JP2003318075A - Process control system - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a process control system capable of discovering abnormalities in advance or at an early stage, and of reducing a labor or time required for a process control. <P>SOLUTION: The process control system is constituted by interconnecting a plurality of terminal devices 100 and a production department server 800 via a network 900. The terminal device 100 inputs data on the process control required for preparing a control chart. The production department server 800 has an X-R control chart process part 810 and a P control chart process part 820 for preparing an X-R control chart and a P control chart based on the input data, and an abnormality determination part 830 for determining presence or absence of abnormalities based on the determination conditions preset based on the input data. <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 process management system for managing a manufacturing process using a control chart or the like.

[0002]

2. Description of the Related Art In general, various control charts are used in order to quickly detect the occurrence of defects such as product defects and take countermeasures during the operation of the manufacturing process. For example, the P chart is
It is used to control the process based on the defect rate p.
Further, the X-R control chart is used for analyzing and controlling the process based on the measured value such as the length.

Conventionally, these control charts are created by a person in charge of the manufacturing process writing data on a sheet of a predetermined form. When a person in charge of looking at the created control chart finds an abnormality in the process, he / she investigates the cause of the abnormality, takes action, and reports to the person in charge such as the person in charge of the manufacturing process if necessary.

[0004]

By the way, in the conventional process control system using the control chart, the person in charge judges whether or not there is an abnormality by looking at the control chart, which may be time-consuming and may cause a discovery error. was there. For example, when looking at the X-R control chart, it is possible to understand that an out-of-specification abnormality will occur if it is left as it is by analyzing that there is a deviation in the series (trend), although it is not out of standard. However, such a deviation of the series is easy to overlook, which is different from the obvious nonstandard. In addition, for the report made when the person in charge discovers an abnormality, the person in charge creates a report of a predetermined form while looking at the screen of the terminal device and sends it by direct communication or sends it once printed. However, it took a lot of time and effort to get the reports to the people concerned. further,
The contents of various control charts can be set at specified intervals (for example, monthly).
Although the data is tabulated, this tabulation work requires a lot of trouble and time.

As described above, it is not easy to detect abnormalities in advance or to detect them early by the conventional process control method which is performed by using the control charts, and the control chart is calculated and a notification is issued when an abnormality occurs. However, there is a problem that it takes time and labor. The present invention was created in view of the above point, and an object thereof is process control capable of detecting anomalies in advance or at an early stage, and reducing labor and time required for process control. To provide a system.

[0006]

In order to solve the above-mentioned problems, a process control system of the present invention is based on a terminal device for inputting data relating to process control necessary for creating a control chart and the data based on the data. A control chart processing means for creating a control chart is provided, and a server having an abnormality determination means for determining presence / absence of abnormality based on preset determination conditions based on data. As a result, data necessary for process control is collected, and the presence / absence of abnormality is automatically determined based on the collected data, so that the occurrence of abnormality can be detected early and reliably. Further, since it becomes possible to automate the creation of a control chart using the collected data, it becomes possible to reduce the time and labor required for process control.

Further, the above-mentioned data is a dimensional measurement value of a predetermined portion of a product or parts constituting the product,
It is desirable that the abnormality determining means determines whether or not there is an abnormality by comparing the standard value of the product or part with the dimension measurement value. By comparing the standard value and the dimension measurement value,
It becomes possible to reliably determine the presence or absence of an abnormality.

Further, the above-mentioned data are dimensional measurement values of a product or predetermined parts of the product,
It is desirable that the abnormality determining means determines whether or not there is an abnormality based on the tendency of the dimensional measurement value to change over time. If the state of dimensional measurement changes over time shows a particular tendency, for example, if there is a deviation in the dimensional measurement each time from the standard value of the standard, or if the upward trend or downward trend continues, then the point Even if there is no out-of-specification, it is considered that if left as it is, an abnormality such as out-of-specification will occur soon. Therefore, it is possible to detect the occurrence of an abnormality in advance by examining the state of such changes over time in the dimension measurement values.

