JP2006018459A - Production history management system - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a production history management system for precisely detecting in which time zone articles which are highly likely to generate any failure in the same way as defective articles have been processed by another production facility when any defective article is generated. <P>SOLUTION: This production history management system is provided with a data acquiring means and a retrieval means, and the data acquiring means time-sequentially totals the cumulative number of non-defective articles and the cumulative number of discharged articles for each production facility. When a labeler is designated as a designated production facility, and "15:20" to "15:25" are designated as a designated time range, a retrieval means 7 detects that the cumulative number of processing (670)(930) calculated by totaling the cumulative number of non-defective articles (640)(895) to the cumulative number of discharged articles (30)(35) processed in the designated time range is included in the cumulative number of non-defective articles (625)(970) of a caper being an upstream side production facility, and makes different the background colors of the columns of the cumulative number of non-defective articles and the cumulative number of discharged articles of the caper. Thus, it is possible to accurately manage a production history by time-sequentially integrating the cumulative number of non-defective articles and the cumulative number of discharged articles into a data file. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a production history management system, and more particularly to a production history management system for a production system that manufactures a product by sequentially processing articles in a plurality of production facilities.

Conventionally, a production system that manufactures products by sequentially processing articles in multiple production facilities has been used in the field of food and beverages. In this production system, the occurrence of defective products or abnormalities in production facilities should be specified. Therefore, a production history management system for managing production history for each production facility is provided.
As such a production history management system, a trace information collecting means for creating a database in which the number of articles processed by each production facility for each predetermined time is recorded for each production facility, and the database according to a specified search condition A production history management system including a lot trace processing means for performing a search is known (Patent Document 1).
In Patent Document 1, when an abnormality occurs in a predetermined production facility, the production facility where the abnormality occurred and the time range where the abnormality occurred are specified as search conditions in the lot trace processing means of the production history management system. Thus, a search was performed from the database, and it was detected in which time range the articles processed in the period in which the abnormality occurred were processed in other production facilities.
Specifically, the lot trace processing means detects the number of processed articles processed at the production facility where the abnormality occurred in the time range where the abnormality occurred as the actual number, and further adds the safety factor to the detected actual number. The count value was calculated.
Based on the calculated count value, the lot trace processing means detects in which time range the article processed in the production facility where the abnormality occurred is processed in the production facility located downstream thereof. .
JP 2003-337610 A (particularly columns 0052 to 0055)

However, in the case of Patent Document 1, the count value is calculated based on a safety factor determined for each production facility regardless of whether or not an abnormality has occurred. Therefore, if no abnormality has occurred in the production facility, There will be a difference between the number of processed articles actually processed and the count value.
In other words, the time range detected by the lot trace processing means may include articles that have nothing to do with the abnormality. It will end up collecting many items that are not available.
In view of such a problem, when a defective product occurs, the present invention shows in which time range an article that may have the same problem as the defective product was processed in another production facility. A production history management system capable of detecting with high accuracy is provided.

That is, the production history management system according to claim 1 is a production history management system of a production system that manufactures products by sequentially processing articles in a plurality of production facilities,
The production history management system specifies a data acquisition unit that acquires, for each production facility, the cumulative number of articles processed by each production facility every predetermined time, and a data file created by the data acquisition unit. Search means for performing a search according to the specified search conditions,
When a designated production facility and a designated time range as a reference for the search are designated, the retrieval means obtains a processing time range in which an article processed in the designated time range by the designated production facility is processed in another production facility. In the production history system to search,
The data acquisition means creates a data file that records, for each production facility, the cumulative number of non-defective items processed by each production facility and the cumulative number of rejected items rejected as defective by each production facility. And
For the upstream adjacent production facility adjacent to the designated production facility, the search means is configured such that the cumulative number of non-defective products in the upstream adjacent production facility is the sum of the cumulative number of non-defective products and the cumulative discharge number in the designated production facility. Search for a time range that includes the processing time range at the upstream adjacent production facility,
When there is an upstream remote production facility further upstream than the upstream adjacent production facility, the search means is located between the designated production facility and the upstream remote production facility in the cumulative processing number of the designated production facility. Calculate the number of virtual processes by adding the cumulative number of emissions in the processing time range for each production facility, and set the time range such that the virtual processing number is included in the cumulative number of non-defective products of the upstream remote production facility It is characterized by searching as.

