TWI540519B - Real-time dynamic factory management system - Google Patents
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/418—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM]
- G05B19/41865—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM] characterised by job scheduling, process planning, material flow
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- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B2219/00—Program-control systems
- G05B2219/30—Nc systems
- G05B2219/32—Operator till task planning
- G05B2219/32248—Create schedule from elementary operations from database
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
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Description
本發明係一種工廠管理系統，尤指一種即時動態工廠管理系統。The invention relates to a factory management system, in particular to an instant dynamic factory management system.
為配合生產線的連續性生產，許多工廠設置有MRP系統及/或ERP系統，以提升自動化生產線的生產效率。In order to cope with the continuous production of the production line, many factories are equipped with MRP systems and / or ERP systems to improve the production efficiency of automated production lines.
如圖13所示，生產的工廠組織主要包含有管理階段、生產階段及品管階段，其中在管理階段視各工廠的需求，通常會編制有研發部、生產管理部、會計部、人資部、資訊部及資材部。而生產階段則通常編制有生技部、生產部、設備部及廠務部，而品管階段則主要編制品管部。As shown in Figure 13, the factory organization of the production mainly includes the management stage, the production stage and the quality control stage. In the management stage, depending on the needs of each factory, the R&D department, the production management department, the accounting department, and the human resources department are usually prepared. , Information Department and Materials Department. In the production stage, the biotechnology department, the production department, the equipment department and the factory department are usually prepared, while the quality control department is mainly the product management department.
欲製作一項製品A，會先由MRP系統及ERP系統依據「物料資料」及「生產管制資料」產生第1~N張工單，再分別由第1~N工作站依據對應的工單進行加工製作，並將完成製品A交由品管人員抽樣檢查後入倉或出貨，同時該工作站的操作人員會在完成其負責的工單後，填寫紙本的生產日報表，並交回管理階段的特定部門，以將該操作人員生產該製品A的該工作站工單的生產日報表輸入至MRP系統或ERP系統，並予以記錄備查。To produce an item A, the first to N work orders will be generated by the MRP system and the ERP system based on the "Material Information" and "Production Control Data", and then processed by the 1~N workstations according to the corresponding work orders. Production, and the finished product A is sampled and inspected by the quality control personnel, and the operator of the workstation will fill in the production date report of the paper after completing the work order for the work, and return it to the management stage. For a specific department, the production date report of the workstation work order that the operator produces the product A is input to the MRP system or the ERP system, and is recorded for reference.
於上述製作製品A的製程期間，突遇某個工作站於製程中發生異常(如設備故障、操作人員操作錯誤等)，假設為第k張工單出製程異常而延宕其完成時間，則必須等待該第k張工單完成後，才由負責該工單的操作員繳回紙本的生產日報表，再等待管理階段的特定部門的人員輸回MRP系統或ERP系統，如此該MRP系統或ERP系統才能得知該第k張工單的製程異常；否則MRP系統或ERP系統無法得知工作站現場的訊息。頂多由生產階段的各部門人員自行橫向聯繫，令接續的工單儘可能地在可接受的時間內被完成。During the manufacturing process of the above-mentioned product A, an abnormality occurs in a certain workstation during the manufacturing process (such as equipment failure, operator operation error, etc.), and it is necessary to wait for the k-th work order out process abnormality and delay the completion time thereof. After the completion of the kth work order, the operator responsible for the work order will return the production daily report of the paper, and wait for the personnel of the specific department in the management stage to return to the MRP system or the ERP system, so that the MRP system or ERP The system can know that the process of the k-th work order is abnormal; otherwise, the MRP system or the ERP system cannot know the information on the workstation site. At most, the personnel of each department in the production stage contact each other horizontally, so that the successive work orders can be completed in an acceptable time as much as possible.
再者，雖然MRP系統或ERP系統可依據各製程站的回報的生產日報表，統計各操作人員的學習曲線，並依據該學習曲線作為規劃下次該工作站製作相同製品部件時，預估該工單的預定完成工時，但由於仍無法及時且全面掌握生產部於當時製程的狀狀況，且依賴生產部操作人員臨時反應的比重仍高，一旦操作人員發生操作上疏漏或由尚不熟悉操作流程的新進操作人員操作，即直接降低整條生產線的製程效率，而相對墊高生產成本。Furthermore, although the MRP system or the ERP system can calculate the learning curve of each operator according to the production daily report of the returns of each process station, and based on the learning curve, the work is estimated when the same product component is produced next time on the workstation. The single scheduled completion of working hours, but still unable to timely and comprehensively grasp the status of the production department at the time of the process, and rely on the proportion of the temporary reaction of the production department operators is still high, once the operator has operational omissions or is not familiar with the operation The new operator operation of the process directly reduces the process efficiency of the entire production line and relatively increases the production cost.
此外，在製品的良率提升方面，通常先以實驗批次的方式，經過多次工單及多次製程參數調整後，才能獲得高良率的最佳製程參數，惟如此作法相當費時且搜集比對過程存在盲點；換言之，目前各工作站於並無法於生產作業同時收集對應製程參數。In addition, in terms of product yield improvement, it is usually first done in the form of experimental batches, after multiple work orders and multiple process parameters adjustments, to obtain high-yield optimal process parameters, but this method is quite time-consuming and collects ratios. There is a blind spot in the process; in other words, at present, each workstation cannot collect corresponding process parameters at the same time as the production operation.