Further, the apparatus further comprises measuring means for outputting a signal corresponding to the result of measuring the dimension at the above-mentioned predetermined position, and by inputting the signal output from the measuring means by the terminal device, input of the dimension measurement value. Is preferably performed. This saves the labor of the person in charge of measurement to manually input the dimension measurement values, which reduces the time and effort required to perform the process control and reduces the time required to input the dimension measurement values required for the process control. It can be shortened.

Further, the above-mentioned data is the number of defective occurrences of the product or the parts constituting the product, and the abnormality determining means compares the number of defective occurrences with a predetermined reference value to determine the presence or absence of abnormality. Is desirable. As a result, it becomes possible to detect an abnormality in the process early and reliably based on the status of occurrence of defects in products and the like.

It is desirable that the above-mentioned server further comprises notifying means for notifying a person concerned when the abnormality determining means determines that there is an abnormality. As a result, it is possible to avoid delaying the notification to the persons concerned and forgetting the notification.

Further, the control chart processing means described above, at a predetermined timing, based on the data acquired so far,
It is desirable to perform a predetermined counting process. Alternatively, it is desirable that the control chart processing means described above performs the control line setting processing at a predetermined timing based on the data acquired up to that point. As a result, it is possible to reduce the time and effort required for the totalization process and the management line setting process that are performed regularly or as needed.

Further, when the operator of the above-mentioned terminal device performs a predetermined operation, and if the operator has a predetermined authority, the control chart created by the control chart processing means is displayed on the screen of the terminal device. It is desirable to display. This allows
Since the contents of the control chart can be confirmed using the terminal device, it becomes possible to easily grasp the current state of the process,
The labor and time required for process control can be reduced.

[0014]

BEST MODE FOR CARRYING OUT THE INVENTION A process control system of an embodiment to which the present invention is applied will be described in detail below with reference to the drawings. FIG. 1 is a diagram showing a schematic configuration of a process control system according to an embodiment. The process control system of the present embodiment shown in FIG. 1 includes a plurality of terminal devices (TE) 100 connected to each other by a predetermined network 900.
And a manufacturing department server 800.

Each of the plurality of terminal devices 100 is arranged in each place of the manufacturing process or in a department or the like that controls the manufacturing process, and is operated by an operator of each component processing process or a person in charge of managing the entire manufacturing process. Operated. FIG. 2 is a diagram showing the configuration of the terminal device 100. As shown in FIG.
The terminal device 100 has a configuration as a general computer, and includes a CPU 110, a ROM 111, and a RAM 1.
12, a hard disk device (HD) 113, a display processing unit 114, a display device 115, an I / O (input / output) processing unit 116, a keyboard 117, a mouse 118, a network processing unit 119, an I / F (interface) processing unit 120, It is configured to include a multiplexer 121. The display processing unit 114 generates an image signal to be displayed on the display device 115. The I / O processing unit 116 detects the operation content of the keyboard 117 and the mouse 118. The network processing unit 119 uses the network 900.
, And processes input / output operations of electric signals between the terminal device 100 and the network 900.
The I / F processing unit 120 converts a signal (analog) input from the outside via the multiplexer 121 into digital data. The multiplexer 121 is connected to a plurality of dimension checkers 122, and selectively inputs the measurement signal output from each dimension checker 122 to the I / F processing unit 120.

In the present embodiment, the dimension checker 122 according to the size and shape of the measurement point is used to measure the dimension of each part in each component processing step in the manufacturing process. For example, each dimension checker 122 outputs a measurement signal having a voltage proportional to the length of the measurement point.

The manufacturing department server 800 includes the terminal devices 100.
X- is for performing various processes necessary for performing process control in response to various operation instructions performed by using the X-
An X-R control chart processing unit 810 that performs a series of processing related to creation of an R control chart, a P control chart processing unit 820 that performs a series of processing related to creation of a P control chart, and an X-R control chart and P management The relation between the abnormality determination unit 830 that determines the presence or absence of an abnormality based on this data when various data necessary for creating the diagram is input, and the fact that the abnormality occurred and the aggregation result when the control chart is aggregated It is configured to include a mail processing unit 840 that sends a mail to notify the person, and a storage DB 850 that stores the processing results by the above-described units and the determination result.

