The embodiment discussed herein is related to a management system, a management method, and a computer-readable recording medium.
Data related to action of companies is accumulated and efficiently used. For example, data related to operation logs or the like of manufacturing apparatuses in assembly lines of products is accumulated and efficiently used to improve manufacturing processes. Furthermore, as the data, log information is sometimes recorded at the timing of the start and/or the end of each of the processes.
By acquiring the log information on each of the processes, it is conceivable to make use of grasping the entire state of a manufacturing process. For example, in a series of manufacturing processes of sequentially assembling a plurality of parts, it is assumed that, every time each of the parts is picked up from a storage site for the manufacture, the pickup time is recorded as log information. In this case, the length of time between the pickup time of a part A and the pickup time of a part B can be assumed to be working time needed for a process of assembling the part A.
However, when a product is assembled at the step of a certain process, if a worker starts to take a break before the end of work performed at the step of the process, there may be a case in which this state is recorded as the working time including the break time. Namely, when considering a case of simply calculating the working time that has been needed for each of the processes based on only the log information indicating the start and/or the end of the processes, there may be a case in which the working time is recorded longer than the actual working time needed for the worker to finish the work.
According to an aspect of an embodiment, a management system that performs, based on sensor information received from a sensor disposed in a manufacturing area, process management in the manufacturing area, the management system includes: a memory; and a processor coupled to the memory, wherein the processor executes a process including: acquiring information on a pause time slot of work in the manufacturing area; and displaying, when displaying temporal transition of a manufacturing process on a time axis based on the sensor information, the temporal transition on a display after having compressed duration from a start time to an end time of the acquired pause time slot.
The object and advantages of the invention will be realized and attained by means of the elements and combinations particularly pointed out in the claims.
It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory and are not restrictive of the invention, as claimed.
Preferred embodiment of a management system, a management method, and a management program disclosed in the present invention will be described in detail below with reference to the accompanying drawings. Furthermore, the disclosed technology is not limited to the embodiment. Furthermore, the embodiment described below may also be used in any appropriate combination as long as the processes do not conflict with each other.
The management system 1 illustrated in
As illustrated in
The communication unit 110 is implemented by, for example, a network interface card (NIC) or the like. The communication unit 110 is a communication interface that is connected to various devices via a network (not illustrated) in a wired or wireless manner and that manages communication of information with the various devices. The communication unit 110 receives log data from the various devices. The communication unit 110 outputs the received log data to the control unit 130.
The display unit 111 is a display device for displaying various kinds of information. The display unit 111 is implemented by, for example, a liquid crystal display or the like as the display device. The display unit 111 displays various screens, such as a display screen, that is input from the control unit 130.
The operation unit 112 is an input device that receives various operations from an administrator of the management system 1. The operation unit 112 is implemented by a keyboard, a mouse, or the like as, for example, an input device. The operation unit 112 outputs the operation that was input by the administrator to the control unit 130 as operation information. Furthermore, the operation unit 112 may also be implemented by a touch panel or the like as an input device. The display device of the display unit 111 and the input device of the operation unit 112 may also be integrated as a single unit.
The storage unit 120 is implemented by, for example, a semiconductor memory device, such as a random access memory (RAM) or a flash memory, or a storage device, such as a hard disk or an optical disk. The storage unit 120 includes a break time master 121, a log storage unit 122, and a correction log storage unit 123. Furthermore, the storage unit 120 stores therein information that is used for the processes performed in the control unit 130.
The break time master 121 stores therein a break time master in which pieces of break time are set in each manufacturing area.
The “manufacturing area” is information indicating the manufacturing location of a product in a plant or the like. The “break B1” to the “break B5” is information indicating the break time of each of the workers in the plant. The “start” is information indicating the start time of the break time. The “end” is information indicating the end time of the break time. In the example in the first line illustrated in
A description will be given here by referring back to
The “product ID” is an identifier for identifying a product. The “time” is information indicating the time at which an event occurred. The “process” is information indicating a process in which the event has occurred. The “phase” is information indicating the state of the event, such as the start or the end of the event. In the example in the first line illustrated in
A description will be given here by referring back to
The “product ID” is an identifier for identifying a product. The “time” is information indicating the time at which an event occurred. The “process” is information indicating a process in which the event has occurred. The “phase” is information indicating the state of an event, such as the start or the end of the event. In the correction log storage unit 123 illustrated in
A description will be given here by referring back to
The acquiring unit 131 acquires log data from the various devices via the communication unit 110. The acquiring unit 131 stores the acquired log data in the log storage unit 122.
