JP5973380B2 - Production index extraction apparatus and program - Google Patents

Description

  The present invention relates to a production index extraction device and a program.

  In Patent Literature 1, a processing target group having a processing end time at a predetermined interval is generated from log information of the production apparatus, and the processing target included in the group is set as the processing target included in the group. It is described that classification is made according to the number, and for each classification, cycle time information for identifying the cycle time included in the classification is generated to identify the production capacity of the production apparatus.

  Patent Document 2 discloses a data storage unit that collects actual data indicating the actual number of substrates processed in the completed work and the actual work time required for the completed work, and the work required for the process of processing the substrate. An event information collection unit that collects event information related to events that affect time, a work number collection unit that collects the number of boards to be processed in unexecuted work, and is not performed based on actual data, event information, and the number of sheets It has a standard work time calculation unit that calculates the standard work time required for work, and when an event that affects work time occurs, it can more accurately estimate the standard work time of unexecuted work to be performed It is described that it is possible to more accurately predict the operating status of the manufacturing processing apparatus in which the line that performs the unexecuted work is operating.

JP 2011-18263 A JP 2009-9380 A

  In factories that produce products, in general, in order to make a production plan, a production amount or the like is predicted using simulation. This simulation predicts a production device used in each production process, a time to be put in each production device, and the like for a product to be produced. In order to execute the simulation, the operator has to manually input indices that specify the capacity of the production equipment used in each production process, and preparations are required in large-scale factories and factories that produce a wide variety of products. The problem was that the man-hours increased.

  However, there are cases where the start time is not started immediately after the start time is entered, or the end time is not entered immediately after the end of the process. . In such a case, in the invention described in Patent Document 1, since the time waiting for processing, the time waiting for input of processing end, and the like are included between the start time and the end time, the cycle time of the processing is specified. It may be difficult to do. Here, the cycle time refers to a time required for one process in a work repeatedly performed (product production in this case). For example, the time from the start to finish of a certain product is the cycle time of this product.

  On the other hand, in the invention described in Patent Document 2, for each production device or process, an elapsed time between the start time at which processing is started on the processing target and the end time at which processing on the processing target is ended, that is, log An upper limit value and a lower limit value of possible work times calculated from the information are prepared in advance, and the standard processing time is calculated from log information excluding logs having work times not included in this range. Therefore, in the invention described in Patent Document 2, as in the invention described in Patent Document 1, a time waiting for processing, a time waiting for input of processing end, and the like are included between the start time and the end time. There is no.

  However, since the invention described in Patent Document 2 needs to prepare an upper limit value and a lower limit value of the elapsed time in advance, in a large-scale factory, a factory taking a form of multi-product low-volume production, etc. There is a problem that preparing the upper limit value and the lower limit value is as difficult as manually managing the cycle time. In addition, in the invention described in Patent Document 2, if the management of the range of values that can be taken from the log information cannot be properly managed, the cycle time cannot be estimated correctly, and this cycle time is input. There is a problem that the accuracy of the simulation is lowered and proper production management cannot be performed.

  The invention described in Patent Document 2 employs a method of removing abnormal values (outliers) included in log information with a histogram. This removal method can accurately estimate both the processing format and processing time in a factory where the production form is mass-produced and the infrastructure for acquiring log information is in place and a large amount of log information with relatively good properties can be obtained. It was. However, in small-quantity products that take the form of individual order production or high-variety medium-mass-product factories that do not have an infrastructure for acquiring log information, log information is input in multiple processes. As described above, if there is a time difference between the input of the start time and the actual process start time, or if the process ends, the end time is not input immediately, and the actual process end time is input. There are many cases where there is a time difference between the end times. If the outlier removal method using the histogram as in the invention described in Patent Document 2 is adopted for log information including outliers due to such summary input or forgetting to input, it is set to draw the histogram. Since the characteristics of the data remarkably change depending on the number and width of the bins, the cycle time cannot be estimated correctly, and there is a problem that the accuracy of simulation using this cycle time as input decreases, and appropriate production management cannot be performed.

  Therefore, an object of the present invention is to provide a production index extraction device and a program that can accurately estimate a cycle time.

In order to solve the above problems, a production index generation device according to the present invention includes a storage unit storing log information including a start time and an end time of production of a product by a production device, and a cycle time based on the log information. A control unit that generates information, and an output unit that outputs the cycle time information or information based on the cycle time information, and the control unit includes the start time for each piece of information included in the log information. An actual measurement work time is calculated from the end time, and each piece of information included in the log information is classified into one of a plurality of groups based on the calculated actual operation time, and is included in the log information For each piece of information, the abnormal value included in the measured work time is removed according to the classified group, and the measured value is removed when the abnormal value is removed. Based on, generates cycle time information related to the predetermined production device and the predetermined varieties, the control unit on the basis of the variation of the median and the actual working time of the actual operation time, it included in the log information Each piece of information is classified into one of a plurality of groups .

  According to the present invention, the cycle time can be estimated with high accuracy.

1 is an example of a configuration diagram of a production index information generation system 10. FIG. 1 is an example of a schematic diagram of a production index information extraction device 100. FIG. It is an example of the log information table 111a. It is an example of the process route information table 112a. It is an example of the cycle time information table 113a. It is an example of the in-process information table 114a. It is an example of the input plan table 115a. It is an example of the production apparatus maintenance plan table 116a. It is an example of the production apparatus information table 117a. It is an example of the production index information table 118a. 2 is a schematic diagram of a hardware configuration for realizing a production index information extraction device 100. FIG. 4 is a flowchart showing processing of the production index information extraction device 100. It is a flowchart which shows a reference value specific process. It is an example of the histogram of the working time in a certain factory data. It is an example of the histogram of the working time in a certain factory data. It is the schematic which shows the output pattern of work time distribution information. It is an example of the classification method of work time distribution. It is the schematic of the method of specifying a reference value with respect to the work time distribution corresponding to pattern 1. It is the schematic of the method of specifying a reference value with respect to the work time distribution corresponding to the pattern 2. 10 is a schematic diagram of a method for specifying a reference value for a work time distribution corresponding to Pattern 3. FIG. 10 is a schematic diagram of a method for specifying a reference value for a work time distribution corresponding to pattern 4. FIG. It is an example of the schematic diagram which shows the output pattern of the cycle time information which estimates the number dependence of work time from the reference value for every number contained in the specified process. It is an example of the schematic which shows the output pattern of cycle time information. It is an example of the schematic which shows the output pattern of cycle time information. It is an example of the schematic diagram which shows the output pattern of production amount prediction information.

