System for visualizing the loss status of production equipment

Abstract

To provide a system capable of easily grasping a loss status of production facilities.SOLUTION: A production facilities loss status visualization system (10) visualizes a loss status of production facilities (70, 71, 72) and comprises: a data acquisition processing unit (101) configured to acquire operation data indicating operation of the production facilities and loss data indicating loss of the production facilities; and a visualization processing unit (102) capable of performing visualization processing to aggregate the acquired operation data and loss data to cause display devices (90, 91, 92, 93) to display operating status information (30) indicating an operation status of the production facilities within a set load time and loss state information (40) indicating a loss status of the production facilities within the load time.SELECTED DRAWING: Figure 3

Description

Technical Field

[0001] The present disclosure relates to a system for visualizing the loss status of production equipment.

Background Art

[0002] At production sites such as factories, it is required to produce a target number of products within a preset time. However, at production sites, temporal losses that hinder productivity occur, such as abnormal shutdowns of production equipment, shutdowns due to setup for product number switching, or shutdowns due to replacement of cutting tools and jigs. The temporal loss occurring at such production sites is referred to as production loss or simply loss. In daily production, this loss often makes it impossible to achieve the target number within the production time. In order to reduce such losses and improve productivity, it is important to grasp the status of the generated losses as accurately as possible, including what kind of factor causes the loss and how long the loss lasts.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problem to be Solved by the Invention

[0004] The present invention has been made in view of the above circumstances, and an object thereof is to provide a system for visualizing the loss status of production equipment that allows the loss status of production equipment to be easily grasped.

Means for Solving the Problem

[0005] The production equipment loss status visualization system according to the embodiment is a system that visualizes the loss status of production equipment on a display device. The production equipment loss status visualization system comprises a data acquisition processing unit capable of performing data acquisition processing to acquire operation data indicating the operation of the production equipment and loss data indicating the loss of the production equipment, and a visualization processing unit capable of performing visualization processing to aggregate the acquired operation data and loss data and display operation status information indicating the operation status of the production equipment within a set load time and loss status information indicating the loss status of the production equipment within the load time on the display device.

[0006] Furthermore, a system for visualizing the loss status of production equipment according to another embodiment comprises a data acquisition processing unit capable of executing a data acquisition process to acquire loss data indicating the loss of the production equipment, and a visualization processing unit capable of executing a visualization process to aggregate the acquired loss data and display loss status information indicating the loss status of the production equipment within a set load time on a display device. [Brief explanation of the drawing]

[0007] [Figure 1] This diagram schematically shows an example of the configuration of a production equipment loss status visualization system according to the first embodiment. [Figure 2] This diagram conceptually shows an example of the hardware configuration of a production equipment loss status visualization system according to the first embodiment. [Figure 3] Figure (1) shows an example of the display content shown on the display device for the loss status visualization system of production equipment according to the first embodiment. [Figure 4] Figure (2) shows an example of the display content shown on the display device for the production equipment loss status visualization system according to the first embodiment. [Figure 5] A flowchart showing an example of the processing performed by the loss status visualization system for production equipment according to the first embodiment. [Figure 6] Diagram showing the formula for calculating overall equipment efficiency. [Figure 7]This figure shows an example of how the production equipment loss status visualization system according to the second embodiment displays operating status information on the display device. [Figure 8] This figure shows an example of how loss status information is displayed on the display device for the loss status visualization system of production equipment according to the second embodiment. [Figure 9] This figure shows an example of how loss status information is displayed on the display device for the loss status visualization system of production equipment according to the third embodiment. [Modes for carrying out the invention]

[0008] The following describes several embodiments of a production equipment loss visualization system with reference to the drawings. Note that in each embodiment, identical components may be denoted by the same reference numerals and their descriptions may be omitted.

[0009] In this specification, the production equipment loss status visualization system may be abbreviated as the visualization system. In this specification, loss means a time loss that hinders the productivity of production equipment, i.e., a factor that reduces production efficiency. Loss state means a state in which loss is occurring in production equipment, i.e., a state in which the production efficiency of production equipment is deteriorating. Loss situation means the status of loss occurrence in production equipment at a certain point in time or over a certain period. Operating state means a state in which production equipment is producing products. And operating status means the operating status of production equipment at a certain point in time or over a certain period.

[0010] (First Embodiment) The first embodiment will be described below with reference to Figures 1 to 6. The visualization system 10 shown in Figure 1 is a system that visualizes the operating status and loss status of production equipment 70 that constitute a production line. The production equipment 70 targeted by the visualization system 10 includes, but is not limited to, processing machines, assembly machines, inspection machines, conveying devices, and robots.

[0011] The visualization system 10 can be configured as, for example, a single computer device, or as, for example, a network system in which multiple devices are interconnected via telecommunications lines such as a LAN (Local Area Network) or WAN (Wide Area Network). Furthermore, the visualization system 10 may be an on-premise system installed on the same network as the production equipment 70 and the display device 90 and managed and operated by the same person who manages and operates the production equipment 70 and the display device 90, or it may be a cloud-based system installed on the internet and managed and operated by a person different from the person who manages and operates the production equipment 70 and the display device 90.

