JP2003303007A - Device and method for production history management - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a production history management device that obtains and manages the results of inspections at shippers and shipping destinations by using a data carrier which is carried with articles and records the results of the inspection in each process, and also provide a method therefor. <P>SOLUTION: The articles are delivered with the data carriers 6, and the results of the inspections in the shipping destinations are stored in the data carriers 6. Reader-writers 4 acquire the results of the inspections recorded on an article unit basis in the data carriers 6 in the shippers and the shipping destinations, and a data analyzing terminal 5 compares the results of the inspections with a preliminarily prepared correlation table between inspection items and related parts to detect the related parts which coincides with the results of the inspections as a trouble. <P>COPYRIGHT: (C)2004,JPO

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a manufacturing history management apparatus that acquires and manages inspection results at a shipping source and a shipping destination by using a data carrier that is carried with an article and records the inspection results in each process. And a manufacturing history management method.

[0002]

2. Description of the Related Art "Object processing method" is disclosed in Japanese Patent Laid-Open No. 2001-139111 as a method for managing information related to a product integrally with the product. This is simplified by adding a data carrier to the intermediate product in the manufacturing process of the product, recording and updating various information on the data carrier, and further sharing information managed corresponding to the product with each other. Thus, the present invention relates to a system capable of flexibly adapting a production line, a product flow path, and a production procedure.

In this "object processing method", information relating to the attributes and status of the product is recorded on a data carrier and conveyed along with the product, and a warning is issued to the outside according to the status,
It describes that various processes are performed in cooperation with other devices and machines.

It is also described in the prior art of "Object processing method" that there is a product inspection result as the information to be recorded on the data carrier.

Normally, the inspection result of a product is managed on a product-by-product basis, and as a matter of course, a product that fails the manufacturing process is not shipped. Therefore, the data carrier recording the inspection result is removed from the product and shipped, and the information regarding the inspection result is not exchanged between the shipping source and the shipping destination.

[0006]

However, even if the inspection at the manufacturing line of the shipping source has passed, there is a situation in which the passing standard cannot be satisfied as a whole when the product is assembled to another product at the shipping destination. There were cases.

[0007] In such a situation, it is very difficult to find out the cause of the defect from the information of only the shipping source or the shipping destination. For example, the problem commonly called “compatibility” cannot be identified only by the inspection result of the product shipping source or the shipping destination, and in order to investigate the cause, the inspection result at the shipping source, Information on both the usage status of the product at the shipping destination, the usage environment, the inspection results, etc. was required.

In view of the above-mentioned circumstances, the present invention ships without removing the data carrier from the product, saves and collects the inspection result at the shipping destination in the data carrier, and stores the data carrier in product units at the shipping source and the shipping destination. By obtaining the recorded test information and further analyzing that information,
An object of the present invention is to provide a manufacturing history management device and a manufacturing history management method for selecting defective parts and reviewing standards.

[0009]

In order to achieve the above object, a manufacturing history management apparatus according to the invention of claim 1 is
A manufacturing history management apparatus for acquiring and managing inspection values at a shipping source and a shipping destination recorded on a data carrier conveyed with an article, wherein the inspection values of the shipping source and the shipping destination in the same inspection item And a database that records the relationship between the change in the reference value of the part related to the inspection item, and the change in the inspection value between the shipping source and the shipping destination in the same inspection item, and the database It is characterized by comprising an abnormality occurrence point extraction means for extracting a component corresponding to the change as an abnormality occurrence point from the recorded relationship.

According to the first aspect of the present invention, the product is shipped without removing the data carrier, the inspection result at the shipping destination is stored and collected in the data carrier, and the shipping source and the shipping destination carry out the data carrier for each product. The problem location is extracted by acquiring the inspection result recorded in (1) and comparing the information with a correlation table prepared in advance to determine whether the inspection results match. Therefore, it is possible to appropriately deal with various problems such as finding a defect.

A manufacturing history management apparatus according to a second aspect of the present invention is the manufacturing history management apparatus according to the first aspect, wherein the inspection value and the reference value are time series information. , A plurality of change patterns of the reference value prepared in advance, a database in which countermeasures for the parts corresponding to the respective change patterns are recorded, and a change pattern calculation means for calculating the change pattern from time series information of the inspection item And a countermeasure extracting means for comparing the change pattern recorded in the database with the change pattern calculated by the change pattern calculating means and extracting a countermeasure for the article.