The network 900 includes each terminal device 100.
And the manufacturing department server 800 are mutually connected, and for example, 100BASE-TX standardized by IEEE (Institute of Electrical and Electronics Engineers) can be used. Further, when the terminal devices 100 are arranged at two or more locations, a public line or a dedicated line may be included in a part of the network 900.

The X-R control chart processing unit 810 and the P control chart processing unit 820 described above serve as control chart processing means, and the abnormality determination unit 83.
0 corresponds to the abnormality determining unit, the dimension checker 122 corresponds to the measuring unit, and the mail processing unit 840 corresponds to the notifying unit. The process management system of the present embodiment has such a configuration, and the operation thereof will be described next in the case of performing process management using an X-R control chart.

3 to 6 are flowcharts showing the operation procedure of the processing performed by using the terminal device 100. For example, the terminal device 100 can be operated by an operator of each processing step included in the manufacturing process or a person who has the authority to display or print the control chart or change the setting content of the control chart, and the like. By operating these, the workers and persons in charge (hereinafter, these persons and persons in charge will be referred to as “persons in charge”) set items in the X-R control chart,
Various instructions such as data input and display and totalization can be performed.

Display device 11 of each terminal device 100
5 includes an X-R control chart processing unit 8 in the manufacturing department server 800.
The menu screen created by 10 is displayed (step 100), and the user is waiting for the user ID and password to be input by the person in charge (step 10).
1).

FIG. 7 is a diagram showing a specific example of the menu screen. As shown in FIG. 7, on the menu screen, a process selection frame 7a for designating a process to be processed, input frames 7b, 7c for inputting a user ID and a password, and an instruction for inputting data of an X-R control chart. "Data input" button 7d
And an “aggregate / print” button 7e for instructing tabulation and printing of the X-R control chart, and an “item setting” button 7f for instructing setting of display items of the X-R chart.

When the keyboard 117 of the terminal device 100 is operated, a person in charge or the like inputs the input frame 7b in the menu screen,
When the user ID and password are entered in 7c, X-R
The control chart processing unit 810 determines based on these input information whether or not the person in charge who has input this information has the proper authority (step 102), and when it does not have the proper authority, a negative determination is made. And a predetermined error is displayed on a part of the screen of the display device 115 (step 10).
3) Return to step 100 and repeat the menu screen display process.

If the person in charge of entering the user ID and password has the proper authority, step 10
In the determination of No. 2, an affirmative determination is made, and then the X-R control chart processing unit 810 determines whether item setting has been instructed (step 104), whether data input has been instructed (step 105), X -It is determined whether or not the totalization or output of the R control chart is instructed (step 106). These judgments are
"Data input" button 7 in the menu screen shown in FIG.
d, "total / print" button 7e, "item setting" button 7
This is done by observing whether each of the f's has been pressed using the mouse 118. If none of these buttons is pressed, a negative determination is made in each determination process, and the process returns to step 104 to repeat these determination processes.

When the person in charge or the like presses the "item setting" button 7f in the menu screen, step 10
In the determination of No. 4, a positive determination is made, and then the X-R control chart processing unit 810 creates an item setting screen, and the display device 115 of the terminal device 100 instructed to set the item.
(Step 200).

FIG. 8 is a diagram showing a specific example of the item setting screen. As shown in FIG. 8, on the item setting screen, in addition to the process designation frame 8a and the line designation frame 8b for designating the process or line for which the X-R control chart is to be created, the display items of the X-R control chart are displayed. A plurality of input frames 8c for newly specifying or changing measurement items, measurement units, etc. are included. Further, the item setting screen shown in FIG. 8 includes a "register" button 8d for instructing to confirm the change of the content of each setting item and an "end" button 8e for instructing to end the item setting process.