除上述人員及工作站設備的問題外，工廠尚有內部與外部工作環境因素影響生產效率，例如若工廠對於生產時所產生的廢氣、廢液排放前的監控鬆散，一旦造成環安問題則容易於遇安檢未通過而遭勒令停產。因此，工廠的生產管理有待進一步改進，以協助該工廠改善其生產管理方式，以及即時監控環保、衛生及勞工安全等設施。In addition to the above-mentioned problems of personnel and workstation equipment, the factory still has internal and external working environment factors that affect production efficiency. For example, if the factory produces loose exhaust gas and waste liquid before production, it is easy to cause environmental problems. He was ordered to suspend production if the security check failed. Therefore, the production management of the plant needs to be further improved to help the plant improve its production management methods and to monitor environmental protection, sanitation and labor safety facilities.
有鑑於上述既有工廠管理系統的缺點，本發明主要目的係提供一種即時動態工廠管理系統，減少生產異常導致生產效率降低的狀況。In view of the shortcomings of the above-mentioned existing plant management system, the main object of the present invention is to provide an instant dynamic plant management system that reduces production abnormalities and leads to a decrease in production efficiency.
欲達上述目的所使用的主要技術手段係令該即時動態工廠管理系統包含有： 一工單規劃單元，係產生一初始工單，並提供一工單修改模組； 至少一運作資訊擷取單元，係連結至該工單規劃單元，且於製作各該初始工單的製程期間內，連續擷取製作各該初始工單之工作站的至少一種運作資訊； 一運作穩定期判斷單元，係連結至該運作資訊擷取單元及該工單規劃單元，以連續獲得該工作站的該至少一種運作資訊，並記錄及計算該連續獲得的運作資訊後，與該初始工單的一標準差相較，判斷該工作站已進入穩定期後，觸發該工單規劃單元的工單修改模組； 上述該工單規劃單元的該工單修改模組係自該運作狀態擷取單元擷取運作資訊，並依據該運作資訊修改該初始工單的完成時間。The main technical means used for the above purposes is to enable the instant dynamic plant management system to include: a work order planning unit that generates an initial work order and provides a work order modification module; at least one operational information capture unit Linking to the work order planning unit, and continuously extracting at least one operational information of the workstations for each of the initial work orders during the manufacturing process of each initial work order; The operation information acquisition unit and the work order planning unit are configured to continuously obtain the at least one operation information of the workstation, and record and calculate the continuously obtained operation information, and compare with a standard deviation of the initial work order. After the workstation has entered the stabilization period, the work order modification module of the work order planning unit is triggered; the work order modification module of the work order planning unit extracts operation information from the operation state extraction unit, and according to the The operational information modifies the completion time of the initial work order.
上述本發明係主要在各初始工單由其負責的工作站開始製作後，擷取產生中的該工作站的運作資訊，以及同時獲得該工作站製作該工單的運作資訊並據以判斷該工作站的穩定期，如該穩定期提早出現，則代表目前操作人員效率佳，依據穩定期的運作資訊修改縮短該初始工單的完成時間；反之，如該穩定期延遲出現，則代表目前操作人員效率差或為新進操作人員，依據穩定期的運作資訊修改增長該初始工單的完成時間；如此，當本系統應用於連續性生產線，接續該工單之後的工單可依序自動調整其預估完成時間，可排除因操作人員的人為因素所造成工單完成延誤，提高工廠的生產效率，降低生產成本。The above-mentioned invention is mainly used after the initial workstations are started by the workstations in charge of the initial work orders, and the operation information of the workstations in the process is obtained, and the operation information of the work orders produced by the workstations is obtained at the same time, and the stability of the workstations is judged accordingly. If the stabilization period occurs earlier, it means that the current operator is efficient. The operation time of the stabilization period is modified to shorten the completion time of the initial work order. Conversely, if the stability period is delayed, it means that the current operator is inefficient or For the new operator, the completion time of the initial work order is modified according to the operation information of the stabilization period; thus, when the system is applied to the continuous production line, the work order after the work order can be automatically adjusted to the estimated completion time in sequence. It can eliminate the delay of the completion of the work order caused by the human factors of the operator, improve the production efficiency of the factory and reduce the production cost.
本發明次一目的係提供一種可立即通報製程異常，加速異常排除效率的即時動態工廠管理系統。The second object of the present invention is to provide an instant dynamic plant management system that can immediately notify process anomalies and accelerate the efficiency of abnormal removal.
