Disclosure of Invention
The application provides a real-time monitoring management method and a real-time monitoring management system for a visual production line, which are used for highlighting the key points of various production information based on different types of production tasks, so that data are more visual.
In a first aspect, the application provides a method for real-time monitoring and management of a visual production line, which is applied to a real-time monitoring and management system, and comprises the steps of receiving and displaying a production plan through a plan billboard, and analyzing the production plan into a specific production task; the method comprises the steps of selecting an information display billboard corresponding to a specific production task, wherein the information display billboard comprises a task billboard, a material billboard, a production line tracking billboard, an abnormal tracking billboard and a comprehensive billboard, extracting task characteristics of the specific production task, counting the specific production task to obtain a production task progress, the task characteristics comprise task duration time, product types and process complexity, selecting key indexes and data update frequencies corresponding to the specific production task based on the task characteristics, wherein the key indexes comprise production efficiency, quality qualification rate, energy consumption and production cycle, acquiring hardware configuration components related to the specific production task, acquiring real-time operation parameters of the hardware configuration components, and displaying the task characteristics, the production task progress, the key indexes and the real-time operation parameters on the information display billboard according to the data update frequencies.
By adopting the technical scheme, the real-time monitoring management system firstly receives the production plan through the plan signboard and analyzes the production plan into specific production tasks, so that the production plan can be particularly realized to an operable level. Then, the information presentation sign corresponding to the specific production task is selected, ensuring that the relevant production information can be presented in the most appropriate manner. And then, extracting task characteristics, counting the progress of the production task, and selecting key indexes and data updating frequency based on the task characteristics so that the manager can focus on the most important indexes. Finally, the real-time operation parameters of the hardware configuration component are obtained, the task characteristics, the production task progress, the key indexes and the real-time operation parameters are displayed on the information display signboard according to the data updating frequency, so that comprehensive, real-time and personalized monitoring management of the production line is realized, the production information is more visual and emphasized, management staff can know the condition of the production line in time, and accurate decisions are made.
In combination with some embodiments of the first aspect, in some embodiments, the step of selecting the key index and the data update frequency corresponding to the specific production task based on the task feature specifically includes classifying the specific production task as a short-term task, a medium-term task or a long-term task according to the task duration, wherein the key index corresponding to the short-term task includes production efficiency and quality qualification rate, the key index corresponding to the medium-term task includes production efficiency, quality qualification rate and energy consumption, and the key index corresponding to the long-term task includes production efficiency, quality qualification rate, energy consumption and production period, and selecting the data update frequency corresponding to the task type of the specific production task in a preset frequency database.
By adopting the technical scheme, the specific production tasks are classified into short-term, medium-term or long-term tasks according to the task duration, corresponding key indexes are matched for different types of tasks, the short-term tasks pay attention to the production efficiency and the quality qualification rate, the medium-term tasks pay attention to the energy consumption, and the long-term tasks comprehensively consider the production efficiency, the quality qualification rate, the energy consumption and the production period, so that the monitoring indexes are more targeted. Meanwhile, the data updating frequency corresponding to the task type is selected from a preset frequency database, so that the balance of the real-time performance and the system performance of the data is ensured.
In combination with some embodiments of the first aspect, in some embodiments, the step of displaying the task feature, the production task progress, the key index and the real-time operation parameter on the information display signboard according to a data update frequency specifically includes obtaining a preset user-defined layout, arranging the information display signboard based on the preset user-defined layout, integrally displaying the task feature, the production task progress, the key index and the real-time operation parameter on the information display signboard, refreshing data on the information display signboard in real time based on the data update frequency, and triggering a visual warning in the information display signboard when any one parameter of the production task progress, the key index and the real-time operation parameter exceeds a preset threshold.
By adopting the technical scheme, the user-defined layout of the preset user is obtained, and the information display signs are arranged based on the user-defined layout, so that the sign display meets the user requirements better. The task characteristics, the production task progress, the key indexes and the real-time operation parameters are integrally displayed on the information display signboard, so that management personnel can conveniently and comprehensively know the production condition. And refreshing the data on the signboard in real time based on the data updating frequency, so as to ensure the timeliness of the information. When any one parameter of the production task progress, the key index and the real-time operation parameter exceeds a preset threshold, a visual warning is triggered in the information display signboard, so that management personnel can be timely reminded of paying attention to the abnormal condition.
In combination with some embodiments of the first aspect, in some embodiments, after the step of displaying the production task progress, the key index and the real-time operation parameter on the information display board, the method further includes determining a specific production task classification according to a task duration of the material management task when the specific production task is the material management task, selecting a task board, a material board and an anomaly tracking board to display information when the specific production task is the material management task and is the short-term task, displaying task characteristics of the material management task, a material production task progress and a real-time operation parameter on the task board, wherein the task characteristics include a material task duration, a material product type and a material process complexity, displaying a bill of materials, material inventory information and a material key index on the material board, wherein the bill of materials includes a material name, a specification and a planned usage amount, the material inventory information includes a current inventory, a safe inventory level and an inventory state, the material critical index includes a material turnover rate, an inventory accuracy and a material utilization rate, displaying material quality information, an inventory quality information and an anomaly quality information including an anomaly quality information, an anomaly quality information and an anomaly quality information, and an equipment quality information including an anomaly quality analysis and an anomaly quality information, and an equipment failure rate.
By adopting the technical scheme, when the specific production task is a material management task, the specific production task classification is determined according to the task duration. For short-term material management tasks, selecting task signboards, material signboards and anomaly tracking signboards for information display. And displaying relevant characteristics, progress and real-time operation parameters of the material management task on the task signboard in real time, so that a manager can intuitively know the task execution condition. The bill of materials, stock information and key index are concentrated to show to the bill of materials, help accurately grasp the material situation. The anomaly tracking billboard displays material quality anomaly information, inventory anomaly alarms and material equipment anomaly information, and can timely discover and process problems. Through the synergistic effect of the signs, the comprehensive and real-time monitoring of the material management task is realized, and the efficiency and accuracy of material management are improved.
