Activity level calculation device, system equipped with an activity level calculation device, and activity level calculation method

Abstract

To solve the problem in which it is necessary to acquire information on all facilities used for manufacturing because activity amounts of the facilities are used to calculate a GREEN HOUSE GAS (GHG) emission, however, not all facilities necessarily include an I / F, and necessary information may not be acquired.SOLUTION: An activity amount calculation apparatus includes a processor, a storage unit, and an interface that acquires information from a facility used for an operation of a process in a manufacturing line. The storage unit manages a standard operation time related to an operation time in the process. The processor acquires, using the interface from a facility that is an observation target in the manufacturing line, an actual value of a work time of the facility, and calculates, using the acquired actual value and the standard operation time of a process performed by a facility that is not the observation target in the manufacturing line, an activity amount of each facility in the manufacturing line.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to an activity amount calculation device, a system including the activity amount calculation device, and an activity amount calculation method.

Background Art

[0002] Patent Document 1 discloses a technique for calculating the environmental load amount of a product, which includes "receiving the actual line power consumption of a production line, the device characteristics of each device on the production line, the rated power of each device, and the numerical data of each specification item for each product (S31), determining the coefficient for each device using the relationship between the device characteristics and the ratio (coefficient) of the actual power consumption to the rated power of the device (S32), and determining the correlated specification item for each device using the device characteristic-correlated specification item relationship that associates the device characteristics with the specification items having a correlation with the device power consumption amount (S 33) 。Using the rated power and coefficient for each device, the actual line power consumption is distributed to each device to obtain the power consumption amount for each device (S34). Using the numerical data related to the correlated specification item for each device, the power consumption amount for each device is distributed to each product to obtain the power consumption amount for each device and each product (S35). Using the power consumption amount for each device and each product, the power consumption amount for manufacturing each product is obtained for each product (S36).".

[0003] Patent Document 2 targets a production line with variable tact times, such as small batches and multiple product types, and discloses a method for estimating the degree of variation, devising line designs, providing assistance to workers, assigning highly skilled workers, and reducing variations.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Patent Document 2

Summary of the Invention

Problems to be Solved by the Invention

[0005] To achieve carbon neutrality (CN), for example, businesses with manufacturing lines are required to manage their green house gas (GHG) emissions when manufacturing products. When using equipment activity levels to calculate GHG emissions, it is considered necessary to obtain information from all equipment used in manufacturing. However, a challenge exists in that not all equipment on a manufacturing line is equipped with an interface for providing information, and it may not be possible to obtain the necessary information. [Means for solving the problem]

[0006] The present invention provides an activity level calculation device and system in the following embodiments. This activity level calculation device comprises a processor, a storage unit, and an interface for acquiring information from equipment used for process work in a manufacturing line. The storage unit manages standard work times related to work time in the process. The processor acquires actual operating times of equipment to be observed in the manufacturing line using the interface. The processor then calculates the activity level of each piece of equipment in the manufacturing line using the acquired actual values ​​and the standard work times of processes performed by equipment that is not observed in the manufacturing line. Furthermore, a system is provided comprising this activity level calculation device and a higher-level system for managing the manufacturing site, wherein the activity level calculation device is used as a relay device between the manufacturing line and the higher-level system.

[0007] The present invention provides an activity level calculation method in the following embodiment. This activity level calculation method is performed using an activity level calculation device comprising a processor, a storage unit for managing standard working times related to work time in a process, and an interface for acquiring information from equipment used for work in a process on a manufacturing line. The processor acquires actual operating times of equipment to be observed on the manufacturing line using the interface, and calculates the activity level of each piece of equipment on the manufacturing line using the acquired actual times and the standard working times of processes performed by equipment that is not observed on the manufacturing line. [Effects of the Invention]

[0008] According to the present invention, even when necessary information cannot be obtained from the equipment, it is possible to calculate the activity level of each piece of equipment on the manufacturing line by using the standard operating time that is managed. Further issues, configurations, and effects not mentioned above will be clarified by the following description of embodiments for carrying out the invention. [Brief explanation of the drawing]

[0009] [Figure 1] This is a diagram showing an example of the configuration of a relay device. [Figure 2] This figure shows an example of a power supply plan configuration. [Figure 3] This figure shows an example of the structure of process environment information. [Figure 4] This figure shows an example of the configuration of manufacturing line configuration information. [Figure 5] This figure shows an example of the configuration of manufacturing line time information. [Figure 6] This figure shows an example of the structure of worker information. [Figure 7] This figure shows an example of the structure of process performance information. [Figure 8] This figure shows an example of the configuration of equipment information. [Figure 9] This flowchart shows an example of the selection of observation equipment. [Figure 10] This is a flowchart illustrating an example of managing standard work times. [Figure 11] This is an example of a formula used to calculate cycle time. [Figure 12] This is a flowchart illustrating an example of calculating activity levels in a manufacturing process. [Figure 13] This is an example of a formula used to calculate activity levels. [Modes for carrying out the invention]

