Processing device group controller, manufacturing process system, processing device group control method, manufacturing optimization system, manufacturing optimization device, and manufacturing optimization method

A manufacturing process system comprising:

• a plurality of first processing devices which processes workpieces, with respective equipment associated with the plurality of first processing devices;
• a plurality of second processing devices which processes workpieces, with respective equipment associated with the plurality of second processing devices;
• a transfer device which transfers the workpieces to the plurality of first and second processing devices;
• a host computer which performs a step of creating a transfer plan including information of timings at which the workpieces are carried in and out by the transfer device and a step of acquiring an operation schedule including information of maintenance time from the plurality of first and second processing devices;
• a first processing device group controller which performs a step of acquiring the transfer plan and the operation schedule of the plurality of first processing devices, a step of comparing the transfer plan and the operation schedule of each first processing device, a step of specifying the last process performed in each first processing device before maintenance, a step of detecting the end timing of the specified process, and a step of instructing each first processing device to be switched to an idle state at the end timing along with the associated equipment;
• a second processing device group controller which performs a step of acquiring the transfer plan and the operation schedule of the plurality of second processing devices, a step of comparing the transfer plan and the operation schedule of each second processing device, a step of specifying the last process performed in each second processing device before maintenance, a step of detecting the end timing of the specified process, and a step of instructing each second processing device to be switched to an idle state at the end timing along with the associated equipment;
• and
• an upper-level controller which performs a step of acquiring the transfer plan and the operation schedules of the plurality of first and second processing devices from the host computer, a step of transmitting the transfer plan and the operation schedule of the plurality of first processing devices to the first processing device group controller, and a step of transmitting the transfer plan and the operation schedule of the plurality of second processing devices to the second processing device group controller.

A processing device group control method comprising:

• acquiring an operation schedule including information of maintenance time for a plurality of processing devices for processing workpieces, with respective equipment associated with the plurality of processing devices;
• acquiring a transfer plan including information of timings at which the workpieces are carried in and out of the plurality of processing devices;
• comparing the transfer plan and the operation schedule of each processing device;
• specifying the last process performed in each processing device before maintenance;
• detecting the end timing of the specified process;
• and
• instructing each processing device to be switched to an idle state at the end timing along with the associated equipment.

A non-transitory computer readable storage medium for storing therein a computer program for a computer to execute a manufacturing optimization method, the method comprising:

• based on a manufacturing plan of a processing device which arbitrarily selects a standby mode consuming energy to allow a process of workpieces to be quickly started and a sleep mode consuming minimal energy to allow the sleep mode to be quickly transitioned to the standby mode and then processes the workpieces, measuring a time interval until the next process is started after the processing device completes the process of the workpieces;
• setting the processing device to the sleep mode if the time interval measured exceeds a predetermined base time, and setting the processing device to the standby mode if the time interval does not exceed the predetermined base time;
• and
• setting a timing at which the sleep mode is transitioned to the standby mode, in consideration of a warming period required until the processing device returned from the sleep mode to the standby mode starts a process.

A manufacturing optimization method comprising:

• based on a manufacturing plan of a processing device which arbitrarily selects a standby mode consuming energy to allow a process of workpieces to be quickly started and a sleep mode consuming minimal energy to allow the sleep mode to be quickly transitioned to the standby mode and then processes the workpieces, measuring a time interval until the next process is started after the processing device completes the process of the workpieces;
• setting the processing device to the sleep mode if the time interval measured exceeds a predetermined base time, and setting the processing device to the standby mode if the time interval does not exceed the predetermined base time;
• and
• setting a timing at which the sleep mode is transitioned to the standby mode, in consideration of a warming period required until the processing device returned from the sleep mode to the standby mode starts a process.

A manufacturing optimization system comprising:

• a scheduler which creates a manufacturing plan for workpieces;
• a dispatcher which makes an operation instruction for a plurality of processing devices to perform a process of the workpieces, based on the manufacturing plan;
• a plurality of energy consumption managing units which are respectively provided for the plurality of processing devices and manage energy consumption of the respective processing devices;
• and
• a manufacturing optimization device which, based on the energy consumption of each processing device managed in each of the energy consumption managing units and a result of the process by the scheduler and the dispatcher, determines for each lot whether each of the plurality of processing devices processes the workpieces in such a manner that the total amount of energy consumption in the plurality of processing devices does not exceed the predetermined maximum of energy consumption, and individually adjusts a processing timing of each processing device operated in each lot in such a manner that the total amount of energy consumption in the plurality of processing devices during a process of each lot does not exceed the maximum of energy consumption.