欲達上述目的所使用主要技術手段係令該即時動態工廠管理系統進一步包含有： 一運作狀態圖形產生單元，係連結至該至少一運作狀態擷取單元，以連續獲得各該至少一工作站的運作資訊，該運作資訊為各部件的完成時間，並取二相鄰部件的完成時間的時間差作為縱軸的數值，時間為橫軸的數值，繪製一運作狀態圖形；及 複數異常警示單元，係可設置於工廠各階段的部門，各異常警示單元於前運作狀態圖形的縱軸數值超過一預設異常時間，即產生一異常警示。The main technical means for achieving the above purpose is that the real-time dynamic plant management system further includes: an operation state graphic generating unit coupled to the at least one operating state capturing unit to continuously obtain the operations of each of the at least one workstation Information, the operation information is the completion time of each component, and takes the time difference of the completion time of two adjacent components as the value of the vertical axis, the time is the value of the horizontal axis, draws a working state graphic; and the plural abnormal warning unit is The department set at each stage of the factory, the abnormal warning unit in the front operating state graph has a vertical axis value exceeding a preset abnormal time, that is, an abnormal warning is generated.
上述本發明的運作狀態圖形繪製單元所繪製出的運作狀態圖形，由於取該工作站前、後完成部件時間的時間差為縱軸數值，一旦前、後完成部件時間的時間間隔太長，則容易由該運作狀態圖形顯現，亦有助於工廠各階段的部門於獲得異常警示時，找到異常發生的時間，快速進行排除。In the operation state diagram drawn by the operation state graphic drawing unit of the present invention, since the time difference between the time of completing the components before and after the workstation is the vertical axis value, once the time interval of completing the component time before and after is too long, it is easy to The graphical representation of the operational status also helps the departments at all stages of the plant to find the time of the abnormality and quickly eliminate it when an abnormal warning is obtained.
本發明再一目的係提供一種提供公平考核操作人員績效的即時動態工廠管理系統。Still another object of the present invention is to provide an instant dynamic plant management system that provides fair assessment of operator performance.
欲達上述目的所提供的主要技術手段係令該即時動態工廠管理系統進一步包含有一績效考核資料收集單元，係擷取該生產相關人員於一考核期間內，各工單在製程期間之穩定期的平均部件完成時間、各製程的異常頻率及製程異常的排除時間，進行考核。The main technical means provided for the above purposes is to enable the instant dynamic plant management system to further include a performance appraisal data collection unit, which is to capture the stable period of each work order during the process period during the assessment period. The average component completion time, the abnormal frequency of each process, and the exclusion time of the process abnormality are evaluated.
上述本發明係藉由擷取各工作站的運作資訊，可反應操作工作站的操作人員的工作能力，當各工作站的製程異常發生，記錄自異常發生至排除的時間，亦可納入操作人員及／或廠務人員的考核；由於該些數據均由實際工作狀況反應而得，避免傳統主管憑工作印象打考績的不公平現象。The above invention can reflect the working ability of the operator of the operating workstation by extracting the operation information of each workstation. When the process abnormality of each workstation occurs, the time from the occurrence of the abnormality to the time of the exclusion can be recorded, and the operator and/or the operator can be included. The assessment of the factory personnel; because the data are obtained from the actual work conditions, to avoid the unfairness of traditional supervisors to test performance based on job impressions.
本發明提出一種即時動態工廠管理系統，可應用於工廠中的單機生產 (如射出成型設備)或手動生產的非連續性生產線，亦可應用於連續性生產線(如印刷電路板的印刷、烘烤、蝕刻等連續製程)。The invention provides an instant dynamic factory management system, which can be applied to single machine production in a factory (such as injection molding equipment) or manually produced non-continuous production line, and can also be applied to a continuous production line (such as printing and baking of printed circuit boards). , etching and other continuous processes).
首先請參閱圖1所示，係為本發明即時動態工廠管理系統10應用於一工廠裡的單一設備30的實施例，該即時動態工廠管理系統10係包含有一工單規劃單元11、一運作資訊擷取單元12及一運作穩定期判斷單元13。工廠的管理人員依目前欲生產的製品設定好相關生產資訊後，由該工單規劃單元11依據該相關生產資訊產生一初始工單，供設備操作人員依該初始工單內容進行製品40或製品部件的生產。該工單規劃單元11另提供有一工單修改模組111，可針對該初始工單進行修改，並重新產生修改後的工單。First, please refer to FIG. 1 , which is an embodiment of the instant dynamic plant management system 10 of the present invention applied to a single device 30 in a factory. The instant dynamic plant management system 10 includes a work order planning unit 11 and an operation information. The capture unit 12 and an operational stability period determination unit 13 are provided. After the management personnel of the factory set relevant production information according to the products currently to be produced, the work order planning unit 11 generates an initial work order based on the relevant production information, and the equipment operator performs the product 40 or the product according to the content of the initial work order. Production of parts. The work order planning unit 11 further provides a work order modification module 111, which can modify the initial work order and regenerate the modified work order.