Hereinafter, embodiments will be described with reference to the drawings.
FIG. 1 is a schematic diagram of a production index information generation system according to this embodiment.

  The production index information generation system 10 includes a production index information extraction device 100, a plan information management device 160, a production site management device 170, a production information management device 180, and a simulation device 190, which are connected via a network 199. Thus, information can be transmitted and received between each other.

  The production index information extraction apparatus 100 generates a production index based on information acquired from the plan information management apparatus 160, the production site management apparatus 170, the production information management apparatus 180, and the like. The production index information extraction device 100 will be described in detail later.

  The plan information management device 160 manages all plans related to manufacturing, such as product shipment plans, new product input plans, production device maintenance plans, worker attendance plans, and worker placement plans. Then, the plan information is transmitted to the production index information extracting apparatus 100 when it is determined in advance or in response to a request from the production index information extracting apparatus 100.

  The production site management device 170 transmits log information to the production index information extraction device 100 when determined in advance or in response to a request from the production index information extraction device 100. Note that one production site management device 170 may manage the work performance information of all production sites, and a plurality of production site management devices 170 may be installed as many as the number of production sites.

  The production information management device 180 manages production capacity of each process, process route information for each product, process route information such as a production device that can be processed, and the like, or a request from the production index information extraction device 100 when determined in advance. In response, the production capacity and process route information are transmitted to the production index information extraction apparatus 100. Further, the production information management device 180 manages the extraction result of the production capacity and the process route information transmitted from the production index information extraction device 100.

  The simulation apparatus 190 creates a simulation model of a production process in a factory on a computer. In the model, according to various process rules for each product type and various dispatch rules for determining the processing priority between products, the progress caused by production equipment, workers, and other products By reproducing the above restrictions on a computer, the time transition of the entire production line and production process is simulated, and a progress plan for all products input to the production line is created. Various statistical values such as products / variety types, processes, processes, production devices, and workers can be output as production index information from the progress plans of all manufactured products.

  The actual information to be considered in the simulation model is predicted to differ in the accuracy of the simulation result depending on the accuracy, but in this embodiment, it is used without specifying the simulation method of the existing simulator And For example, a discrete event type simulation method is generally used for simulation of a production process in a factory.

  In addition, when creating a simulation model, an input specification specific to the present embodiment is provided, and data including the simulation model including data input according to the input specification can be executed. Since the processing performed by the simulation apparatus 190 is already known, detailed description thereof is omitted.

  In the example illustrated in FIG. 1, the simulation device 190 is implemented in a device different from the production index information extraction device 100, but the function of the simulation device 190 is incorporated in the production index information extraction device 100. A conceivable form is also conceivable.

  Further, the production index information extraction device 100, the plan information management device 160, the production site management device 170, and the production information management device 180 are from MES (Manufacturing Executing System) that manages the production devices in the target production line. Log information data, process route information data, production device maintenance plan data, input plan data, in-process information data, and production device information data are extracted from the obtained MES data, and the log of the production index information extraction device 100 It is also possible to take a form of transmitting to the information acquisition management unit 121 (see FIG. 2) via the network 199.

  FIG. 2 is a configuration diagram of the production index information extraction device 100. As illustrated, the production index information extraction device 100 includes a storage unit 110, a control unit 120, an input unit 130, an output unit 140, and a communication unit 150.

  The storage unit 110 includes a log information storage area 111, a process route information storage area 112, a cycle time information storage area 113, an in-process information storage area 114, an input plan storage area 115, and a production equipment maintenance plan storage area 116. A production device information storage area 117 and a production index information storage area 118.

  The log information storage area 111 stores, for each lot, information for identifying the process, the time when the process was started, the time when the process was completed, and the processed production apparatus.

  FIG. 3 is a diagram showing an outline of the log information table 111 a stored in the log information storage area 111.

  The log information table 111a includes a lot ID column 111b, a product name column 111c, a number column 111d, a process name column 111e, a process No column 111f, a start time column 111g, an end time column 111h, and a production device name. Column 111i. The lot ID column 111b, the product name column 111c, the number column 111d, the process name column 111e, the process No column 111f, the start time column 111g, the end time column 111h, and the production device name column 111i are respectively Associated.

  In the lot ID column 111b, information specifying a lot ID, which is identification information that can uniquely identify a lot of a manufacturing unit of each product, is stored.

  The product name column 111c stores information for specifying the product type specified in the lot ID column 111b.

  The number field 111d stores information for specifying the quantity of products included in the lot specified in the lot ID field 111b.

  The process name column 111e stores information for specifying a process name for identifying a process that processes the lot specified in the lot ID column 111b.

  The process No column 111f stores the currently performed process of the lot specified in the lot ID column 111b.

  The start time column 111g stores information that specifies the time at which the process specified in the process name column 111e is started for the lot specified in the lot ID column 111b.

  The end time column 111h stores information for specifying the time when the process specified in the process name column 111e is completed for the lot specified in the lot ID column 111b.

  In the production device name column 111i, the process name column 111e is assigned to the lot specified in the lot ID column 111b in the period from the start time specified in the start time column 111g to the end time specified in the start time column 111g. The information for specifying the name of the production apparatus responsible for the process in the process specified in is stored.

  Returning to the description of FIG. In the process path information storage area 112, information for specifying a manufacturing process of a product for each product type and a processing apparatus that can be used in each process is stored for each product product type.