[0012] The visualization system 10 has the function of acquiring operational data and loss data from the production equipment 70, and the function of aggregating and visualizing the acquired operational data and loss data and displaying it on the display device 90. The visualization system 10 can be connected to the production equipment 70 via wired or wireless communication and acquire each data directly from the production equipment 70, or it can acquire each data indirectly through workers or other intermediaries.

[0013] For example, if the production equipment 71 is equipped with a communication function and is configured to output signals indicating that it is operating and signals indicating that it is in a loss state, the visualization system 10 can acquire operating data and loss data by receiving the signals output from the production equipment 71. In this case, the production equipment 71 is connected to the visualization system 10 in a communicable manner, either directly or via a relay device 60 such as a network hub, by, for example, a PLC (Programmable Logic Controller) or control device incorporated into the production equipment 71. Alternatively, if the production equipment 71 is not equipped with the function to output the aforementioned signals, the visualization system 10 can acquire operating data and loss data by having an operator input the operating data and loss data into external input devices 80, 91, and 92.

[0014] Operational data is data indicating the operation of production equipment 70, that is, data indicating whether or not production equipment 70 is in operation. Loss data is data indicating that production equipment 70 is in a loss state. Operational data may also include information on the period during which production equipment 70 is in operation, that is, information on the start time and end time of operation. Loss data may also include information on the period during which production equipment 70 is in a loss state, that is, information on the start time and end time of the loss.

[0015] In this embodiment, losses include the so-called seven major losses that are significant factors in degrading equipment efficiency: defective product losses, speed losses, abnormal product losses, stoppage losses, start-up losses, setup losses, and tool / jig losses. Defective product losses, also called rework losses, are losses caused by the occurrence of defective products or the rework of defective products. Speed ​​losses, also called performance losses, are losses caused by a decrease in the actual speed compared to the speed set in the production equipment 70. Abnormal product losses, also called failure losses, are losses caused by sudden or chronic abnormalities or failures in the production equipment 70.

[0016] Downtime loss is loss caused by the production equipment 70 being temporarily stopped or running idle. Startup loss is loss that occurs when starting up after periodic maintenance, after a long period of downtime, after a holiday, after a break, etc., and includes losses associated with warm-up, pre-cooling, and pre-heating operations. Setup loss is loss caused by changing or adjusting settings when switching between types and part numbers of products produced by the production equipment 70. Tool and jig loss, also called consumable replacement loss, is loss caused by replacing or switching consumables such as tools and jigs.

[0017] The display device 90 is, for example, an external device separate from the visualization system 10, and has a function of displaying images and videos. Note that the display device 90 may be incorporated into the visualization system 10. The personal computer 91, the mobile terminal 92, and the large display 93 shown in Figure 1 are examples of the external display device 90. Examples of the personal computer 91 include, for example, a stationary desktop personal computer and a portable notebook personal computer. Examples of the mobile terminal 92 include, for example, a smartphone and a tablet terminal. Further, the large display 93 is premised on being installed at a specific location, and can be configured with, for example, a display of about several tens of inches. In this case, a device provided with an input interface such as the personal computer 91 or the mobile terminal 92 also functions as an external input device. Further, a two-dimensional code reading device 80 can also be connected to the visualization system 10 as an external input device. In addition, the display device 90 can also be configured as a so-called wearable device such as a head-mounted display worn on the head by a worker or a smart watch worn on the arm.

[0018] Note that in the present embodiment, the left-right direction of the screen of the display device 90 means the left-right direction when viewed from the user. Further, the up-down direction of the screen of the display device 90 means the up-down direction when the screen of the display device 90 is stood vertically, and when the screen of the display device 90 is arranged horizontally, the side closer to the user is the lower side and the side farther away from the user is the upper side. Further, when the display device 90 is a device provided with an input interface such as the personal computer 91 or the mobile terminal 92, the worker can operate the display content displayed on the personal computer 91 or the mobile terminal 92 using the input interface of the personal computer 91 or the mobile terminal 92.

[0019] The visualization system 10 is configured to include a data acquisition processing unit 101 and a visualization processing unit 102. Each of the data acquisition processing unit 101 and the visualization processing unit 102 can be configured as a functional unit virtually implemented by executing a computer program on a CPU, for example. The data acquisition processing unit 101 and the visualization processing unit 102 may be configured with the same or common hardware, or may be configured with different hardware.

[0020] As shown in FIG. 2, the hardware configuration of the visualization system 10 can be configured to include a CPU 11, a main storage device 12, an auxiliary storage device 13, and an interface 14. The auxiliary storage device 13 stores a loss status visualization program 21 as a computer program for virtually implementing the data acquisition processing unit 101 and the visualization processing unit 102 on a computer. In the visualization system 10, the CPU 11 reads the loss status visualization program 21 from the auxiliary storage device 13, loads it into the main storage device 12, and executes it, whereby the data acquisition processing unit 101 and the visualization processing unit 102 can be virtually implemented on the computer respectively.

[0021] The auxiliary storage device 13 is constituted by a tangible and non-transitory computer-readable medium. Examples of the auxiliary storage device 13 include an HDD (Hard Disk Drive), an SSD (Solid State Drive), a magnetic disk, a magneto-optical disk, a CD-ROM (Compact Disc Read Only Memory), a DVD-ROM (Digital Versatile Disc Read Only Memory), a semiconductor memory, and the like. The auxiliary storage device 13 may be an internal medium directly connected to the bus of the computer constituting the visualization system 10, or may be an external medium connected to the visualization system 10 via the interface 14 or an electric communication line. Further, when the loss status visualization program 21 is distributed to the visualization system 10 via an electric communication line, the visualization system 10 that has received the distribution loads the loss status visualization program 21 into the main storage device 12 and executes it, whereby the respective processing units 101 and 102 described above are implemented.

