JPH0612544A - Operation process predicting device - Google Patents

Abstract

PURPOSE:To provide the device which displays a Gantt chart and the occurrence prediction chart of a manual operation process. CONSTITUTION:The start time and end time of a future process are predicted on the basis of the contents of an operation result data base 4a which controls past operation results, process operation information which is inputted sequentially, and the contents of the production schedule file 4d, and then displayed on a CRT 8. Predicted values regarding manual operation are stored 10 a manual operation prediction file 4b and also displayed on the CRT 8.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a device for predicting and displaying the operating process of a plant in a factory, and particularly proposes a useful operating process predicting device applied to a batch plant.

[0002]

2. Description of the Related Art A predictive control device for efficiently monitoring and controlling the operating state of a plant in a chemical factory is disclosed.
58-213302.

[0003]

[Problems to be Solved by the Invention] This is to integrally display the actual values of process variables, prediction results, related data, and plant operation data. In addition, useful information cannot be obtained for drafting personnel imposition plans and preparing for each process.

The present invention has been made in order to meet the demand for such information, and the progress of the entire manufacturing process can be displayed including future information so that it can be grasped at a glance and the personnel charge plan An object of the present invention is to provide an operation process prediction device that can provide useful information for the preparation of each process.

[0005]

According to a first aspect of the present invention, there is provided an operation process prediction device for predicting an operation process of a plant, an operation result database holding an operation result of the plant, holding data of the operation result database, and It is characterized by comprising a prediction means for predicting a future operating state of the plant using the operating information of the present plant and a means for graphically displaying the past, present and future operating states of each plant.

The operating process predicting apparatus according to the second aspect of the present invention is an apparatus for predicting an operating process of a plant, an operating result database holding the operating results of the plant, holding data of the operating result database, and current operating information of the plant. Predict the future operating state of the plant using, and if there is a manual process in the prediction result, the content of the manual work,
The present invention is characterized by comprising means for predicting one or a plurality of information relating to the time of occurrence, the generating plant and its installation location, and means for graphically displaying the result of this prediction.

[0007]

In the case of the first aspect of the invention, a display such as a Gantt chart can be obtained, and the transition of the entire manufacturing process can be understood at a glance. In the second aspect of the invention, it is possible to obtain information on the manual labor of the personnel, which is highly likely to change in the process transition, which is useful in making arrangements such as personnel imposition and preparation for this in advance.

[0008]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described below in detail with reference to the drawings showing the embodiments. FIG. 1 is a block diagram of an operation process prediction device (enclosed by a broken line) of the present invention, and a process computer 20 that manages the operation of each of a plurality of plants (equipment).
a, 20b, ... 20n and its input / output unit 2 are connected, and operation information of each plant is sequentially input to the device of the present invention,
It is stored in the operation result database 4a of the RAM 4 via the input / output unit 2 and the CPU 5. The keyboard 1 is for inputting various commands and data, and these are input to the CPU 5 via the input / output unit 2. The timer 6 measures the actual time,
This is given to CPU 5. The CRT 8 is for displaying a process chart and a manual chart of a mode described later, and the input / output unit 7 is an interface between the CPU 5 and the CRT 8.

The device of the present invention is provided with a ROM 3 storing various control programs, and the RAM 4 is constructed with a plurality of data files in addition to the operation record database 4a. These data files will be described below. The operation record database accumulates various data regarding the operation record, and as shown in FIG. 2, information (name and / or code) for identifying the equipment, product code, and one of the equipment in the case of a chemical product plant. It has the name of the vessel (vessel) provided in the section, the number that identifies the process, the average value of the time required for the process, the maximum and minimum values, and the number of batches used to obtain these time data. ing.

The manual work prediction file 4b is for accumulating the result of the manual work prediction calculation executed as will be described later and the actual result thereof, and as shown in FIG. , Information specifying each step of manual work. The operation information includes equipment code, name, tank classification (type of reaction tank, measuring tank, etc.), tank name, scheduled production start time, actual production start time, estimated production end time, progress time (process start scheduled time and Difference from process start time), tank operation end prediction time, number of batches used for prediction, product code,
The name and lot number.

The information for identifying a process includes its number, name, scheduled process start time determined from the entire production plan, predicted process start time, actual start time, and a flag indicating that the process is manual work. , And a code indicating a place where manual work is performed. The manual work place file 4c stores information about each place for manual work.

FIG. 4 shows an example of the case where the raw material is charged manually in a chemical factory. A code indicating the place of manual work, a code of equipment related to manual work, division of tanks, and manual process The number that identifies the
Work status classification (“0”: not started, “1”: finished,
"2": During work), information on raw materials related to manual work, their codes, the amount of each raw material, and the order of preparation.

The production schedule file 4d is for accumulating the production schedule for each time, and the contents thereof are information for identifying the equipment, the production start date and time, the product code, the lot number and the production quantity as shown in FIG. .