[0010] Embodiments of the present invention will be described below with reference to the drawings. The embodiments are illustrative examples for explaining the present invention, and have been omitted and simplified as appropriate for clarity of explanation. The present invention can also be implemented in various other forms. Unless otherwise specified, each component may be singular or plural. The positions, sizes, shapes, and ranges of the components shown in the drawings may not represent their actual positions, sizes, shapes, and ranges in order to facilitate understanding of the invention. Therefore, the present invention is not necessarily limited to the positions, sizes, shapes, and ranges disclosed in the drawings. Examples of various types of information may be described using terms such as "table," "list," and "queue," but these types of information may also be represented by other data structures. For example, various types of information such as "XX table," "XX list," and "XX queue" may be referred to as "XX information." When describing identification information, terms such as "identification information," "identifier," "name," "ID," and "number" are used, and these terms are interchangeable. When there are multiple components with the same or similar function, they may be described using the same symbol but with different subscripts. Furthermore, when it is not necessary to distinguish between these multiple components, the subscripts may be omitted in the description. In the embodiments, the processes performed by executing a program may be described. Here, a computer executes a program by a processor (e.g., CPU, GPU), and performs the processes defined in the program while using a storage resource (e.g., memory) and an interface device (e.g., communication port), etc. Therefore, the subject of the processes performed by executing the program may be the processor. Similarly, the subject of the processes performed by executing the program may be a controller, a device, a system, a computer, or a node having a processor. The subject of the processes performed by executing the program may be an arithmetic unit, and may include a dedicated circuit that performs a specific process. Here, the dedicated circuit is, for example, an FPGA (Field Programmable Gate Array), an ASIC (Application Specific Integrated Circuit), a CPLD (Complex Programmable Logic Device), etc. The program may be installed in the computer from a program source. The program source may be, for example, a program distribution server or a storage medium readable by the computer. When the program source is a program distribution server, the program distribution server includes a processor and a storage resource that stores the program to be distributed, and the processor of the program distribution server may distribute the program to be distributed to other computers. Also, in the embodiments, two or more programs may be realized as one program, or one program may be realized as two or more programs.

[0011] The relay device will be described while referring to FIG. 1. The relay device 200 (activity amount calculation device) is a device that relays between the field and the upper-level system, and is a device that sends the acquired information, the information generated by processing, etc. to the upper-level system. In the present embodiment, the relay device 200 relays between one or a plurality of production lines 100 at the manufacturing site and the management system of the manufacturing site via communication. Here, various facilities used for performing work are prepared for each process in the production line 100.

[0012] As shown in FIG. 1, the relay device 200 includes a memory 210 that stores various programs and data, a processor 250 that executes the programs stored in the memory 210, an auxiliary storage device 260 for permanently holding programs and data, a network interface 271 that provides a connection by communicating with an external computer or the like, and an external interface 272 that connects various input / output devices such as a keyboard and a display (in FIG. 1, a peripheral device 500).

[0013] The memory 210 stores a production line management unit 220, which is a program that realizes functions related to the management of the production line 100, and an environmental load management unit 230, which stores a program that realizes functions related to the management of the environmental load of the production line 100. Also, in the memory 210, storage areas (241 to 245) for storing data are arranged for the processing of the production line management unit 220 and the environmental load management unit 230.

[0014] As an example, the production line management unit 220 is composed of functions of a process management unit 221, a standard operation time management unit 222, a cycle time management unit 223, and a tact time management unit 224. The process management unit 221 handles information on each process constituting the production line 100. The standard operation time management unit 222 handles the standard operation time for the operations performed for each process. Note that the standard operation time is the standard operation time in the process. The cycle time management unit 223 handles the work achievement time (so-called cycle time) of the production line 100 composed of each process. The tact time management unit 224 handles the work planned time (so-called tact time) of the production line 100.

[0015] The Environmental Load Management Unit 230, as an example, consists of the following functions: Observation Equipment Management Unit 231, Standard Work Time Correction Unit 232, Work Status Collection Unit 233, Cycle Time Correction Unit 234, Activity Level Calculation Unit 235, and GHG Emission Calculation Unit 236. The Observation Equipment Management Unit 231 manages the equipment used to observe the operating status of the manufacturing line 100 managed by the Manufacturing Line Management Unit 220. The Standard Work Time Correction Unit 232 corrects the standard work time handled by the Standard Work Time Management Unit 222 of the Manufacturing Line Management Unit 220 by referring to observation results of the equipment and past performance information. The Work Status Collection Unit 233 collects information on the work status of the process performed by the equipment selected as the observation target by the Observation Equipment Management Unit 231. The Cycle Time Correction Unit 234 corrects the Cycle Time handled by the Cycle Time Management Unit 224 by referring to actual performance information such as cycle time and observation results of the equipment. The activity level calculation unit 235 calculates the activity level and calculates the activity level for each process by considering, for example, information on the processes managed by the manufacturing line management unit 220, the standard working time for each process, the takt time and cycle time of the manufacturing line 100, as well as actual performance information obtained by observing each piece of equipment and the type of power supply used when manufacturing was carried out. The GHG emission calculation unit 236 calculates the GHG emission using the calculated activity level and information on the unit intensity related to GHG. For example, the GHG emission calculation unit 236 calculates the GHG emission from the product of the activity level and the unit intensity.

[0016] The memory 210 contains a production plan information storage unit 241, a process information storage unit 242, an equipment configuration information storage unit 243, a performance information storage unit 244, and a unit consumption information storage unit 245, all related to the manufacturing line 100 targeted by the relay device 200. The production plan information storage unit 241 stores production plans and plans for the types of power supplied to the production equipment. The process information storage unit 242 stores information related to each process. The equipment configuration information storage unit 243 stores information related to the equipment operating in each process. The performance information storage unit 244 stores information obtained by observing the operating equipment. The unit consumption information storage unit 245 stores information related to unit consumption that is referenced when calculating GHG emissions.

[0017] Next, various types of data will be explained with reference to Figures 2-8. First, an example of a power supply plan will be explained with reference to Figure 2. The power supply plan 610 is information about the power supply plan to be used for the manufacturing line 100 targeted by the relay device 200, and is stored in the production plan information storage unit 241. The power supply plan 610 is referenced, for example, by the process control unit 221, which handles information on each process constituting the manufacturing line, in the processing of the manufacturing line management unit 220. In addition, the power supply plan 610 is referenced, for example, by the activity amount calculation unit 235, which calculates the activity amount of each process, in the environmental load management unit 230.