請同時參閱圖1及圖2A，上述運作資訊擷取單元12係連結至該工單規劃單元11，且連續擷取該設備30於製程過程中的至少一種運作資訊。目前以設備30為例，係已具備有至少一動作檢知器31，以檢知設備30各結構的運作狀態(如夾治具)，本發明的運作資訊擷取單元12可與該至少一動作檢知器31連接後，將該至少一動作檢知器31的檢知訊號轉換為運作資訊後輸出或儲存。另外，如圖2B及圖2C所示，本發明的運作資訊擷取單元12亦可配合連結外裝的至少一動作檢知器31，該至少一動作檢知器31可裝設於非自動化傳統設備30a或手工生產線30b，以檢知傳統設備30a的進料口或出口，獲得製品40完成時間，或檢知該手工生產線30b的置物處，同樣獲得製品40於操作人員組裝完成製品40後的完成時間。該動作檢知器31可為紅外線遮斷器、超音波感應器或其類似可檢知物品的感測器等。Referring to FIG. 1 and FIG. 2A, the operation information capturing unit 12 is coupled to the work order planning unit 11 and continuously retrieves at least one operation information of the device 30 during the process. For example, the device 30 is provided with at least one motion detector 31 for detecting the operating state of each structure of the device 30 (such as a fixture). The operation information capturing unit 12 of the present invention can be combined with the at least one After the motion detector 31 is connected, the detection signal of the at least one motion detector 31 is converted into operation information and output or stored. In addition, as shown in FIG. 2B and FIG. 2C, the operation information capturing unit 12 of the present invention can also be coupled with at least one action detector 31 coupled to the exterior, and the at least one motion detector 31 can be installed in a non-automatic tradition. The device 30a or the manual production line 30b detects the feed port or the outlet of the conventional device 30a, obtains the completion time of the product 40, or detects the storage portion of the manual production line 30b, and also obtains the product 40 after the operator assembles the finished product 40. Complete time. The motion detector 31 may be an infrared ray interrupter, an ultrasonic sensor or the like that senses an article or the like.
再請參閱圖1及圖3所示，上述運作穩定期判斷單元13係連結至該運作資訊擷取單元12及該工單規劃單元11，以連續獲得該設備30的該至少一種運作資訊，並記錄及計算該連續獲得的運作資訊後，與該初始工單的一標準差相較。如圖3A及圖3B所示，該設備由二位不同操作人員A、B操作後，在不同製程時間分別連續獲得運作資訊，並將其繪製成二條學習曲線L1、L2及經驗曲線L1-1、L2-1。假設各該運作資訊是各製品的完成時間，則由此二條學習曲線L1、L2可知，其中一位操作人員B操作該設備時，該設備較早進入穩定期，而另一位操作人員操A作該設備的穩定期出現較晚。該運作穩定期判斷單元13主要判斷前後製品的完成時間差相近，代表目前設備30已進入穩定期，此時設備30仍處於執行該初始工單的製程時間內，故該運作穩定期判斷單元13係觸發該工單規劃單元11的工單修改模組111。請配合參閱圖4A至4C所示，在此同時，該工單修改模組111即自該運作狀態擷取單元12擷取目前運作資訊，即擷取該設備30於穩定期的各製品完成時間Ts1、Ts2或複數製品完成時間總合再取平均的平均完成時間Ts1、Ts2，並依據該製品完成時間預估剰餘製品個數的完成時間，將該初始工單預計完成N個製品的完成時間(Tp=Td*N)，修改為TP1=Ts1*(N-k)或TP2=Ts2*(N-k)；其中k為穩定期之前完成的製品個數。如此，本發明即可在該設備執行該初始工單的製程時間內，依照目前操作人員操作該設備的實際運作狀況，而更精準預估該工單的完成時間。Referring to FIG. 1 and FIG. 3, the operational stability period determining unit 13 is coupled to the operational information capturing unit 12 and the work order planning unit 11 to continuously obtain the at least one operational information of the device 30, and After recording and calculating the continuously obtained operational information, it is compared with a standard deviation of the initial work order. As shown in FIG. 3A and FIG. 3B, after the two operators are operated by two different operators A and B, the operation information is continuously obtained in different process times, and is drawn into two learning curves L1 and L2 and an experience curve L1-1. L2-1. Assuming that each of the operational information is the completion time of each product, then the two learning curves L1, L2 can be seen that when one operator B operates the device, the device enters a stable period earlier, and another operator operates A. The stabilization period for the device appeared later. The operation stability period judging unit 13 mainly judges that the completion time difference of the products before and after is similar, and represents that the current device 30 has entered a stable period. At this time, the device 30 is still in the process time for executing the initial work order, so the operation stability period judging unit 13 is The work order modification module 111 of the work order planning unit 11 is triggered. Please refer to FIG. 4A to FIG. 4C. At the same time, the work order modification module 111 retrieves the current operation information from the operation state extraction unit 12, that is, captures the completion time of each product of the device 30 during the stable period. The average completion time Ts1, Ts2 of the Ts1, Ts2 or multiple product completion time sums is averaged, and the completion time of the remaining products is estimated according to the completion time of the product, and the initial work order is expected to complete the completion of N products. Time (Tp=Td*N), modified to TP1=Ts1*(Nk) or TP2=Ts2*(Nk); where k is the number of products completed before the stabilization period. In this way, the present invention can more accurately estimate the completion time of the work order according to the actual operation state of the current operation of the equipment in the process time during which the device executes the initial work order.
