Operation status management system, operation status management device, program, and operation status management method

Abstract

To provide an operation state management system capable of grasping a preparation state in a production interval between a previous production and a next production in a production line, an operation state management device, a program, and an operation state management method.SOLUTION: An operation state management system 100 comprises a production device 130, an operation state management device 110 acquiring data from the production device, and a display device 120 displaying the information acquired from the operation statement management device. The operation state management device comprises delay rate storage means 112 for storing a relationship between a work process conducted in a production interval in the production device and a delay rate influencing a preparation delay in the production interval and a predictive production interval time calculation means 115 for calculating a predictive production interval time on the basis of a required process time, which is a required time of each work process received from the production device and a delay rate of each work process. The display device displays prediction information based on a predictive production time.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 Art

[0002] Conventionally, various products have been produced (manufactured) by various production lines installed in a factory. In a production line, production devices that execute various processes are combined. In order to efficiently produce products using such a production line, techniques for managing its operation have been developed (see, for example, Patent Document 1).

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] In production equipment that performs high-speed production, such as a PET bottle aseptic filling line, after producing a previous product and before producing the next product, there is a state during production between the previous production and the next production. During this production interval, cleaning and washing of the production equipment are performed to prepare for the production of the next product. However, in the production interval, since work is performed simultaneously in a plurality of processes and a plurality of equipment, it is difficult to grasp the factors causing a delay in the production interval time and the end time.

[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 can grasp the status of preparation in the production interval between the previous production and the next production in a production line.

Means for Solving the Problems

[0006] To address the above issues, this disclosure provides: An operational status management system comprising a production apparatus for producing products, an operational status management device for acquiring data from the production apparatus, and a display device for displaying information acquired from the operational status management device, wherein the operational status management system manages the status of the production apparatus between production cycles, which is between the previous production cycle and the next production cycle. The aforementioned operating status management device is A delay rate storage means that stores the relationship between the work processes performed between production cycles in the production apparatus and the delay rate that affects the delay in preparation between production cycles, The system includes a process duration calculation means that calculates a predicted production interval based on the process duration, which is the duration of each work process received from the production apparatus, and the delay rate of each work process. The display device provides an operational status management system that displays forecast information based on the predicted production interval.

[0007] Furthermore, in the operational status management system described in this disclosure, The aforementioned operating status management device is A production schedule storage means that stores production schedule information including work processes scheduled between productions, The system further includes an estimated end time calculation means that calculates the estimated end time using the predicted production interval calculated by the aforementioned predicted production interval calculation means and the production interval start time, which is the start time of the production interval. The display device may display the estimated completion time as the prediction information.

[0008] Furthermore, the operational status management system described in this disclosure is A process performance storage means stores process performance information, which records the process time required for each work process and the inter-production time of the production equipment in association with the manufacturing lot of the product being produced. A delay rate calculation means that, by referring to the aforementioned process performance information, performs a simple regression analysis with the production interval time as the dependent variable and the time information of the work process as the independent variable, and calculates the delay rate of each work process. It may further have

[0009] Furthermore, in the operational status management system described in this disclosure, The delay rate calculation means may perform a simple linear regression analysis using the process duration, which is the time required for the work process, as the time information for the work process.

[0010] Furthermore, in the operational status management system described in this disclosure, The delay rate calculation means may calculate the delay rate by associating it with one or more of the following: the type of product to be produced, the liquid contents, the bottle shape, the type of labeler, the bottle capacity, whether it is acidic or neutral, the type of cap, and the label material.

[0011] Furthermore, in this disclosure, An operational status management device connected to a production machine that produces products and a display device that displays information, which acquires production information from the production machine and manages the status in the production interval between the previous and next production in the production machine, The aforementioned operating status management device is A delay rate storage means that stores the relationship between the work processes performed between production cycles in the production apparatus and the delay rate that affects the delay in preparation between production cycles, The system includes a predictive production interval calculation means that calculates a predictive production interval based on the process duration of each process received from the production apparatus and the delay rate for each process type. The present invention provides an operational status management device that displays predictive information based on the predicted production interval.

[0012] Furthermore, in this disclosure, A program used in a computer that is connected to a production device for producing products and a display device for displaying information, and which acquires production information from the production device and manages the status in the production interval between the previous and next production in the production device, The aforementioned computer, A delay rate storage means that stores the relationship between the work process performed between production cycles in the production apparatus and the delay rate that affects the delay in preparation between production cycles. Predicted production interval time calculation means for calculating a predicted production interval time based on the process required time for each process received from the production device and the delay rate for each process type. Provide a program for causing it to function.