There are a manual process master 4e and a process name master 4f as files for managing the master data necessary for creating the above-mentioned data file. The manual work process master 4e shown in FIG. 6 stores the numbers of processes that require manual work. Further, the process name master 4f shown in FIG. 7 stores the process number and the name of the corresponding process. The contents of these master files 4e, 4f can be changed by input from the keyboard 1.

The production schedule file 4d is updated by receiving the production schedule data of the entire factory, which the host computer (not shown) has. Operation results database 4a is ROM
3 is updated by the operation result database update program 3a stored in 3. Figure 8 shows the procedure of this program.
Follow the instructions below.

First, the process computers 20a, 20b ... 20n
To access the operation record information, that is, the information for identifying each of the equipment, the tank and the product, the executed process and the time required to execute the process, etc. (S1). The CPU 5 extracts the required data from these data (S2), and only the production-completed data (S3) is given to the operation result database 4a and updated (S4). This is done for all equipment (S5).
The update items are related to the process required time, and the maximum or minimum is updated if necessary according to the newly acquired results, and the average value is recalculated and updated. The number of batches is incremented by 1.

Next, the creation and update of the manual work prediction file 4b and the manual work location file 4c will be described. The program 3b for this purpose is stored in the ROM 3, and its procedure will be described with reference to FIG.

First, the process computers 20a, 20b ... 20n
To collect operation record information (S11). Collected information is information that identifies the equipment used in the target process, the tank, and the target product and the lot number, information about the process that the product goes through, the process being executed and the raw material to be charged into the tank (manually performed) Information. Based on these, the CPU 5 creates a manual work prediction file 4b for each operating facility and tank (S12). Next, operation information is created for each facility based on the information collected in step S11, the production schedule file 4d, the production schedule read out from the operation result database 4a, the actual process required time, and the number of batches, and the operational information for each process is also created. Do
(S13). Further, the scheduled start time, predicted start time, and predicted tank operation end time of each process are calculated based on the process required time information in the operation record database 4a (S14).

Next, it is checked whether or not it is manual work by comparing the process number with the manual work process master 4e (S15), and if it is manual work, the manual work flag in the operation information for each process is set (S1).
6). Whether or not it is manual work (S15) is determined to be manual work even when the judgment target process is the preparation process and there is manual work input based on the information obtained in step S11. Further, in this step S16, the location code is obtained from the manual work location file 4c based on the equipment, tank, and process number, and this location code is set in the file 4b (S16).

In the next step S17, the manual work location file
Create 4c and register the estimated process start time for the manual process. Regarding the charging process, the raw material information such as the raw material name, the raw material code, the charging amount, and the charging order are extracted from the information obtained in step S11 and stored in the file 4c.

Next, it is checked whether there is a process transition (S
18) If so, first register the start time of the process,
Next, the difference between this time and the predicted time is obtained, the predicted process start time after that is calculated and updated, and the predicted tank operation end time is further calculated and updated (S19). The difference calculated in step S19 is registered in the manual operation prediction file 4b as the progress time of the operation (S20).

For the manual work process, the place code in the manual work prediction file is referred to, and the predicted process start time updated in step S19 is written in the manual work place file 4c (S21).
. Then, similar to step S11, the plant operation information is collected (S22), and the process proceeds to step S18. If there is no process transfer in step S18, the process moves to step S22 and new data is read.

As described above, the following graphic representation is displayed on the CRT 8 using the operation record database 4a created, updated, the manual work prediction file 4b, and the manual work location file 4c.
To be done. FIG. 10 is a Gantt chart showing past and future processes centered on the present time (horizontal axis scale 0) by facility and tank. The product name and lot number are also shown on the horizontal bar. The horizontal stripes in the horizontal bars indicate the cleaning step, the vertical and horizontal grids indicate the process interruption, and the shaded areas indicate the manual work. Different color displays are provided on the CRT 8. The part to the left of the present time (past) is illustrated by the operation record information, and the part to the right of the present time (future) is illustrated from the manual work prediction file and the contents of the operation record database 4a. Further, the production which has not started yet is diagrammed from the production schedule file 4d and the operation result database 4a.

FIG. 11 is a flow chart showing the procedure of the operation result prediction display program 3d for performing this display.
Similar to steps S11 and S22, the plant operation information is collected (S3
1) By this, the past amount, that is, the process operation record information is displayed (S32). Next, the process start prediction time for each tank is read from the manual operation prediction file 4b, and the process operation prediction information is displayed thereby. Further, if the operation is not started at the current time, the production schedule file 4d is accessed and displayed graphically (S34).