[0022] Furthermore, the implementation of each processing unit 101 and 102 is not limited to the combination of the hardware and the loss status visualization program 21 described above. Each processing unit 101 and 102 may be implemented using hardware alone, such as an integrated circuit that implements the loss status visualization program 21, or some functions may be implemented with dedicated hardware, and the rest with a combination of hardware and the loss status visualization program 21.

[0023] The data acquisition processing unit 101 is capable of performing at least one or both of the following as data acquisition processes: automatic data acquisition processing or manual data acquisition processing. Automatic data acquisition processing is, for example, the process of acquiring operation data and loss data of production equipment 71 based on signals received from production equipment 71. Manual data acquisition processing is, for example, the process of acquiring operation data and loss data of production equipment 72 based on information input via external input devices 80, 91, and 92. In this embodiment, the data acquisition processing unit 101 is capable of performing both automatic data acquisition processing and manual data acquisition processing. The data acquisition processing unit 101 associates, for example, signals acquired from production equipment 71 and information input via external input devices 80, 91, and 92 with the time at which those signals or information were acquired, and stores them in an auxiliary storage device 13 or the like as operation data 22 or loss data 23, as shown in Figure 2.

[0024] The visualization processing unit 102 is capable of performing visualization processing. The visualization processing includes aggregating and visualizing operational data and loss data acquired by the data acquisition processing unit 101 and displaying them on the display device 90. In this case, the visualization processing unit 102 may be configured to directly control the display device 90, or it may be configured to output a program to control the display and indirectly control the display content of the display device 90 by executing that program on a computer that controls the display of the display device 90, for example, on a browser.

[0025] The visualization process includes aggregating the acquired operational data and loss data, and displaying the operational status information 30 and loss status information 40 on the display device 90. The visualization process includes aggregating the acquired operational data and loss data, and displaying the operational status information 30 and loss status information 40 simultaneously on the same screen of the display device 90, as shown in Figure 3, for example.

[0026] In this embodiment, the visualization process includes the process of displaying the operating status information 30 and the loss status information 40 side by side on the same screen, for example, vertically or horizontally. The operating status information 30 is information indicating the operating status of the production equipment 70 within a set load time. The load time is the time allocated to the production equipment 70 for production activities, and is calculated by subtracting the time when the production equipment is not operating, such as for morning meetings, breaks, cleaning, and planned shutdowns, from the operating time. The load time can be set and changed as appropriate by a user of the visualization system 10, for example, using the input interface 14.

[0027] In this embodiment, displaying two or more pieces of information on the same screen means that the two or more pieces of information or displays are all displayed on the same screen during the same period of time, that is, that the two or more pieces of information or displays are displayed on the same screen simultaneously. In this case, "same screen" refers to the screen of the display device under the control of the visualization processing unit 102, and is a concept that includes not only the screen of a single display device, but also the screens of two or more physically separated display devices. For example, a configuration that expands the display range and divides it into multiple display devices, such as a so-called dual display, can also be considered as displaying on the same screen.

[0028] Furthermore, displaying two or more pieces of information simultaneously does not require them to be strictly simultaneous; it is sufficient that the viewer perceives them as being displayed at the same time. For example, even if two or more pieces of information are displayed in short intervals, if the viewer can grasp both pieces of information simultaneously, that display method is included in the concept of simultaneous display in this embodiment.

[0029] Furthermore, the visualization system 10 can be configured to simultaneously display the operating status information 30 and the loss status information 40 on different display devices 90. For example, the system can be configured to display only the loss status information 40 on the personal computer 91 and only the operating status information 30 on the mobile terminal 92. In other words, the visualization system 10 can be configured to display the operating status information 30 and the loss status information 40 within the worker's field of view. In this case, the system can be configured to display both within the worker's field of view so that a worker who has seen one of the operating status information 30 or the loss status information 40 can immediately see the other if they wish. Furthermore, in this case, the visualization processing unit 102 that controls the display of the operating status information 30 and the visualization processing unit 102 that controls the display of the loss status information 40 may be configured to be independent of each other, that is, physically or electrically separated. Note that the dashed lines shown in Figures 3 and 4 virtually represent the areas of the operating status information 30 and the loss status information 40, and are not actually displayed on the display devices 90.

[0030] The operational status information 30 is information that mainly focuses on the operational status of the production equipment 70. Note that the operational status information 30 does not need to consist solely of information regarding the operational status; it may also include information regarding loss status. As shown in Figure 3, the operational status information 30 includes, for example, status information 31, overall equipment efficiency information 32, load time information 33, and an operational status graph 34. Status information 31 indicates the current operational status of the production equipment 70. In this embodiment, status information 31 indicates whether the production equipment 70 is currently operating or stopped, and if stopped, the reason for the stop. In this case, status information 31 displays the word "Operating" if the production equipment 70 is currently operating, and the word "Stopped" if the production equipment 70 is currently stopped. Note that status information 31 may also be displayed using colors, for example, along with or in place of the above-mentioned words.