After displaying the item setting screen shown in FIG. 8, the X-R control chart processing unit 810 determines whether registration has been instructed (step 201) or termination has been instructed (step 202). To do. When neither instruction is given, a negative determination is made in each, and the process returns to step 200 and the display of the item setting screen is repeated. In addition, when the person in charge or the like changes each item in the item setting screen, the mouse 118 of the terminal device 100 is operated and the “register” button 8d in the item setting screen is pressed, In the determination of 201, an affirmative determination is made, and then the X-R control chart processing unit 810 performs a process of registering after the changed content is confirmed (step 20).
3). This registration processing is performed by registering the setting contents of the X-R control chart in the storage DB 850. When the registration process ends, the process returns to step 200 and the display of the item setting screen is repeated. In addition, the mouse 11 of the terminal device 100
8 is operated and the "end" button 8e in the item setting screen is pressed, an affirmative judgment is made in the judgment of step 202, and the process returns to step 100 shown in FIG. 3 to display the menu screen. Be seen.

When the person in charge or the like presses the "data input" button 7d in the menu screen, step 1
In the determination of 05, an affirmative determination is made, and then the X-R control chart processing unit 810 creates an input screen, and the display device 115 of the terminal device 100 instructed to input data.
(Step 300).

FIG. 9 is a diagram showing a specific example of the input screen. As shown in FIG. 9, on the input screen, an input frame 9a for directly inputting the dimension measurement value X, a confirmation window 9b that is temporarily displayed when the dimension measurement value X is input, and the dimension measurement that has already been input. An X-R control chart display area 9c for displaying the value X and its range R as a time series graph is included.

After the input screen shown in FIG. 9 is displayed, the X-R control chart processing unit 810 operates the keyboard 117 and the mouse 118 of the terminal device 100 by the person in charge of measurement and the like to obtain data (dimension measurement value X). It is determined whether or not is input (step 301). In addition to the method of inputting the data by the operator or the like using the keyboard 117 to directly enter a number in the input frame 9a of the input screen, the dimension checker 122
A method is conceivable in which an electric signal corresponding to the dimension measurement value output from the terminal device 100 is converted into input data in the terminal device 100 so that the converted input data corresponds to a predetermined input frame 9a. By adopting the method of converting the electric signal into the input data, it becomes possible to reduce the labor and time of data input.

If no data is input, a negative determination is made in step 301, and step 3
Returning to 00, the display of the input screen is repeated. When the measurement value is input in the input frame 9a in the input screen and the "OK" button in the confirmation window 9b displayed thereafter is pressed by operating the mouse 118, step 301
In the determination of No, an affirmative determination is made, and then the abnormality determination unit 8
30 determines whether or not there is an abnormality in the manufacturing process to be managed based on the input data (step 302). If there is no obvious abnormality, a negative determination is made, and then the abnormality determination unit 830 determines whether there is a clear standard such as deviation of the run or continuous increase or decrease of the dimension measurement value X. It is not a deviation, but if left as it is, the tendency of the dimensional measurement value X to change over time, which is considered to lead to an out-of-specification abnormality in the near future, is checked to determine whether a warning is necessary (step 303). If there is no deviation of the series, a negative determination is made, and then the X-R control chart processing unit 810 determines whether or not there is another input item (step 304). If there is no other input item, it is assumed that the "end" button 9d in the input screen is pressed, and if this button is not pressed, an affirmative judgment is made in the determination in step 304, and the process returns to step 300. The display of the input screen is repeated.

If an obvious abnormality such as nonstandard is found based on the input data, step 30
An affirmative determination is made in the determination of 2, and then the abnormality determination unit 830 displays the content of the abnormality that has occurred (step 305) and then determines whether or not any treatment content has been input (step 306).

FIG. 10 is a diagram showing a display example of a warning window for displaying the details of the abnormality that has occurred. The warning window 10a is displayed in an overlapping manner on the input screen shown in FIG. Further, in the warning window 10a, a message prompting the user to take some action against the occurrence of the abnormality together with the content of the abnormality (in the example shown in FIG. 10, "out of control limit line! Please ")
It is included.