請參閱圖5 所示，上述的工單規劃單元11及一運作穩定期判斷單元13亦可整合於一MRP系統及/或ERP系統20，成為MRP系統及/或ERP系統20的功能模組，即工單規劃模組21及一運作穩定期判斷模組22。該運作資訊擷取單元12亦可配合設置一資料庫DB，將設備30的運作資訊儲存該資料庫DB中，由該MRP系統及/或ERP系統20周期性讀取該設備30的運作資訊，並同樣在該設備30執行該初始工單的製程時間內，依照該設備30的運作資訊，精準預估該工單的完成時間。請配合參閱圖6所示，係為該MRP系統及/或ERP系統即時動態管理該初始工單完成時間的流程圖，係首先由工單規劃模組21產生一初始工單S10，再自該資料庫中讀取或由已完成部件讀取該設備的周期性即時運作資訊S12，並由該運作穩定期判斷模組22比較該運作資訊與該標準差的差異，意即，各製品完成時間是否落入該標準差的範圍中S12，若是，則代表該設備進入穩定期，並接著自該資料庫中或由已完成部件讀取該設備於穩定期中一個製品的完成時間，或數個製品的完成時間加總後取平均獲得平均完成時間S13，再以完成時間或平均完成時間計算尚未製作的製品個數的完成時間S14。Referring to FIG. 5, the work order planning unit 11 and the operational stability period determining unit 13 may be integrated into an MRP system and/or an ERP system 20 to become a functional module of the MRP system and/or the ERP system 20. That is, the work order planning module 21 and an operational stability period determining module 22. The operation information capture unit 12 can also be configured to store a database DB, and store the operation information of the device 30 in the database DB. The MRP system and/or the ERP system 20 periodically read the operation information of the device 30. And in the process time during which the device 30 executes the initial work order, the completion time of the work order is accurately estimated according to the operation information of the device 30. Please refer to FIG. 6 as a flowchart for dynamically managing the initial work order completion time of the MRP system and/or the ERP system. First, the work order planning module 21 generates an initial work order S10, and then The periodic real-time operation information S12 of the device is read or read by the completed component, and the difference between the operation information and the standard deviation is compared by the operation stability period determination module 22, that is, the completion time of each product Whether it falls within the range of the standard deviation S12, and if so, represents that the device enters a stable period, and then reads from the database or from the completed component the completion time of the article in the stable period, or several articles After the completion time is added up, the average completion time S13 is obtained, and the completion time S14 of the number of products that have not been produced is calculated by the completion time or the average completion time.
以下再進一步說明本發明的即時動態工廠管理系統應用於一連續式生產之工廠的實施例，請參閱圖7所示，該工廠組織主要包含有管理階段、生產階段及品管階段，其中在管理階段視各工廠的需求，通常會編制有研發部、生產管理部、會計部、人資部、資訊部及資材部。而生產階段則通常編制有生技部、生產部、設備部及廠務部，而品管階段則主要編制品管部。The following further describes an embodiment of the instant dynamic plant management system of the present invention applied to a continuous production plant. Referring to FIG. 7, the plant organization mainly includes a management phase, a production phase, and a quality control phase, among which management According to the needs of each factory, the R&D department, production management department, accounting department, human resources department, information department and materials department are usually prepared. In the production stage, the biotechnology department, the production department, the equipment department and the factory department are usually prepared, while the quality control department is mainly the product management department.
請配合參閱圖8所示，本實施例的即時動態工廠管理系統10a係包含有一工單規劃單元11、複數運作資訊擷取單元12及一運作穩定期判斷單元13。工廠的管理階段的其中一部份的管理人員可依目前欲生產的製品設定好相關生產資訊後，由該工單規劃單元11依據該相關生產資訊產生複數初始工單，供連續式生產的複數道工作站1~M的設備操作人員依對應的初始工單內容進行製品的生產。該工單規劃單元11同樣提供有一工單修改模組111，可針對各該初始工單進行修改，並重新產生修改後的工單。As shown in FIG. 8, the instant dynamic plant management system 10a of the present embodiment includes a work order planning unit 11, a plurality of operational information capturing units 12, and an operational stability period determining unit 13. After a part of the management personnel of the management stage of the factory can set relevant production information according to the current product to be produced, the work order planning unit 11 generates a plurality of initial work orders based on the relevant production information for the plural of continuous production. The equipment operators of the road workstations 1~M carry out the production of the products according to the contents of the corresponding initial work orders. The work order planning unit 11 also provides a work order modification module 111, which can modify each initial work order and regenerate the modified work order.