[0031] The Overall Equipment Efficiency (AQE) information 32 is information that numerically represents the AQE of the production equipment 70. AQE can be calculated using the formula in Figure 6. AQE represents the overall efficiency including the so-called seven major losses mentioned above, and is used as one of the indicators of reliability of production equipment and production lines. The load time information 33 is information that numerically represents the load time during a period from a certain reference point, such as the start time of operation on a given day, to the present. Since loss information is also necessary for calculating AQE, it can be said that AQE effectively includes information on loss conditions.

[0032] The operating status graph 34 is a graph that graphically shows the operating status of the production equipment 70 over time during the load period. The operating status graph 34 is composed of a so-called stacked bar graph. The operating status graph 34 is information that shows the history of the operating status and loss status of the production equipment 70 up to the present. In this embodiment, the operating status graph 34 is composed of a horizontal bar graph with time on the horizontal axis. In this case, the left end of the horizontal bar 34a of the operating status graph 34 shows the state at the start of operation. The right end of the horizontal bar 34a shows the state at the current time. In this case, the horizontal bar 34a extends to the right as time progresses.

[0033] The bars 34a of the operational status graph 34 are composed of an operational area 341 indicating the time period during which the production equipment 70 was in operation, and a loss area 342 indicating the time period during which the production equipment 70 experienced losses. In this embodiment, the bars 34a of the operational status graph 34 are composed of an operational area 341 and a loss area 342. The bars 34a of the operational status graph 34 are colored differently for the operational area 341 and the loss area 342. In this case, the operational area 341 is preferably colored with a color that evokes safety, such as green or blue. The loss area 342 is preferably colored with a color that attracts attention, such as orange or red. Note that if the operating time or loss time is 0, the operational area 341 or loss area 342 where the time is 0 is not displayed in the operational status graph 34. Since loss information is also necessary to draw the operational status graph 34, it can be said that the operational status graph 34 substantially includes information on loss situations.

[0034] Loss status information 40 is information that mainly focuses on the loss status of the production equipment 70. Note that loss status information 40 does not need to consist solely of information regarding loss status; it may also include information regarding operating status. Loss status information 40 includes, for example, a percentage graph 41, a breakdown graph 42, and history information 43. In this embodiment, the visualization processing unit 102 arranges the percentage graph 41, the breakdown graph 42, and the history information 43 on a straight line on the screen, in this case, displaying them side-by-side along the long side of the screen. Furthermore, the visualization processing unit 102 displays the percentage graph 41 and the breakdown graph 42 adjacent to each other, that is, without placing any other information between the percentage graph 41 and the breakdown graph 42.

[0035] The ratio graph 41 shows the ratio of operation to loss during the load period for the production equipment 70, that is, the ratio of the total operating time during which the production equipment 70 was operating to the total loss time during which losses occurred. The breakdown graph 42 shows the breakdown of the loss time that occurred during the load period, that is, the breakdown of the loss time included in the ratio graph 41. The ratio graph 41 and the breakdown graph 42 can be constructed using, for example, a pie chart, a donut chart, or a bar graph.

[0036] The ratio graph 41 is composed of an operating area 411 showing the total time the production equipment 70 was operating during the load period, and a loss area 412 showing the total time the production equipment 70 experienced losses during the load period. In this embodiment, the ratio graph 41 is composed of an operating area 411 and a loss area 412. In this case, the ratio of the operating area 411 to the loss area 412 in the ratio graph 41 is equal to the ratio of the operating area 341 to the loss area 342 in the horizontal bar 34a of the operating status graph 34.

[0037] The ratio graph 41 is colored differently for the operating area 411 and the loss area 412. In this case, the operating area 411 is preferably colored with a color that evokes safety, such as green or blue. The loss area 412 is preferably colored with an attention-grabbing color, such as orange or red. In this embodiment, the operating area 411 and the loss area 412 of the ratio graph 41 are colored with the same colors as the operating area 341 and the loss area 342 of the operating status graph 34. Note that if the operating time or loss time is 0, the operating area 411 or the loss area 412 where the time is 0 is not displayed in the ratio graph 41. Since the operating status is also necessary to draw the ratio graph 41, it can be said that the ratio graph 41 substantially includes information about the operating status.

[0038] The breakdown graph 42 is composed of detail areas that show the details of the losses. The breakdown graph 42 is colored differently in each detail area. The detail areas include, for example, a defective loss area, a speed loss area, an abnormal loss area, a stop loss area, a start-up loss area, a setup loss area, and a cutting tool / jig loss area. In this embodiment, the breakdown graph 42 shown in Figure 3 displays, for example, a defective loss area 421, a setup loss area 422, a speed loss area 423, an abnormal loss area 424, and a start-up loss area 425 as detail areas. In this case, stop losses and cutting tool / jig losses are not displayed in the breakdown graph 42 because the time for each loss is 0 or not set. The visualization processing unit 102 may also display the name of the detail area and the loss time when the cursor 55 is moved to each detail area or each detail area is touched, for example, as shown in Figure 3.