In combination with some embodiments of the first aspect, in some embodiments, after the step of displaying the production task progress, the key indicator and the real-time operation parameter on the information display billboard, the method further includes obtaining an actual completion time of the specific production task, calculating a production line efficiency indicator based on the task duration and the actual completion time, comparing the production line efficiency indicator with a preset target efficiency to obtain an efficiency difference value, automatically generating an efficiency optimization suggestion based on the task feature and the real-time operation parameter when the efficiency difference value exceeds a preset threshold, and displaying the efficiency optimization suggestion on the anomaly tracking billboard.
By adopting the technical scheme, the actual completion time of a specific production task is acquired, and the efficiency index of the production line is calculated by combining the task duration. And comparing the comprehensive production line efficiency index with a preset target efficiency to obtain an efficiency difference value. When the efficiency difference value exceeds a preset threshold value, efficiency optimization suggestions are automatically generated based on task characteristics and real-time operation parameters, and the suggestions are displayed on an abnormal tracking billboard, so that a manager can know the efficiency condition of the production line in time, take measures to optimize according to the suggestions, accurately monitor and analyze the efficiency of the production line, and timely provide optimization suggestions, thereby being beneficial to improving the overall efficiency of the production line, reducing the production cost and enhancing the competitiveness of enterprises.
In combination with some embodiments of the first aspect, in some embodiments, after the step of displaying the production task progress, the key indicator and the real-time operation parameter on the information display sign, the method further includes setting a multi-level abnormality pre-warning threshold based on the key indicator and the real-time operation parameter displayed on the information display sign, monitoring changes in the key indicator and the real-time operation parameter in real time, and triggering a preset level of abnormality alarm on the abnormality tracking sign when exceeding the pre-warning parameter threshold is detected, the preset level corresponding to the multi-level abnormality pre-warning threshold.
By adopting the technical scheme, the multistage abnormality early warning threshold is set based on the key indexes and the real-time operation parameters displayed on the information display signboard. And monitoring the changes of the key indexes and the real-time operation parameters in real time, and triggering an abnormal alarm of a preset level on the abnormal tracking billboard when the change exceeding of the early warning parameter threshold value is detected. This hierarchical alarm mechanism enables the manager to quickly identify the severity of the anomaly and take corresponding action. By timely finding and processing the abnormal conditions, the stable operation of the production line is ensured, the influence of the abnormal conditions on production is reduced, and the reliability of production and the stability of product quality are improved.
In combination with some embodiments of the first aspect, in some embodiments, after the step of displaying the production task schedule, the key indicators, and the real-time operational parameters on the information presentation sign, the method further includes identifying a type, a function, and a communication protocol of the hardware component if an access operation of the hardware component is detected, assigning a unique identifier to the hardware component based on the type, the function, and the communication protocol, marking a component location of the hardware component in a production line layout based on the unique identifier, and displaying a status of the hardware component at the component location on the integrated sign.
By adopting the technical scheme, when the access operation of the hardware component is detected, the system can automatically identify the type, the function and the communication protocol of the hardware component, and a unique identifier is allocated to the hardware component based on the identified information, so that each hardware component is ensured to have a unique identifier in the system, and the system can accurately manage and track the hardware component conveniently. Then, the unique identifier is used for marking the component position of the hardware component in the production line layout, the component position and the state of the hardware component are displayed on the comprehensive billboard, and a manager can intuitively know the specific position and the running state of each hardware component on the comprehensive billboard, so that the accurate positioning and the real-time monitoring of the hardware component are realized.
In a second aspect, embodiments of the present application provide a real-time monitoring management system comprising one or more processors and a memory coupled to the one or more processors, the memory for storing computer program code comprising computer instructions that the one or more processors invoke to cause the real-time monitoring management system to perform a method as described in the first aspect and any of the possible implementations of the first aspect.
In a third aspect, embodiments of the present application provide a computer program product comprising instructions which, when run on a real-time monitoring management system, cause the real-time monitoring management system to perform a method as described in the first aspect and any one of the possible implementations of the first aspect.
In a fourth aspect, an embodiment of the present application provides a computer readable storage medium, including instructions that, when executed on a real-time monitoring management system, cause the real-time monitoring management system to perform a method as described in the first aspect and any possible implementation manner of the first aspect.
It will be appreciated that the real-time monitoring management system provided in the second aspect, the computer program product provided in the third aspect and the computer storage medium provided in the fourth aspect are each configured to perform the method provided by the embodiment of the present application. Therefore, the advantages achieved by the method can be referred to as the advantages of the corresponding method, and will not be described herein.
One or more technical solutions provided in the embodiments of the present application at least have the following technical effects or advantages:
1. The application firstly receives the production plan through the plan signboard and analyzes the production plan into specific production tasks through the real-time monitoring management system, so that the production plan can be particularly realized to an operable level. Then, the information presentation sign corresponding to the specific production task is selected, ensuring that the relevant production information can be presented in the most appropriate manner. And then, extracting task characteristics, counting the progress of the production task, and selecting key indexes and data updating frequency based on the task characteristics so that the manager can focus on the most important indexes. Finally, the real-time operation parameters of the hardware configuration component are obtained, the task characteristics, the production task progress, the key indexes and the real-time operation parameters are displayed on the information display signboard according to the data updating frequency, so that comprehensive, real-time and personalized monitoring management of the production line is realized, the production information is more visual and emphasized, management staff can know the condition of the production line in time, and accurate decisions are made.
2. According to the application, the information display signs are arranged based on the preset user-defined layout, so that the sign display meets the user requirements. The task characteristics, the production task progress, the key indexes and the real-time operation parameters are integrally displayed on the information display signboard, so that management personnel can conveniently and comprehensively know the production condition. And refreshing the data on the signboard in real time based on the data updating frequency, so as to ensure the timeliness of the information. When any one parameter of the production task progress, the key index and the real-time operation parameter exceeds a preset threshold, a visual warning is triggered in the information display signboard, so that management personnel can be timely reminded of paying attention to the abnormal condition.