A negative judgment is made in the judgment of step 306 until the measurer or the like takes some action, and this judgment is repeated. In addition, after some processing is performed by the person in charge of measurement and the content is input to the comment input frame 10b of the warning window 10a,
When the "OK" button 10c is pressed by operating the mouse 118, a positive determination is made in the determination of step 306. After that, the email processing unit 840 sends an email including the fact that an abnormality has occurred and the content of the processing performed for this abnormality to the supervisors such as the person in charge of measurement and the related persons in other related departments. (Step 307). The person in charge of the transmission can operate the terminal device 100 to display the content of this mail on the screen of the display device 115 and confirm it. After the transmission of the mail corresponding to the abnormality that has occurred in this way is completed, the process proceeds to step 304 described above, and the determination as to whether or not there is another input item is repeated.

Further, when there is a series of deviations in the dimension measurement value X and a warning is required, a positive determination is made in step 303, and then the abnormality determination unit 8
30 displays the content of a predetermined warning (step 30).
8). FIG. 11 is a diagram showing a display example of a warning window displaying the content of the warning. This warning window 11a
Is overlaid and displayed on the input screen shown in FIG. Further, the warning window 11a includes a message indicating the content of the warning (in the example shown in FIG. 11, "upper 6 consecutive points. Start cause investigation."). "OK" button 11 in this warning window 11a
When b is pressed by the operation of the mouse 118, the process proceeds to step 307 described above, the mail transmission process is performed, and the warning content displayed in step 308 is sent to the related persons.

When the input of the dimension measurement value X is completed for all the input items and the "end" button 9d in the input screen shown in FIG. 9 is pressed by operating the mouse 118, a negative judgment is made in step 304. Then, the process returns to step 100 shown in FIG. 3 to display the menu screen.

When the person in charge or the like presses the "total / print" button 7e in the menu screen, step 1
An affirmative determination is made in the determination of 06, and then the X-R control chart processing unit 810 creates a tallying screen and displays it on the display device 115 of the terminal device 100 instructed to tabulate (step 400). .

FIG. 12 is a diagram showing a specific example of the totalizing screen. As shown in FIG. 12, on the tabulation screen, a “tabulation” button 12a for instructing tabulation processing, a “print” button 12b for instructing to print the created X-R control chart, and termination of tabulation processing or printing processing are displayed. An "end" button 12c for instructing is included.

The X-R control chart processing unit 810 displays the totalizing screen shown in FIG. 12, and then the person in charge or the like operates the mouse 118 of the terminal device 100 to execute the “totalizing” button 12.
Whether a is pressed to give a totaling instruction (step 4)
01), it is determined whether the "print" button 12b has been pressed to instruct to print the X-R control chart (step 402). If neither the “total” button 12a nor the “print” button 12b is pressed, steps 401, 40
In both cases, a negative determination is made, and the process returns to step 400 and the display of the counting screen is repeated. Also, "print"
When the button 12b is pressed, an affirmative determination is made in the determination in step 402, and then the X-R control chart processing unit 810 creates print data for the X-R control chart and uses it for the terminal device. It is sent to 100 and displayed on the display device 115 of this terminal device 100, and its contents (X-R control chart) are printed from a printer (not shown) connected to this terminal device 100 (step 403).

If the "total" button 12a is pressed, an affirmative judgment is made in the judgment of step 401, and then the X-R control chart processing section 810 carries out a predetermined total processing (step 404). ), And displays the totalized result (step 405). FIG. 13 is a diagram showing a display example of a tallying execution window showing the contents of tallying. This tallying execution window 13a is displayed in an overlapping manner on the tallying screen shown in FIG. Further, in the totalization execution window 13a, the average value of the measurement values X, the standard deviation σ, the range R of the measurement values,
Process control indexes Cp and Cpk for each aggregation result frame 13b to 13
f, date frames 13g and 13h that specify the start date and end date of the aggregation period for inputting the aggregation period, a "aggregate" button 13i for instructing execution of aggregation, and "registration" for instructing to register the aggregation result. Button 13j is included.