[0039] History information 43 provides a list of the most recent events that occurred in the production equipment 70. Events that occurred in the production equipment 70 include the operation and shutdown of the production equipment 70. For example, in addition to "Operating," which indicates that the production equipment 70 is in operation, there are also losses in the production equipment 70 that can be determined from the current state of the production equipment 70, such as "Abnormal," "Stopped," "Starting Up," "Setting Up," and "Cutting Tool / Jig Change." The most recent history refers to the number of history entries that can be displayed on the display device 90, going backward from the most recent one. History information 43 includes the fields "Name," "Event No.," and "Event Time."

[0040] "Name" is the name of the event that occurred in production equipment 70. "Abnormal" indicates that an abnormality occurred in production equipment 70. "Stopped" indicates that production equipment 70 was stopped. "Starting up" indicates that production equipment 70 was starting up. "Setting up" indicates that production equipment 70 was being set up. "Cutting tool / jig replacement in progress" indicates that cutting tools or jigs in production equipment 70 were being replaced. "Event No." is a number indicating the event that occurred in production equipment 70, namely "Operating," "Abnormal," "Stopped," "Starting up," "Setting up," and "Cutting tool / jig replacement in progress." Note that the content of the event, i.e., the "Name" of the event, may match the details of the loss, but does not necessarily have to. "Event Time" indicates the time when the above-mentioned event occurred. Since the operating status is also necessary to generate the history information 43, it can be said that the history information 43 essentially includes information about the operating status.

[0041] The visualization processing unit 102 displays a predetermined number of history entries in chronological order, starting with the most recent, for the display of history information 43. In the example shown in Figure 3, the visualization processing unit 102 displays 10 history entries in chronological order, starting with the most recent. Then, for example, if a new event occurs in the production equipment 70 in the state shown in Figure 3, the bottom row of the history information 43 disappears, each row moves down by one position, and the most recent history entry is added to the top.

[0042] Furthermore, the data acquisition processing unit 101 is configured to acquire operational data and loss data related to the production equipment 71 based on the output signals from the production equipment 71, in the case of production equipment 71 having a communication function. That is, in the case of production equipment 71 having a communication function, the production equipment 71 outputs a signal that indicates the current state of the production equipment 71, that is, an event currently occurring.

[0043] This signal includes at least an operating signal and an abnormal signal. The operating signal indicates that the production equipment 70 is in operation, i.e., running. The abnormal signal indicates that an abnormality has occurred in the production equipment 71, and abnormal losses can be measured. Other signals include cycle trigger signals, planned stop signals, setup signals, and tool / jig signals. The cycle trigger signal indicates the start and end of the cycle of the production equipment 71, and the current cycle time can be measured, thereby allowing for the measurement of speed losses. The planned stop signal indicates that the production equipment 71 is undergoing a planned stop, and stops other than losses can be measured. The setup signal indicates that the production equipment 71 is in the process of setup, and setup losses can be measured. The tool / jig signal indicates that the production equipment 71 is changing a tool or jig, and tool / jig losses can be measured.

[0044] Furthermore, the data acquisition processing unit 101 is configured to acquire operational data and loss data related to production equipment 72 that does not have communication functions, based on input from the worker. In this case, the data acquisition processing unit 101 can acquire operational data and loss data by two methods: input to a personal computer 91 or a mobile terminal 92, and input using a two-dimensional code reader 80.

[0045] In the case of input methods for a personal computer 91 or a mobile terminal 92, the visualization processing unit 102 displays start buttons 511, 512, and 513, and end buttons 521, 522, and 523 on the screen of the display device 90, as shown in Figure 4. The operator can register the start and end of losses and planned stoppages corresponding to each button 511-513 and 521-523 by clicking or touching the start buttons 511, 512, and 513 and the end buttons 521, 522, and 523, for example, using a cursor.

[0046] The data acquisition processing unit 101 acquires loss time, i.e., loss data, related to setup loss and jig / cutting tool loss, based on the operator's operation of the start buttons 511 and 512 and the end buttons 521 and 522. The data acquisition processing unit 101 also acquires the planned stop time based on the operation of the start button 513 and the end button 523, which correspond to planned stoppages. Then, the data acquisition processing unit 101 calculates the load time from the acquired planned stoppage time, and calculates and acquires the operating time, i.e., operating data, from that load time and loss time.

[0047] In this case, the start button 511 and end button 521 displayed near the word "setup" are buttons for registering the start and end of setup loss, and function as loss start and loss end buttons, respectively. Similarly, the start button 512 and end button 522 displayed near the word "fixture / tool ​​change" are buttons for registering the start and end of fixture / tool ​​loss, and function as loss start and loss end buttons, respectively. And the start button 513 and end button 523 displayed near the word "planned stop" are buttons for registering the start and end of planned stop.

[0048] In the input method using the two-dimensional code reader 80, the data acquisition processing unit 101 displays the start codes 531, 532, and 533, and the end codes 541, 542, and 543 on, for example, a personal computer 91 or a mobile terminal 92, as shown in Figure 4. The start codes 531, 532, and 533 and the end codes 541, 542, and 543 may also be printed on paper or the like. By reading the start codes 531, 532, and 533 and the end codes 541, 542, and 543 with the two-dimensional code reader 80, the operator can register the start and end of losses and planned stoppages corresponding to each code 531-533 and 541-543.