  FIG. 4 is a diagram showing an outline of the process route information table 112 a stored in the process route information storage area 112. The process route information table 112a is input from the production information management device 180.

  The process route information table 112a includes a product name column 112b, a process No column 112c, a process name column 112d, and a production device name column 112e. The product name column 112b, the process number column 112c, the process name column 112d, and the production device name column 112e are associated with each other.

  The product name column 112b stores information for specifying the product product type.

  The process No. column 112c stores information for specifying the process No., which is identification information for uniquely identifying the manufacturing process of the product for the type specified in the type name column 112b.

  In the process name column 112d, information specifying a process name for identifying a process identified in the process No column 112c is stored for the type specified in the type name column 112b.

  The production device name column 112e stores information for identifying the name of a production device that can be used in the process specified in the process number column 112c and the process name column 112d for the type specified in the type name column 112b. Is done. For example, in the present embodiment, the production device name column 112e includes the product name column 112b, the production device 1 name column 112f, the application device 2 name column 112g, the application device 3 name column 112h,. The names of all the production devices that can be used in the process specified in the process No column 112c and the process name column 112d are listed.

  Returning to the description of FIG. The cycle time information storage area 113 stores information for specifying a manufacturing process of a product by type and a processing apparatus usable in each process.

  FIG. 5 is a diagram showing an outline of the cycle time information table 113 a stored in the cycle time information storage area 113.

  The cycle time information table 113a has a product name column 113b, a process number column 113c, a process name column 113d, a production device name column 113e, a processing number column 113f, and a processing time column 113g. The product name column 113b, the process number column 113c, the process name column 113d, the production apparatus name column 113e, the processing number column 113f, and the processing time column 113g are associated with each other.

  The product name column 113b stores information for specifying the product product type.

  The process number column 113c stores information for identifying the process number, which is identification information that can uniquely identify the manufacturing process of the product.

  The process name column 113d stores information for specifying the process name for identifying the process identified in the process No column 113c for the type specified in the type name column 113b.

  The production device name column 113e stores information for identifying the name of a production device that can be used in the process specified in the process number column 113c and the process name column 113d for the type specified in the type name column 113b. Is done.

  The processing number column 113f can be used when the process specified in the process number column 113c and the process name column 113d is processed by the production apparatus in the production apparatus name column 113e for the type specified in the type name column 113b. Stores information specifying the number of processes.

  In the processing time column 113g, the process specified in the process number column 113c and the process name column 113d for the type specified in the type name column 113b is specified by the production device in the production device name column 113e and the processing number column 113f. The information regarding the processing time when processing the number to be processed is stored.

  In the cycle time information table 113a, the product name column 113b, the process number column 113c, the process name column 113d, and the production device name column 113e are input via the input device 906 (see FIG. 11) or the like. The processing number column 113f and the processing time column 113g in the cycle time information table 113a are generated by the cycle time information generation unit 122 (detailed later).

  Returning to the description of FIG. In the in-process information storage area 114, for each lot existing in the production line, the shipping request date, the number of products included in the lot, the process number of the process in progress, and the lot status And information for identifying.

  FIG. 6 is a diagram showing an outline of the in-process information table 114 a stored in the in-process information storage area 114. The in-process information table 114a is input from the plan information management device 160.

  The in-process information table 114a includes a lot ID field 114b, a product name field 114c, a shipping request date field 114d, a number field 114e, a process number field 114f, and a status field 114g. The lot ID column 114b, the product type column 114c, the shipping request date column 114d, the number column 114e, the process number column 114f, and the status column 114g are associated with each other.

  The lot ID column 114b stores information for identifying a lot ID, which is identification information for uniquely identifying each lot.

  In the product name column 114c, information for specifying the product name of the lot specified in the lot ID column 114b is stored.

  The shipping request date column 114d stores information for specifying the shipping request date of the lot specified in the lot ID column 114b.

  The number field 114e stores information for specifying the quantity of products included in the lot specified in the lot ID field 114b.

  The process No. column 114f stores information for specifying the process in which the lot specified in the lot ID column 114b is in progress.

  In the status column 114g, information for specifying the status of the lot specified in the lot ID column 114b is stored.

  Returning to the description of FIG. The input plan storage area 115 stores information for specifying the lot ID, product name, shipping request date, quantity, and date on which the product is scheduled to be input.

  FIG. 7 is a diagram showing an outline of the input plan table 115 a stored in the input plan storage area 115. The input plan table 115 a is input from the plan information management device 160.

  The input plan table 115a includes a lot ID field 115b, a product name field 115c, a shipping request date field 115d, a quantity field 115e, and an input date field 115f. The lot ID column 115b, the product name column 115c, the shipping request date column 115d, the quantity column 115e, and the input date column 115f are associated with each other.

  In the lot ID column 115b, information for identifying a lot ID, which is identification information that can uniquely identify a lot of a manufacturing unit of each product, is stored.

  The product name column 115c stores information for specifying the product product name specified in the lot ID column 115b.

  The shipping request date column 115d stores information for specifying the shipping request date of the product specified in the lot ID column 115b.

  The number field 115e stores information for specifying the quantity of products included in the lot specified in the lot ID field 115b.

  In the input date column 115f, information for specifying the input date of the product specified in the lot ID column 115b to the manufacturing process is stored.

  Returning to the description of FIG. In the production device maintenance plan storage area 116, for each production device stop plan scheduled for maintenance or the like, the name of the production device to be stopped, the reason for the stop such as maintenance contents, and the time at which maintenance is scheduled to start, that is, stop Stores information for specifying the scheduled time when the maintenance starts, the scheduled time when the maintenance is scheduled to end, and the scheduled time when the stoppage of the production apparatus can be resumed.

  FIG. 8 is a diagram showing an outline of the production device maintenance plan table 116 a stored in the production device maintenance plan storage area 116. The production device maintenance plan table 116a is input via the input device 906 (see FIG. 11) or the like.