In the initial state of the tallying execution window 13a, the day after the previous tallying is the start date of the tallying period, and the day when the "tally" button 13i is pressed is the last day of the tallying period. Each is set. The aggregation period can be changed by directly rewriting the contents of the date frames 13g and 13h. After determining the aggregation period,
When the "total" button 13i is pressed, the total measurement result frames 13b to 13f are calculated using the dimension measurement values X accumulated during this period.
A value corresponding to each of is calculated. In addition to the values corresponding to each of these tabulation result frames 13b to 13f, the values of the control lines such as the upper control limit UCL and the lower control limit LCL used in the next tabulation period are automatically calculated, Is set.

The X-R control chart processing unit 810 displays "register" in the state in which the above-described tabulation execution window 13a is displayed.
It is determined whether the button 13j has been pressed (step 406). When the button is not pressed, a negative determination is made, the process returns to step 405, and the display of the tallying execution window 13a is repeated. If the "register" button 13j is pressed, an affirmative decision is made in the decision at step 406, and then the mail processing unit 840 directs the person in charge (eg, boss) who approves the aggregation result. And sends the mail (step 407). After sending the email,
Alternatively, after the printing process in step 403 is completed, the process returns to step 100 shown in FIG. 3 and the menu screen is displayed.

14 to 16 are diagrams showing the operation procedure of the process performed by the person in charge of approval who has received the tabulation result using the terminal device 100. On the display device 115 of the terminal device 100 operated by the person in charge of approval,
The menu screen created by the X-R control chart processing unit 810 in the manufacturing department server 800 is displayed (step 500), and is in a state of waiting for input of the user ID and password by the person in charge of approval ( Step 50
1).

FIG. 17 is a diagram showing a specific example of the menu screen. As shown in FIG. 17, in the menu screen for the person in charge of approval, like the menu screen shown in FIG. 7, a process selection frame 17a for designating a process and input frames 17b, 17c for inputting a user ID and a password. In addition to this, a "control chart display" button 17d for instructing to display the X-R control chart to be approved and an "approval processing" button for instructing to execute the approval processing of the X-R control chart 17e and 17e are included.

The keyboard 117 of the terminal device 100 is operated and the person in charge of approval inputs the input frame 1 in the menu screen.
When the user ID and the password are input to 7b and 17c, the X-R control chart processing unit 810 determines whether the person who inputs this information has the proper authority to approve based on the input information. Is determined (step 502), a negative determination is made when the user does not have the proper authority, a predetermined error is displayed on a part of the screen of the display device 115 (step 503), and the process returns to step 500. The display process of the menu screen is repeated.

If the person in charge of inputting the user ID and password has the proper authority to approve, an affirmative decision is made in step 502, and then X
The −R control chart processing unit 810 determines whether display of a control chart has been instructed (step 504) and whether approval processing has been instructed (step 505). These judgments are made by the "display control chart" button 1 in the menu screen shown in FIG.
7d or "approval processing" button 17e is mouse 118
Is performed by monitoring whether or not the button has been pressed. If none of these buttons is pressed, a negative determination is made in each determination process, and step 504
Then, these determination processes are repeated.

When the person in charge of approval depresses the "display control chart" button 17d in the menu screen, an affirmative decision is made in the decision at step 504, and then X
The -R control chart processing unit 810 creates a control chart display screen and displays it on the display device 115 of the terminal device 100 instructed to display the control chart (step 600). This control chart display screen has substantially the same contents as the tallying screen shown in FIG. 12, for example (however, the "tally" button 12a
Is unnecessary and has been removed).

Next, the X-R control chart processing unit 810 determines whether or not a "print" button in the control chart display screen has been pressed to issue a print instruction (step 601). If printing is instructed, an affirmative determination is made, and then the X-R control chart processing unit 810 creates print data for the X-R control chart and sends it to the terminal device 100, and this terminal Device 10
0 on the display device 115 and the contents (X
-R control chart) is printed (step 602).

After the printing of the X-R control chart is completed in this way, or when the "end" button in the control chart display screen is pressed without giving a print instruction, the determination in step 601 is negative. Judgment is made and then Figure 1
Returning to step 500 shown in 4, the menu screen is displayed.