[0018] The power usage plan 610, as an example, includes the #field 611, the date field 612, and the breaker I D-Field 6 It includes 13, a power type field 614, a start time field 615, and an end time field 616. #Field 611 indicates information that identifies the entry. Date field 612 indicates the date of the information that the entry represents. Breaker I D-Field 6 13 indicates information identifying the power source indicated by the entry. The power source type field 614 indicates the power source type indicated by the entry. The start time field 615 indicates the time when the use of power of the power source type indicated by the entry begins at the location specified by the breaker ID. The end time field 616 indicates the time when the use of power of the power source type indicated by the entry ends at the location specified by the breaker ID.

[0019] Next, an example of process environment information will be described with reference to Figure 3. The process environment information 620 is stored in the process information storage unit 242, which manages information related to each process for the manufacturing line 100 targeted by the relay device 200. The process environment information 620 is referenced, for example, in the manufacturing line management unit 220 by the process management unit 221, the standard work time management unit 222 which manages the standard work time for each process, and the cycle time management unit 223 which manages the cycle time of the manufacturing line. In addition, the process environment information 620 is referenced, for example, in the environmental load management unit 230 by the standard work time correction unit 232 which determines the correction of the standard work time for each process, and the activity amount calculation unit 235.

[0020] Process environment information 620 includes, as an example, #field 621, process #field 622, name field 623, and breaker I D-Field 6 It includes 24, an observation equipment ID field 625, a standard work time field 626, and a correction threshold field 627. #Field 621 indicates information that identifies the entry. Process #Field 622 indicates information that identifies the process indicated by the entry. Name field 623 indicates information that is assigned to the process to make it easier for a person to understand or remember the process indicated by the entry. Breaker I D-Field 6 Field 24 indicates information identifying the power source used in the process indicated by the entry. The observation equipment ID field 625 indicates information identifying the equipment used in the process indicated by the entry. The standard work time field 626 represents the standard work time for the process indicated by the entry. The correction threshold field 627 indicates information to refer to in order to determine whether or not to correct the value of the standard work time for the process indicated by the entry when the work is performed.

[0021] Next, an example of manufacturing line configuration information will be described with reference to Figure 4. The manufacturing line configuration information 630 is stored in the process information storage unit 242, which manages information related to each process constituting the manufacturing line 100 targeted by the relay device 200. The manufacturing line configuration information 630 is referenced, for example, by the process control unit 221 in the manufacturing line management unit 220. In addition, the manufacturing line configuration information 630 is referenced, for example, by the observation equipment management unit 231 in the environmental load management unit 230, which manages the equipment observed in the manufacturing line 100.

[0022] The manufacturing line configuration information 630 includes, as an example, a #field 631 that identifies an entry, a line #field 632 that identifies the manufacturing line indicated by the entry, and a process #field 633 that identifies the process indicated by the entry.

[0023] Next, an example of manufacturing line time information will be explained with reference to Figure 5. The manufacturing line time information 640 is stored in the performance information storage unit 244, which manages information observed at the manufacturing line 100 targeted by the relay device 200. The manufacturing line time information 640 is referenced, for example, in the manufacturing line management unit 220 by the cycle time management unit 223, which manages the cycle time, which is the actual work time taken for manufacturing on the manufacturing line 100, and by the takt time management unit 224, which manages the takt time, which is the planned work time for manufacturing on the manufacturing line. In addition, the manufacturing line time information 640 is referenced, for example, in the environmental load management unit 230 by the takt time correction unit 234, which corrects the takt time, which is the planned work time for manufacturing on the manufacturing line.

[0024] The manufacturing line time information 640 includes, as an example, a # field 641, a line # field 642, a takt time field 643, a cycle time field 644, and a correction threshold field 645. The # field 641 indicates information that identifies an entry. The line # field 642 indicates information that identifies the manufacturing line indicated by the entry. The takt time field 643 indicates the planned takt time value for the line indicated by the entry. The cycle time field 644 indicates the observed cycle time value for the line indicated by the entry. The correction threshold field 645 indicates information to refer to in order to determine whether to correct the takt time value indicated by the entry when work is completed through the line.

[0025] The value of the cycle time field 644 may be replaced with an estimated value, which may be, for example, a value estimated using standard working time.

[0026] Next, an example of worker information will be described with reference to Figure 6. The worker information 650 is a record of workers who performed work on the manufacturing line and is stored in the production plan information storage unit 241, which manages production plans and plans for the types of power supplied to production equipment. The worker information 650 is referenced, for example, by the work status collection unit 233 in the environmental load management unit 230, which collects the work status of processes on the manufacturing line 100.

[0027] The worker information 650 includes, as an example, a # field 651 that identifies an entry, a worker ID field 652 that identifies the worker indicated by the entry, a date field 653 that indicates the date of the information indicated by the entry, and a process # field 654 that identifies the process indicated by the entry.

[0028] Next, an example of process performance information will be described with reference to Figure 7. The process performance information 660 is a record of when work is performed at each stage of the manufacturing line 100, and is stored in the performance information storage unit 244 which manages the information observed at the manufacturing line 100 targeted by the relay device 200. The process performance information 660 is referenced, for example, by the cycle time management unit 223 in the manufacturing line management unit 220. In addition, the process performance information 660 is referenced, for example, by the standard work time correction unit 232, the work status collection unit 233, the takt time correction unit 234, and the activity amount calculation unit 235 in the environmental load management unit 230.

[0029] Process performance information 660 includes, as an example, a #field 661, a process #field 662, a date and time field 663, a worker ID field 664, and a work time (actual) field 665. The #field 661 indicates information that identifies the entry. The process #field 662 indicates information that identifies the process indicated by the entry. The date and time field 663 indicates the date and time of the information indicated by the entry. The worker ID field 664 indicates information that identifies the worker, etc., indicated by the entry. The work time (actual) field 665 indicates the work time when the process indicated by the entry was performed by the worker, etc., indicated by the worker ID field 664, at the date and time indicated by the date and time field 663.