上述複數運作資訊擷取單元12係連結至該工單規劃單元11，以分別連續擷取該對應工作站於製程中的至少一種運作資訊，可為設備或手工組裝，以下以設備為例說明之。因此，該工單規劃單元11即可獲得各設備30的即時運作資訊。上述運作穩定期判斷單元13連結至該複數運作資訊擷取單元12及該工單規劃單元11，以獲得各設備30的即時運作資訊。以一條連續性生產線的複數道工作站~M為例，當該運作穩定期判斷第一工作站1的設備30已進入穩定期時，即觸發該工單規劃單元11的工單修改模組111，修改對應該設備30的初始工單的完成時間，並據以同時修改第二道工作站2至最後一道工作站M的對應工單的完成時間；如此，本發明即可在各條連續性生產線的各工作站1~M運作期間，調整正在運作工作站與接續其後之工作站的具體完成時間。當各工作站的設備運作順利，則本發明可減少各工作站等待時間，進而提高整條生產線的生產效率；如若其中一工作站突遇故障，接續其後的工作站的初始工單會被即時修改，避免待機過久。The plurality of operational information capture units 12 are coupled to the work order planning unit 11 to continuously retrieve at least one operational information of the corresponding workstation in the process, which may be assembled by equipment or manually. The following is an example of the device. Therefore, the work order planning unit 11 can obtain the real-time operation information of each device 30. The operational stability period determining unit 13 is coupled to the plurality of operational information capturing units 12 and the work order planning unit 11 to obtain real-time operational information of each device 30. Taking the multi-channel workstation ~M of a continuous production line as an example, when it is determined that the device 30 of the first workstation 1 has entered the stable period, the work order modification module 111 of the work order planning unit 11 is triggered to be modified. Corresponding to the completion time of the initial work order of the equipment 30, and simultaneously modifying the completion time of the corresponding work order of the second workstation 2 to the last workstation M; thus, the present invention can be performed on each workstation of each continuous production line. During the operation of 1~M, adjust the specific completion time of the workstations that are running and the workstations that continue to be connected. When the equipment of each workstation runs smoothly, the invention can reduce the waiting time of each workstation, thereby improving the production efficiency of the entire production line; if one of the workstations fails suddenly, the initial work order of the subsequent workstation will be modified immediately, avoiding Standby for too long.
誠如上述所述，工廠突遇設備故障或人為操作疏失造成停產，直接衝擊對工廠整體生產效率。因此，如圖9所示，本發明的即時動態工廠管理系統10b進一步包含有一運作狀態圖形產生單元14及複數異常警示單元15。該運作狀態圖形產生單元14係連結至各該運作狀態擷取單元12，以連續獲得各該工作站的設備30運作資訊，由於各設備30的運作資訊為各製品或製品部件的完成時間，故可取二相鄰製品或製品部件的完成時間(如圖10A)之時間差作為縱軸的數值，時間為橫軸的數值，繪製一運作狀態圖形，如圖10B所示，顯示此一運作狀態圖形，一旦前、後完成部件時間的時間間隔太長，則容易由該運作狀態圖形顯現，亦有助於工廠各階段的部門於獲得異常警示時，找到異常發生的時間，快速進行排除。As mentioned above, the factory suddenly encounters equipment failure or human operation and causes production stoppage, which directly impacts the overall production efficiency of the factory. Therefore, as shown in FIG. 9, the instant dynamic plant management system 10b of the present invention further includes an operational status graphic generating unit 14 and a plurality of abnormal warning units 15. The operation state graphic generating unit 14 is coupled to each of the operating state capturing units 12 to continuously obtain the operation information of the devices 30 of each workstation. Since the operation information of each device 30 is the completion time of each product or product component, it is desirable. The time difference between the completion time of two adjacent articles or product components (as shown in FIG. 10A) is taken as the value of the vertical axis, and the time is the value of the horizontal axis. A working state graphic is drawn, as shown in FIG. 10B, and the operational state graphic is displayed once. The time interval between the completion of the parts before and after is too long, and it is easy to be visualized by the operation state graphic. It also helps the departments at all stages of the factory to find the time when the abnormality occurs when the abnormal warning is obtained, and quickly eliminate it.
上述複數異常警示單元15則可設置於工廠各階段的部門，如圖7所示，各異常警示單元15於前運作狀態圖形的縱軸數值超過一預設異常時間，即產生一異常警示，例如以一顯示器顯示紅色標記(斜線所示)。舉例來說，該設備出現製程異常的原因不外乎有屬生技部負責的前端加工異常或生產模治具異常、品管部負責的前端加工異常或原料異常/錯料或連續產出整批異常、設備部負責的設備設備異常或製損率異常 、廠務部負責的水或氣或化或電供應異常或環境其他影響品質異常、資材部負責的供料異常或原料異常/錯料等。故當某一設備的該運作狀態圖形上出現突出點，代表該設備於穩定期後送出已烘烤的前、後基板時間差距太遠，為製程異常。此時，該管理階段的研發部、品管階段的品管部、生產階段的生技術、生產部、設備部或廠務部的異常警示單元會發出警示，而及時進行橫向聯繫製程異常的瞭解。The plurality of abnormality warning units 15 can be installed in the departments of each stage of the factory. As shown in FIG. 7, each abnormal warning unit 15 generates an abnormal warning when the vertical axis value of the front operation state graph exceeds a predetermined abnormal time, for example, A red mark (shown by a slash) is displayed on one display. For example, the process abnormality of the equipment is caused by the abnormality of the front end processing or the abnormality of the production mold, the front end processing abnormality of the quality control department or the raw material abnormality/wrong material or continuous output. Abnormal batch, equipment and equipment abnormalities or damage rate abnormalities in charge of the equipment department, water or gas or chemical or electrical supply abnormalities in charge of the plant department or abnormal environmental impacts, material supply abnormalities or raw material abnormalities/wrong materials Wait. Therefore, when a prominent point appears on the operational state of a certain device, it means that the time difference between the front and rear substrates of the device after the stable period is too far, which is abnormal for the process. At this time, the R&D department of the management stage, the quality control department of the quality control stage, the production technology of the production stage, the production department, the equipment department, or the abnormal warning unit of the factory department will issue a warning, and timely understand the abnormality of the horizontal contact process. .