When the person in charge of approval presses the "approval processing" button 17e in the menu screen, an affirmative judgment is made in the judgment of step 505, and then X-
The R control chart processing unit 810 creates the approval screen, and the display device 11 of the terminal device 100 instructed to perform the approval process.
5 is displayed (step 700).

FIG. 18 is a diagram showing a specific example of the approval screen. As shown in FIG. 18, on the approval screen, in addition to the X-R control chart that is the approval target, a “comment” button 18a for instructing the input of a comment at the time of approval and an “approval” button for performing the approval process 18b and are included.

After displaying the approval screen shown in FIG. 18, the X-R control chart processing unit 810 operates the mouse 118 of the terminal device 100 by the person in charge of approval to press the "comment" button to make a comment. It is determined whether or not an input is instructed (step 701) and whether or not the "approval" button 18b is pressed to instruct the approval processing (step 702). If neither instruction is given, a negative determination is made in both of these determinations, and step 700
The display of the approval screen is repeated by returning to.

When the "comment" button 18a is pressed, an affirmative judgment is made in the judgment of step 701, and then the X-R control chart processing section 810 displays a predetermined comment input window. Input processing of the approval comment is performed (step 703).

FIG. 19 is a diagram showing a display example of the comment input window. This comment input window 19a
Is overlaid and displayed on the approval screen shown in FIG. In addition to the comment input frame 19b, the comment input window 19a also includes an "OK" button 19c for instructing confirmation of the input content of the comment. After the comment is entered by the person in charge of approval, the “OK” button 19
When c is pressed, the process proceeds to step 702, and it is determined whether or not there is an approval instruction.

When the "approve" button 18b is pressed, an affirmative decision is made in the determination at step 702, and then the X-R control chart processing section 810 causes the approved X-R control chart. Is stored in the storage DB 850 (step 704). Then, the process returns to step 500 shown in FIG. 14 and the menu screen is displayed.

As described above, in the process control system of this embodiment, the data necessary for the process control using the X-R control chart is collected, and the presence or absence of abnormality is automatically judged based on the collected data. Therefore, the occurrence of abnormality can be detected early and surely. Further, since it becomes possible to automate the creation of the X-R control chart using the collected data, it becomes possible to reduce the time and labor required for the process control. In particular, by comparing the standard value and the dimension measurement value X, it becomes possible to reliably determine the presence or absence of an abnormality. Alternatively, it is possible to detect the occurrence of an abnormality in advance by examining the state of temporal change of the dimension measurement value such as deviation of the dimension measurement value X.

The present invention is not limited to the above embodiment, and various modifications can be made within the scope of the gist of the present invention. For example, in the embodiment described above,
Although the case where the process control is performed using the X-R control chart has been described, the present invention can also be applied to the case where the process control is performed using the P control chart created by the P control chart processing unit 820.

20 to 23 are diagrams showing specific examples of display screens relating to the P control chart. FIG. 20 shows a specific example of the data input screen. This input screen is for inputting the number of defects (number of defects generated) and the number of passes necessary for creating the P control chart, and corresponds to the input screen shown in FIG. 9 for the X-R control chart. .

Further, FIG. 21 shows a specific example of the warning window when an abnormality occurs. This warning window is for notifying the person in charge of the occurrence of an abnormality when the defect rate P exceeds a target rate or a control limit which is a predetermined reference value, and with respect to the X-R chart, FIG. It corresponds to the warning window shown in. Further, FIG. 22 shows a specific example of the comment input window when an abnormality occurs. This comment input window is for inputting the processing contents performed by the person in charge,
This corresponds to the warning window shown in FIG. 10 for the X-R control chart. Further, FIG. 23 shows a specific example of the display screen of the P management chart.

Further, the process management may be performed by combining the X-R control chart and the P control chart described above, or the process control may be performed using another control chart.

[Brief description of drawings]

FIG. 1 is a diagram showing a schematic configuration of a process control system according to an embodiment.

FIG. 2 is a diagram showing a configuration of a terminal device.

FIG. 3 is a flowchart showing an operation procedure of processing performed using the terminal device.