  The production device maintenance plan table 116a has a stop No column 116b, a production device name column 116c, a work content column 116d, a start time column 116e, and an end time column 116g. The stop No column 116b, the production device name column 116c, the work content column 116d, the start time column 116e, and the end time column 116g are associated with each other.

  The stop No column 116b stores information for specifying a stop No, which is identification information that can uniquely identify a stop event of the apparatus.

  In the production device name column 116c, information for specifying the name of the production device targeted by the production device stop event identified in the stop No column 116b is stored.

  The work content column 116d stores information for identifying the work content that is the reason for the stop when the production device specified by the stop No column 116b and the production device name column 116c is stopped.

  The start time column 116e stores information for specifying the scheduled start time for stopping the production apparatus specified in the stop No column 116b and the production apparatus name column 116c.

  The end time column 116g stores information for specifying the scheduled time to stop the stop of the production device specified in the stop No column 116b and the production device name column 116c.

  Returning to the description of FIG. The production device information storage area 117 includes information for specifying the state of each production device in the factory.

  FIG. 9 is a diagram showing an outline of the production apparatus information table 117a stored in the production apparatus information storage area 117. The production apparatus information table 117a is input from the production information management apparatus 180.

  The production device information table 117a has a production device number column 117b, a production device name column 117c, and a status column 117d. The production device No column 117b, the production device name column 117c, and the status column 117d are associated with each other.

  In the production apparatus No column 117b, information for identifying the production apparatus No. is stored which is identification information for uniquely identifying each production apparatus.

  The production device name column 117c stores information for specifying the production device name specified in the production device No column 117b.

  In the status column 117d, information for specifying the status of the production device specified in the device No column 117b is stored.

  Returning to the description of FIG. The production index information storage area 118 includes information predicted by simulation or information related to a production index obtained from information predicted by simulation.

  FIG. 10 is a diagram showing an outline of the production index information table 118 a stored in the production index information storage area 118. The production index information table 118a is generated by a production index information generation unit 124 (detailed later). The production index information table 118a indicates that the time required for the work can be known by designating the process, the apparatus, and the number.

  The production index information table 118a includes a lot ID field 118b, a product name field 118c, a number field 118d, a process number field 118e, a process name field 118f, a production device name field 118g, a start time field 118h, and an end. It has a time column 118i and a previous process end time column 118j. Lot ID column 118b, product type column 118c, quantity column 118d, process number column 118e, process name column 118f, production device name column 118g, start time column 118h, end time column 118i, and previous process The end time column 118j is associated with each other.

  In the lot ID column 118b, information for identifying a lot ID, which is identification information that can uniquely identify a lot of a production unit of each product, is stored.

  The product name column 118c stores information for specifying the product product type.

  The number field 118d stores information for specifying the quantity of products included in the lot specified in the lot ID field 118b.

  The process number column 118e stores information for identifying the process number, which is identification information that can uniquely identify the manufacturing process of the product for the type specified in the type name column 118c.

  The process name column 118f stores information for specifying a process name for identifying the process identified in the process No column 118e for the type specified in the type name column 118c.

  In the production device name column 118g, information for specifying the name of the production device used in the process specified in the process number column 118e and the process name column 118f is stored for the product specified in the product name column 118c.

  The start time column 118h stores information for specifying the time at which the process specified in the process name column 118f is started for the lot specified in the lot ID column 118b.

  The end time column 118i stores information for specifying the time at which the process specified in the process name column 118f for the lot specified in the lot ID column 118b ends. The time stored in the end time column 118i can be calculated based on the information stored in the start time column 118h, the number column 118d, etc., and the cycle time information generated by the process described in detail later.

  The previous process end time column 118j stores information for specifying the time at which processing in the process before the process specified in the process name column 118f for the lot specified in the lot ID column 118b ends.

  Returning to the description of FIG. The control unit 120 of the production index information extraction apparatus 100 includes a log information acquisition management unit 121, a cycle time information generation unit 122, a production simulation unit 123, and a production index information generation unit 124.

  The log information acquisition management unit 121 manages information on the log information table 111a at the production site when it is determined in advance, at a predetermined cycle (for example, every day at 7:00 AM, or every day), or when requested. The log information table 111a is acquired from the device 170 and updated.

  The cycle time information generation unit 122 displays the information stored in the log information table 111a at a predetermined period (for example, every day at 7:00 am, every day) at a predetermined time, or at any requested time. Acquire and generate information related to the cycle time information table 113a from this information. The cycle time information generation unit 122 updates the cycle time information table 113a based on the generated information. The processing of the cycle time information generation unit 122 will be described in detail later.

  In the production simulation unit 123, the in-process information table 114a is stored in the simulation device 190 at a predetermined period (for example, every day at 7:00 am, every day) at a predetermined period, or at any requested time. The process route information table 112a, the cycle time information table 113a, the input plan table 115a, and the production device maintenance plan table 116a are output. Further, the production simulation unit 123 generates a progress plan for the processing of all the products in the designated planning period from the present to the future based on the information output from the simulation device 190.

  In the production index information generation unit 124, the progress plan generated by the production simulation unit 123 is generated at a predetermined period (for example, every day at 7:00 am, every day) at a predetermined time, or at any requested time. The production index information is edited to generate information related to the production index information table 118a. The production index information generation unit 124 updates the production index information table 118a based on the generated information.

The input unit 130 receives information input from the plan information management device 160, the production site management device 170, the production information management device 180, the simulation device 190, the input device 906 (see FIG. 11), and the like.
The output unit 140 outputs information to the simulation device 190, the output device 906 (see FIG. 11), and the like.
The communication unit 150 transmits and receives information via the network 199 illustrated in FIG.

  FIG. 11 is a schematic diagram showing a hardware configuration for realizing the production index information extracting apparatus 100. As shown in FIG. The production index information extraction device 100 includes a central processing unit (CPU) 901, a memory 902, an external storage device 903 such as a hard disk device (Hard Disk Drive: HDD), a CD (Compact Disk), a DVD ( Through a portable storage medium 904 such as a digital versatile disk), a reading device 905 such as a keyboard and a mouse, an output device 907 such as a display, and a communication network such as the Internet. And a general computer 900 including a communication device 908 that communicates with other computers.