3. According to the application, when the specific production task is a material management task, the specific production task classification is determined according to the task duration. For short-term material management tasks, selecting task signboards, material signboards and anomaly tracking signboards for information display. And displaying relevant characteristics, progress and real-time operation parameters of the material management task on the task signboard in real time, so that a manager can intuitively know the task execution condition. The bill of materials, stock information and key index are concentrated to show to the bill of materials, help accurately grasp the material situation. The anomaly tracking billboard displays material quality anomaly information, inventory anomaly alarms and material equipment anomaly information, and can timely discover and process problems. Through the synergistic effect of the signs, the comprehensive and real-time monitoring of the material management task is realized, and the efficiency and accuracy of material management are improved.
Detailed Description
The terminology used in the following embodiments of the application is for the purpose of describing particular embodiments only and is not intended to be limiting of the application. As used in the specification of the present application, the singular forms "a", "an", "the" and "the" are intended to include the plural forms as well, unless the context clearly indicates to the contrary. It should also be understood that the term "and/or" as used in this disclosure is intended to encompass any or all possible combinations of one or more of the listed items.
The terms "first," "second," and the like, are used below for descriptive purposes only and are not to be construed as implying or implying relative importance or implicitly indicating the number of technical features indicated. Thus, a feature defining "a first" or "a second" may explicitly or implicitly include one or more such feature, and in the description of embodiments of the application, unless otherwise indicated, the meaning of "a plurality" is two or more.
For ease of understanding, the method provided in this embodiment is described in the following. Fig. 1 is a schematic flow chart of a method for real-time monitoring and managing a visual production line according to an embodiment of the application.
S101, receiving and displaying a production plan through a plan signboard, and analyzing the production plan into a specific production task.
Specifically, this step is performed when the production management system receives a new production plan. The system first receives and visually displays the production plan through the plan bulletin board, so that the manager can visually check the whole production arrangement. The system then disassembles and parses the overall production plan, converting it into a series of specific, operational production tasks.
In some embodiments, the receiving, displaying and analyzing of the production plan can be achieved in various ways, wherein the system can automatically acquire production plan data from the ERP system through an API interface, then display the whole production schedule on a plan billboard in the form of Gantt chart, then split each production project in the plan into specific working procedure tasks by utilizing a preset task disassembly rule, and can also provide a man-machine interaction interface to allow production managers to manually input production plan information, then display the input plan on the billboard in the form of a table, then understand the plan content through natural language processing technology and automatically generate a corresponding specific task list based on a product production flow template. It will be appreciated that the process of receiving, displaying and analyzing the production plan may also be implemented in other ways, and is not limited herein.
S102, selecting an information display billboard corresponding to the specific production task, wherein the information display billboard type comprises a task billboard, a material billboard, a production line tracking billboard, an abnormal tracking billboard and a comprehensive billboard.
The information display signboard is an interface for visually displaying production-related information. The task board is used for displaying detailed information of specific production tasks. The material signboard is used for displaying the related information of the materials required by production. The production line tracking signboard is used for monitoring the running condition of the production line in real time. The anomaly tracking billboard is used for displaying the anomaly in the production process. The comprehensive billboard is used for integrating and displaying various production information.
Specifically, this step is performed after a specific production task is determined. The system will select the type of sign best suited to display information about each particular production task based on the characteristics and information requirements of that task. This selection process takes into account the nature, complexity, resources required, etc. of the task to ensure that the relevant production information can be presented to the user in the most appropriate, intuitive manner.
In some embodiments, the selection of information display signs corresponding to specific production tasks may be achieved in a variety of ways, alternatively, the system may automatically select the most appropriate sign type based on preset task-sign mapping rules, according to the type, priority and involved production links of the task, for example, the material signs are preferentially selected for the task related to the material, the anomaly tracking signs are selected for the quality control task, alternatively, the system may also employ a machine learning method, recommend the most appropriate sign type for each new production task by analyzing historical task data and sign usage, and allow the user to confirm or adjust, and then the system may continuously optimize the recommendation algorithm according to the user's selection. It will be appreciated that the selection of the information presentation sign may also be accomplished in other ways, and is not limited in this regard.
S103, extracting task characteristics of the specific production task, and counting the specific production task to obtain the production task progress, wherein the task characteristics comprise task duration, product type and process complexity.
Wherein task features refer to key attributes that enable describing and distinguishing different production tasks. The task duration represents the length of time expected to be required to complete the task. The product type is used to indicate the product category to which the task relates. The process complexity refers to the complexity of the production process to which the task relates. The production task progress is used to indicate the extent or status of the completion of the current task.
Specifically, this step is performed after the information presentation sign is selected. The system first extracts key task features from detailed information of specific production tasks, and the features can comprehensively reflect the properties and requirements of the tasks. Then, the system can track the execution condition of the task in real time, and calculate the current task progress by comparing the planning progress and the actual completion condition.
In some embodiments, task feature extraction and progress statistics may be implemented in a variety of ways, optionally, the system may automatically identify and extract relevant features from the task types using predefined feature extraction templates, such as extracting predicted start and end times from a production plan, calculating task duration, obtaining product types from a product information database, evaluating process complexity by analyzing process flow charts, then the system may obtain task execution data on the production line via a real-time data acquisition device, periodically update task progress in conjunction with a preset progress calculation formula, and finally the system stores the extracted features and calculated progress in a task database. Optionally, the system can also adopt a machine learning method to train a feature extraction model by analyzing historical task data, automatically extract key features from task descriptions and related documents, simultaneously predict future progress of the task based on current progress and historical data by using a predictive analysis technology, dynamically adjust a progress calculation method, and finally, visually present the extracted features and the predicted progress by the system and allow manual intervention and adjustment. It will be appreciated that the task feature extraction and progress statistics may also be implemented in other ways, not limited herein.