[0013] Also, in the present disclosure, An operating status management device including production schedule storage means for storing production schedule information of a production device, work processes for each process type, and delay rate storage means for storing the relationship between the work processes and the delay rate affecting the delay of work during the production interval time, is an operating status management method for managing the status of the production device, comprising: Calculating a predicted production interval time based on the process required time for each work process received from the production device and the delay rate for each process type; Calculating an estimated completion time using the predicted production interval time; <​​​​​​​​​​​​​​​​​​​​​​​​​​​​​​​​​This figure shows an example of delay rates for different bottle capacities. [Figure 8] This figure shows an example of production schedule information stored in the production schedule storage means. [Figure 9] This is a diagram showing product information, including the variety. [Figure 10] This figure shows the hardware configuration of the display device 120. [Figure 11] Flowchart showing the processing operation of the operational status management system. [Figure 12] This figure shows the display image on the display device 120. [Figure 13] This figure shows another example of process performance information stored in the process performance storage means 111. [Figure 14] This figure shows yet another example of process performance information stored in the process performance storage means 111. [Figure 15] This figure shows an example of the work process in a sterile filling line for PET bottles. [Modes for carrying out the invention]

[0016] Preferred embodiments of this disclosure will be described in detail below with reference to the drawings. <System Configuration> Figure 1 shows an operational status management system using an operational status management device according to one embodiment of the present disclosure. In Figure 1, 100 is the operational status management system, 110 is the operational status management device, 120 is a display device, 130 is a production device, 140 is a gateway device, and 150 is 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 able to communicate data with each other. The production device 130 is connected to the gateway device 140 so as to be able to communicate data. 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 it.

[0017] In the example in Figure 1, for the sake of explanation, only one display device 120 is shown. However, in reality, the operational status management device 110 can be accessed from multiple display devices 120 via the network 150. Also, in the example in Figure 1, for the sake of explanation, three production devices 130, which are production facilities, are shown. However, in reality, more production devices 130 are usually installed in production sites. The operational status management system 100 according to this embodiment is particularly useful when there are many production devices constituting the production line and the overall production line has a complex configuration.

[0018] Figure 2 shows the details of the operational status management device 110. Of these, Figure 2(a) is a hardware configuration diagram of the operational status management device 110. The operational status management device 110 can be implemented using a general-purpose server computer. Specifically, as shown in Figure 2, the hardware configuration of the operational status management device 110 includes a CPU (Central Processing Unit) 110a, RAM (Random Access Memory) 110b which is the main memory of the computer, a large-capacity storage device 110c (e.g., hard disk, flash memory, etc.) for storing programs and data executed by the CPU, an input I / F (interface) 110d which accepts input from input devices such as a keyboard and mouse, a data input / output I / F (interface) 110e which communicates data with external devices (data storage media, etc.), a display output I / F (interface) 110f which sends information to a display device (liquid crystal display, etc.), and a communication unit 110g which communicates 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. Furthermore, the operational status management device 110, implemented in the server computer, has an internal clock (not shown), allowing the CPU 110a to obtain the current time from this internal clock.

[0019] Figure 2(b) is a functional block diagram of the operational status management device 110. In the hardware configuration shown in Figure 2(a), the CPU 110a reads the 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 shown in Figure 2(b). As shown in Figure 2(b), the operational status management device 110 includes a process performance storage means 111, a delay rate storage means 112, a production interval schedule storage means 113, a delay rate calculation means 114, a predicted production interval time calculation means 115, and a scheduled end time calculation means 116.

[0020] The process performance storage means 111 is a storage means that stores process performance information. Process performance information is information that aggregates the time required for each work process between productions at each production device 130, categorized by product manufacturing lot. Therefore, the process performance information is recorded in association with the manufacturing lot of the product being produced. At each production device 130, product production (manufacturing) is carried out continuously. Therefore, once the production of one lot (previous production) is completed, preparations are made for the production of the next lot (next production). Then, once the preparations are complete, production of the next lot begins. In this way, a time for preparation is provided between the production of the previous lot and the production of the next lot. This time is called the time between productions because it is between the end of the previous production and the start of the subsequent production. Each lot can also be identified by part number.

[0021] Figure 3 shows an example of process performance information stored in the process performance storage means 111. As shown in Figure 3, the process performance storage means 111 stores the previous production end time, the next production start time, the time between productions, the previous production product type, and the process duration as process performance information.