欲加速各工作站的製程異常排除，可進一步將設備的環境參數予以檢知後輸出至資料庫DB，與同製程的製品或製品部件的完成時間一併儲存。意即，各設備30進一步設置有不同環境檢知器，包含有溫度檢知器、壓力檢知器、濃度檢知器等，於該運作資訊擷取單元擷取各機的運作資訊時，一併擷取該設備製程中的環境參數，並可進一步與操作人員、設備型號歸納為該初始工單的一生產履歷，如圖11所示，以供備查。因此，當各相關部份人員於檢視該運作狀態圖形上出現突出點，或收到異常警示，可自該資料庫中擷取該製程異常之設備的生產履歷，並由該突出點的時間讀取該時間點的製程參數，快速判斷是否因製程參數的異常而造成該製程異常。In order to speed up the process abnormality of each workstation, the environmental parameters of the equipment can be further detected and output to the database DB, and stored together with the completion time of the products or product parts of the same process. That is, each device 30 is further provided with a different environment detector, including a temperature detector, a pressure detector, a concentration detector, etc., when the operation information acquisition unit captures the operation information of each machine, The environmental parameters in the process of the device are taken and further classified with the operator and the device model as a production history of the initial work order, as shown in FIG. 11 for reference. Therefore, when the relevant part of the personnel displays a prominent point on the viewing of the operational status graphic, or receives an abnormal warning, the production history of the device with the abnormal process can be retrieved from the database, and the time of the protruding point is read. Take the process parameters at this time point and quickly determine whether the process is abnormal due to an abnormality of the process parameters.
此外，除各部門藉由異常警示單元發出異常警示而主動檢視責屬工作範圍是否異常外，如圖12所示，亦可匯整一異常排除流程，即當出現製程異常S20時，由生產部的操作人員進行異常原因確認及初步製程異常排除S21，再由品管部依據排除後生產的製品S22或製品部份，依據品管檢驗標準判斷是否需停機S23，若需停機S24，則由品管單位協調各部門協商對策，再次進行製程異常排除S25，待確定排除後再上線生產，並記錄製程異常原因及排除對策，通常將製程異常原因、排除對策及排除人員儲存於該設備的資料庫DB，或輸入MRP系統及/或ERP系統(若有)，以利後續查詢用。In addition, except for the abnormal warning units issued by the abnormal warning units to actively check whether the scope of work is abnormal, as shown in Figure 12, an abnormality elimination process can also be collected, that is, when the process abnormality S20 occurs, the production department The operator performs the abnormal cause confirmation and the preliminary process abnormality exclusion S21, and then the quality control department judges whether it is necessary to stop the S23 according to the quality inspection standard according to the product S22 or the product part which is produced after the exclusion, and if the S24 is required to be stopped, The management unit coordinates the consultation measures of each department, and then repeats the process abnormality exclusion S25. After the elimination is confirmed, the production is completed, and the process abnormality reason and the elimination countermeasures are recorded. Usually, the process abnormality reason, the elimination countermeasure and the excluded personnel are stored in the database of the equipment. DB, or enter the MRP system and / or ERP system (if any) for subsequent queries.
由於工廠主管於考核其所屬部門員工的績效仍有主觀的工作印象分數，難謂公平；因此，如圖 9所示，本發明即時動態工廠管理系統10b可進一步將上述與生產作業直接相關之人員，於生產當時或製程異常排除後記錄的各種數據予以儲存，並提供一績效考核資料收集單元16，以擷取該生產相關人員於一考核期間內，各工單在製程期間之穩定期的平均部件完成時間、各製程的異常頻率及製程異常的排除時間，進行考核。具體而言，該績效考核資料收集單元16係於一考核期間內，至各該資料庫擷取各操作人員於穩定期的平均部件完成時間、各製程的異常頻率及製程異常的排除時間，進行考核。Since the factory supervisor still has a subjective job impression score in assessing the performance of the employees of his department, it is difficult to be fair; therefore, as shown in FIG. 9, the instant dynamic plant management system 10b of the present invention can further further relate the above-mentioned personnel directly related to the production operation. The various data recorded at the time of production or after the abnormal removal of the process is stored, and a performance appraisal data collecting unit 16 is provided to obtain an average of the stability periods of the work orders during the process period of the production related personnel during the inspection period. The component completion time, the abnormal frequency of each process, and the exclusion time of the process abnormality are evaluated. Specifically, the performance appraisal data collection unit 16 is configured to collect the average component completion time of each operator during the stabilization period, the abnormal frequency of each process, and the exclusion time of the process abnormality during each assessment period. Assessment.