  For example, the control unit 120 can be realized by loading a predetermined program stored in the external storage device 903 into the memory 902 and executing it by the CPU 901, and the input unit 130 is used by the CPU 901 using the input device 906. The output unit 140 can be realized by the CPU 901 using the output device 907, and the communication unit 150 can be realized by the CPU 901 using the communication device 908, and the storage unit 110. Can be realized by the CPU 901 using the memory 902 or the external storage device 903.

  The predetermined program is downloaded from the storage medium 904 via the reading device 905 or from the network via the communication device 908 to the external storage device 903, and then loaded onto the memory 902 and executed by the CPU 901. You may do it. Further, the program may be directly loaded on the memory 902 from the storage medium 904 via the reading device 905 or from the network via the communication device 908 and executed by the CPU 901.

  The plan information management device 160, the production site management device 170, and the production information management device 180 can also be realized by a general computer 900 as shown in FIG.

  Further, the production index information extracting apparatus 100 of the present invention can be constructed not only on a computer system having a general configuration as shown in FIG. 11 but also on a network system including a plurality of such computer systems.

  Next, characteristic processing executed by the production index information extraction apparatus 100 will be described.

  FIG. 12 is a flowchart showing processing executed by the production index information extraction device 100 according to the embodiment of the present invention.

(Step S10)
The log information acquisition management unit 121 identifies one production device name for a production device that has not generated production index information in step S90 described later. For example, the log information acquisition management unit 121 refers to the processing time column 113g of the cycle time information table 113a and identifies a record for which production index information has not been generated. As a result, information on the production apparatus whose processing time has not been calculated is obtained from the production apparatus name column 113e. And the log information acquisition management part 121 specifies arbitrary one apparatus among the production apparatuses in which the obtained processing time is not calculated.

Further, the log information acquisition management unit 121 obtains the process name input in the process name field 113d when data is not stored in the production apparatus name field 113e as in the process not using the production apparatus. And the log information acquisition management part 121 selects one arbitrary process among the obtained process names.
The log information acquisition management unit 121 stores the number and names of the obtained production apparatuses or process names in an arbitrary storage area. This information is used in step S8 (detailed later).

(Step S20)
In the log information table 111a, the log information acquisition management unit 121 sets all the product names stored in the product name column 111c for all records in which the production device name specified in step S10 is stored in the production device name column 111i. Extract.

  In addition, the log information acquisition management unit 121 sets all the product names stored in the product name column 111c for all records in which the process name specified in step S10 is stored in the process name column 111e in the log information table 111a. Extract.

Then, the log information acquisition management unit 121 identifies one product name that has not been generated by the production index information in step S80 from the extracted product name. For example, the log information acquisition management unit 121 refers to the processing time column 113g of the cycle time information table 113a and identifies a record for which production index information is not generated, thereby generating production index information from the product name column 113b. It is possible to obtain the name of the product that is not. The log information acquisition management unit 121 identifies any one of the acquired product type information.
The log information acquisition management unit 121 stores the number and name of the obtained product names in an arbitrary storage area. This information is used in step S70 (detailed later).

(Step S30)
Next, the log information acquisition management unit 121 includes the production device name or process name specified in step S10 and the product name specified in step S20 as the production device name column 111i or the process name column 111e, respectively. Information stored in all fields of the record stored in the product name field 111c is extracted as log information.

  The log information acquisition management unit 121 counts the number of products for which processing has been completed between the preset start time and end time from the log information extracted in step S30, thereby accumulating the processing. It is also possible to generate throughput information that specifies the quantity (throughput).

(Step S40)
The cycle time information generation unit 122 classifies the log information extracted in step S30 for each number based on the number field 111d. When the number is only a multiple of a predetermined value (for example, 6, 12, 18..., Etc.), the number is classified for each value.
This process is performed in order to know whether or not it depends on the number when obtaining the cycle time in step S50 (detailed later).

(Step S50)
The cycle time information generation unit 122 removes the abnormal value for each classification performed in step S40 and generates a reference value for the work time for each classification. Hereinafter, the process of step S50 will be described in detail.

  FIG. 13 is a flowchart illustrating an example of processing in which the cycle time information generation unit 122 removes abnormal values for each classification and generates a reference value for work time for each classification.

(Step S51)
The cycle time information generation unit 122 calculates the actual measurement work time from the start time and the end time for each log included in each classification defined in step S40.

  FIG. 14 and FIG. 15 show an example of the distribution pattern of the actually measured work time with a histogram 230 and a histogram 240.

  The example shown in FIG. 14 is an example of actually measured work time in a factory that produces a small quantity product in the form of individual order production. In the histogram 230, a plurality of peaks are seen in the work time histogram. This factory often forgets to input the end time, and the end time is not input immediately after the processing is completed, and there is a time difference between the actual processing end time and the input end time.

  The example shown in FIG. 15 is an example of the actual measurement work time of a factory that produces a variety of medium-volume products. In the histogram 240, the actual measurement work time varies greatly. This factory often forgets to input the start time, and also inputs the end time in multiple processes, and if there is a time difference between the input of the start time and the actual process start time, or the process ends. Even if the end time is not input immediately, there is a case where there is a time difference between the actual process end time and the input end time.

  In addition, the cycle time information generation unit 122 calculates the first quartile (Q1), the median (M), and the third quartile (Q3) from the measured work times of all the logs included in the classification. To do.

  The first quartile (Q1) is a value of 25% from the bottom of the measured work time, the median value (M) is a value of 50% from the bottom of the measured work time, and the third quartile (Q3) is The value is 75% from the lower part of the actual measurement work time. These values are necessary for drawing a box-and-whisker diagram (described later), which is one of the graphical display methods used to display the distribution form of data in data analysis.

(Step S52)
Returning to the description of FIG. The cycle time information generation unit 122 calculates feature amounts U, L, and M.