[0022] Process performance information is managed by manufacturing lot of completed products. Furthermore, process performance information is managed in chronological order, sorted from the earliest manufacturing lot with the earliest previous production end time. The time between production cycles is the time from the end of the previous production cycle to the start of the next production cycle. Multiple work processes are performed during this time between production cycles. These work processes include, for example, cleaning and washing of production equipment 130. Process duration is the time required for each work process. Some work processes are performed in parallel. In the example in Figure 3, the process duration is stored for four processes, A to D. As shown in the bottom row of Figure 3, the average time between production cycles is calculated, and the average process duration is calculated and stored for each process.

[0023] Figure 3 shows an example where products of previous production varieties a and b were produced once each, and product c was produced twice, as different production lots. In Figure 3, equipment P and equipment Q are production devices 130. In the example in Figure 3, processes A and B are performed at equipment P, and processes C and D are performed at equipment Q.

[0024] To explain using the top row of Figure 3 as an example, the previous production of product a by production equipment 130 ended at "2021 / 04 / 10 21:36", and the next production start time for that production equipment 130 is "2021 / 04 / 11 04:58". Therefore, the production interval from the end of the previous production to the start of the next production is "7:22" (7 hours and 22 minutes). During this production interval, four work processes were performed, and the required times for processes A to D were "1:10" (1 hour and 10 minutes), "0:20" (20 minutes), "0:45" (45 minutes), and "0:35" (35 minutes). In addition, the average time between productions, which is the average of all time between productions, is calculated as needed. In the example in Figure 3, the average of four time between productions is recorded, but in reality, it is common for the average of more time between productions to be recorded.

[0025] The delay rate storage means 112 is a storage means that stores delay rate information. The delay rate is the rate by which each work process delays the start of the next production. In other words, the delay rate is the rate that affects the delay in preparation between productions. Naturally, the effect on delays differs depending on the type of work process. Therefore, the delay rate also differs depending on the type of work process. Figure 4 is a diagram showing an example of a delay rate that does not depend on product information. As shown in Figure 4, the delay rate storage means 112 stores the delay rate in association with each work process.

[0026] The delay rates shown in Figure 4 are not based on product information, but delay rates managed by product information may also be used. For example, delay rates for each product type, bottle shape, and bottle capacity can be used from the product information. Figures 5, 6, and 7 show the delay rates for each product type, bottle shape, and bottle capacity, respectively. As shown in Figures 5, 6, and 7, even for the same type of work process, the delay rates differ depending on the product type, bottle shape, bottle capacity, etc. produced in the previous production run.

[0027] The inter-production schedule storage means 113 is a storage means that stores inter-production schedule information, including the product numbers and varieties of the previous and next productions, and the planned work processes. Figure 8 is a diagram showing an example of inter-production schedule information stored in the inter-production schedule storage means 113. As shown in Figure 8, the inter-production schedule information includes the previous product number indicating the lot number of the previous production, the variety to be produced with the previous product number, the next product number indicating the lot number of the next production, the variety to be produced with the next product number, and the work processes. Between the production of the previous and next product numbers, one or more work processes are scheduled. For example, in the example in Figure 8, it is shown that at least process A and process B are prepared as work processes.

[0028] The "product type" used in the process performance information in Figure 3 and the production schedule information in Figure 8 can be accompanied by product information such as bottle shape, labeler type, bottle capacity, acidity / neutrality, liquid contents, cap type, and label material. Figure 9 shows an example of product information. In the example in Figure 9, the product information includes bottle shape, labeler type, bottle capacity, acidity / neutrality, liquid contents, cap type, and label material, along with the product type information. Such product information can be stored in a predetermined storage area within the storage device 110c. Product information may also include attributes other than those shown in Figure 9.

[0029] The delay rate calculation means 114 is a means for calculating the delay rate of each work process by referring to the process performance information stored in the process performance storage means 111. Specifically, it uses the time between productions as the dependent variable and the process time of each work process as the independent variable, and performs a simple linear regression analysis on each dependent variable. For example, the least squares method can be used for the simple linear regression analysis. Through this simple linear regression analysis, the p-value (reliability) and slope are calculated for each work process. This slope is then taken as the delay rate. In this way, the delay rate calculation means 114 calculates the delay rate of each work process. Note that the delay rate may also be calculated using a regression analysis other than simple linear regression. For example, the delay rate calculation means 114 may use multiple linear regression as the regression analysis to calculate the delay rate.

[0030] The predicted production interval calculation means 115 calculates the predicted production interval based on the delay rate calculated by the delay rate calculation means 114. Specifically, the predicted production interval calculation means 115 calculates the predicted production interval by performing the following process according to [Formula 1].