[0030] The worker ID field 664 basically stores ID information that identifies the worker (a 6-digit number in the example in Figure 7). However, if the worker's ID information is unknown, N / A is stored. Also, if the work is performed automatically by equipment rather than by an individual worker, information identifying the equipment may be stored.

[0031] Next, an example of equipment information will be described with reference to Figure 8. The equipment information 670 is stored in the equipment configuration information storage unit 243, which manages information about the equipment operating in each process. The equipment information 670 is referenced, for example, by the observation equipment management unit 231 and the work status collection unit 233 in the environmental load management unit 230.

[0032] Equipment information 670, as an example, includes a # field 671 that identifies the entry, an equipment ID field 672 that identifies the equipment used in the process indicated by the entry, and the equipment I indicated by the entry. D-Field 6 The system includes a providing I / F field 673 that indicates an I / F provided by the equipment identified by 72 for exchanging observation data with the outside. If the equipment does not have such an I / F, N / A is stored in the providing I / F field 673 corresponding to the equipment ID indicating the equipment.

[0033] Next, we will explain an example of the operation of the relay device with reference to Figures 9-11. First, we will explain an example of the process for selecting observation equipment with reference to Figure 9. The observation equipment is the equipment that the relay device uses to perform observations and acquire observation data when calculating GHG emissions in the manufacturing line.

[0034] In the observation equipment selection process (P100), the observation equipment management unit 231 is executed. First, the relay device 200 (specifically, the processor 250) specifies the target manufacturing line for observation and identifies the manufacturing line 100 for which GHG emissions will be calculated (P101).

[0035] Next, the relay device 200 specifies the maximum number of pieces of equipment that can be used as observation equipment on the target manufacturing line, taking into consideration the allowable processing volume, processing time, and power consumption associated with processing on the manufacturing line (P102).

[0036] Furthermore, the relay device 200 creates an equipment list listing the equipment operating on the target manufacturing line specified in P101 (P103). In creating the equipment list, the relay device 200 refers to the manufacturing line configuration information 630 to identify which processes make up the target manufacturing line. The relay device 200 also refers to the process environment information 620 to identify which equipment is operating in each identified process.

[0037] Then, the relay device 200 extracts equipment equipped with an interface (I / F) for exchanging observation data with the outside world from the equipment list created on P103, thereby creating a list of candidate observation equipment (P104). In creating the list of candidate observation equipment, the relay device 200 refers to the equipment information 670 to identify the interface of each piece of equipment.

[0038] Then, in order to select observation equipment, the relay device 200 distributes the processing by considering the maximum number of equipment that can be observed as specified in P102 and the number of observable equipment equipped with an I / F that can be used for observation as listed in P104 (P105, P106).

[0039] When there is only one object to be observed (i.e., the first piece of equipment is the object to be observed), the relay device 200 estimates the cycle time of the manufacturing line based on the actual working time of the one process to be observed and the standard working time of other processes that are not the object to be observed. Therefore, the accuracy of the estimation is improved by selecting the process with the largest deviation in working time. Accordingly, the relay device 200 selects the process with the longest standard working time among the processes in which the observable equipment listed on P104 is in operation as the process to be observed, and the equipment that performs that process becomes the observation equipment (P107).

[0040] When there are two observation targets (i.e., the first and second pieces of equipment are to be observed), the relay device 200 estimates the cycle time of the manufacturing line based on the actual working times of the two processes being observed and the standard working times of other processes that are not being observed. Therefore, the accuracy of the estimation is improved by maximizing the observation interval (i.e., the distance between the two processes being observed). To this end, the relay device 200 selects the two end processes that can be observed from the processes in which the observable equipment listed on P104 is in operation (i.e., selects the processes so that the distance between them is the greatest), and designates the equipment performing those processes as the observation equipment (P108).

[0041] When there are three or more observation targets (i.e., when the first, second, and third pieces of equipment are included in the observation targets), the relay device 200 first selects two processes that maximize the observation interval (i.e., the distance between two processes to be observed), and designates the equipment performing these processes as observation equipment. Then, it selects a process with a large deviation in work time, which is likely to affect the accuracy of cycle time estimation, and designates the equipment performing this process as observation equipment (P109). By maximizing the observation interval, the accuracy of cycle time estimation can be improved. At the same time, by selecting a process with a large deviation in work time, which is likely to affect the accuracy of cycle time estimation, the accuracy of the estimation can be improved. Therefore, the relay device 200 selects the two end processes that can be observed from the processes in which the observable equipment listed on P104 is in operation, and further selects the process with the longest standard work time among the processes in which the observable equipment listed on P104 is in operation as the process to be observed. The relay device 200 performs selections regarding this standard work time up to the number of observation targets.

[0042] In Figure 9, P107 and P109 illustrate how the length of the standard work time can significantly affect the cycle time estimation. However, the relay device 200 may, for example, refer to the longest actual work time value in the historical performance information for each process stored in the process performance information 660. It is also possible to identify processes with large deviations in work time from a perspective other than the length of the standard work time, thereby identifying processes that have a significant impact on the cycle time estimation. Then, it is possible to select the equipment that performs the identified processes as the observation target. After performing the above processing, the observation equipment selection process (P100) is completed (P110).

[0043] Next, an example of standard work time management will be explained with reference to Figure 10. By managing standard work time, it is possible to improve the accuracy of estimating the activity level of each process, which is necessary when calculating GHG emissions in the manufacturing line observed by the relay device.

[0044] In standard work time management (P200), the standard work time management unit 222, the standard work time correction unit 232, etc. are executed. The relay device 200 (specifically, the processor 250) collects the start and end times of the work performed by each piece of equipment from all the operational equipment selected as observation targets on the manufacturing line in the observation equipment selection process P100, as actual work time values ​​(P201).

[0045] The relay device 200 adds the observed data as a new entry to the process performance information 660, based on the performance information of all the processes being observed collected by P201 (P202).

