Line Management Control for Network-Failure Production Continuity
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Solution Overview
Problem
The existing manufacturing systems face disruptions when a network failure occurs between the centralized management apparatus and a manufacturing line, leading to potential production halts due to the inability to download control data, which affects the reliability of managing multiple manufacturing lines.
Innovation Solution
A manufacturing system with a line management device that pre-acquires control data from a centralized management apparatus and continues production using locally stored data in case of network failures, while also temporarily saving quality data for transmission after the failure is resolved, ensuring continuous operation and reliable data management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If control data is managed by a centralized management apparatus, then data consistency across multiple manufacturing lines is improved, but production reliability deteriorates when network failure occurs
Solution Approach 1:
The line management device performs preliminary action by acquiring and storing control data locally from the centralized management apparatus before network failure occurs. This pre-acquisition ensures that when network failure happens, the manufacturing line can continue operation using the stored control data, thus resolving the contradiction between centralized data management and production reliability during network failures.
2Loss of information
If control data is downloaded from centralized management apparatus during operation, then data freshness is improved, but production continuity deteriorates when network failure occurs
Solution Approach 1:
The system performs preliminary action by acquiring control data in advance before network failure occurs. The line management device stores this data locally, ensuring that production can continue without interruption even when the network is unavailable. This resolves the contradiction between maintaining data freshness and ensuring production continuity during network failures.
3Measurement precision
If quality data is transmitted to centralized management apparatus in real-time, then data accuracy is improved, but system reliability deteriorates when network failure occurs
Solution Approach 1:
The line management device performs preliminary action by storing quality data locally when network failure is detected, rather than attempting real-time transmission. This ensures that quality data is preserved and can be transmitted later when the network is restored, resolving the contradiction between real-time data accuracy and system reliability during network failures.
Solution Approach 2:
The system provides beforehand cushioning by implementing a local storage buffer for quality data at the line management device. This buffer acts as a cushion that prevents data loss during network failures, allowing the system to maintain reliability by preserving data integrity until network connectivity is restored.
Data Source
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AI summary
To provide a manufacturing system that is capable of still continuing work in a case in which a failure occurs in the network connection between the centralized management apparatus and a manufacturing line and a control method of the manufacturing system. When activation of all of the work machines (a screen printer 22, and the like) in a manufacturing line 11A is completed, a line management device 26 acquires, from a centralized management apparatus 13, material data D1 and control data D2 required in one day of manufacturing of the manufacturing line 11A. Further, in a case in which a failure in a wide area network WAN that connects the line management device 26 and a centralized management apparatus 13 is detected, the line management device 26 causes a manufacturing work of mounting boards by a work machine to be continued on the basis of the control data D2, and the like, corresponding to one day, which is saved in advance.