[0031] [Formula 1] Predicted production interval = Average production interval + ( (Process A duration - Average Process A duration) × α) + ((Process B duration - Average Process B duration) × β) + ((Process C duration - Average Process C duration) × γ) + ... + ((Process Z duration - Average Process Z duration) × ζ)

[0032] In [Equation 1], α, β, γ, and ζ are the delay rates corresponding to each work process. In [Equation 1] above, the delay rates α, β, γ, and ζ represent the delay rates of the work processes A, B, C, and Z, respectively. Therefore, if the time required for each work process is greater than the average time required, the greater the delay rate for each work process, the greater the predicted time between productions. In [Equation 1] above, when the delay rate for all work processes is 0, the predicted time between productions equals the average time between productions, which is the minimum value.

[0033] The scheduled end time calculation means 116 calculates the scheduled end time using the predicted production interval calculated by the predicted production interval calculation means 115. Specifically, the scheduled end time calculation means 116 calculates the scheduled end time by performing the following process according to [Formula 2].

[0034] [Formula 2] Estimated end time = Production interval start time + Forecasted production interval

[0035] In [Equation 2], the start time of the production interval corresponds to the end time of the previous production as shown in Figure 3. Therefore, the start time of the production interval is obtained from the process performance information stored in the process performance storage means 111 of the operational status management device 110. As shown in [Equation 2], the scheduled end time is calculated by adding the predicted production interval calculated by the predicted production interval calculation means 115 to the start time of the production interval.

[0036] The operational status management device 110 also performs various processes not included in the above means by having the CPU 110a read the program stored in the storage device 110c into the RAM 110b and execute it. The operational status management device 110 may be implemented as a single computer or as multiple computers. Alternatively, it may be implemented as a cloud system distributed across multiple locations on the network 150.

[0037] The display device 120 is a terminal device that displays information stored and managed by the operational status management device 110. Figure 10 is a hardware configuration diagram of the display device 120. The display device 120 can be implemented, for example, by a general-purpose computer with browser software installed.

[0038] As shown in Figure 10, the display device 120 comprises a CPU (Central Processing Unit) 120a, a RAM (Random Access Memory) 120b which is the main memory, a non-volatile storage device 120c (e.g., flash memory) 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 the network 150, and these components are connected to each other via a bus.

[0039] The display device 120 only needs to have a processing unit such as a CPU, and possess display functions, information processing functions, network communication functions, etc., and general-purpose devices such as notebook PCs, tablets, and smartphones can be used. In this embodiment, the display device 120 is equipped with a web browser and uses the web browser to access the operational status management device 110, which has functions as a web server. As a result, the display device 120 can acquire and display information managed by the operational status management device 110.

[0040] The production equipment 130 is equipment for producing a predetermined type of product. Each production equipment 130 is equipped with a PLC (Programmable Logic Controller), various sensors, and communication devices, and acquires production information and transmits it to the gateway device 140. In this embodiment, signals indicating the end of the previous production and the start of the next production are also transmitted to the gateway device 140 as a type of production information. Furthermore, the production equipment 130 also transmits signals indicating the start and end of each work process to the gateway device 140 as a type of production information.

[0041] The gateway device 140 aggregates production information acquired from multiple production devices 130. It then transmits the aggregated production information to the operational status management device 110 via the network 150. The timing of the transmission of production information to the operational status management device 110 may be at regular intervals (e.g., every 5 minutes), or it may be transmitted in real time each time information is received from each production device 130. In this embodiment, signals indicating the end of the previous production cycle, the start of the next production cycle, and the start and end of each work process are also transmitted to the operational status management device 110 via the gateway device 140 as part of the production information. Alternatively, the production devices 130 may be directly connected to the network 150 and transmit production information directly to the operational status management device 110 without going through the gateway device 140.

[0042] <Collection of process performance information> Next, the collection of process performance information in the operational status management system shown in Figure 1 will be explained. As shown in Figure 1, the production equipment 130 can transmit data to the operational status management device 110 via the gateway device 140 and the network 150. Therefore, the production equipment 130 transmits production information detected by attached sensors, etc., to the operational status management device 110 via an attached PLC. The operational status management device 110 stores the collected production information in the process performance storage means 111.

[0043] Regarding the previous production end time and the next production start time, the production equipment 130 transmits information and the time indicating this when the previous production ends and when the next production starts, and the operation status management device 110 stores the acquired time information as the previous production end time and the next production start time. As for the product type, the information of the previous production type acquired from the production equipment 130 is stored.

[0044] For each work process, at the start and end times of the work process, the PLC installed in each production device 130 transmits the type of work process and whether it is a start or end to the operational status management device 110 via the gateway device 140. The operational status management device 110 then calculates the process duration based on the acquired start and end times of the work process. The operational status management device 110 stores the calculated process duration in the process performance storage means 111, associating it with each lot.