[0046] The relay device 200 compares the standard work time for each process in the manufacturing line to be observed, which is stored in the process environment information 620, with the actual work time for each observed process, which is stored in the process performance information 660. If the difference between the standard work time and the actual value exceeds the correction threshold stored in the process environment information 620, the standard work time stored in the process environment information 620 is corrected (P203). The degree of correction can be specified in advance, for example, by correcting by half of the threshold.

[0047] If there is only one piece of equipment being observed (P204), the standard work time management process is terminated (P207). If there is more than one piece of equipment being observed (P204), the relay device 200 refers to the manufacturing line time information 640. The relay device 200 then compares the takt time and cycle time of the referenced manufacturing line time information 640 with the takt time of the observed manufacturing line and the cycle time estimated from the measured values ​​of the observed process and the standard work time of the unobserved process. As an example of a method for calculating the takt time of a manufacturing line, the takt time is taken as the sum of the standard work times set for each process that makes up the manufacturing line. If the difference exceeds the correction threshold set for the manufacturing line, the takt time of the manufacturing line time information 640 is corrected (P205). The degree of correction can be specified in advance, for example, by correcting by half of the threshold.

[0048] If the cycle time of the production line is corrected in P205, the relay device 200 corrects the standard work time of the non-observed processes that make up the production line to match the corrected cycle time (P206).

[0049] After performing the above steps, the standard work time management process is completed (P207). In standard work time management (P200), for example, the cycle time for each product to be manufactured can be calculated using the formula shown in Figure 11. The cycle time can be defined as the time the product remains on the production line ([time the product leaves the production line] - [time the product enters the production line]), and the assumed production line is a straight line without branches. Therefore, if it is possible to measure at three or more points, the cycle time can be calculated by selecting the two points that allow for the longest interval on the production line and applying the formula used when two points can be observed. Furthermore, for processes where actual measured values ​​can be obtained, the obtained measured values ​​can be used to correct the standard work time of that process using a threshold.

[0050] Next, an example of activity level calculation will be explained with reference to Figure 12. Figure 12 shows a flowchart of an example of activity level calculation, which is necessary to estimate the activity level of each process in the manufacturing line that is observed by the relay device when calculating GHG emissions.

[0051] In the activity level calculation (P300), first, the relay device 200 (specifically, the processor 250) specifies the target manufacturing line to be observed in order to identify the target manufacturing line (P301). Then, it specifies the date and time for calculating the activity level of the manufacturing line to be observed (P302). Next, based on the information of the manufacturing line specified in P301, it refers to the manufacturing line configuration information 630 to identify which processes make up the target manufacturing line. Furthermore, in order to identify which equipment is operating in each identified process, it refers to the process environment information 620 and creates an equipment list listing the equipment operating in the target manufacturing line (P303).

[0052] The relay device 200 refers to the list created in P303 and, referring to the process performance information 660, extracts performance information for each piece of equipment that was in operation on the production line at the date and time specified in P302 (P304).

[0053] The relay device 200 extracts the operating time from the operational performance information of the observed target equipment based on the results of P304, and uses this as the activity level of the equipment operating in the process (P305). On the other hand, for equipment operating in processes that are not observed in the target manufacturing line, the standard working time of that process is used as the activity level (P306).

[0054] The relay device 200 identifies the breaker information used by the equipment operating in each process and the power source type supplied to each breaker based on the power source plan 610, and adjusts the activity level according to the power source type used in each process, such as reducing the activity level if renewable energy is to be used as the power source (P307).

[0055] After performing the above steps, the activity level calculation process is completed (P308). Note that the activity level can be calculated using the formula shown in Figure 13 (P300).

[0056] In manufacturing lines, not all equipment is equipped with an information-providing interface (I / F), and it may be impossible to obtain the necessary information for calculating activity levels. For example, replacing all equipment at once is not easy from the perspective of production planning and investment budgets. Alternatively, some equipment may be outdated, making it difficult to add interfaces due to high costs. Therefore, it is conceivable to calculate equipment activity levels using cycle time, which is the time required to produce one product through multiple processes ("operating time ÷ actual production quantity"). However, if the breakdown of the cycle time is unknown, the accuracy may be low.

[0057] Even in such cases, by supplementing equipment information using managed standard working hours, it becomes possible to calculate activity levels while suppressing a decrease in accuracy. Based on these activity levels, GHG emissions can then be calculated, thus contributing to the environment.

[0058] Furthermore, when estimating the activity levels of processes that cannot be observed using standard work times, the accuracy of the estimation is likely to be low in high-mix, low-volume production because the work times for each process fluctuate. As a result, the accuracy of the calculated GHG emissions is likely to be low.

[0059] Even in this case, the decrease in estimation accuracy can be suppressed by extracting the observation targets as explained above. Furthermore, it is possible to select the equipment to be observed from a list, taking into account factors such as power consumption.

[0060] Furthermore, for example, standard working hours may be managed from the following perspectives to improve estimation accuracy. The relay device 200 may manage, for example, production plans for manufacturing products, equipment maintenance plans, and personnel calculations for workers. Please refer to the image. Standard working hours may be adjusted based on the data examined. Regarding production planning, for example, when manufacturing the same product over a long period, the skill level of workers can be expected to improve over time, so adjustments to shorten standard working hours may be made as needed. Regarding maintenance planning, immediately after the completion of equipment maintenance work and immediately before maintenance work, the likelihood of equipment malfunction is considered to increase as the date and time of the planned maintenance work approaches, so adjustments to lengthen the standard working hours for the processes in which the relevant equipment operates may be made. Regarding personnel planning, the skill level of workers can be expected to improve depending on how often they are assigned to the same process, so adjustments to shorten standard working hours may be made.

[0061] Furthermore, the relay device 200 may, for example, refer to the worker's skill information and adjust the standard work time. The skill information can be used as a weight, for example, to shorten the standard work time for a process if the worker in charge of that process has a high skill level, and to lengthen the standard work time for a process if the worker in charge of that process has a low skill level.