The production history management system according to claim 2 is a production history management system of a production system that manufactures a product by sequentially processing articles in a plurality of production facilities,
The production history management system specifies a data acquisition unit that acquires, for each production facility, the cumulative number of articles processed by each production facility every predetermined time, and a data file created by the data acquisition unit. Search means for performing a search according to the specified search conditions,
When a designated production facility and a designated time range as a reference for the search are designated, the retrieval means obtains a processing time range in which an article processed in the designated time range by the designated production facility is processed in another production facility. In the production history system to search,
The data acquisition means creates a data file that records, for each production facility, the cumulative number of non-defective items processed by each production facility and the cumulative number of rejected items rejected as defective by each production facility. And
The search means, for the downstream side adjacent production facility adjacent to the designated production facility, the cumulative number of processed products, which is the sum of the cumulative number of non-defective products and the cumulative discharge number of the downstream side adjacent production facility, is the designated time range in the designated production facility. The time range that includes the cumulative number of non-defective products at is searched as the processing time range at the downstream adjacent production facility,
When there is a downstream remote production facility further downstream than the downstream adjacent production facility, the search means is located between the designated production facility and the downstream remote production facility based on the cumulative number of non-defective products of the designated production facility. The number of virtual processes is calculated by subtracting the cumulative number of emissions in the above processing time range for each production facility, and the time range in which the virtual processing number is included in the cumulative number of processes in the downstream remote production facility is the processing time range. It is characterized by searching as.

According to the first and second aspects of the invention, since the data acquisition means records the cumulative number of non-defective products and the cumulative discharge number for each production equipment, the designated production equipment to be searched and the search By designating a reference time range as a reference, articles other than articles rejected as defective products are not counted as defective products.
For production facilities located upstream from the designated production facility, the processing time range is searched based on the cumulative number of processes in the designated production facility, and downstream from the designated production facility. Since the processing time range is searched based on the cumulative number of non-defective products in the designated production facility, the items processed in the designated time range in the designated production facility Then, it is possible to accurately grasp in which time range the processing was performed.
Moreover, for upstream remote production facilities and downstream remote production facilities that are not adjacent to the designated production facility, the number of virtual processes is calculated taking into account the number of containers discharged before reaching the corresponding production facility. So you can search more accurately.

The illustrated embodiment will be described below. FIG. 1 shows a bottling line 1 serving as a production system for producing a beverage product and a production history of the bottling line 1 by filling a container as an article from beverage filling to boxing. The production history management system 2 is shown.
The bottling line 1 includes a plurality of production facilities 3 such as an answerer 3A and a filler 3D described later, and each production facility 3 includes a control terminal 4 such as a programmable controller (PLC). The control terminal 4 controls each production facility 3.
The production history management system 2 is communicably connected to each control terminal 4 via a communication line 5 such as a LAN, and the number and occurrence of containers processed from the control terminal 4 every predetermined time or every occurrence of an event. A data acquisition unit 6 that collects various data such as abnormalities and creates a data file for each type of data, and a search unit 7 that searches a data file or data in a data file according to a specified search condition And an operation terminal 8 for displaying instructions to the search means 7 and search results.
According to this production history management system 2, a desired search is performed by the search means 7 from the data collected by the data acquisition means 6, so that the semi-finished products in the production system are processed in which time range in each production facility 3. Can be identified.