[0045] As described above, various information from the end time of the previous production to the start time of the next production is sent from each production device 130 to the operational status management device 110, and process performance information is accumulated in the process performance storage means 111. When the next production starts and the start time of the next production is determined, the operational status management device 110 calculates the time between productions from the difference between the end time of the previous production and the start time of the next production. The operational status management device 110 stores the calculated time between productions in the process performance storage means 111, associating it with each lot. Furthermore, the operational status management device 110 calculates the average of the time between productions and stores it as the average time between productions.

[0046] <Calculation of delay rate> Once the next production run for a particular manufacturing lot has started and the time between production runs has been determined, the operational status management device 110's delay rate calculation means 114 calculates the delay rate for each type of work process. Specifically, the delay rate calculation means 114 performs a simple linear regression analysis using the time between production runs and the process duration for each work process from the process performance information shown in Figure 3, and calculates the p-value and slope for each work process.

[0047] The calculated p-value represents the reliability of the numerical value. If this p-value is not sufficiently small, the reliability of the data is low. Therefore, a predetermined threshold is set, and if the p-value is greater than this threshold, the data is excluded from the data to be used. Consequently, if the p-value is greater than the threshold, the delay rate is not calculated, and the delay rate becomes 0. In this way, each calculated delay rate is stored in the delay rate storage means 112. The delay rate calculation means 114 can calculate a delay rate that does not depend on product information, as shown in Figure 4, but it may also calculate a delay rate for each type, bottle shape, and bottle capacity, as shown in Figures 5, 6, and 7. Furthermore, it may also calculate a delay rate for other attributes, which are attribute information shown in the product information in Figure 9. For example, the delay rate calculation means 114 may calculate the delay rate by associating it with one or more of the following pieces of information: type, bottle shape, labeler type, bottle capacity, acidity / neutrality, liquid contents, cap type, and label material.

[0048] <Calculation of estimated end time> As described above, the delay rate is calculated using the latest process performance information, and the delay rate of each work process in the delay rate storage means 112 is always updated to the latest information. In the operational status management system according to this embodiment, the predicted inter-production time and the scheduled completion time are calculated as predicted information during or between product production. The operational status is managed by obtaining this predicted information. For this purpose, the inter-production schedule information for the product to be produced is prepared in the inter-production schedule storage means 113. The inter-production schedule information is as shown in Figure 8, as described above.

[0049] Figure 11 is a flowchart of the operational status management method according to this embodiment. When the production equipment 130 starts production with the delay rate and production schedule information prepared, the production equipment 130 transmits the production information to the operational status management device 110, as in the case described above. The operational status management device 110 acquires the production information from the production equipment 130, as in the case described above (step S1). The received production information is stored in the process performance storage means 111.

[0050] The predicted production interval calculation means 115 calculates the predicted production interval 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 a delay occurs. When the predetermined timing is reached, the predicted production interval calculation means 115 calculates the predicted production interval. Specifically, the predicted production interval calculation means 115 calculates the predicted production interval by executing the process according to [formula 1] above.

[0051] The predicted production interval calculation means 115 obtains the process duration for each work process in order to execute the process according to [Equation 1] above. The predicted production interval calculation means 115 also obtains the delay rate for each work process from the delay rate storage means 112. Then, using the process duration and delay rate of each work process, it executes the process according to [Equation 1] above to calculate the predicted production interval.

[0052] Once the predicted production interval is calculated, the scheduled end time calculation means 116 uses that predicted production interval to calculate the scheduled end time (step S3). Specifically, the scheduled end time calculation means 116 calculates the scheduled end time by performing the process according to the above [formula 2].

[0053] The completion time calculation means 116 acquires information on the start time of the inter-production time and the predicted inter-production time in order to perform the processing according to the above [Equation 2]. The start time of the inter-production time is the same as the previous production completion time, so it is acquired from the process performance information stored in the process performance storage means 111 of the operation status management device 110. For the predicted inter-production time, the current predicted inter-production time calculated by the predicted inter-production time calculation means 115 is used. Then, using the acquired information, the processing according to the above [Equation 2] is performed to calculate the completion time.

[0054] The operational status management device 110 calculates the predicted production interval and the scheduled end time as predictive information as the production equipment 130 is in operation. The calculated values ​​are stored along with the calculation time and transmitted in response to a request from the display device 120. The display device 120 then displays the acquired predictive information (step S4). Figure 12 shows an image of the display on the display device 120.

[0055] On the left side of Figure 12, a thick arrow points downwards. This arrow indicates the progression of time, with the further down the arrow points, the further the time has progressed. In the example in Figure 12, it is assumed that during production, process A finishes at a certain time, followed by processes B and C, which finish sequentially. On the right side of Figure 12, three screens G1 to G3 are shown. Screens G1 to G3 correspond to the progression of time indicated by the downward-pointing arrow on the left side of Figure 12.