[0062] Skill information can be managed for each process, for example, and can be stored as table-formatted data containing the worker's skill level and the corresponding standard work time. Furthermore, the worker's skill level may be updated as needed, for example, according to the experience of the worker in charge of the process. Also, if the worker in charge of a process changes, the content of the skill information may be changed accordingly.

[0063] Based on the above description, the following relay device and method are provided. Specifically, a relay device is provided that refers to the production plan, equipment maintenance plan, personnel plan, and power usage plan for manufacturing a product, manages the processes and standard working hours that make up the manufacturing line, the equipment in operation and its specifications, and the interfaces of each piece of equipment, manages the expected skill level and corresponding standard working hours for the workers in charge of each process, selects the equipment from which information should be acquired in order to calculate GHG emissions, acquires information observed during the manufacturing of the product, corrects the standard working hours of the processes related to the equipment based on the information observed from the equipment, calculates the cycle time of the product in the manufacturing line, determines the breakdown of the cycle time for each process, and calculates the GHG emissions when manufacturing each product.

[0064] Furthermore, even in high-mix, low-volume production where the work content changes before workers have a chance to become proficient, causing significant fluctuations in the work time for each process, a method is provided to adjust the standard work time for each process by considering the cycle time (actual value) required to manufacture the product on the target manufacturing line, the operating time (actual value) of the equipment in the process from which information can be obtained, and the production plan for manufacturing the product. The production plan may include information such as, for example, what product to manufacture, when to manufacture it, how many units to produce, who will manufacture it, and when and which process will be handled by whom.

[0065] This relay device and method allows for the selection of appropriate equipment to acquire information for observing the operating status of a manufacturing line in order to calculate GHG emissions from that line. It also allows for the correction of standard working hours used to estimate the operating status of equipment that cannot be observed, based on the observed operating status of some of the equipment on the manufacturing line. Furthermore, in calculating the activity level, the electricity used by each piece of equipment is also considered. Power The activity level of the manufacturing line can be calculated by considering the type of energy source (conventional / renewable).

[0066] Furthermore, by using a relay device to observe, for example, at the start and end points of the production line being observed, or near the start and end points, the accuracy of cycle time estimation can be improved, and as a result, an improvement in the accuracy of GHG emission estimation can be expected. In addition, if it is possible to observe three or more pieces of equipment, the accuracy of GHG emission estimation can be expected to be improved by selecting equipment with a high environmental impact (power consumption), equipment installed in difficult processes, or equipment installed in processes handled by less experienced workers as the target of observation.

[0067] Although embodiments have been described above, the present invention is not limited to the embodiments described above, and includes various modifications and equivalent configurations within the spirit of the attached claims. For example, the embodiments described above are described in detail for the purpose of explaining the present invention in an easy-to-understand manner, and the present invention is not necessarily limited to having all the configurations described above. Furthermore, some of the configurations of one embodiment may be replaced with those of another embodiment. Furthermore, some of the configurations of one embodiment may be added to those of another embodiment. Furthermore, some of the configurations of each embodiment may be added, deleted, or replaced with those of other embodiments.

[0068] The various data described above are stored in the auxiliary storage device 260, and the relay device 200 may read the data into the memory 210 and process it as needed. As an example of an activity level calculation device, a relay device 200 that uploads information to a higher-level system has been described, but the activity level calculation device may be configured as a computer different from the relay device. [Explanation of Symbols]

[0069] 100: Manufacturing Line 200: Relay device 210: Memory 220: Manufacturing Line Management Department 230:Environmental Load Management Department 241: Production plan information storage unit 242: Process information storage unit 243: Equipment configuration information storage unit 244: Performance Information Storage Unit 245: Unit Cost Information Storage Unit 250: Processor 260:Auxiliary storage device 271: Network Interface 272: External Interface 500: Peripheral devices

Claims

1. Processor and Memory unit and, An interface for acquiring information from equipment used in process operations on a manufacturing line, Equipped with, The aforementioned storage unit is We manage standard working times for tasks in each process. The processor is, From the equipment to be observed within the aforementioned manufacturing line, the actual operating time of the equipment is obtained using the interface. Using the acquired actual values ​​and the standard work time of the processes performed by equipment in the manufacturing line that are not subject to observation, which are acquired using the memory unit, the activity level of each piece of equipment in the manufacturing line is calculated. The aforementioned processor, When calculating the activity level using the first piece of equipment as the observation target among the equipment that can be observed in the aforementioned manufacturing line, the first piece of equipment is defined as the equipment that performs the process with the longest standard working time among the equipment that can be observed, and the actual values ​​are obtained from the first piece of equipment. In the aforementioned manufacturing line, equipment different from the first equipment is identified as equipment that is not subject to observation. An activity level calculation device characterized by the following features.

2. Processor and Memory unit and, An interface for acquiring information from equipment used in process operations on a manufacturing line, Equipped with, The aforementioned storage unit is We manage standard working times for tasks in each process. The processor is, From the equipment to be observed within the aforementioned manufacturing line, the actual operating time of the equipment is obtained using the interface. Using the acquired actual values ​​and the standard work time of the processes performed by equipment in the manufacturing line that are not subject to observation, which are acquired using the memory unit, the activity level of each piece of equipment in the manufacturing line is calculated. The aforementioned processor, When calculating the activity level using the first and second pieces of equipment as observation targets among the equipment that can be observed in the aforementioned manufacturing line, the first and second pieces of equipment are selected from among the equipment that can be observed to have the longest interval between processes performed, and the actual values ​​are obtained from the first and second pieces of equipment. In the aforementioned manufacturing line, equipment different from the first equipment and the second equipment is identified as equipment that is not subject to observation. An activity level calculation device characterized by the following features.

