, calculating a predicted operating efficiency based on alert occurrence information for each alert type received from the production device and the degradation coefficient for each alert type; and calculating an estimated end time using the predicted operation efficiency, storing operation performance information in which the alert occurrence results for each alert type and the operating efficiency of the production equipment are recorded in association with the manufacturing lot of the production target; a step of referring to the operation performance information, performing a simple regression analysis using the operation efficiency as a response variable and the occurrence result of the alert as an explanatory variable, and calculating a reduction coefficient of an alert for each alert type; The operating status management method further comprises:

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