If operation information indicating that the time line graph is displayed is input from the operation unit 112 by an administrator, the acquiring unit 131 refers to the break time master 121 and determines whether a break time master related to a manufacturing area targeted for display is present. If the break time master is not present, the acquiring unit 131 creates a break time master. The acquiring unit 131 allows, for example, the display unit 111 to display an input screen of the break time and urges the administrator to input the break time. If the break time is input by the administrator, the acquiring unit 131 stores the input break time in the break time master 121. Furthermore, the acquiring unit 131 may also acquire the break time related to the subject manufacturing area from, for example, a device that manages on/off duty and automatically creates the break time master.
If the break time master is present, the acquiring unit 131 acquires the break time master in the manufacturing area targeted for display from the break time master 121. Namely, the acquiring unit 131 acquires information on the pause time slot of the work in the manufacturing area. If the acquiring unit 131 acquires or creates the break time master, the acquiring unit 131 determines whether the end time of the break time has elapsed. This determination determines that, if, for example, it is desired to see the time line graph of a one-day work performed in the manufacturing area on the previous day, all of the pieces of break time have elapsed. Furthermore, for example, if the break at noon on that day has been ended, it is determined that the break time in the morning and at noon has elapsed.
If the end time of the break time has not elapsed, i.e., no break time is present in the target period of time in the time line graph, the acquiring unit 131 waits until the first break time has elapsed. If the end time of the break time has elapsed, the acquiring unit 131 outputs, to the correction unit 132, a start instruction to start adjustment of the break time and the break time master with respect to the log data.
If the start instruction and the break time master are input from the acquiring unit 131, the correction unit 132 refers to the log storage unit 122 and determines whether the event data is present in the break time. If the event data is present in the break time, the correction unit 132 corrects the start and end time of the break time. For example, if the break time is 12:00 to 13:00 and if the event data indicating that a process has been ended at 12:01 is present, the correction unit 132 corrects the start time of the break time such that the start time is changed from 12:00 to 12:01. The correction unit 132 acquires the log data from the log storage unit 122 and inserts the corrected break time into the acquired log data. Namely, the correction unit 132 inserts, for example, the start event and the end event of the corrected break time. The correction unit 132 stores, in the correction log storage unit 123, the log data into which the break time has been inserted and then outputs a display instruction to the display processing unit 133.
If the event data is not present in the break time, the correction unit 132 acquires the log data from the log storage unit 122 without correcting the break time and then inserts the break time into the acquired log data. The correction unit 132 stores, in the correction log storage unit 123, the log data into which the break time has been inserted and then outputs the display instruction to the display processing unit 133.
A description will be given here by referring back to
The display processing unit 133 creates the time axis that indicates the elapsed time in each of the processes and creates a line segment (trace graph) that connects the time axis for each product. The display processing unit 133 creates the orientation of the time axis in the order of, for example, time from top to bottom in the time line graph. The display processing unit 133 similarly creates a line segment for each product. Regarding the portion associated with the break time, the display processing unit 133 compresses the duration from the start time to the end time of the break time and sets the compressed portion to zero. Namely, the display processing unit 133 creates a time line graph in which no break time is present. Furthermore, the display processing unit 133 draws the line segment indicating the compressed break time on the time line graph. The display processing unit 133 creates a display screen including the time line graph, in which the time axes associated with the corresponding processes are arranged and the line segments associated with the corresponding products and break time are arranged, and then outputs and displays the created display screen onto the display unit 111.