FIG. 16 shows an example of a box plot 250.
In the boxplot 250, the lower end of the box is the first quartile of data (Q1), the upper end is the third quartile of data (Q3), and the line in the box is the median (M). The length of the whiskers extending up and down is the distance to the maximum and minimum values within 1.5 times the length of the box. Data exceeding 1.5 times the length of the box is indicated by a cross.

  As shown in FIG. 16, the cycle time information generation unit 122 calculates the length of the box at the top of the box plot 250 (the length between the third quartile (Q3) and the median (M)). The distance from the median above the median by 1.5 times is U, and the length of the lower box (the length between the median (M) and the first quartile (Q1)) is 1.5. Let L be the distance from the median to the point below the median. Thereby, the feature amount of the distribution shape of the data is calculated.

(Step S53)
Returning to the description of FIG. The cycle time information generation unit 122 applies the classification to one of the plurality of patterns based on the feature amount calculated in step S52.

  FIG. 17 shows an example of a pattern table 260 that applies the work time distribution. In the pattern table 260, the classification is applied to the four patterns based on the feature amounts U, L, and M calculated in step S52. Thereby, an abnormal value can be appropriately removed from the actually measured work time in the next step, step S54 (detailed later). The four patterns will be described in detail later.

(Step S54)
Returning to the description of FIG. The cycle time information generation unit 122 removes the abnormal value of the work time for each classification according to the pattern applied in step S53, and specifies the reference value.

  Here, the four patterns, removal of abnormal values for each pattern, and specification of reference values will be described in detail.

  FIG. 18 is a schematic diagram 270 for explaining a method of removing the abnormal value of the work time and specifying the reference value of the work time in the case of the pattern 1 shown in FIG.

  Pattern 1 corresponds to the case where the median work time is sufficiently far from zero (M / L> α) and the work time variation is large (U / L> 1). In this case, the median value M is used as it is as a reference value for the work time of the classification.

  Here, the value α for judging whether the median of the working time is sufficiently far from zero is a parameter of 2 or more, and is determined empirically, or the accuracy of the production index generated by the processing described later is optimized. It is also possible to specify to do so.

  FIG. 19 is a schematic diagram 280 for explaining a method of removing the abnormal value of the work time and specifying the reference value of the work time in the case of the pattern 2 shown in FIG.

  Pattern 2 corresponds to the case where the median of the work time is sufficiently far from zero (M / L> α) and the work time variation is small (U / L ≦ 1). In this case, the median value of the data within the range of L is set as a reference value for the work time of the classification.

  FIG. 20 is a schematic diagram 290 for explaining a method of removing the abnormal value of the work time and specifying the reference value of the work time in the case of the pattern 3 shown in FIG.

  Pattern 3 corresponds to the case where the median work time is close to zero (M / L ≦ α) and the work time variation is large (U / L> 1). In this case, the median of the work time with the lower 25% removed is set as the reference value for the work time.

  FIG. 21 is a schematic diagram 300 for explaining a method of removing the abnormal value of the work time and specifying the reference value of the work time in the case of the pattern 4 shown in FIG.

  Pattern 4 corresponds to the case where the median of work time is close to zero (M / L ≦ α) and the work time variation is small (U / L ≦ 1). In this case, the median working time after removing both ends of the upper portion 25U / (L + U)% and the lower portion 25L / (L + U)% is set as a reference value for the working time.

  Thereby, an abnormal value can be appropriately removed from the actually measured work time based on the median value and variation of the actually measured work time. In the processing of step S54 shown here, depending on the distribution shape of the work time, whether the classification tends to forget to input the start time or whether to tend to forget to input the end time. By analogy whether it is close to the pattern, the data for calculating the reference value is selected asymmetrically above and below the median value for each pattern based on the above-mentioned tendency.

  Above, the process of step S50 is complete | finished. As another example of the processing from step S51 to step S54, a probability distribution of work time is estimated from a log of the classification using a statistical model such as Generalized Linear Model (GLM), and a reference value is obtained from this distribution. There are also methods such as specifying.

(Step S60)
Returning to the description of FIG. The cycle time information generation unit 122 generates cycle time information from the log information extracted in step S30 and the reference value of the work time for each classification specified in step S50, and stores the cycle time information in the cycle time information table 113a. The process of step S60 will be specifically described.

  FIG. 22 is a schematic diagram of the cycle time information output screen 310. For example, the cycle time information generation unit 122 plots a graph with the classification performed in step S40, that is, the number of products included in the lot as the x axis and the reference value of the work time specified in step S50 as the y axis. The regression line is drawn by the least square method etc. with respect to the reference value. Thereby, a function indicating the relationship between the reference value of the work time and the number is obtained.

  The cycle time information generation unit 122 estimates the number dependency of the work time based on the regression line.

  23 and 24, as an example, forgetting to enter the start time obtained at a factory that produces a variety of medium and mass-produced products, and often entering the end time collectively in a plurality of processes, When there is a time difference between the input and the actual processing start time, or when the end time is not input immediately after the processing is completed, and there is a time difference between the actual processing end time and the input end time (that is, actual measurement work) This is a case where data of a large time) is input. FIG. 23 shows an output screen 320 as a result of estimating the number dependency of work time by the method described in Patent Document 2. FIG. 24 shows an example of an output screen in which the number dependence of the work time is estimated in the processing steps S10 to S60 shown in FIG. 12 using the log information similar to FIG.

  In FIG. 23, since the abnormal value is not removed, the result is that there is no number dependency. On the other hand, in FIG. 24, since the abnormal value is removed, the result is that there is a number dependency. In this way, by removing the abnormal value, the number dependency of the work time is accurately estimated.

The cycle time information generation unit 122 stores the result of removing the abnormal value in the cycle time information table 113a for each number of products. The generation of the cycle time information table 113a will be described in detail.
The cycle time information generation unit 122 uses the information stored in the process number column 111f of the log information table 111a (see FIG. 3) as the process number. Stored in the column 113b.
The cycle time information generation unit 122 stores the information stored in the process name column 111e of the log information table 111a (see FIG. 3) in the process name column 113d.