According to the second aspect of the present invention, the time-series information recorded on the data carrier is analyzed, and the change pattern resulting from the analysis is compared with a change pattern prepared in advance to determine whether the change patterns match. A countermeasure is extracted by making a determination. Therefore, it is possible to appropriately deal with various problems such as reviewing standards and finding defects.

The manufacturing history management method according to the present invention is a manufacturing history management method for acquiring and managing inspection values at a shipping origin and a shipping destination recorded on a data carrier carried with an article. In the same inspection item, a step of referring to a database that records the relationship between the change of the inspection value between the shipping source and the destination and the change of the reference value of the component related to the inspection item, and the same inspection item And calculating a change in the inspection value between the shipping source and the shipping destination in, and extracting a part corresponding to the change as an abnormality occurrence location from the relationship recorded in the database. .

According to the third aspect of the invention, the product is shipped without removing the data carrier, the inspection result at the shipping destination is stored and collected in the data carrier, and the shipping source and the shipping destination carry out the data carrier for each product. The problem location is extracted by acquiring the inspection result recorded in (1) and comparing the information with a correlation table prepared in advance to determine whether the inspection results match. Therefore, it is possible to appropriately deal with various problems such as finding a defect.

A manufacturing history management method according to a fourth aspect of the present invention is the manufacturing history management method according to the third aspect, wherein the inspection value and the reference value are time series information. , Calculating a change pattern from a plurality of change patterns of the reference value prepared in advance, a step of referring to a database recording a countermeasure for the part corresponding to each change pattern, and time series information of the inspection item It is characterized by including a step and a step of comparing the change pattern recorded in the database with the change pattern calculated by the change pattern calculating means and extracting a countermeasure for the article.

According to the fourth aspect of the present invention, the time-series information recorded on the data carrier is analyzed, and the change pattern resulting from the analysis is compared with a change pattern prepared in advance. A countermeasure is extracted by making a determination. Therefore, it is possible to appropriately deal with various problems such as reviewing standards and finding defects.

[0017]

BEST MODE FOR CARRYING OUT THE INVENTION Embodiments of the present invention will be described with reference to FIGS.
It will be described based on 3.

First, the structure of the manufacturing history management system 1 will be described.

FIG. 1 shows a manufacturing history management system 1 of the present invention.
It is a figure which shows the example of a system configuration. This system is composed of a manufacturing line of a shipping source and an assembling line of a shipping destination. The data carrier 6 is used to transfer the inspection result of the product. In the present invention, products (including unfinished intermediate products) manufactured on the manufacturing line and shipped to the assembly line are called "workpieces".

The production line which is the shipping source is the server 2a,
The terminals 3a, 3b, 3c installed for each process, the reader / writer 4, and the data analysis terminal 5 are provided and are connected to each other by a network 11. Similarly, the assembly line, which is the shipping destination, also includes the server 2b, the terminal 3d, and the reader / writer 4.

FIG. 1 shows a CS tuner production line as an example of the production line. In this CS tuner manufacturing line, step 1 is to attach a power supply unit, step 2 is to attach a board, and step 3 is to perform a packing operation. A circuit diagram of the board (inspection target) attached in step 2 is shown in FIG.
Shown in.

The assembly line carries out the work of assembling the unit of the broadcasting equipment as shown in FIG. 3 using the products shipped from the manufacturing line.

Therefore, the shipping source for shipping the work to the assembling line is not limited to the CS tuner manufacturing line shown in FIG. In addition, there are a descrambler manufacturing line, a scramble encoder manufacturing line, a stereo multiplex encoder built-in TV modulator manufacturing line, etc. Each manufacturing line is the same as the CS tuner manufacturing line. A reader / writer 4 is provided.

The server 2a is provided with a data table in which inspection items in each process before shipment and inspection reference values for each inspection item are recorded. As an example of this data table,
FIG. 4 shows a data table (1) in which the inspection reference values in the process 2 of the CS tuner manufacturing line are recorded. Since the inspection item differs depending on each process and product, a data table is prepared for each process and product.