S104, selecting a key index and a data updating frequency corresponding to the specific production task based on the task characteristics, wherein the key index comprises production efficiency, quality qualification rate, energy consumption and production period.
The key indexes are important parameters for evaluating and monitoring the execution condition of the production task. Production efficiency represents the throughput per unit time. The quality qualification rate is used for measuring the proportion of the product reaching the quality standard. The energy consumption refers to the total amount of energy used in the production process. A production cycle refers to the total time required from the start to completion of a production task. The data update frequency represents the time interval between system refresh and update of the relevant data.
Specifically, this step is performed after extracting the task features and calculating the task progress. The system will select the most relevant and important key indicators for each particular production task based on the previously extracted task features. This selection process takes into account the nature, importance and complexity of the task. Meanwhile, the system can determine proper data updating frequency according to the characteristics of the task so as to ensure the balance of the real-time performance of the data and the system performance.
In some embodiments, the selection of the key indicators and the data update frequency may be achieved in a variety of ways, alternatively, the system may use a preset rule engine to automatically match the corresponding set of key indicators according to the task characteristics, such as to preferentially select production efficiency and quality yield for short-term tasks and to include all four indicators for long-term tasks, then the system selects the appropriate update frequency from a predefined frequency list according to the time span and urgency of the task, and finally the system applies the selected indicators and frequencies to the corresponding data acquisition and processing module. Optionally, the system can also adopt an intelligent recommendation algorithm to recommend the most relevant index combination for each new task by analyzing historical task data and index use conditions, and simultaneously, the system dynamically adjusts the data updating frequency by using an adaptive algorithm, increases the frequency in a task key stage and reduces the frequency in a stable stage so as to optimize system resources, and finally, the system presents recommendation results to management staff to allow the management staff to carry out fine adjustment and confirmation. It will be appreciated that the selection of key indicators and data update frequencies may also be accomplished in other ways, and is not limited herein.
S105, acquiring a hardware configuration component related to the specific production task, and acquiring real-time operation parameters of the hardware configuration component.
Wherein hardware configuration components refer to various machine devices and tools for performing specific production tasks. The real-time operation parameters represent various indexes and state data of the hardware configuration component in the operation process. Related hardware configuration components refer to devices that are directly related to or participate in the execution of a particular production task.
Specifically, this step is performed after the key index and the data update frequency are selected. The system first needs to identify all hardware devices associated with the current production task, including machines, tools, sensors, etc. on the production line. The system will then establish a connection with these hardware devices and begin collecting their operational data in real time. The data includes various parameters of the operating state, temperature, pressure, speed, etc. of the device. This process involves not only the collection of data, but also the preliminary processing and verification of the data to ensure that the information obtained is accurate and reliable.
In some embodiments, the identification of hardware configuration components and the acquisition of real-time operating parameters may be achieved in a variety of ways, optionally, the system may automatically identify related hardware components according to task type using a preset task-device mapping table, then connect each hardware component to a central monitoring system through an industrial internet of things (IIoT) technology, and finally continuously collect the operating parameters of each component at a predefined sampling rate using a real-time data acquisition (SCADA) system. Optionally, the system can also adopt a dynamic equipment discovery technology to automatically identify the currently active production equipment through network scanning, then use an intelligent sensor network to collect various operation data of the equipment in real time, and finally use an edge computing technology to perform preliminary processing and screening at a data source and only transmit key information to a central system. It will be appreciated that the identification of hardware configuration components and the acquisition of real-time operating parameters may also be accomplished in other ways, and are not limited herein.
And S106, displaying the task characteristics, the production task progress, the key indexes and the real-time operation parameters on the information display signboard according to the data updating frequency.
The information display signboard is an interface for visually displaying various production-related information. The data update frequency represents the time interval between system refresh and update of the display data on the sign. The task features contain information describing the key attributes of the production task. The production task progress represents the extent to which the current task is completed. The key index refers to an important parameter for evaluating the performance of a task. The real-time operation parameters refer to current operation state data of the hardware equipment.
Specifically, this step is performed after the hardware operating parameters are obtained. The system integrates various information collected and processed in the previous steps, and performs visual presentation on the information display signboard according to a preset layout and format. This process involves not only the organization and typesetting of data, but also the periodic refreshing of the display content according to the frequency of data updates. The system may select an appropriate presentation based on different types of data, such as in the form of a chart, dashboard, or text, to ensure that information is visually and clearly communicated to the user. Meanwhile, the system also carries out logic grouping and layout on related information based on the relevance between the data, so that a user can conveniently and quickly acquire the required information.
In some embodiments, the integrated presentation and dynamic update of information may be achieved in a variety of ways, including, optionally, the system may create separate display modules for each type of information (e.g., task features, progress, key indicators, and operational parameters) using a modular interface design, then organize the modules into appropriate positions on the sign according to a preset layout template, and finally, set a timer to trigger a data refresh event according to a specified update frequency, updating the display content of each module. Optionally, the system can also adopt a responsive design method to create a dynamically adjusted interface frame, then use a data binding technology to associate a background data source with the front display element, finally realize a real-time pushing mechanism, automatically update the corresponding display element when the data source changes, and ensure the real-time performance of the information. It will be appreciated that other ways of implementing integrated presentation and dynamic updating of information may be employed, as is not limited herein.
The method provided in this embodiment will be described in more detail. Fig. 2 is a schematic flow chart of a method for real-time monitoring and managing a visual production line according to an embodiment of the application.
S201, receiving and displaying a production plan through a plan billboard, and analyzing the production plan into a specific production task.
It is understood that this step is similar to step S101, and will not be described here.
S202, selecting an information display billboard corresponding to the specific production task, wherein the information display billboard type comprises a task billboard, a material billboard, a production line tracking billboard, an abnormal tracking billboard and a comprehensive billboard.
It is understood that this step is similar to step S102, and will not be described here.
S203, extracting task characteristics of the specific production task, and counting the specific production task to obtain the production task progress, wherein the task characteristics comprise task duration, product type and process complexity.