[0049] Specifically, the data acquisition processing unit 101 reads start codes 531 and 532 and end codes 541 and 542 to acquire loss time, or loss data, related to setup loss and jig / cutting tool loss. The data acquisition processing unit 101 also reads start code 533 and end code 543, which correspond to planned downtime, to acquire the planned downtime. Then, the data acquisition processing unit 101 calculates the load time from the acquired planned downtime, and calculates and acquires the operating time, or operating data, from the load time and loss time.

[0050] The visualization processing unit 102 displays a toggle button 56, as shown in Figures 3 and 4. Based on the operation of the toggle button 56, the visualization processing unit 102 switches the display content between Figure 3 and Figure 4. The visualization processing unit 102 also processes the display of the date display 57 and the time display 58 on the same screen as the operating status information 30 and the loss status information 40, as shown in Figure 3. The date display 57 shows the current date. The time display 58 shows the current time or the time when the last abnormal status data was acquired.

[0051] Next, with reference to Figure 5, the control flow executed by the visualization system 10 will be described. Prior to the series of processes in the visualization system 10, the user sets the operating time as described above. When the visualization system 10 starts processing, it moves to step S11 and acquires the pre-set operating time. Next, in step S12, the visualization system 10 determines whether the operating time has elapsed. If the operating time has not elapsed (YES in step S12), the visualization system 10 terminates the series of processes. On the other hand, if the operating time has not elapsed (NO in step S12), the visualization system 10 moves to step S13. Then, the visualization system 10 executes data acquisition processing using the functions of the data acquisition processing unit 101 and acquires the operation data and loss data of the production equipment 70.

[0052] Subsequently, the visualization system 10 moves the process to step S14. The visualization system 10 then performs visualization processing using the functions of the visualization processing unit 102, and displays the operating status information 30 and the loss status information 40 on the same screen of the display device 90, as shown in Figure 3. After that, the visualization system 10 returns the process to step S12 and repeats the steps from step S12 onward.

[0053] For example, if an operator were to manually measure the downtime of production equipment, they would need to measure the time for each cause of downtime using a stopwatch, and then record the results on paper or as data. In this case, the operator would need to be constantly present at the production equipment in question, which is inefficient. Therefore, with the conventional setup, it was difficult to track downtime for each cause of downtime of production equipment.

[0054] In contrast, according to the embodiment described above, the visualization system 10 is a system that visualizes the loss status of the production equipment 70 and displays it on the display device 90. The visualization system 10 comprises a data acquisition processing unit 101 and a visualization processing unit 102. The data acquisition processing unit 101 is capable of executing data acquisition processing. The data acquisition processing includes the process of acquiring operation data indicating the operation of the production equipment 70 and loss data indicating the loss of the production equipment 70.

[0055] The visualization processing unit 102 is capable of performing visualization processing. The visualization processing includes aggregating the acquired operational data and loss data and displaying operational status information 30, which shows the operational status of the production equipment 70 within a set load time, and loss status information 40, which shows the loss status of the production equipment 70 within the load time, on the same screen of the display device 90.

[0056] According to this, operating status information 30 showing the operating status of the production equipment 70 and loss status information 40 showing the loss status are displayed on the same screen of the display device 90, so that workers can easily grasp the operating status and loss status of the production equipment 70.

[0057] Furthermore, in the visualization system 10, losses include defective losses, speed losses, abnormal losses, stop losses, start-up losses, setup losses, and tool / jig losses. According to this, by viewing the loss status information 40 displayed on the display device 90, the operator can grasp the status of the so-called seven major losses, which are significant factors in reducing production efficiency. Therefore, the operator can easily obtain information that is useful for improving work efficiency.

[0058] The loss status information 40 includes a ratio graph 41 showing the ratio of the operating time during which the production equipment 70 was operating to the loss time during which losses occurred, and a breakdown graph 42 showing the breakdown of the loss time. According to this, workers can easily grasp the ratio of losses to the total operating time by first looking at the ratio graph 41. Furthermore, by looking at the breakdown graph 42, workers can easily identify the type of loss that accounts for a large proportion and is a cause of decreased production efficiency, that is, the type of loss that should be addressed as a priority.

[0059] Loss status information 40 further includes historical information 43. Historical information 43 provides a list of the most recent history of events that occurred in the production equipment 70. This allows workers to easily understand the current behavior of the production equipment 70 by looking at the historical information 43 in conjunction with, for example, the percentage graph 41 or the breakdown graph 42, and as a result, to more easily develop countermeasures against losses.

[0060] The operating status information 30 further includes equipment overall efficiency information 32, load time information 33, and an operating status graph 34. The equipment overall efficiency information 32 is information showing the overall efficiency of the equipment. The load time information 33 is information showing the load time set for the production equipment 70. The operating status graph 34 shows the changes in the operating status of the production equipment 70 over time, that is, the changes in the operating status over time, in a graph. According to this, by looking at the operating status graph 34, the worker can visually grasp the changes in the operating status of the production equipment 70, and furthermore, by looking at the equipment overall efficiency information 32 and load time information 33, they can accurately grasp the equipment overall efficiency and load time, which are important for evaluating equipment efficiency, in numerical terms. As a result, the worker can quickly, accurately, and easily grasp the production efficiency of the production equipment 70.