The servers 2a and 2b also include a data table in which inspection items on the assembly line and inspection reference values for each inspection item are recorded. As an example of this data table, a data table (2) is shown in FIG. The inspection standard value recorded in this data table (2) represents the range of responsibility on the assembly line, and if the result of the inspection is within this range of responsibility and the acceptance criteria are not met, then the assembly line Some measures will be taken.

Further, the server 2a, after shipping,
Inspection items of each product after assembled on the assembly line,
It is provided with a data table in which inspection reference values for each inspection item are recorded. As an example of this data table, a data table (3) is shown in FIG. The inspection standard value recorded in this data table (3) represents the range of responsibility in the manufacturing line. If the inspection result exceeds this inspection standard value,
Some measures will be taken on the production line.

The terminal 3 installed in each process is the server 2
a, 2b and the reader / writer 4 are connected to read the reference values of the inspection items recorded in the servers 2a, 2b,
It has a function of comparing the inspection result acquired by the inspection work with the reference value and notifying that the inspection has failed if the reference value is not satisfied. Further, when the acceptance criteria are satisfied, the inspection result is transferred to the reader / writer 4 and the data carrier 6 is instructed to write the inspection result.

The data analysis terminal 5 is a computer terminal equipped with an input / output device such as a display and a keyboard, and the inspection results recorded on the data carrier 6 collected from the assembly line are stored in a data table prepared in advance. It has a function of comparing data with data and analyzing data, such as identifying abnormal points. The data analysis function will be described later.

Further, the data analysis terminal 5 corresponds to information used when analyzing the inspection result, a data table showing a correlation between the inspection value and the reference value of the related component, and a change in the inspection value in the continuous test. It is provided with a data table in which countermeasures are recorded. FIG. 5 and FIG. 6 show an example of each data table. In addition, the direction of the arrow in each item of FIG.
Indicates the change in value. For example, the upward arrow in the manufacturing-assembly line item indicates that the inspection result on the assembly line is larger than the value on the production line, and the downward arrow indicates the opposite. Also, the arrow in each item of the related parts indicates a possible change state of the reference value of the related parts in the combination of the arrows in the item of manufacturing-assembly.

The reader / writer 4 has a function of writing an inspection result to the data carrier 6 and a function of reading it based on an instruction from the connected terminal 3.

Data carrier 6 attached to the work
Has a patch shape with a mounting clip on the back side as shown in FIG. 7, and is attached to the work by the clip. The product name (model) is attached to the surface of the data carrier 6,
The product number, shipping date, carrier number, etc. are printed. It should be noted that although the method of attachment is shown by a clip, it is not limited to this, and other methods such as an adhesive sheet and a magnet that can be attached and detached can be used.

The data carrier 6 also includes a storage unit 8 and a communication unit 7 inside. The communication unit 7 is a reader / writer 4
It also has a function of communicating with the storage unit 8 and a function of communicating information such as an inspection result transmitted from the reader / writer 4 to the storage unit 8. In addition, the recording section includes a process management file 9 and
It has a function of saving a plurality of inspection result files 10.

The process control file 9 is a data table having the items of date, time, charge, and inspection result file 10, and stores the date and time of inspection, the name of the operator who performed inspection, and the inspection result. Inspection result file 1
Record a file name of 0. FIG. 8 is an example of a process management file 9 included in the data carrier 6 used in the CS tuner manufacturing line. The number of data items recorded in the process control file 9 varies depending on the configuration of the work process of the manufacturing line.

In the inspection result file 10, inspection items are set for each manufacturing line and each process, and the inspection results are recorded. FIG. 9 is an example of the inspection result file 10 stored for each process, and the number of inspection result files depends on the number of processes.

Further, as shown in FIG. 10, the inspection of the continuous test recorded on the assembly line is also stored as the inspection result file 10. The data table (1) of FIG. 10 is an example of the inspection result of the continuous test, and FIG. 10 (2) is a graph showing the inspection result.

Next, the operation of the manufacturing history management system will be described.

<Identification of problem area> First, the procedure of analyzing the inspection result stored in the data carrier 6 returned from the shipping destination and identifying the problem area will be described with reference to FIG.
Will be described with reference to the circuit diagram of FIG. 4, the data tables of FIGS. 4 and 5, the inspection result file 10 of FIG. 9, and the flowchart of FIG.