Furthermore, the display processing unit 133 may also insert the portion associated with the break time so as to be distinguished from the working time slot in which work is performed. As a method of drawing a time line graph, first, the display processing unit 133 draws a graph in which a duration of the break time is set to zero by excluding the break time, i.e., by compressing the time axis. Then, the display processing unit 133 records the contact point of the line segment indicating pieces of the break time and trace graphs. Subsequently, the display processing unit 133 inserts pieces of the break time into the time line graph and draws the lines, which are parallel with the time axes, between the recorded points, i.e., between the trace graphs, that come into contact with the break time.
In the following, a normal display that displays the break time without compressing the time axis and a compression display that displays the break time by compressing the time axis will be described.
In the following, the operation of the management system 1 according to the embodiment will be described.
If the operation information indicating that the time line graph is displayed is input by an administrator from the operation unit 112, the acquiring unit 131 in the management device 100 refers to the break time master 121 and determines whether the break time master in the manufacturing area targeted for a display is present (Step S1). If the break time master is not present (No at Step S1), the acquiring unit 131 creates a break time master (Step S2). If the break time master is present (Yes at Step S1), the acquiring unit 131 acquires, from the break time master 121, the break time master in the manufacturing area targeted for the display (Step S3).
If the acquiring unit 131 acquires or creates the break time master, the acquiring unit 131 determines whether the end time of the break time has elapsed (Step S4). If the end time of the break time has not elapsed (No at Step S4), the acquiring unit 131 repeats the determination performed at Step S4 until the break time elapses. If the end time of the break time has elapsed (Yes at Step S4), the acquiring unit 131 outputs, to the correction unit 132, the start instruction to start adjustment of the break time with respect to the log data and the break time master (Step S5).
If the start instruction and the break time master are input from the acquiring unit 131, the correction unit 132 refers to the log storage unit 122 and determines whether the event data is present in the break time (Step S6). If the event data is present in the break time (Yes at Step S6), the correction unit 132 corrects the start and end time of the break time (Step S7). The correction unit 132 acquires the log data from the log storage unit 122 and inserts the corrected break time into the acquired log data (Step S8).
If the event data is not present in the break time (No at Step S6), the correction unit 132 acquires the log data from the log storage unit 122 without correcting the break time and inserts the break time into the acquired log data (Step S8). The correction unit 132 stores, in the correction log storage unit 123, the log data into which the break time is inserted and then outputs the display instruction to the display processing unit 133.
If the display instruction is input from the correction unit 132, the display processing unit 133 refers to the correction log storage unit 123 and creates the time line graph (Step S9). Namely, the display processing unit 133 creates a display screen that includes the time line graph in which the time axis that is associated with each of the processes and the line segment that is associated with each of the products and pieces of the break time are disposed and then outputs and displays the created display screen onto the display unit 111 (Step S10). Consequently, the management device 100 can display the temporal transition of the manufacturing process by taking the pause time into consideration.
In this way, the management device 100 acquires the information on the pause time slot of the work in the manufacturing area. Furthermore, when the management device 100 displays, based on the sensor information, the temporal transition of the manufacturing process on the time axis, the management device 100 compresses the duration from the start time to the end time of the acquired pause time slot and displays the duration on the display unit 111. Consequently, it is possible to display the temporal transition of the manufacturing process by taking the pause time into consideration.
Furthermore, the management device 100 performs compression such that the duration becomes zero.
Consequently, because the inclinations and the area of the trace graph are not affected by the pause time, for example, it is possible to easily compare a plurality of time line graphs in a plurality of manufacturing areas that have different break time slots.
Furthermore, the management device 100 inserts the duration in distinction from the working time slot in which work is performed. Consequently, it is possible to display the temporal transition of the manufacturing process such that the inclination and the area of the trace graph are not affected by the pause time even if the pause time is displayed.
Furthermore, in the management device 100, the sensor information is information on an RFID tag attached to the product manufactured in the manufacturing area. Consequently, it is possible to easily manage the start time and the end time of each of the processes of the products.
Furthermore, in the management device 100, the sensor information is an operation log of a device in a manufacturing area. Consequently, it is possible to display the temporal transition of the manufacturing processes on the time axes by efficiently using the track record data that is based on the operations of workers in each of the processes.
Furthermore, when the management device 100 creates a time line graph, the process that is longer than the reference value may also be highlighted. Specifically, the management device 100 may also calculate, based on the start time and the end time of each of the processes, the working time in each of the processes; compare and determine the calculated working time with the reference value of each of the processes; and highlight the process with the working time that is longer than that of the reference value as an abnormal value of the working time. Consequently, an administrator can immediately check the process in which the work is highly likely to be abnormal.
In this case, if the break time is not taken into account, the break time is inserted in the middle of the process although the actual working time is not abnormal and, consequently, the process is highlighted as abnormality of the working time. Thus, the management device 100 may also correct the working time based on the start time and the end time of the process and based on the start time and the end time of the break time and then perform comparison and determination of the working time and the reference value.
Furthermore, the method of detecting the abnormal value of the working time is not limited to the comparison and determination of the working time and the reference value. For example, the management device 100 may also detect the value based on the length or the inclination of the line segment of each of the processes in the time line graph.
Furthermore, in the embodiment described above, the break time is used as an example of the pause time slot of work; however, the embodiment is not limited to this. For example, in a manufacturing process in which maintenance is performed during work after a certain number of products has been manufactured, it may also possible to display the time line graph by compressing the maintenance time as the pause time slot of the work.
Furthermore, the components of each unit illustrated in the drawings are not always physically configured as illustrated in the drawings. In other words, the specific shape of a separate or integrated device is not limited to the drawings. Specifically, all or part of the device can be configured by functionally or physically separating or integrating any of the units depending on various loads or use conditions. For example, the correction unit 132 and the display processing unit 133 may also be integrated. Furthermore, each of the process illustrated in the drawings is not limited to the order described above and may also be simultaneously performed or may also be performed by changing the order of the processes as long as the processes do not conflict with each other.
Furthermore, all or any part of various processing functions performed by each unit may also be executed by a CPU (or a microcomputer, such as an MPU, a micro controller unit (MCU), or the like). Furthermore, all or any part of various processing functions may also be, of course, executed by programs analyzed and executed by the CPU (or the microcomputer, such as the MPU or the MCU), or executed by hardware by wired logic.
The various processes described in the above embodiments can be implemented by programs prepared in advance and executed by a computer. Accordingly, in the following, an example of a computer that executes programs having the same function as that described in the embodiments described above will be described.
As illustrated in
The hard disk device 208 stores therein a management program having the same function as that performed by each of the processing units, such as the acquiring unit 131, the correction unit 132, and the display processing unit 133 illustrated in
The CPU 201 reads each of the programs stored in the hard disk device 208 and loads and executes the programs in the RAM 207, thereby executing various kinds of processing. Furthermore, these programs can allow the computer 200 to function as the acquiring unit 131, the correction unit 132, and the display processing unit 133 illustrated in
Furthermore, the management program described above does not always need to be stored in the hard disk device 208. For example, the computer 200 may also read and execute the program stored in a storage medium that can be read by the computer 200. Examples of the computer 200 readable storage medium include a portable recording medium, such as a CD-ROM, a DVD disk, a universal serial bus (USB) memory, or the like, a semiconductor memory, such as a flash memory or the like, and a hard disk drive. Furthermore, the management program may also be stored in a device connected to a public circuit, the Internet, a LAN, or the like and execute the management program from the recording medium described above.
It is possible to display temporal transition of a manufacturing process by taking the pause time into consideration.
All examples and conditional language recited herein are intended for pedagogical purposes of aiding the reader in understanding the invention and the concepts contributed by the inventor to further the art, and are not to be construed as limitations to such specifically recited examples and conditions, nor does the organization of such examples in the specification relate to a showing of the superiority and inferiority of the invention. Although the embodiment of the present invention has been described in detail, it should be understood that the various changes, substitutions, and alterations could be made hereto without departing from the spirit and scope of the invention.
This application is a continuation of International Application No. PCT/JP2015/077361, filed on Sep. 28, 2015, the entire contents of which are incorporated herein by reference.
Number | Date | Country | |
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Parent | PCT/JP2015/077361 | Sep 2015 | US |
Child | 15922388 | US |