[0056] As shown in screens G1 to G3 of Figure 12, during production, the display device 120 displays the scheduled completion time and the delayed process. A delayed process refers to a process that has experienced a delay. In addition, the predicted delay time may also be displayed. Furthermore, for delayed processes, the extended time for each process and the impact time based on the delay of each process may also be displayed.

[0057] The scheduled end time is displayed as the scheduled end time calculated by the scheduled end time calculation means 116. The predicted delay time is displayed as the scheduled end time minus the planned end time. The delayed processes are displayed as processes that have experienced delays up to that point. The scheduled end time, predicted delay time, and impact time are all predicted information based on predicted production intervals.

[0058] The duration of each process is determined when it is completed. Then, the delay time is calculated by subtracting the average duration of that process from the determined process duration. If this value is positive, it means the delay time remains the same; if it is negative, it means the time has been reduced.

[0059] At the start of the production interval and before the first work process is completed, the display device 120 displays content as shown in screen G1 of Figure 12. At the time screen G1 is displayed, no work processes have been completed since the start of the production interval. Therefore, the process to be delayed is undecided, and "No delayed processes" is displayed. The planned completion time is the time when the process is scheduled to be completed if there are no delays.

[0060] The planned end time is calculated immediately after the start of the inter-production time. The planned end time is calculated by adding the average inter-production time to the start time of the inter-production time (the end time of the previous production). If no processes have finished since the start of the inter-production time, even if the above formula [Formula 1] is applied, the predicted inter-production time will equal the average inter-production time. Therefore, when the above formula [Formula 2] is applied, the scheduled end time will be the same as the planned end time. Thus, on screen G1, the scheduled end time and the planned end time are both 4:00.

[0061] Once process A is completed, the time required for process A is determined. Then, by comparing this with the average time required for the work process, the delay time can be calculated. In the example in Figure 12, it is assumed that process A is delayed by 1 minute. Once the delay of the work process is determined, the predicted production interval calculation means 115 executes a process according to [Formula 1] to calculate the predicted production interval. Furthermore, it executes a process according to [Formula 2] to add the predicted production interval to the production interval start time to calculate the planned end time. It also subtracts the planned end time from the planned end time to calculate the predicted delay time. In addition, the impact of delays (extensions) in each work process on the production interval is also calculated. If there is only one delayed process, the predicted delay time can simply be used as the impact time on the production interval. In this way, the content shown in screen G2 is displayed.

[0062] Once process B is completed, the time required for process B is determined. Then, by comparing it with the average time required for the work process, the delay time for process B can be calculated. At this point, the predicted production interval calculation means 115 uses the time required for processes A and B, and the average time required for processes A and B, to calculate the predicted production interval according to [Equation 1]. Then, it switches from screen G2 to display a new screen. In Figure 12, the screen at this point is omitted.

[0063] Furthermore, once process C is completed, the duration of process C is determined. Then, by comparing it with the average duration of the work processes, the delay time of process C can be calculated. If the delay time value is negative, it represents a reduction in time. At this point, the predicted production interval calculation means 115 calculates the predicted production interval by performing processing according to [Equation 1] using the process durations of processes A, B, and C, and the average duration of processes A, B, and C. It is also possible to calculate the impact of each delayed process on the production interval. This can be calculated by using the average duration of processes other than the delayed process of interest as the average duration. As a result, a new screen G3 is displayed.

[0064] In screen G3 of Figure 12, it is shown that if process A is extended by 1 minute, the impact on the time between production is +5 minutes (delay); if process A is extended by 8 minutes, the impact on the time between production is +30 minutes (delay); and if process C is shortened by 15 minutes, the impact on the time between production is -5 minutes (shortening).

[0065] <Examples of explanatory variables> In the above explanation, process duration was used as the explanatory variable for the simple linear regression analysis. However, variables other than process duration may be used as explanatory variables. Figure 13 shows another example of process performance information stored in the process performance storage means 111. In the example in Figure 13, in addition to the process duration shown in Figure 3, the difference from the average process time is also stored. A positive value indicates that the time was greater than the average, and a negative value indicates that the time was shorter than the average. When process performance information like that shown in Figure 13 is available, the delay rate calculation means 114 performs a simple linear regression analysis on each dependent variable, using the time between production cycles as the dependent variable and the difference from the average process time for each work process as the explanatory variable. In this way, the delay rate calculation means 114 calculates the delay rate for each work process.