In each process of the production line and the assembly line, the inspection result is written in the data carrier 6 by the reader / writer 4 and returned to the data analysis terminal 5 of the shipping source.

First, the data analysis terminal 5 uses the connected reader / writer 4 to read the inspection result from the returned data carrier 6 (step S01).

Next, the data analysis terminal 5 reads the data table recording the inspection reference values stored in the server 2a (step S02), and compares the inspection result read from the data carrier 6 with the inspection reference values. Pass / Fail determination is performed to extract rejected items (step S03).
Comparing the data table (1) and the data table (2) in FIG. 9, the video output impedance in the assembly line is increased from 78V to 85V, which satisfies the reference value of the data table (3) shown in FIG. Absent. In addition, the output power supply voltage from 8.01V to 7.93V, the output video voltage level
It can be seen that it has dropped from 0.9Vp-p to 0.78Vp-p.

Next, the data table of FIG. 5 showing the correlation between the inspection result and the reference value of the related parts is read, and the inspection result of the failed inspection item is compared with the correlation table (step S0
4) It is determined whether there is a pattern that matches the inspection result (step S05). If there is a matching pattern, the problematic part indicated by the pattern is displayed on the display (step S06). Since the pattern shown in (1) of FIG. 5 corresponds to the inspection results of the data tables (1) and (2) of FIG. 9, the cause of the inspection failure shown in FIG. 9 is caused by the distribution resistance R105 and the distribution resistance of FIG. R106, AGC function R1
It can be seen that it is related to the change of any value of 07. If there is no matching pattern, it is displayed on the display that the problem location is unknown (step S07).

As described above, the data carrier 6 is shipped from the product without being detached, the inspection result at the shipping destination is stored and collected in the data carrier 6, and the product is recorded in the data carrier 6 at the shipping source and the shipping destination. The problem location can be extracted by acquiring the inspection result obtained, comparing the information with a data table prepared in advance, and determining whether the inspection results match. Therefore, it is possible to appropriately deal with various problems such as finding a defect.

<Trend Analysis> Next, regarding the processing procedure for analyzing the result of the continuous test among the inspection results stored in the data carrier 6 returned from the shipping destination and making a review judgment of the manufacturing standard, FIG. Data table of FIG.
The inspection result file 10 and the flowchart of FIG. 12 will be described.

In each process of the manufacturing line and the assembly line, the inspection result is written in the data carrier 6 by the reader / writer 4 and returned to the data analysis terminal 5 of the shipping source.

First, the reader / writer 4 connected to the data analysis terminal 5 reads the inspection result of the data table (1) shown in FIG. 10 from the returned data carrier 6 (step S11).

Next, the data analysis terminal 5 reads the data table recording the waveform pattern which is the inspection standard stored in the server 2a (step S12), and based on the inspection result read from the data carrier 6, the inspection is performed. The change pattern of the result is analyzed (step S13), and the state of the inspection result such as convergence and divergence is obtained. As the analysis method, trend analysis, moving average analysis, etc. can be mentioned, and the change of the inspection value is predicted from the time series information. Further, when the data table (1) of FIG. 10 is expressed as a graph, it becomes as shown in FIG. 10 (2).

Next, the data table recording the countermeasures corresponding to the inspection result of the continuous test shown in FIG. 6 is read, the waveform pattern of the inspection result is compared with the waveform pattern of the data table (step S14), and the inspection result is obtained. It is determined whether there is a waveform pattern that coincides with (step S15), and if there is a coincident waveform pattern, the countermeasures indicated by the waveform pattern are displayed on the display (step S16).
From the inspection results shown in FIGS. 10A and 10B, it can be seen that the inspection values diverge upward. 5
The “Review standard review” indicated by the waveform pattern is displayed on the display. If there is no matching waveform pattern, it is displayed on the display that the countermeasure is unknown (step S
17).

In this way, the data carrier 6 is shipped from the product without being removed, and the inspection result of the continuous test at the shipping destination is stored and collected in the data carrier 6, and the inspection result of the continuous test recorded in the data carrier 6 is obtained. By comparing the waveform pattern that is the analysis result with a waveform pattern prepared in advance and determining whether the waveform patterns match, it is possible to extract countermeasures for various problems such as reviewing the standard. it can. Therefore, it is possible to appropriately deal with various problems such as reviewing standards and finding defects.