3. Processor and Memory unit and, An interface for acquiring information from equipment used in process operations on a manufacturing line, Equipped with, The aforementioned storage unit is We manage standard working times for tasks in each process. The processor is, From the equipment to be observed within the aforementioned manufacturing line, the actual operating time of the equipment is obtained using the interface. Using the acquired actual values ​​and the standard work time of the processes performed by equipment in the manufacturing line that are not subject to observation, which are acquired using the memory unit, the activity level of each piece of equipment in the manufacturing line is calculated. The aforementioned processor, When calculating the activity level using three or more predetermined number of pieces of equipment as observation targets among the equipment that can be observed in the aforementioned manufacturing line, the two pieces of equipment with the longest interval between processes performed are selected as the observation targets, and the actual values ​​are obtained from these two pieces of equipment. Among the equipment that can be observed in the manufacturing line, which is different from the two equipment mentioned above, a predetermined number of equipment that performs a process with a longer standard working time than other processes will be selected as the equipment to be observed, and the actual values ​​will be obtained from the predetermined number of equipment. The number of observed objects is the predetermined number plus 2. The aforementioned processor, In the aforementioned manufacturing line, equipment different from the equipment to be observed is identified as equipment that is not subject to observation. An activity level calculation device characterized by the following features.

4. Processor and Memory unit and, An interface for acquiring information from equipment used in process operations on a manufacturing line, Equipped with, The aforementioned storage unit is We manage standard working times for tasks in each process. The processor is, From the equipment to be observed within the aforementioned manufacturing line, the actual operating time of the equipment is obtained using the interface. Using the acquired actual values ​​and the standard work time of the processes performed by equipment in the manufacturing line that are not subject to observation, which are acquired using the memory unit, the activity level of each piece of equipment in the manufacturing line is calculated. The aforementioned storage unit is Store past performance information for each process regarding work time. The aforementioned processor, When calculating the activity level using the first piece of equipment as the observation target among the equipment that can be observed in the aforementioned manufacturing line, the first piece of equipment is defined as the equipment that performed the process with the longest working time in the aforementioned performance information, and the aforementioned performance value is obtained from the first piece of equipment. In the aforementioned manufacturing line, equipment different from the first equipment is identified as equipment that is not subject to observation. An activity level calculation device characterized by the following features.

5. Processor and Memory unit and, An interface for acquiring information from equipment used in process operations on a manufacturing line, Equipped with, The aforementioned storage unit is We manage standard working times for tasks in each process. The processor is, From the equipment to be observed within the aforementioned manufacturing line, the actual operating time of the equipment is obtained using the interface. Using the acquired actual values ​​and the standard work time of the processes performed by equipment in the manufacturing line that are not subject to observation, which are acquired using the memory unit, the activity level of each piece of equipment in the manufacturing line is calculated. The aforementioned storage unit is Store past performance information for each process regarding work time. The aforementioned processor, When calculating the activity level using three or more predetermined number of pieces of equipment as observation targets among the equipment that can be observed in the aforementioned manufacturing line, the two pieces of equipment with the longest interval between processes performed are selected as the observation targets, and the actual values ​​are obtained from these two pieces of equipment. From among the equipment that can be observed in the manufacturing line, which is different from the two equipment mentioned above, a predetermined number of equipment that performed a process with a longer working time than other processes in the performance information will be selected as the equipment to be observed, and the performance values ​​will be obtained from the predetermined number of equipment. The number of observed objects is the predetermined number plus 2. The aforementioned processor, In the aforementioned manufacturing line, equipment different from the equipment to be observed is identified as equipment that is not subject to observation. An activity level calculation device characterized by the following features.

6. An activity level calculation device according to any one of claims 1 to 5, The aforementioned processor, If the difference between the standard work time of the process stored in the memory unit and the acquired actual value for the process exceeds a predetermined threshold, the standard work time of the process stored in the memory unit is corrected. An activity level calculation device characterized by the following features.

7. An activity level calculation device according to any one of claims 1 to 5, The aforementioned storage unit is The planned value of takt time and the actual value of cycle time related to the production of products in the aforementioned manufacturing line are managed. The aforementioned processor, If the difference between the cycle time and cycle time of the manufacturing line stored in the memory unit and the acquired cycle time and cycle time for the manufacturing line exceeds a predetermined threshold, the standard work time of the process performed by equipment not subject to observation, which is stored in the memory unit, is corrected. An activity level calculation device characterized by the following features.

8. An activity level calculation device according to any one of claims 1 to 5, The aforementioned processor, Based on the production plan for manufacturing the product, the standard work time managed using the memory unit is corrected. An activity level calculation device characterized by the following features.

9. An activity level calculation device according to any one of claims 1 to 5, The aforementioned processor, Based on the equipment maintenance plan, the standard working hours managed using the memory unit are corrected. An activity level calculation device characterized by the following features.

10. An activity level calculation device according to any one of claims 1 to 5, The aforementioned processor, Based on the worker staffing plan, the standard work time managed using the memory unit is corrected. An activity level calculation device characterized by the following features.

11. An activity level calculation device according to any one of claims 1 to 5, The aforementioned processor, Based on the power usage plan of the manufacturing line, the standard working time managed using the memory unit is corrected. An activity level calculation device characterized by the following features.

12. An activity level calculation device according to any one of claims 1 to 5, The aforementioned processor, Based on the worker's skill information, the standard work time managed using the memory unit is corrected. An activity level calculation device characterized by the following features.

13. An activity level calculation device according to any one of claims 1 to 5, The aforementioned storage unit is The equipment stores information about the type of power supply used in the process. The aforementioned processor, Further using the information regarding the type of power supply stored in the memory unit, the activity level of each piece of equipment in the manufacturing line is calculated. An activity level calculation device characterized by the following features.