It is understood that this step is similar to step S103, and will not be described here.
S204, selecting a key index and a data updating frequency corresponding to the specific production task based on the task characteristics, wherein the key index comprises production efficiency, quality qualification rate, energy consumption and production period.
The method specifically comprises the following steps:
And classifying the specific production task into a short-term task, a medium-term task or a long-term task according to the task duration, wherein the key indexes corresponding to the short-term task comprise production efficiency and quality qualification rate, the key indexes corresponding to the medium-term task comprise production efficiency, quality qualification rate and energy consumption, and the key indexes corresponding to the long-term task comprise production efficiency, quality qualification rate, energy consumption and production period.
For a particular production task, it is first necessary to sort the tasks according to their duration. The task duration herein refers to the length of time that is expected to be required to complete the task. The division of tasks into short-term, medium-term and long-term tasks can be based on a pre-set time threshold, e.g., short-term tasks lasting less than 1 day, medium-term tasks between 1 week and 1 month, long-term tasks exceeding 1 month. Then, different key monitoring indexes are selected according to different task classifications. For short-term tasks, short-term key indexes such as production efficiency and quality qualification rate are highlighted due to short time span, medium-term tasks need to display energy consumption besides production efficiency and quality indexes, and long-term tasks need to monitor comprehensive indexes from execution efficiency, quality, energy use to the whole production period.
And selecting the data updating frequency corresponding to the task type of the specific production task from a preset frequency database.
This step is to select matching data update frequencies in a pre-established frequency database according to the type of task after a specific production task has been classified. The frequency database is preset with the update frequencies corresponding to different types of tasks. The update frequency refers to the refresh time interval of the system for each item of monitoring data on the display board. Different update frequencies can be preset according to the type of task and the time span difference. For example, for short-term tasks, more frequent updates may be set, with refreshing every 5 minutes, mid-term tasks may be set to update every 15 minutes or 30 minutes, depending on the production phase, and long-term tasks may use less frequent updates, with refreshing every hour or hours.
S205, acquiring a hardware configuration component related to the specific production task, and acquiring real-time operation parameters of the hardware configuration component.
It is understood that this step is similar to step S105, and will not be described here.
S206, displaying the task features, the production task progress, the key indexes and the real-time operation parameters on the information display signboard according to the data updating frequency.
In this step, the step may specifically include the following:
acquiring a preset user-defined layout, and arranging the information display signs based on the preset user-defined layout;
Integrating and displaying the task characteristics, the production task progress, the key indexes and the real-time operation parameters on the information display signboard;
refreshing the data on the information display signboard in real time based on the data updating frequency;
when any one of the production task progress, the key index and the real-time operation parameter exceeds a preset threshold, a visual warning is triggered in the information display signboard.
S207, when the specific production task is a material management task, determining specific production task classification according to the task duration of the material management task.
When a specific production task belongs to a material management category, a detailed task classification needs to be determined according to the task duration of the material management task. The material management task herein refers to a management task related to production materials such as raw materials and parts. The task duration is the length of time expected to be required to complete the material management task. The material management tasks may be divided into short-term tasks, medium-term tasks, and long-term tasks according to different time thresholds, for example short-term tasks lasting for 1 day, medium-term tasks lasting for 1 week to 1 month, and long-term tasks lasting for more than 1 month. Further classification can help follow-up more accurately monitor key indicators corresponding to material management tasks of different durations.
S208, when the specific production task is a material management task and is the short-term task, selecting a task board, a material board and an anomaly tracking board for information display.
After determining that a specific production task belongs to a material management task which can be completed within a short term range, an information display signboard matched with the characteristics of the short term material management task needs to be selected for displaying production data. According to the characteristics of the short-term material management task, three information display tools, namely a task signboard, a material signboard and an anomaly tracking signboard, are selected. The task board can display the execution state of a specific task and various information in real time, the material board can display data related to various materials in a concentrated mode, such as the current stock level, quality condition and the like, and the abnormal tracking board can monitor abnormal conditions possibly occurring in the production process.
S209, displaying task characteristics of the material management task, material production task progress and real-time operation parameters on the task board in real time, wherein the task characteristics comprise material task duration, material product type and material process complexity.
After selecting the task sign, multiple types of information related to the short-term material management task need to be displayed on the sign in real time. Firstly, task characteristics are displayed, wherein the material task characteristics comprise task duration time, material product type, process complexity and the like, and the completion progress of the current task is required to be displayed in real time. At the same time, real-time operating parameters, i.e., real-time status data of the devices and systems performing the tasks, are also presented.
S210, a bill of materials, stock of materials information and a key index of materials are displayed on the bill of materials in a centralized mode, wherein the bill of materials comprises a name of materials, specifications and planned usage, the stock of materials information comprises a current stock quantity, a safe stock level and a stock state, and the key index of materials comprises a turnover rate of materials, an inventory accuracy rate and a utilization rate of materials.
The material signboard is an important component in the production line real-time monitoring management system and is used for displaying various information related to materials in a centralized manner. The bill of materials contains the name, specification and plan consumption of the materials, is a detailed list of the materials required in the production process, the stock information of the materials contains the current stock quantity, the safety stock level and the stock state, reflects the real-time stock condition of the materials, and the key indexes of the materials comprise the turnover rate, the stock accuracy and the utilization rate of the materials, which are important indexes for measuring the management efficiency of the materials.
The system will present this information in a clear and intuitive way on the material sign. For example, a bill of materials may be presented in tabular form, in which the name, specification, and planned usage of each material are listed. The stock information may be presented in the form of a chart or dashboard that visually displays a comparison of the current stock level to the safe stock level, as well as the stock status (e.g., adequate, alert, or out of stock). The material key indexes can be displayed in a digital, percentage or trend chart mode, so that a manager can quickly master the overall efficiency of material management. The system can be provided with color coding, such as green for normal, yellow for attention, and red for warning, so that the manager can quickly identify the problem of attention
S211, displaying material quality abnormal information, inventory abnormal alarm and material equipment abnormal information on the abnormal tracking billboard, wherein the material quality abnormal information comprises failure rate, batch quality problem and quality trend analysis, and the material equipment abnormal information comprises storage equipment fault information and transportation equipment abnormal information.