Further, as shown in FIG. 13, by collecting the inspection results over a long period of time, it is possible to perform an analysis in consideration of seasonal variations and the like.

In the present invention, the data carrier 6
The information recorded in is not limited to the inspection result in each step. By recording information that can be effective in reviewing the status of inspection (inspection environment), requests from each process, planning, quality, process, etc., various problems can be dealt with appropriately.

[0051]

As described above, according to the present invention,
Ships without removing the data carrier from the product, stores and collects the inspection result at the shipping destination in the data carrier, acquires the inspection result recorded for each product, and further changes the inspection value between the shipping source and the shipping destination By comparing the change of the inspection value prepared in advance, and the database that records the relationship between the change of the reference value of the part related to the inspection item, by determining whether the change of the inspection value is the same, Extract problem areas. Therefore, it is possible to appropriately deal with various problems such as finding a defect.

Further, the time series information recorded on the data carrier is analyzed, the change pattern as the analysis result is compared with the change pattern prepared in advance, and it is determined whether the change patterns match or not. Extract a plan. Therefore, it is possible to appropriately deal with various problems such as reviewing standards and finding defects.

[Brief description of drawings]

FIG. 1 is an overall configuration diagram of a manufacturing history management system.

FIG. 2 is a circuit diagram of components used in step 2 of the manufacturing line.

FIG. 3 is a configuration example of a unit assembled on a distribution line.

FIG. 4 is a data table of inspection reference values.

FIG. 5 is a data table showing a correlation between inspection items and related parts.

FIG. 6 is a data table recording countermeasures corresponding to changes in inspection values in a continuous test.

FIG. 7 is an external view and functional block diagram of a data carrier.

FIG. 8 is a data table of a process management file.

FIG. 9 is a data table of an inspection result file.

FIG. 10 is a data table and a graph of an inspection result file of a continuous test.

FIG. 11 is a flowchart showing a processing procedure for identifying a problem location.

FIG. 12 is a flowchart showing a processing procedure of trend analysis.

FIG. 13 is a graph showing long-term changes in test results.

[Explanation of symbols]

1 Manufacturing history management system 2 servers 3 terminals 4 Reader / Writer 5 Data analysis terminal 6 data carriers 7 Communication section 8 memory 9 Process control file 10 inspection result file 11 network

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Claims (4)

[Claims] 1. A manufacturing history management apparatus for acquiring and managing inspection values at a shipping origin and a shipping destination recorded on a data carrier conveyed with an article, wherein the shipping origin and the shipping destination in the same inspection item. And a database that records the relationship between the change in the inspection value and the change in the reference value of the part related to the inspection item, and the change in the inspection value between the shipping source and the shipping destination in the same inspection item And a manufacturing history management device comprising: an abnormality occurrence point extraction unit that extracts a part corresponding to the change as an abnormality occurrence point from the relationship recorded in the database. 2. The inspection value and the reference value are time-series information, and record a plurality of change patterns of the reference value prepared in advance and a countermeasure for the part according to each change pattern. The database, the change pattern calculating means for calculating the change pattern from the time-series information of the inspection item, the change pattern recorded in the database, and the change pattern calculated by the change pattern calculating means are compared, The manufacturing history management apparatus according to claim 1, further comprising: a handling measure extraction unit that extracts a handling measure for the article. 3. A manufacturing history management method for acquiring and managing inspection values at a shipping source and a shipping destination recorded on a data carrier that is conveyed together with an article, wherein the shipping source and the shipping destination in the same inspection item are A step of referring to a database that records the relationship between the change of the inspection value and the change of the reference value of the part related to the inspection item, and the change of the inspection value between the shipping source and the shipping destination in the same inspection item And a step of calculating a component corresponding to the change from the relationship recorded in the database as an abnormal occurrence point, and manufacturing history management method. 4. The inspection value and the reference value are time-series information, and record a plurality of change patterns of the reference value prepared in advance and a countermeasure for the part according to each change pattern. The step of referring to the database, the step of calculating the change pattern from the time series information of the inspection item, the change pattern recorded in the database, and the change pattern calculated by the change pattern calculation means are compared, The manufacturing history management method according to claim 3, further comprising: a step of extracting a countermeasure for the article.