  The cycle time information generation unit 122 stores the information stored in the production device name column 111i of the log information table 111a (see FIG. 3) in the production device name column 113e.

  When the slope of the regression line is larger than the prediction error, the cycle time information generation unit 122 determines that the process of the production apparatus is a process having number dependency. In this case, the cycle time information generation unit 122 stores the information stored in the number column 111d of the log information table 111a (see FIG. 3) in the processing number column 113f. Then, the cycle time information generation unit 122 calculates the processing time based on the regression line (see FIG. 24 and the like) and stores it in the processing time column 113g. The processing time y can be calculated by substituting the value stored in the processing number column 113f for x of the regression line.

  If the slope of the regression line is smaller than the prediction error, the cycle time information generation unit 122 determines that the process of the production apparatus is a batch process that does not depend on the number of processes (no number dependency). In this case, the cycle time information generation unit 122 does not store the number information in the process number column 113f of the cycle time information table 113a, but stores the median reference value in the process time column 113g.

  In the present embodiment, the prediction error can be the magnitude of the variation in work time after the abnormal value is removed. The prediction error is not limited to this, and various values can be set.

(Step S70)
Returning to the description of FIG. The log information acquisition management unit 121 confirms from the log information table 111a whether or not there is a type for which cycle time information has not been generated in step S60 among the number and name of the type names obtained in step S20. .

  Specifically, in step S20, the number of product names and names are grasped. Therefore, the log information acquisition management unit 121 determines whether or not the processing of steps S10 to S60 is repeated for the number of product types, and whether or not the processing of steps S10 to S60 is repeated for all product names.

  When there is a product type for which cycle time information has not been generated (Yes in step S70), the log information acquisition management unit 121 returns to step S20 and repeats the process. When there is no product that has not generated cycle time information (No in step S70), the log information acquisition management unit 121 proceeds to step S80. By obtaining the cycle time for each product type, an accurate cycle time can be obtained. If the cycle time information table 113a has only information on a single product type, the processing in steps S20 and S70 is not necessary.

(Step S80)
Based on the log information table 111a, the log information acquisition management unit 121 determines whether there is a production device or process that has not generated cycle time information in step S60 among the production devices obtained in step S10 and the types produced in the process. To check.

  Specifically, in step S10, the number and names of production apparatuses or processes are grasped. Therefore, the log information acquisition management unit 121 repeats the processes of steps S10 to S60 by the number of production apparatuses or processes, and whether or not the processes of steps S10 to S60 are repeated for all the production apparatuses or processes. Judging.

  If there is a production apparatus or process that has not generated cycle time information (Yes in step S80), the log information acquisition management unit 121 returns to step S10 and repeats the process. When there is no production apparatus or process that has not generated the cycle time information (No in step S80), the log information acquisition management unit 121 proceeds to step 90. Accurate cycle time can be obtained by obtaining the cycle time for each production device and process. If the cycle time information table 113a has only a single production device and process information, the processes in steps S10 and S80 are not necessary.

(Step S90)
Next, the production simulation unit 123 acquires information from the process route information table 112a, the cycle time information table 113a, the in-process information table 114a, the input plan table 115a, the production device maintenance plan table 116a, and the production device information table 117a. This is output to the simulation apparatus 190.

  Differences in the accuracy of simulation results are predicted according to the actual information and accuracy considered in the simulation model. In the present embodiment, the simulation apparatus 190 is used without specifying a simulation method of an existing simulator. For example, since a discrete event type simulation method is generally used for simulation of a production process in a factory, the simulation apparatus 190 may perform a simulation using a discrete event type simulation method. Since the discrete event type simulation method is a known technique, the description thereof is omitted.

  The simulation apparatus 190 outputs the simulation result to the production simulation unit 123. Based on the acquired information, the production simulation unit 123 generates a process progress plan (information including the number, time, etc.) of all products in the specified plan period from the present to the future, and produces a production index information generation unit. It outputs to 124.

  For example, the production simulation unit 123 acquires a process number, a production device name, and a processing time from the cycle time information table 113a. In addition, the production simulation unit 123 acquires information on the production apparatus from the production apparatus information table 117a. Then, if the production apparatus can start construction, the production simulation unit 123 sets the previous process end time (information stored in the previous process end time field 118j) based on the cycle time information table 113a to the start time (start time field 118h). And the end time (information stored in the end time column 118i) can be calculated. Further, if the production apparatus cannot be started, the production simulation unit 123 sets the accident time stored in the end time column 116g of the production apparatus maintenance plan table 116a as the start time (information stored in the start time column 118h). The end time (information stored in the end time column 118i) can be calculated.

The production index information generation unit 124 stores the acquired result in the production index information table 118a. For example, the production index information generation unit 124 may store information in the log information table 111a or the cycle time information table 113a in the columns from the lot ID column 118b to the production device name column 118g. Further, the production index information generation unit 124 may store the contents of the progress plan generated by the production simulation unit 123 for the columns after the start time column 118h.
Thereby, a series of processes performed by the production index information extraction device 100 is completed. The output unit 140 outputs a display screen including information of the production index information table 118a to the output device 907 and the like.

According to the present embodiment, outliers can be appropriately removed by classifying log information. In addition, since log information is used, outliers can be removed without increasing man-hours, compared to the case where the upper and lower limits of work time are set and the outliers are individually removed. Therefore, the cycle time can be estimated with high accuracy.
In addition, since the cycle time can be estimated with high accuracy, as a result, the accuracy of simulation using this cycle time can be improved.

  In the present embodiment, in step S90, the result of simulation based on the cycle time calculated in step S60 is output. However, the output form of information based on the estimated cycle time information is not limited to this. As another embodiment for implementing the present invention, the production index information generation unit 124 generates a production amount prediction information table based on the cycle time calculated in step S60, and the output unit 140 outputs a display screen including the production amount prediction information table. Or the like.