14. An activity level calculation device according to any one of claims 1 to 5, Equipped with a higher-level system for managing the manufacturing site, The activity level calculation device is This device acts as a relay between the manufacturing line at the aforementioned manufacturing site and the aforementioned higher-level system. A system characterized by the following features.

15. An activity level calculation method performed using an activity level calculation device comprising a processor, a memory unit for managing standard work times related to work time in a process, and an interface for acquiring information from equipment used for work in a process on a manufacturing line, The aforementioned processor, From the equipment to be observed within the aforementioned manufacturing line, the actual operating time of the equipment is obtained using the interface. Using the acquired actual values ​​and the standard work time of the processes performed by equipment in the manufacturing line that are not subject to observation, which are acquired using the memory unit, the activity level of each piece of equipment in the manufacturing line is calculated. The aforementioned processor, When calculating the activity level using the first piece of equipment as the observation target among the equipment that can be observed in the aforementioned manufacturing line, the first piece of equipment is defined as the equipment that performs the process with the longest standard working time among the equipment that can be observed, and the actual values ​​are obtained from the first piece of equipment. In the aforementioned manufacturing line, equipment different from the first equipment is identified as equipment that is not subject to observation. A method for calculating activity levels characterized by the following features.

16. An activity level calculation method performed using an activity level calculation device comprising a processor, a memory unit for managing standard work times related to work time in a process, and an interface for acquiring information from equipment used for work in a process on a manufacturing line, The aforementioned processor, From the equipment to be observed within the aforementioned manufacturing line, the actual operating time of the equipment is obtained using the interface. Using the acquired actual values ​​and the standard work time of the processes performed by equipment in the manufacturing line that are not subject to observation, which are acquired using the memory unit, the activity level of each piece of equipment in the manufacturing line is calculated. The aforementioned processor, When calculating the activity level using the first and second pieces of equipment as observation targets among the equipment that can be observed in the aforementioned manufacturing line, the first and second pieces of equipment are selected from among the equipment that can be observed to have the longest interval between processes performed, and the actual values ​​are obtained from the first and second pieces of equipment. In the aforementioned manufacturing line, equipment different from the first equipment and the second equipment is identified as equipment that is not subject to observation. A method for calculating activity levels characterized by the following features.

17. An activity level calculation method performed using an activity level calculation device comprising a processor, a memory unit for managing standard work times related to work time in a process, and an interface for acquiring information from equipment used for work in a process on a manufacturing line, The aforementioned processor, From the equipment to be observed within the aforementioned manufacturing line, the actual operating time of the equipment is obtained using the interface. Using the acquired actual values ​​and the standard work time of the processes performed by equipment in the manufacturing line that are not subject to observation, which are acquired using the memory unit, the activity level of each piece of equipment in the manufacturing line is calculated. The aforementioned processor, When calculating the activity level using three or more predetermined number of pieces of equipment as observation targets among the equipment that can be observed in the aforementioned manufacturing line, the two pieces of equipment with the longest interval between processes performed are selected as the observation targets, and the actual values ​​are obtained from these two pieces of equipment. Among the equipment that can be observed in the manufacturing line, which is different from the two equipment mentioned above, a predetermined number of equipment that performs a process with a longer standard working time than other processes will be selected as the equipment to be observed, and the actual values ​​will be obtained from the predetermined number of equipment. The number of observed objects is the predetermined number plus 2. The aforementioned processor, In the aforementioned manufacturing line, equipment different from the equipment to be observed is identified as equipment that is not subject to observation. A method for calculating activity levels characterized by the following features.

18. An activity level calculation method performed using an activity level calculation device comprising a processor, a memory unit for managing standard work times related to work time in a process, and an interface for acquiring information from equipment used for work in a process on a manufacturing line, The aforementioned processor, From the equipment to be observed within the aforementioned manufacturing line, the actual operating time of the equipment is obtained using the interface. Using the acquired actual values ​​and the standard work time of the processes performed by equipment in the manufacturing line that are not subject to observation, which are acquired using the memory unit, the activity level of each piece of equipment in the manufacturing line is calculated. The aforementioned storage unit is Store past performance information for each process regarding work time. The aforementioned processor, When calculating the activity level using the first piece of equipment as the observation target among the equipment that can be observed in the aforementioned manufacturing line, the first piece of equipment is defined as the equipment that performed the process with the longest working time in the aforementioned performance information, and the aforementioned performance value is obtained from the first piece of equipment. In the aforementioned manufacturing line, equipment different from the first equipment is identified as equipment that is not subject to observation. A method for calculating activity levels characterized by the following features.

19. An activity level calculation method performed using an activity level calculation device comprising a processor, a memory unit for managing standard work times related to work time in a process, and an interface for acquiring information from equipment used for work in a process on a manufacturing line, The aforementioned processor, From the equipment to be observed within the aforementioned manufacturing line, the actual operating time of the equipment is obtained using the interface. Using the acquired actual values ​​and the standard work time of the processes performed by equipment in the manufacturing line that are not subject to observation, which are acquired using the memory unit, the activity level of each piece of equipment in the manufacturing line is calculated. The aforementioned storage unit is Store past performance information for each process regarding work time. The aforementioned processor, When calculating the activity level using three or more predetermined number of pieces of equipment as observation targets among the equipment that can be observed in the aforementioned manufacturing line, the two pieces of equipment with the longest interval between processes performed are selected as the observation targets, and the actual values ​​are obtained from these two pieces of equipment. From among the equipment that can be observed in the manufacturing line, which is different from the two equipment mentioned above, a predetermined number of equipment that performed a process with a longer working time than other processes in the performance information will be selected as the equipment to be observed, and the performance values ​​will be obtained from the predetermined number of equipment. The number of observed objects is the predetermined number plus 2. The aforementioned processor, In the aforementioned manufacturing line, equipment different from the equipment to be observed is identified as equipment that is not subject to observation. A method for calculating activity levels characterized by the following features.

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