The anomaly tracking billboard is an interface for monitoring and displaying various anomalies occurring in the production process in real time. The material quality abnormal information comprises reject rate, batch quality problems and quality trend analysis, and reflects the problems in material quality. Inventory anomaly alarms are used to alert to an abnormal inventory level condition. The abnormal information of the material equipment comprises storage equipment fault information and transportation equipment abnormal information, and reflects the running condition of the equipment related to the material.
The system updates and displays the anomaly information on the anomaly tracking bulletin board in real time. For example, the material quality anomaly information may show a trend of variation in reject rate in a chart form, a list form shows a specific lot quality problem, and a long-term quality variation is reflected by a quality trend analysis chart. Inventory anomaly alarms may be presented by conspicuous icons or text cues to indicate which materials are experiencing inventory anomalies, as well as the degree of anomalies. The abnormal information of the material equipment can be displayed in the form of an equipment state diagram or a list to indicate specific storage or transportation equipment fails and the type and severity of the failure. The system may also set different levels of alarms, such as by color, flashing or audible prompts to distinguish between the urgency of an anomaly, helping the manager quickly identify and address the most urgent problem.
S212, acquiring the actual completion time of the specific production task, and calculating the production line efficiency index based on the task duration and the actual completion time.
The actual completion time of a production task refers to the actual time taken from the beginning to the end of a particular production task. The task duration refers to the time preset in the production plan to complete the task. The line efficiency index is an important parameter for measuring the operation efficiency of the line, and is usually calculated by comparing the actual completion time with the planned time.
The system automatically records the start and end times of each production task to obtain the actual completion time. The system then compares this actual completion time to a preset task duration to calculate a line efficiency index. The calculation method can be a simple time ratio (planned time/actual time), or a more complex efficiency formula, and factors such as yield, quality and the like are considered. For example, if a mission plan takes 8 hours and is actually completed for 7 hours, then a simple efficiency indicator might be 114% (8/7 x 100%). The system can set a plurality of efficiency indexes such as single-task efficiency, daily efficiency, zhou Xiaolv and the like, and display the efficiency change trend in a chart form, so that a manager can know the running condition of a production line in time, find efficiency problems and take improvement measures.
It will be appreciated that this step may be performed after step S211 or after step S206.
S213, comparing the production line efficiency index with a preset target efficiency to obtain an efficiency difference value.
The comprehensive production line efficiency index is a comprehensive index reflecting the overall operation efficiency of the whole production line, and is obtained by weighting and calculating a plurality of sub-indexes, including the equipment utilization rate, the product qualification rate, the production plan completion rate and the like. The preset target efficiency is an efficiency standard set by the management layer according to the ideal running state of the production line and the strategic targets of the enterprises. The efficiency difference value is the difference between the actual efficiency and the target efficiency, expressed as an absolute value or percentage.
The system automatically calculates the efficiency index of the comprehensive production line and compares the efficiency index with the preset target efficiency. According to the practical case, assuming that the efficiency index of the comprehensive production line is 85% and the preset target efficiency is 90%, the efficiency difference value is-5% or-5% points. The system displays the comparison result in a visual mode such as a dashboard, a progress bar or a trend chart. At the same time, the system sets different levels of discrepancy warnings, e.g. discrepancy shows green (normal) within + -3%, + -3% to + -7% show yellow (care is taken) and over + -7% show red (immediate treatment is required).
And S214, automatically generating an efficiency optimization suggestion based on the task characteristics and the real-time operation parameters when the efficiency difference value exceeds a preset threshold.
The efficiency difference value is the gap between the actual efficiency and the target efficiency. The preset threshold is an acceptable efficiency difference range set by the management layer. Task characteristics include attributes of task type, complexity, duration, etc. The real-time operating parameters are real-time operating data of various equipment and processes in the production process. The efficiency optimization suggestion is a specific suggestion that the system gives to improve production efficiency based on the analysis results.
When the system detects that the efficiency difference value exceeds a preset threshold value, an optimization suggestion generation mechanism is automatically triggered. The system first analyzes the causes of the efficiency differences, such as equipment failure, personnel operation problems, untimely material supply, etc. Then, the system combines the characteristics (such as task type and complexity) of the current task and real-time operation parameters (such as equipment operation state and production line speed), and utilizes a preset rule base or a machine learning algorithm to generate a targeted efficiency optimization suggestion.
For example, the system detects that the equipment utilization of a process is low, and generates a recommendation "adjust process schedule or increase personnel configuration for the process". As another example, the system finds that there is often a delay in the supply of a certain material, generates a recommendation "optimize inventory management policies or find alternative suppliers".
And S215, displaying the efficiency optimization suggestion on the anomaly tracking billboard.
The anomaly tracking billboard is an interface used for intensively displaying various anomalies and alarms in the production management system. The efficiency optimization proposal is a specific proposal for improving the production efficiency, which is given by the system based on the efficiency analysis result.
The system displays the automatically generated efficiency optimization suggestions on the anomaly tracking billboard in real time, so that the manager can acquire the information in time. The display mode adopts a list form, and various suggestions are arranged according to the priority or time sequence. Each suggestion contains a question description, a degree of influence, suggested measures, expected effects, etc. The specific example is that the utilization rate of equipment in the process A is lower than 70%, the overall efficiency is reduced by 5%, the configuration of process personnel is recommended to be adjusted, 1 operator is increased, and the expected effect is that the utilization rate of the equipment is improved to 85%, and the overall efficiency is improved by 3%. The system sets different display styles, such as color coding or icons, for different types or degrees of urgency of the advice so that the manager quickly identifies the most interesting problem. In addition, the system provides interactive functionality allowing the manager to feed back, mark or assign advice to the relevant responsible person and track the performance of the advice.