FIG. 25 is a diagram showing an outline of the production amount prediction information table 119a. The production amount prediction information table 119a is stored in the production index information storage area 118.
The production amount prediction information table 119a includes a production month column 119b, a product name column 119c, and a production number column 119d.

  The production month column 119b stores information for specifying the production month. The production index information generation unit 124 can enter an arbitrary value as information in the production month column 119b, or may input a value input via the input device 906.

  The product name column 119c stores information for specifying the product name. The production index information generation unit 124 can input, for example, information on the product name column 113b as information on the product name column 119c.

  The production number column 119d stores information for specifying the production quantity of the type specified in the type name column 119c in the month specified in the production month column 119b. The production index information generation unit 124 can calculate the production quantity based on the actual working hours of the production month and the cycle time calculated in step S60.

  In addition, as an output form of information based on another cycle time information for implementing the present invention, for example, the production index information generation unit 124 uses information stored in the process route information table 112a and the cycle time information table 113a. Thus, for all the lots stored in the in-process information table 114a and the input plan table 115a, the date when all the processes are completed is predicted, and the number of lots completed every month is totaled, and the result is obtained. The output may be stored in the production index information table 118a and the output unit 140 may output the display screen including the output to the output device 907 or the like.

  In another embodiment for implementing the present invention, the information of all the tables shown in FIGS. 3 to 9 is not essential, and the information of the tables shown in FIGS. 3 to 9 is acquired and used as necessary. do it.

  In addition, this invention is not limited to an above-described Example, Various modifications are included. For example, the above-described embodiments have been described in detail for easy understanding of the present invention, and are not necessarily limited to those having all the configurations described. It is also possible to add the configuration of another embodiment to the configuration of one embodiment. Further, it is possible to add, delete, and replace other configurations for a part of the configuration of each embodiment.

  In addition, each of the above-described configurations, functions, processing units, processing means, and the like may be partially or entirely realized by hardware, for example. Each of the above-described configurations, functions, and the like may be realized by software by interpreting and executing a program that realizes each function by the processor. Information such as programs, tables, and files for realizing each function can be stored in a recording device such as a memory, a hard disk, or an SSD (Solid State Drive), or a recording medium such as an IC card, an SD card, or a DVD.

  Further, control lines and information lines indicate what is considered necessary for the explanation, and not all control lines and information battles are necessarily shown on the product. In practice, it may be considered that almost all the components are connected to each other.

DESCRIPTION OF SYMBOLS 10 ... Production index extraction system, 100 ... Production index extraction device, 110 ... Storage part, 111 ... Log information storage area, 112 ... Process path information storage area, 113 ... Cycle time Storage area, 114 ... In-process information storage area, 115 ... Input plan storage area, 116 ... Production equipment maintenance plan storage area, 117 ... Production equipment information storage area, 118 ... Production index information Storage area, 120 ... control section, 121 ... log information acquisition management section, 122 ... cycle time information generation section, 123 ... production simulation section, 123 ... production index information generation section, 130 ..Input unit 140 ... Output unit 150 ... Communication unit 160 ... Planning information management device 170 ... Production site management device 180 ... Production information management device 90 ... simulation apparatus, 199 ... network,

Claims (5)

A storage unit in which log information including a start time and an end time of production of a product by the production apparatus is stored;
A control unit that generates cycle time information based on the log information;
An output unit for outputting the cycle time information or information based on the cycle time information;
With
The controller is
For each piece of information included in the log information, calculate the actual work time from the start time and the end time,
Based on the calculated actual work time, each of the information included in the log information is classified into one of a plurality of groups,
For each piece of information included in the log information, an abnormal value included in the actual measurement work time is removed according to the classified group,
Based on the actually measured work time from which the abnormal value has been removed, generates cycle time information relating to the predetermined production device and the predetermined product type ,
Prior Symbol controller, based on the variation of the median and the actual working time of the actual operation time, and wherein the classifying each of the information included in the log information in any of a plurality of groups Production index generation device. The production index generation device according to claim 1,
The log information is associated with the start time and the end time, a production device, and a type produced by the production device,
The control unit extracts information on a predetermined production apparatus and a predetermined product type from the log information,
Each of the extracted information is classified into any one of a plurality of groups. The production index information generating device according to claim 1,
Based on the cycle time information, the control unit predicts a future plan for each product or each production device and a specified unit,
The output unit outputs the predicted plan as information based on the cycle time information. A production index generation method for an apparatus comprising a control unit and an output unit,
The controller is
Acquire log information including the start time and end time of production of the product by the production device,
For each piece of information included in the log information, calculate the actual work time from the start time and the end time,
Based on the calculated actual work time, each of the information included in the log information is classified into one of a plurality of groups,
For each piece of information included in the log information, an abnormal value included in the actual measurement work time is removed according to the classified group,
Based on the actually measured work time from which the abnormal value has been removed, generates cycle time information relating to the predetermined production device and the predetermined product type,
The output unit outputs information based on the cycle time information or the cycle time information ,
The control unit classifies each piece of information included in the log information into one of a plurality of groups based on a median value of the measured work time and a variation in the measured work time. Indicator generation method. A production index generation program for causing a device including a control unit and an output unit to perform processing,
In the control unit,
Acquire log information including the start time and end time of production of the product by the production device,
For each piece of information included in the log information, calculate the actual work time from the start time and the end time,
Based on the calculated actual work time, each of the information included in the log information is classified into one of a plurality of groups,
For each piece of information included in the log information, an abnormal value included in the actual measurement work time is removed according to the classified group,
Based on the actually measured work time from which the abnormal value has been removed, a process for generating cycle time information related to the predetermined production apparatus and the predetermined product type is performed.
Causing the output unit to perform processing for outputting the cycle time information or information based on the cycle time information ;
The control unit classifies each piece of information included in the log information into one of a plurality of groups based on a median value of the measured work time and a variation in the measured work time. Indicator generator.

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