[0066] Figure 14 shows yet another example of process performance information stored in the process performance storage means 111. In the example in Figure 14, in addition to the process duration shown in Figure 3, the process start time and process end time are also stored. When process performance information such as that shown in Figure 13 is available, the delay rate calculation means 114 performs a simple linear regression analysis on each dependent variable, with the production interval as the dependent variable and the process start time and process end time of each work process as the independent variables. In this way, the delay rate calculation means 114 calculates the delay rate for each work process.

[0067] As described above, the operational status management system 100 according to this embodiment comprises a production apparatus 130 that produces products, an operational status management device 110 that acquires data from the production apparatus 130, and a display device 120 that displays information acquired from the operational status management device 110. The operational status management system manages the status between productions in the production apparatus, which is the period between previous and next productions. The operational status management device 110 includes a delay rate storage means 112 that stores the relationship between the work processes performed between productions in the production apparatus 130 and the delay rate that affects the delay in preparation between productions, and a predicted production interval calculation means 115 that calculates a predicted production interval based on the process time, which is the time required for each work process received from the production apparatus, and the delay rate for each work process. The display device 120 displays predicted information based on the predicted production interval, making it possible to grasp the preparation status between productions in the production line, which is the period between previous and next productions.

[0068] Furthermore, the operational status management system 100 according to this embodiment is The operational status management device 110 further includes a production schedule storage means 113 that stores production schedule information including work processes scheduled between productions, and a scheduled end time calculation means 116 that calculates the scheduled end time using the predicted production time calculated by the predicted production time calculation means and the production time start time, which is the start time of the production time. The display device 120 displays the scheduled end time as predicted information, so if the end time is delayed from the original plan due to delays in the work process, it becomes possible to know the new scheduled end time, making it easier to adjust the schedule for subsequent processes.

[0069] Furthermore, the operational status management system according to this embodiment is The system further includes a process performance storage means 111 that stores process performance information, which records the process time required for each work process and the time between production cycles of production equipment in association with the production lot of the target product, and a delay rate calculation means 114 that calculates the delay rate of each work process by performing a simple linear regression analysis using the time between production cycles as the dependent variable and the time information of the work process as the independent variable, based on the process performance information. Therefore, the relationship between each work process and the delay in preparation can be kept up to date, which is useful for calculating accurate predicted time between production cycles and scheduled completion times.

[0070] The delay rate calculation means 114 may perform a simple linear regression analysis using the process duration, which is the time required for the work process, as time information for the work process. By performing a simple linear regression analysis using the process duration as an explanatory variable, the delay rate can be calculated simply and accurately. The delay rate calculation means 114 may also calculate the delay rate in association with one or more of the following: the type of product to be produced, the liquid contents, the bottle shape, the bottle capacity, the cap type, and the label material. In this case, by using a delay rate specific to each attribute, it is possible to calculate a more accurate predicted production interval and the scheduled completion time.

[0071] The operational status management system described herein is applicable to any production equipment equipped with means for detecting the state of the production equipment during the production interval between the previous and next production processes. Therefore, it can be applied to a variety of products and production equipment, regardless of the product being produced or the type of production equipment used to produce it.

[0072] For example, the operational status management system described herein can be applied to an aseptic filling line for PET (polyethylene terephthalate) bottles. When applied to an aseptic filling line for PET bottles, the production equipment used includes facilities that perform the mixing process, liquid processing process, molding process, filling process, or packaging process. These facilities are equipped with a PLC, which transmits information detected during the production interval between the previous and next production processes to the operational status management system via a gateway device.

[0073] Figure 15 shows an example of the work process in a sterile filling line for PET bottles. As the work processes of the entire production line are aggregated, a variety of work processes exist, as shown in Figure 15. Multiple work processes are executed within the time between production cycles for each piece of production equipment. In the operational status management system according to this embodiment, by accurately setting the delay rate of the work processes based on actual results, it becomes possible to calculate the predicted time between production cycles and the scheduled completion time, which cannot be fully grasped by the workers' senses.

[0074] While 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 production interval and scheduled end time are received from the operational status management device via a network and displayed on a display device, but they may also be displayed on a display device directly connected to the display output I / F of the operational status management device.