綜上所述，本發明即時動態工廠管理系統係具有以下數項優點： 1. 提高工廠的生產效率，降低生產成本：判斷各該工作站的穩定期後，於製程期間內依照實際製品或製品部件完成時間，準確預估該工作站完成該工單的時間，排除因操作人員的人為因素所造成工單完成延誤。 2．立即通報製程異常，提高製程異常排除效率：當前、後完成部件時間的時間間隔太長，該工作站之設備的運作狀態圖形會出現明顯的突出點，亦有助於工廠各階段的部門快速注意該設備的製程異常。 3. 快速排除製程異常：同時檢知各工作站設備的環境參數，當製程異常警示發生後，可以當製程異常間點擷取當時的環境參數，由環境參數排除是否為設備異常引發的製程異常。 4. 提供數據化的公平考核制度：於一考核期間內，各工單在製程期間之穩定期的平均部件完成時間、各製程的異常頻率及製程異常的排除時間，進行考核。In summary, the instant dynamic plant management system of the present invention has the following advantages: 1. Increasing the production efficiency of the factory and reducing the production cost: after judging the stability period of each workstation, according to the actual product or product component during the manufacturing process The completion time accurately estimates the time at which the workstation completes the work order, eliminating the delay in completing the work order due to human factors of the operator. 2. Immediately notify process anomalies and improve process exception elimination efficiency: the time interval between the current and post-complete component time is too long, and the operation status graph of the equipment of the workstation will have obvious prominent points, which also helps the departments at all stages of the plant to pay close attention to the The process of the device is abnormal. 3. Quickly eliminate process exceptions: At the same time, check the environmental parameters of each workstation device. When the process abnormality warning occurs, you can retrieve the current environmental parameters when the process is abnormal. The environmental parameters exclude whether the process abnormality is caused by the device abnormality. 4. Provide a fair evaluation system for data: During the assessment period, the work time of each work order during the stable period of the process, the abnormal frequency of each process and the exclusion time of the process anomaly are evaluated.
10、10a、10b 即時動態工廠管理系統 11 工單規劃單元 111 工單修改模組 12 運作資訊擷取單元 13 運作穩定期判斷單元 14 運作狀態圖形產生單元 15 異常警示單元 16 績效考核資料收集單元 20 ERP系統 21 工單規劃模組 22 運作穩定期判斷模組 30 設備 30a 設備 30b 手工生產線 31 動作檢知器 40 製品 50 生產履歷表10, 10a, 10b Real-time dynamic plant management system 11 Work order planning unit 111 Work order modification module 12 Operation information acquisition unit 13 Operation stability period judgment unit 14 Operation status graphic generation unit 15 Abnormal warning unit 16 Performance evaluation data collection unit 20 ERP system 21 Work order planning module 22 Operational stability period judgment module 30 Equipment 30a Equipment 30b Manual production line 31 Motion detector 40 Product 50 Production resume
圖1：本發明即時動態工廠管理系統的第一較佳實施例的方塊圖。 圖2A至圖2C：本發明應用於不同設備及手工生產線的示意圖。 圖3：本發明單一設備由不同操作人員的學習曲線圖。 圖4A至圖4C：本發明初始工單及修改後工單的完成時間示意圖。 圖5：本發明即時動態工廠管理系統的第二較佳實施例的方塊圖。 圖6：本發明整合於一MRP系統及/或ERP系統的工單管理流程圖。 圖7：本發明即時動態工廠管理系統應用於連續性生產線的示意圖。 圖8：本發明即時動態工廠管理系統的第三較佳實施例的方塊圖。 圖9：本發明即時動態工廠管理系統的第四較佳實施例的方塊圖。 圖10A：本發明擷取設備於製程中的運作資訊統計圖。 圖10B：本發明轉換圖10A為一運作狀態圖。 圖11：本發明一工作履歷表的示意圖。 圖 12：本發明排除製程異常的流程圖。 圖 13：既有工廠工單製程示意圖。Figure 1 is a block diagram of a first preferred embodiment of the instant dynamic plant management system of the present invention. 2A to 2C are schematic views of the present invention applied to different equipment and manual production lines. Figure 3: A learning curve of a single device of the present invention by different operators. 4A to 4C are schematic diagrams showing the completion time of the initial work order and the modified work order of the present invention. Figure 5 is a block diagram of a second preferred embodiment of the instant dynamic plant management system of the present invention. Figure 6: Flow chart of work order management integrated into an MRP system and/or ERP system of the present invention. Figure 7 is a schematic illustration of the application of the instant dynamic plant management system of the present invention to a continuous production line. Figure 8 is a block diagram of a third preferred embodiment of the instant dynamic plant management system of the present invention. Figure 9 is a block diagram of a fourth preferred embodiment of the instant dynamic plant management system of the present invention. FIG. 10A is a statistical diagram of operation information of the capture device of the present invention in a process. Fig. 10B: The transition diagram of the present invention is shown in Fig. 10A. Figure 11 is a schematic illustration of a work history of the present invention. Figure 12: Flow chart of the present invention excluding process anomalies. Figure 13: Schematic diagram of the existing factory work order process.
10 即時動態工廠管理系統 11 工單規劃單元 111 工單修改模組 12 運作資訊擷取單元 13 運作穩定期判斷單元 30 設備10 Real-time dynamic plant management system 11 Work order planning unit 111 Work order modification module 12 Operation information acquisition unit 13 Operation stability period judgment unit 30 Equipment
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