S216, setting a multistage abnormality early warning threshold based on the key index and the real-time operation parameter displayed on the information display signboard.
The information display signboard is an interface for displaying various production information in the production line real-time monitoring management system. The key index is an important parameter reflecting the running condition of the production line, such as production efficiency, quality qualification rate and the like. The real-time operating parameters are real-time data of various equipment and processes in the production process. The multi-level abnormality early warning threshold is a series of reference values for judging whether the production state is abnormal, and is generally classified into a plurality of levels such as normal, attention, warning, serious, and the like.
The system sets a multi-level abnormality early warning threshold for each key index and real-time operation parameters based on data on the information display signboard. For example, for this parameter of device temperature, the system may set a threshold of 0-50 ℃ to normal (green), 51-60 ℃ to attention (yellow), 61-70 ℃ to warning (orange), and 71 ℃ or more to severe (red). The system determines these thresholds by analyzing the historical data, taking into account equipment specifications and production requirements. The manager can also adjust these thresholds according to actual production needs. The system stores these thresholds in a database and associates them with corresponding metrics and parameters.
It will be appreciated that this step may be performed after step S215 or after step S206.
S217, monitoring the key index and the change of the real-time operation parameter in real time, and triggering an abnormal alarm of a preset level on the abnormal tracking billboard when the threshold value of the early warning parameter is exceeded, wherein the preset level corresponds to the multi-level abnormal early warning threshold value.
The key indicators and real-time operating parameters are important data reflecting the status of the production line. The early warning parameter threshold is a criterion for judging whether the data are abnormal or not. The anomaly tracking billboard is an interface for displaying various anomalies. The abnormal alarms of the preset level are warning information of different levels triggered by the system according to the degree of abnormality.
The system continuously monitors all key indicators and changes in real-time operating parameters. When any one index or parameter exceeds the corresponding early warning threshold value, the system immediately triggers the alarm of the corresponding grade on the anomaly tracking billboard. For example, if the temperature of a device reaches 65 ℃, exceeds the threshold of the "warning" level (61-70 ℃), the system will display an orange warning message on the anomaly tracking billboard, possibly including information such as the device name, the current temperature, the degree of superscalar, etc. The system sets different display modes according to different levels of alarms, such as color codes (green, yellow, orange and red), icon changes or flashing effects, and the like, so as to draw the attention of the manager. Meanwhile, the system can ensure that related personnel can know abnormal conditions in time through voice prompt, short message or mail notification and other modes.
S218, in the case that the access operation of the hardware component is detected, the type, function and communication protocol of the hardware component are identified.
Hardware components are various devices and sensors in a production line. An access operation is a process of connecting a new hardware component to the system. The type of hardware component refers to which class of device it belongs to, such as a sensor, controller, actuator, etc. The function refers to the role of the assembly in the production process. Communication protocols are rules and formats for the exchange of data between hardware components and the system.
The system automatically initiates an identification process upon detecting the access of a new hardware component. First, the system detects the presence of a new device through a hardware interface or network connection. The system then reads the identification information of the hardware component, such as device ID, model number, etc. Based on the information, the system queries a preset device database to identify the specific type and function of the hardware component. For example, the system may recognize that a newly accessed device is a temperature sensor that functions to monitor the temperature of a particular process. At the same time, the system determines the communication protocol used by the hardware component, such as Modbus, PROFINET or OPC UA, etc. And the system automatically configures corresponding driving programs and communication parameters according to the identification result to ensure that the data of the hardware component can be correctly read and analyzed.
It will be appreciated that this step may be performed after step S217 or after step S206.
S219, assigning a unique identifier to the hardware component based on the type, the function, and the communication protocol.
The type of hardware component refers to its class of device, such as a sensor, controller, or actuator. The function refers to the specific role of the assembly in the production process. Communication protocols are rules and formats for the exchange of data between hardware components and the system. The unique identifier is a unique code or string that uniquely identifies the hardware component in the system.
The system generates and assigns a unique identifier based on the identified type, function, and communication protocol of the hardware component. This identifier is typically a structured string containing key information about the component. For example, for a temperature sensor, its unique identifier may be "TS-001-MOD-TEMP," where "TS" indicates the sensor type, "001" is the serial number, "MOD" indicates the use of the Modbus protocol, and "TEMP" indicates the temperature measurement function. The system stores this unique identifier in a database along with the hardware component's detailed information. The identification mode enables the system to quickly and accurately identify and manage each hardware component, and facilitates subsequent configuration, monitoring and maintenance work. At the same time, the system ensures that all assigned identifiers are unique, avoiding duplication or confusion.
S220, marking the component position of the hardware component in the production line layout based on the unique identifier, and displaying the state of the hardware component at the component position on the integrated billboard.
The unique identifier is code for uniquely identifying the hardware component in the system. The component position refers to a specific installation position of a hardware component in the whole production line layout, the production line layout is a plan view or a perspective view of the whole production line, and the state of the hardware component refers to the current working condition of the component, such as normal operation, standby, failure and the like.
The system marks the exact location of the hardware component in the production line layout using the unique identifier assigned to that component. This may be done by manually entering the coordinates or using a drag and drop interface. For example, for a temperature sensor identified as "TS-001-MOD-TEMP," the system will add an icon or label at the corresponding location in the line map. The system then displays the location and real-time status of this hardware component in the production line layout on the integrated sign. The status display may be represented by different colors or icons, such as green for normal operation, yellow for maintenance, and red for failure. When a user clicks or hovers over an icon of the component, the system will display more detailed information such as current readings, run time, most recent maintenance records, etc.
An embodiment of the present application is described below from the perspective of system architecture, as shown in fig. 3, and fig. 3 is an architecture diagram of a method for real-time monitoring and management of a visualization production line in an embodiment of the present application.