[0075] Furthermore, in the above embodiment, the operational status management device calculates the predicted production interval and the scheduled end time, and the display device displays them. However, the system may be configured to calculate and display only the predicted production interval, without calculating and displaying the scheduled end time. This is because, even if the scheduled end time cannot be known, knowing the predicted production interval makes it possible to anticipate some time delays. [Explanation of Symbols]

[0076] 100... Operational status management system 110...Operational 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...Process performance storage means 112... Delay rate storage means 113. Production schedule storage means 114. Delay Rate Calculation Method 115. Predicted production interval calculation method 116...Method for calculating the scheduled end time 120...Display device 120a...CPU(Central Processing Unit) 120b...RAM(Random Access Memory) 120c...Storage device 120d...Instruction input section 120e...Data Input / Output Interface 120f...Display section 120g... Communications Department 130... Production equipment 140... Gateway device 150... Network

Claims

1. An operational status management system comprising a production apparatus for producing products, an operational status management device for acquiring data from the production apparatus, and a display device for displaying information acquired from the operational status management device, wherein the operational status management system manages the status of the production apparatus between production cycles, which is between the previous production cycle and the next production cycle. The aforementioned operating status management device is The production apparatus includes a delay rate storage means that stores the relationship between a plurality of work processes performed between productions and the delay rate that affects the delay in preparation between productions, A predicted production interval calculation means calculates a predicted production interval based on the process duration, which is the time required for each work process received from the production apparatus, and the delay rate of each work process. A process performance storage means stores process performance information, which records the process time required for each work process and the inter-production time of the production equipment in association with the manufacturing lot of the product being produced. The system includes a delay rate calculation means that, by referring to the aforementioned process performance information, performs a simple regression analysis with the production interval as the dependent variable and the time information of the work process as the independent variable, and calculates the delay rate of each work process. The display device is an operational status management system that displays forecast information based on the forecast interval between productions.

2. The aforementioned operating status management device is A production schedule storage means that stores production schedule information including work processes scheduled between productions, The system further includes an estimated end time calculation means that calculates the estimated end time using the predicted production interval calculated by the aforementioned predicted production interval calculation means and the production interval start time, which is the start time of the production interval. The operational status management system according to claim 1, wherein the display device displays the scheduled end time as the predicted information.

3. The operational status management system according to claim 1 or 2, wherein the delay rate calculation means performs a simple linear regression analysis using the process duration, which is the time required for the work process, as the time information for the work process.

4. The operational status management system according to claim 3, wherein the delay rate calculation means calculates the delay rate in association with one or more of the following: the type of product to be produced, the liquid contents, the bottle shape, the type of labeler, the bottle capacity, whether it is acidic or neutral, the type of cap, and the label material.

5. An operational status management device connected to a production machine that produces products and a display device that displays information, which acquires production information from the production machine and manages the status in the production interval between the previous and next production in the production machine, The aforementioned operating status management device is The production apparatus includes a delay rate storage means that stores the relationship between a plurality of work processes performed between productions and the delay rate that affects the delay in preparation between productions, A predicted production interval calculation means calculates a predicted production interval based on the process duration of each process received from the production apparatus and the delay rate for each process type. A process performance storage means stores process performance information, which records the process time required for each work process and the inter-production time of the production equipment in association with the manufacturing lot of the product being produced. An operational status management device having delay rate calculation means that performs a simple linear regression analysis using the production interval as the dependent variable and the work process time information as the independent variable, by referring to the aforementioned process performance information, and calculates the delay rate of each work process.

6. A program used in a computer that is connected to a production device for producing products and a display device for displaying information, and which acquires production information from the production device and manages the status in the production interval between the previous and next production in the production device, The aforementioned computer, A delay rate storage means that stores the relationship between a plurality of work processes performed between production cycles in the production apparatus and the delay rate that affects the delay in preparation between production cycles. A predictive production interval calculation means calculates a predictive production interval based on the process duration of each process received from the production apparatus and the delay rate for each process type. Process performance storage means that stores process performance information, which records the process time required for each work process and the production interval of the production equipment in association with the manufacturing lot of the product being produced. A delay rate calculation means that, by referring to the aforementioned process performance information, performs a simple regression analysis with the production interval time as the dependent variable and the work process time information as the independent variable, and calculates the delay rate of each work process. A program designed to function as such.

7. An operating status management device comprising an operating status management device having an inter-production schedule storage means that stores inter-production schedule information for a production device, and a delay rate storage means that stores the relationship between multiple work processes for each process type and the delay rate that affects work delays during inter-production time, is used to manage the status of the production device, The steps include calculating the predicted production interval based on the process duration of each work process received from the production apparatus and the delay rate for each process type, The steps include storing process performance information, which records the process time required for each work process and the production interval of the production equipment, in association with the manufacturing lot of the product being produced, The steps include:

1. Referencing the aforementioned process performance information, performing a simple linear regression analysis with the production interval time as the dependent variable and the work process time information as the independent variable, and calculating the delay rate for each work process. The steps include: calculating the planned completion time using the predicted production interval; A method for managing the operational status of an operating environment.

Images