[0061] In some older production facilities, there is no function to output signals for operation and shutdown. In such cases, it is possible to add signal output functionality by modifying the production facility. However, when production facilities are modified, production is suspended during the modification period. Therefore, it is often difficult to find time to carry out such modifications while being busy with daily production activities. In addition, depending on the production facility, there may be no free memory in the computer that is built into the facility, making it impossible to add new programs.

[0062] Therefore, according to this embodiment, the data acquisition processing unit 101 is configured to acquire operation data and loss data based on output signals from the production equipment 70, and is also configured to acquire operation data and loss data based on input from the worker.

[0063] According to this, the visualization system 10 can not only automatically acquire operational data and loss data from the production equipment 70, but can also acquire operational data and loss data through input from the worker. As a result, even older production equipment that does not have a signal output function can be used with the visualization system 10 without modification.

[0064] The visualization process includes displaying loss start buttons 511 and 512 for registering the start of loss and loss end buttons 521 and 522 for registering the end of loss on the display device 90. The data acquisition process includes acquiring loss data based on the operation input to the loss start buttons 511 and 512 and the loss end buttons 521 and 522. As a result, the operator can register loss data simply by operating the respective buttons 511, 512, 521, and 522 displayed on the display device 90, improving the efficiency of loss data registration. Consequently, the operator can use the visualization system 10 without hindering their original production activities.

[0065] Furthermore, the data acquisition process includes a process in which the operator reads loss start codes 531 and 532, which are two-dimensional codes indicating the start of loss, and loss end codes 541 and 542, which are two-dimensional codes indicating the end of loss, using the reader device 80 to acquire loss data. This also allows the operator to register loss data simply by reading each code 531, 532, 541, and 542 with the reader device 80, improving the efficiency of loss data registration. As a result, the operator can use the visualization system 10 without hindering their original production activities.

[0066] (Second Embodiment) Next, a second embodiment will be described with reference to Figures 7 and 8. In the second embodiment, the specific details of the visualization process differ from those of the first embodiment, while other configurations are the same as those of the first embodiment. The visualization process of this embodiment includes a process of switching between operating status information 30 as shown in Figure 7 and loss status information 40 as shown in Figure 8, either automatically or based on operator input, and displaying them on the display device 90.

[0067] When switching between the operational status information 30 and the loss status information 40 automatically, the visualization processing unit 102 switches and displays the operational status information 30 and the loss status information 40 at intervals that allow the viewer to perceive that they are not displayed simultaneously, such as every few seconds to tens of seconds. Furthermore, when switching between the operational status information 30 and the loss status information 40 based on operator operation, the visualization processing unit 102 switches the display between the operational status information 30 shown in Figure 7 and the loss status information 40 shown in Figure 8 based on the operation of the switching buttons 591 and 592.

[0068] According to this, compared to the case where the operating status information 30 and the loss status information 40 are displayed simultaneously on the screen of a single display device 90, for example, a wider display area can be secured for each of the operating status information 30 and the loss status information 40. In other words, the operating status information 30 and the loss status information 40 can be displayed on a larger scale. As a result, the visibility of the operating status information 30 and the loss status information 40 is improved, and as a result, the loss situation can be grasped easily and accurately.

[0069] In this case, the color, shape, size, or position of the toggle button 591 for switching from operating status information 30 to loss status information 40, and the toggle button 592 for switching from loss status information 40 to operating status information 30 may be changed. Figures 7 and 8 show examples where the shape of the toggle buttons 591 and 592 is changed, but their position and size remain the same. In addition, other displays different from the operating status information 30 and loss status information 40 may be inserted in the middle of the switch between the operating status information 30 and loss status information 40.

[0070] (Third embodiment) Next, a third embodiment will be described with reference to Figure 9. In this embodiment, the data acquisition processing unit 101 executes a data acquisition process to acquire loss data indicating the loss of the production equipment 70. In this embodiment, the acquisition of operational data is not essential for the data acquisition processing unit 101. Furthermore, the visualization process executed by the visualization processing unit 102 includes a process to aggregate the acquired loss data and display loss status information 40A, which indicates the loss status of the production equipment 70 within a set load time, on the display device 90. In this case, the loss status information 40A consists only of information that does not include information regarding the operational status, i.e., information regarding the loss status.

[0071] Loss status information 40A may consist of, for example, loss list information 44. Loss list information 44 may consist of, for example, a table including loss type 441, percentage display 442, and time display 443. Loss type 441 indicates the type of loss in a manner other than a graph, such as letters, numbers, symbols, or colors. Percentage display 442 indicates, for example, the breakdown graph 42 of Figure 3 in a manner other than a graph, such as letters, numbers, symbols, or colors. Time display 443 indicates the percentage display 442 converted to time in a manner other than a graph, such as letters, numbers, symbols, or colors.

[0072] In this embodiment, the percentage display 442 and the time display 443 are displayed using numbers and colors. In the example shown in Figure 9, the percentage display 442 and the time display 443 are set to different colors in several stages, for example, depending on the magnitude of the numerical value. For example, the percentage display 442 can be set to different colors in four stages: 0% or more but less than 5%, 5% or more but less than 10%, 10% or more but less than 20%, and 20% or more. In this case, the color can be made darker as the numerical value of the percentage display 442 increases, or the colors can be set in the order of blue or green, yellow or red, from small to large values.