In fig. 3, the whole system is composed of a plurality of key parts, including a planning billboard and a task billboard, a PC and a display, an anomaly tracking billboard, a data collector, a network connection identification cloud computing resource, LED lamps and alarm devices, a barcode scanner and printer, and a device control system, wherein the planning billboard is used for receiving and displaying an overall production plan, the task billboard displays a specific production task and the progress thereof, and the functions of receiving the production plan through the planning billboard and displaying the analysis of the production plan into the specific production task according to the description of a document are achieved. The PC and the display are used as operation interfaces of the system, are used for displaying real-time data and monitoring interfaces, are matched with the hardware configuration of the management system, and the anomaly tracking signboard is specially used for displaying the anomaly in the production process, so that any parameter exceeding a preset threshold can be timely identified and warning is triggered, and the anomaly information monitoring and warning functions are directly related to the monitoring and warning functions of the anomaly information in the document. The data collector is responsible for collecting real-time operation data from various sensors and equipment of the production line, and the system performs data processing and storage through cloud computing resources so as to support efficient data management and possible remote operation functions. The LED lights and alarm devices are then used to provide visual and audible warnings when any anomaly is detected to prompt the operator to take the necessary countermeasures. Bar code scanners and printers support the instant identification and tracking of materials, which is critical to ensuring the accuracy and efficiency of material management. Finally, the equipment control system adjusts the operation parameters of the production equipment according to the real-time data, and optimizes the production process.
The following describes the real-time monitoring management system in the embodiment of the present application from the perspective of hardware processing, please refer to fig. 4, which is a schematic diagram of a physical device structure of the real-time monitoring management system in the embodiment of the present application.
It should be noted that the structure of the real-time monitoring management system shown in fig. 4 is only an example, and should not limit the functions and the application scope of the embodiments of the present invention.
As shown in fig. 4, the real-time monitoring management system includes a central processing unit (Central Processing Unit, CPU) 401 that can perform various appropriate actions and processes, such as performing the methods described in the above embodiments, according to a program stored in a Read-Only Memory (ROM) 402 or a program loaded from a storage section 408 into a random access Memory (Random Access Memory, RAM) 403. In the RAM403, various programs and data required for the system operation are also stored. The CPU401, ROM402, and RAM403 are connected to each other by a bus 404. An Input/Output (I/O) interface 405 is also connected to bus 404.
Connected to the I/O interface 405 are an input section 306 including an audio input device, a push button switch, and the like, an output section 407 including a Liquid crystal display (Liquid CRYSTAL DISPLAY, LCD) and an audio output device, an indicator lamp, and the like, a storage section 408 including a hard disk, and the like, and a communication section 409 including a network interface card such as a LAN (Local Area Network) card, a modem, and the like. The communication section 409 performs communication processing via a network such as the internet. The drive 310 is also connected to the I/O interface 405 as needed. A removable medium 411 such as a magnetic disk, an optical disk, a magneto-optical disk, a semiconductor memory, or the like is installed on the drive 410 as needed, so that a computer program read therefrom is installed into the storage section 408 as needed.
In particular, according to embodiments of the present invention, the processes described above with reference to flowcharts may be implemented as computer software programs. For example, embodiments of the present invention include a computer program product comprising a computer program embodied on a computer readable medium, the computer program comprising a computer program for performing the method shown in the flowchart. In such an embodiment, the computer program may be downloaded and installed from a network via the communication portion 409 and/or installed from the removable medium 411. When executed by a Central Processing Unit (CPU) 401, the computer program performs various functions defined in the present invention.
Specific examples of a computer-readable storage medium include, but are not limited to, an electrical connection having one or more wires, a portable computer diskette, a hard disk, a Random Access Memory (RAM), a read-Only Memory (ROM), an erasable programmable read-Only Memory (Erasable Programmable Read Only Memory, EPROM), a flash Memory, an optical fiber, a portable compact disc read-Only Memory (CD-ROM), an optical storage device, a magnetic storage device, or any suitable combination of the foregoing. In the context of this document, a computer readable storage medium may be any tangible medium that can contain, or store a program for use by or in connection with an instruction execution system, apparatus, or device.
The flowcharts and block diagrams in the figures illustrate the architecture, functionality, and operation of possible implementations of systems, methods and computer program products according to various embodiments of the present invention. Where each block in the flowchart or block diagrams may represent a module, segment, or portion of code, which comprises one or more executable instructions for implementing the specified logical function(s). It should also be noted that, in some alternative implementations, the functions noted in the block may occur out of the order noted in the figures.
Specifically, the real-time monitoring and managing system of the embodiment includes a processor and a memory, and the memory stores a computer program, and when the computer program is executed by the processor, the real-time monitoring and managing method of the visual production line provided by the embodiment is implemented.
As another aspect, the present invention also provides a computer-readable storage medium, which may be included in the real-time monitoring management system described in the above embodiment, or may exist alone without being assembled into the real-time monitoring management system. The storage medium carries one or more computer programs which, when executed by a processor of the real-time monitoring and management system, cause the real-time monitoring and management system to implement the visual production line real-time monitoring and management method provided in the above embodiment.
While the application has been described in detail with reference to the foregoing embodiments, it will be understood by those skilled in the art that the foregoing embodiments may be modified or equivalents may be substituted for some of the features thereof, and that the modifications or substitutions do not depart from the spirit of the embodiments.
As used in the above embodiments, the term "when..is interpreted as meaning" if..or "after..or" in response to determining..or "in response to detecting..is" depending on the context. Similarly, the phrase "when determining..or" if (a stated condition or event) is detected "may be interpreted to mean" if determined.+ -. "or" in response to determining.+ -. "or" when (a stated condition or event) is detected "or" in response to (a stated condition or event) "depending on the context.
Those of ordinary skill in the art will appreciate that implementing all or part of the above-described method embodiments may be accomplished by a computer program to instruct related hardware, the program may be stored in a computer readable storage medium, and the program may include the above-described method embodiments when executed. The storage medium includes a ROM or a random access memory RAM, a magnetic disk or an optical disk, and other various media capable of storing program codes.