FIG. 4 is a flowchart showing an operation procedure of processing performed using the terminal device.

FIG. 5 is a flowchart showing an operation procedure of processing performed using the terminal device.

FIG. 6 is a flowchart showing an operation procedure of processing performed using the terminal device.

FIG. 7 is a diagram showing a specific example of a menu screen.

FIG. 8 is a diagram showing a specific example of an item setting screen.

FIG. 9 is a diagram showing a specific example of an input screen.

FIG. 10 is a diagram showing a display example of a warning window for displaying details of an abnormality that has occurred.

FIG. 11 is a diagram showing a display example of a warning window that displays the content of a warning.

FIG. 12 is a diagram showing a specific example of a tallying screen.

FIG. 13 is a diagram showing a display example of a tallying execution window showing the contents of tallying.

FIG. 14 is a diagram showing an operation procedure of a process performed by the person in charge of approval who has received the counting result using the terminal device.

FIG. 15 is a diagram showing an operation procedure of processing performed by the person in charge of approval who has received the counting result using the terminal device.

FIG. 16 is a diagram showing an operation procedure of processing performed by the person in charge of approval who has received the aggregation result using the terminal device.

FIG. 17 is a diagram showing a specific example of a menu screen.

FIG. 18 is a diagram showing a specific example of an approval screen.

FIG. 19 is a diagram showing a display example of a comment input window.

FIG. 20 is a diagram showing a specific example of a display screen regarding a P management chart.

FIG. 21 is a diagram showing a specific example of a display screen regarding a P management chart.

FIG. 22 is a diagram showing a specific example of a display screen regarding a P management chart.

FIG. 23 is a diagram showing a specific example of a display screen regarding a P management chart.

[Explanation of symbols]

100 terminal equipment (TE) 122 Dimension checker 800 Manufacturing Department Server 810 X-R control chart processing unit 820P control chart processing unit 830 Abnormality determination unit 840 mail processing unit 850 Storage DB (database)

   ─────────────────────────────────────────────────── ─── Continued front page    (72) Inventor Takafumi Kurokawa             1-1, Showa-cho, Kariya city, Aichi stock market             Inside the company DENSO

Claims (9)

[Claims] 1. A terminal device for inputting data relating to process control necessary for creating a control chart, a control chart processing means for producing the control chart based on the data, and a control chart processing means for producing the control chart, A process management system, comprising: a server having an abnormality determination unit that determines the presence or absence of an abnormality based on a determination condition set in advance. 2. The data according to claim 1, wherein the data is a dimensional measurement value of a product or a component of the product at a predetermined location, and the abnormality determining means is a standard of the product or the component and the dimensional measurement value. A process control system characterized by determining the presence or absence of an abnormality by comparing with. 3. The data according to claim 1, wherein the data is a dimensional measurement value of a predetermined portion of a product or a component forming the product, and the abnormality determining means is based on a tendency of the dimensional measurement value to change with time. A process control system which determines whether or not there is an abnormality. 4. The measuring device according to claim 2, further comprising a measuring unit that outputs a signal corresponding to a result of measuring the dimension of the predetermined portion, and the terminal unit captures the signal output from the measuring unit. The process management system is characterized in that the dimension measurement value is input thereby. 5. The data according to claim 1, wherein the data is the number of defective products or a component of the product, and the abnormality determining means compares the number of defective products with a predetermined reference value. A process control system which determines whether or not there is an abnormality. 6. The server according to any one of claims 1 to 5, wherein the server further comprises notifying means for notifying a person concerned when the abnormality determining means determines that there is an abnormality. Process control system characterized by. 7. The process according to any one of claims 1 to 6, wherein the control chart processing unit performs a predetermined totalizing process at a predetermined timing based on the data acquired so far. Management system. 8. The control chart processing means according to claim 1, wherein the control chart processing means performs control line setting processing at a predetermined timing based on the data acquired so far. Process control system. 9. The control chart processing means according to claim 1, wherein when the operator of the terminal device performs a predetermined operation, and the operator has a predetermined authority, A process control system for displaying the generated control chart on a screen of the terminal device.