[0073] Furthermore, the visualization processing unit 102 may automatically or based on operator input sort and display each row, which consists of the loss type 441, the percentage display 442, and the time display 443, in descending or ascending order based on the percentage display 442 or the time display 443. This embodiment also provides the same effects and advantages as those of the embodiments described above.

[0074] This disclosure is described in accordance with the embodiments, but it is understood that this disclosure is not limited to such embodiments or structures. This disclosure also includes various modifications and variations within the equivalence. In addition, various combinations and forms, as well as other combinations and forms that include only one, more, or fewer of those elements, fall within the scope and concept of this disclosure. [Explanation of Symbols]

[0075] 10...Production equipment loss status visualization system, 101...Data acquisition processing unit, 102...Visualization processing unit, 22...Operation data, 23...Loss data, 30...Operation status information, 32...Overall equipment efficiency information, 33...Load time information, 34...Operation status graph, 40...Loss status information, 41...Percentage graph, 42...Breakdown graph, 43...History information, 511, 512...Loss start button, 521, 522...Loss end button, 531, 532...Loss start code, 541, 542...Loss end code, 70, 71, 72...Production equipment, 80...Reading device, 90, 91, 92, 93...Display device

Claims

1. This is a system that visualizes the loss status of production equipment. A data acquisition processing unit capable of executing a data acquisition process to acquire operational data indicating the operation of the production equipment and loss data indicating the loss of the production equipment, The system includes a visualization processing unit capable of aggregating the acquired operational data and loss data and performing visualization processing to display operational status information, which shows the operational status of the production equipment within a set load time, and loss status information, which shows the loss status of the production equipment within the load time, on a display device. The visualization process includes a process for simultaneously displaying the operating status information and the loss status information on different display devices. A system for visualizing the loss status of production equipment.

2. This is a system that visualizes the loss status of production equipment. A data acquisition processing unit capable of executing a data acquisition process to acquire operational data indicating the operation of the production equipment and loss data indicating the loss of the production equipment, The system includes a visualization processing unit capable of aggregating the acquired operational data and loss data and performing visualization processing to display operational status information, which shows the operational status of the production equipment within a set load time, and loss status information, which shows the loss status of the production equipment within the load time, on a display device. The aforementioned losses include defective losses, speed losses, abnormal losses, stop losses, start-up losses, setup losses, and tool / jig losses. A system for visualizing the loss status of production equipment.

3. This is a system that visualizes the loss status of production equipment. A data acquisition processing unit capable of executing a data acquisition process to acquire operational data indicating the operation of the production equipment and loss data indicating the loss of the production equipment, The system includes a visualization processing unit capable of aggregating the acquired operational data and loss data and performing visualization processing to display operational status information, which shows the operational status of the production equipment within a set load time, and loss status information, which shows the loss status of the production equipment within the load time, on a display device. The aforementioned operating status information further includes overall equipment efficiency information that numerically indicates the overall equipment efficiency, load time information that numerically indicates the load time, and an operating status graph that graphically shows the changes in the operating status of the production equipment during the load period. A system for visualizing the loss status of production equipment.

4. This is a system that visualizes the loss status of production equipment. A data acquisition processing unit capable of executing a data acquisition process to acquire operational data indicating the operation of the production equipment and loss data indicating the loss of the production equipment, The system includes a visualization processing unit capable of aggregating the acquired operational data and loss data and performing visualization processing to display operational status information, which shows the operational status of the production equipment within a set load time, and loss status information, which shows the loss status of the production equipment within the load time, on a display device. The data acquisition processing unit is configured to acquire the operation data and the loss data based on input from the operator. The data acquisition process includes a process in which an operator reads a loss start code, which is a two-dimensional code indicating the start of the loss, and a loss end code, which is a two-dimensional code indicating the end of the loss, using a reader to acquire the loss data. A system for visualizing the loss status of production equipment.

5. This is a system that visualizes the loss status of production equipment. A data acquisition processing unit capable of executing a data acquisition process to acquire loss data indicating the losses of the aforementioned production equipment, The system includes a visualization processing unit capable of aggregating the acquired loss data and performing visualization processing to display loss status information, which shows the loss status of the production equipment within a set load time, on a display device. The aforementioned losses include defective losses, speed losses, abnormal losses, stop losses, start-up losses, setup losses, and tool / jig losses. A system for visualizing the loss status of production equipment.

6. The visualization process includes a process for displaying the operating status information and the loss status information on the same screen of the display device. A system for visualizing the loss status of production equipment according to any one of claims 2 to 4.

7. The visualization process includes a process of switching and displaying the operating status information and the loss status information on the display device automatically or based on the operator's operation. A system for visualizing the loss status of production equipment according to any one of claims 2 to 4.

8. The loss status information includes a ratio graph showing the ratio of the operating time during which the production equipment was operating and the loss time during which the loss occurred, and a breakdown graph showing the ratio of the breakdown of the loss time. A system for visualizing the loss status of production equipment according to any one of claims 1 to 5.

9. The aforementioned loss status information further includes historical information that lists the most recent history of events that occurred in the production equipment. A system for visualizing the loss status of production equipment according to claim 8.

10. The visualization process includes a process of displaying a loss start button for registering the start of the loss and a loss end button for registering the end of the loss on the display device, The data acquisition process includes a process for acquiring the loss data based on the operation input to the loss start button and the loss end button. A system for visualizing the loss status of production equipment according to claim 4.

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