In the example shown in FIG. 10, the DI-800 with lot number 2202 is a B1V-420 tank, and it is predicted that if cleaning is included, it will take time T ₁ . Those of the next scheduled production and is EMULGEN312 lot number 2220 estimated starting time T ₂ of the production process of a bath B1V-420, is predicted ending time T ₃ are predicted. The product name EMULGEN312 lot number 2220 has not yet started the process at the current time. Therefore, the display depends on the contents of the production schedule file 4d, but the scheduled start time T
_{If 2} comes before T _1, the process of two products in tank B1V-420 will overlap. This overlap is displayed in a special color on the screen to warn that the process progress will be abnormal.

Regarding the equipment currently in operation, the details of the manufacturing conditions are displayed in the window by matching the cursor to the product name display portion and clicking with the mouse. The contents of the production scheduled file 4d are displayed in the window by performing the same operation for the unstarted ones. Further, by clicking the past operation process portion, the actual results, that is, the start time, the end time, and the required time are displayed in a window. In addition, it also has a simulation function. By clicking the future process part and inputting the time corresponding to this part, it is possible to display the subsequent process changes.

FIG. 12 shows an example of a display screen which is a graphic representation of a prediction result of manual work. The lower part of the screen shows the layout of the equipment in the plant in a schematic elevation view, with the floor (F
It is indicated by L), and the horizontal section number (for example, the number of the area divided by the pillar) is shown. The position on the grid indicates the manual work occurrence position, and the information on the occurrence time is indicated by the color of the rectangular pattern inside the grid. The upper left note the relationship between this color and the time of occurrence, but it does not have to be displayed. The upper right area shows the details of the manual work. The manual work to be displayed can be specified by placing the cursor on the lower rectangular pattern and clicking the mouse. The functions of the five function keys are displayed below this area. By placing the cursor on the corresponding function key and clicking the mouse, the previous work and next work of the display work can be displayed. Has become. Further, the rectangular pattern corresponding to the manual work being displayed blinks.

FIG. 13 is a flow chart showing the procedure of the manual operation prediction information display program 3c for causing the display of FIG. 12 to be performed. First, the manual operation process is extracted by looking at the manual operation flag of the manual operation prediction file 4b (S41, S42), and for the process for which the manual operation flag is set, the location code and the estimated process start time are taken in (S43). . The difference between the current time read from the timer 6 and the process start time is calculated, and the rectangular pattern of the corresponding color is displayed in the grid on the screen corresponding to the place code (S44). When the manual work place is clicked by the mouse (S45), the manual work place file 4c is accessed and the contents of the relevant place are read out and displayed at the upper right (S46). It waits for the completion of the check of all the processes and ends (S47).

[0029]

In the case of the first aspect of the invention as described above, the operating state of the process can be represented as past to future in the manner as shown in FIG. 10, so that the process progress state can be understood at a glance. Further, in the case of the second invention, since the process information relating to the manual work can be displayed in the mode as shown in FIG. 12,
It is possible to perform personnel charges, prepare raw materials, etc., in advance,
It is useful for smoothing the process.

[Brief description of drawings]

FIG. 1 is a block diagram of a device of the present invention.

FIG. 2 is a conceptual diagram of a driving record database.

FIG. 3 is a conceptual diagram of a manual work prediction file.

FIG. 4 is a conceptual diagram of a manual work location file.

FIG. 5 is a conceptual diagram of a production schedule file.

FIG. 6 is a conceptual diagram of a manual work process master.

FIG. 7 is a conceptual diagram of a process name master.

FIG. 8 is a flowchart of an operation result database update program.

FIG. 9 is a flowchart of a manual work prediction file creation / update program.

FIG. 10 is a diagram illustrating a display example of a Gantt chart.

FIG. 11 is a flowchart of a driving process prediction display program.

FIG. 12 is a diagram showing a display example of handwork prediction information.

FIG. 13 is a flow chart of a program for displaying handwork prediction information.

[Explanation of symbols]

 4a Operation results database 4b Manual work prediction file 4c Manual work location file 4d Production schedule file 4e Manual work process master 4f Process name master

Front page continuation (72) Inventor Akinori Shimamoto 32 Maison Takada D Room No. 32, Nogamichu, Kainan City, Wakayama Prefecture

Claims (3)

[Claims] 1. In a device for predicting an operation process of a plant, a future operation state of the plant is calculated by using an operation record database that holds the operation record of the plant, and data stored in the operation record database and the operation information of the current plant. An operating process prediction apparatus comprising: a prediction unit that predicts the above, and a unit that graphically displays past, present, and future operating states of each plant. 2. The operating process prediction apparatus according to claim 1, wherein the prediction unit predicts one or more of information for identifying a process to be executed in the plant, content of the process, start time of the process, and required time of the process. . 3. In a device for predicting a plant operation process, a future operation state of a plant is calculated by using an operation record database that holds the operation record of the plant, and data stored in the operation record database and the operation information of the current plant. If there is a manual process in the prediction result, the contents of the manual work, information related to the time of occurrence, one or more of the generation plant and its installation location, and a method of graphically displaying this prediction result An operating process prediction device comprising: