JP-7854885-B2 - Automatic process model generation system and automatic process model generation method

JP7854885B2JP 7854885 B2JP7854885 B2JP 7854885B2JP-7854885-B2

Inventors

川村陸
石田仁志
天野隆
萩原岳大
宮本啓生

Assignees

株式会社日立製作所

Dates

Publication Date: 20260507
Application Date: 20220714

Claims (10)

A work performance data storage unit that stores work performance data collected at the manufacturing site, A work performance data selection unit selects from the work performance data stored in the aforementioned work performance data storage unit to be used as material for generating a process model , A process flow generation unit that generates process flows for each product, A composite flow generation unit generates a composite flow by adding together a plurality of process flows selected by the aforementioned work performance data selection unit , An automatic production method determination unit that determines the production method between each process from the structure of the aforementioned synthesis flow, It includes a synthetic flow restoration unit that generates a process model consisting of a flow shop and a job shop based on the determined production method, When generating the process flow, if there is a closed loop in the flow, the process flow generation unit performs preprocessing to delete a part of the flow so that there are no closed loops in the process flow. The production method automatic determination unit generates the process model by determining that a job shop exists when a closed loop exists in the synthesis flow. The process model automatic generation system is characterized in that the composite flow restoration unit completes the process model by combining a composite flow that restores part or all of the composite flow that was deleted by the preprocessing .
The process model automatic generation system according to claim 1, characterized in that the work performance data includes a product identifier that identifies a product, a process identifier that identifies a process, and the work date and time on which the process was executed.
A process model display unit that displays the process model generated by the aforementioned synthetic flow restoration unit as a process model composed of a flow shop and a job shop, The process model automatic generation system according to claim 1 or 2 , further comprising a process model modification unit that provides an interface enabling the user to modify the displayed process model.
A master data storage unit that stores master data in which the production methods between each process are predetermined, The process model automatic generation system according to claim 3, further comprising: an anomaly detection unit that, when master data corresponding to the master data storage unit exists, compares the difference between the process model generated by the process model automatic generation system and information in which the production methods between each process are predetermined, thereby performing at least one of anomaly detection and production method planning.
A process model automatic generation method is achieved by having a computer with a processor that has a work performance data storage unit for storing work performance data collected at the manufacturing site, and by executing a specific program on the computer, Using the work performance data stored in the aforementioned work performance data storage unit, a process flow is generated for each product. A composite flow is generated by adding up multiple process flows. The production method between each process is automatically determined from the structure of the created synthesis flow. A method for automatically generating a process model, characterized by automatically generating a process model in which flow shops and job shops coexist by replacing a flow shop with a job shop when a flow shop is included in the closed loop of the composite flow based on the results of the automatic determination.
The process model automatic generation method according to claim 5 , characterized in that, in the step of generating the process flow, the process flow is generated using all or part of the work performance data of the product stored in the work performance data storage unit.
In the step of generating the process flow for each product, if a circular path exists within a single product, the last edge is removed. The process model automatic generation method according to claim 6 , characterized in that, after a process model in which the flow shop and the job shop are mixed is automatically generated, the removed edges are restored.
The system includes a display means for displaying the generated process model and an input means for modifying the displayed process model. When displaying the process model as a mixture of the flow shop and the job shop, the job shop is drawn as a single node. The process model automatic generation method according to claim 7 , characterized in that it provides an interface that allows a user to arbitrarily modify a process model in which the production method has been automatically determined.
The process model automatic generation method according to claim 8, characterized in that, if master data exists which defines the production methods between each process, the process model automatic generation system compares the difference between the process model it generates and the information which defines the production methods between each process in advance, thereby performing at least one of anomaly detection and production method planning.
Continuous flow, line flow, and batch flow are identified as flow shops. The process model automatic generation method according to claim 9 , characterized in that it automatically generates the process model from work performance data that occurred within a period specified by the user.

Description

This invention relates to a process model creation system and a method for automatically generating process models using the same. In manufacturing, on-site data is generated and collected in each task upon completion of the task or the occurrence of a predetermined event. On-site workers and data analysts analyze this data to improve the efficiency of each task. However, when different departments manage different tasks, information sharing between departments can become difficult. This is likely due to differences in the systems used for task management across departments. While analyzing collected on-site data aims to improve the efficiency of tasks within each department, collaboration between departments is essential for improving the efficiency of the entire business process. Therefore, it is necessary to manage on-site data generated not only within departments but also throughout the entire business process in a correlated manner, and to use this data analysis to improve the efficiency of the entire business process. Patent Document 1 discloses an information collection and display system comprising a data generation device that generates field data, a storage device that stores the field data generated by the data generation device, and a related data storage unit that stores related data. The information collection and display system includes a related data storage unit that stores related data defining the relationships between multiple pieces of information included in the field data, a related data search unit that searches for second information related to a first piece of information included in the multiple pieces of information based on the related data stored in the related data storage unit, and a user interface unit that displays the connection relationships of the multiple pieces of information linked by the related data. The related data search unit searches for second information related to the first piece of information based on the related data, according to the selection of the first piece of information in the connection relationships of the multiple pieces of information displayed in the user interface unit, and displays the first and second pieces of information, along with the connection relationships of the multiple pieces of information, in the user interface unit. Japanese Patent Publication No. 2019-153051Japanese Patent Publication No. 2002-62922US2013/0208315 publication This figure shows an overview of an embodiment of the present invention.This block diagram shows an example of a network configuration to which the overall system 200 for automatic process model generation according to the first embodiment is applied.This is a block diagram showing an example of the functional configuration of the overall system 200 in Figure 2.Figure 2 shows an example of the operation procedure of the overall system 200, from creating a model from work performance data to registering it in the process model storage unit.Figure 2 shows an example of work performance data stored in the work performance data storage unit.This figure shows examples of closed-circuit data stored in the closed-circuit storage unit for each product in Figure 2.Figure 2 shows an example of process model data stored in the process model storage unit.This diagram shows examples of a flow shop and a job shop.Figure 2 is a flowchart showing the procedure by which the automated process model generation system 210 generates a process model consisting of a flow shop and a job shop.Figure 9 shows a diagram that divides the process of generating a process model consisting of a flow shop and a job shop into three steps.Figure 2 shows a specific example of the process model automatic generation system 210 performing automatic process model determination (part 1).Figure 2 shows a specific example of the process model automatic generation system 210 performing automatic process model determination (part 2).Figure 2 shows a specific example (part 1) of the process model automatic generation system 210 performing automatic determination of the process model when a closed circuit exists within one product.Figure 2 shows a specific example of the process model automatic generation system 210 performing automatic determination of the process model when a closed circuit exists within one product (part 2).Figure 2 shows an example of a screen displaying a process model consisting of a flow shop and a job shop in the automated process model generation system 210.This block diagram shows a functional configuration example of an automatic process model generation system according to the second embodiment, which includes a function for detecting abnormalities in the production method.This figure shows examples of a flow shop and a job shop in the process model automatic generation system according to the third embodiment.This is a block diagram showing a functional configuration example of the process model automatic generation system