The bottling line 1 includes, in order from the upstream production facility 3, an anchor 3A for taking out an empty container packed in a case supplied from a depalletizer, a bottle washer 3B for washing the container, and an empty bottle for detecting cracks and chips in the container. Inspection machine 3C, filler 3D for filling beverage, capper 3E for capping, labeler 3F for labeling containers, appearance inspection machine 3G for visual inspection of beverage products, cartner 3H for storing beverage products in a box, the above box And a palletizer 3I that is placed on a pallet, and a container and a box conveying means are provided between the facilities to constitute a series of production systems.
And the beverage product produced by this bottling line 1 is shipped to the customer by the pallet unit.
A predetermined production facility 3 of the bottling line 1 is provided with a material supply means 11 for supplying materials such as empty containers, caps, and labels.
In this embodiment, as the material supply means 11, a depalletizer 11A for supplying an empty container accommodated in a case in the answerer 3A, a cap supply means 11E for supplying a cap to the capper 3E, and a roll label on the labeler 3F. A label supply means 11F for supplying and a box supply means 11H for supplying an empty box to the cartner 3H are provided.
Further, the filler 3D in the bottling line 1 is provided with a preparation means 12 as a beverage supply means for preparing raw materials and supplying beverages to the filler 3D.
The bottling line 1 is provided with a printing means 13 between the labeler 3F and the appearance inspection machine 3G, and according to the setting of the date and time when the printing means 13 passed through the printing means 13 and the production lot number. Is printed. The printing means 13 is provided immediately after the labeler 3F, and when the passage date and time of the container is printed on time, the printed date and time can be regarded as the processing time of the labeler 3F.

Next, the control terminal 4 collects the following production-related data together with the processed time range, or is input by an operator.
First, as the number of non-defective products and the number of discharged products, the control terminal 4 automatically counts the number of containers that each production facility 3 supplies to the downstream production facility 3 as non-defective products and the number of containers that are rejected as defective products. The
Further, for each container rejected by each production facility 3, the date and content of the rejection are automatically saved by the control terminal 4 as the waste data, and the production facility having a number of processing heads such as a filler 3D and a capper 3E, for example. In the case of 3, the data of the head number that has processed the rejected container is also stored.
Furthermore, when an abnormality such as a machine stoppage occurs in the production equipment 3 as alarm data, the date and time of occurrence and the content of the abnormality are automatically saved by the control terminal 4, and for example, in the filler 3D, a lack of beverage or an abnormal liquid temperature is considered. In addition, the cap 3E may be short of caps.
As the actual value trace data, the state of each production facility at each predetermined time has been stored. For example, the control terminal 4D of the filler 3D constantly monitors the liquid temperature of the beverage in the filler tank in the filler 3D. Is saved.

In addition to this, when various types of production-related data are input to the control terminal 4 by an operator and the data is changed, the control terminal 4 stores the change contents and the change date and time.
First, in the control terminal 4 of the production facility 3 to which each material supply means 11 is connected, as material data, the material lot number of the material supplied from the material supply means 11, the use start date and time, the use end date and time of the material, Material manufacturer name and delivery date and time are stored.
Further, in the control terminal 4D of the filler 3D to which the preparation means 12 is connected, the preparation lot number of the beverage supplied from the preparation means 12, the raw material input amount, the supply start date and time, the supply end date and time, etc. In addition, the raw material lot number of the raw material used as the raw material of the beverage, the supply start date and time, the supply end date and time, the manufacturer name of the raw material, the date and time of delivery, etc. are stored as raw material data.
These material data, preparation data, and raw material data may be automatically collected via the material supply means 11 and the preparation means 12.
Further, various set values necessary for each production facility 3 are stored as facility set value data. For example, in the case of the filler 3D, the filling amount of the beverage for each container is stored. In the capper 3E, the capping torque to the cap is stored. Is saved.
And as inspection data, the inspection result which the operator performed about the product extracted from each production equipment 3 during the operation of the bottling line 1 is stored. For example, in the filler 3D, the inspection result of the filling amount into the container is stored. In 3E, the capping torque is stored as an inspection result.
Further, as the exception processing data, data when a predetermined container is processed differently from other containers is stored. For example, the filling amount of the beverage is changed with the filler 3D, or the capping torque is changed with the capper 3E. Or data such as when each production facility 3 is manually operated is stored.
In addition to this, the name of the worker in charge of each production facility 3 as worker data, the contents of modification or remodeling applied to the production facility 3 as work data, the temperature in the factory and power outages as environmental data The presence / absence of each is stored.
Data that can be input by these workers may be directly input to the production history management system 2.
And the production lot number is defined in advance for the beverage product to be produced, and this production lot number is registered in each control terminal 4 via the production history management system 2, and when the type of product to be produced is changed, The production lot number is changed.

The operation of the bottling line 1 having such a configuration will be described below. The preparation means 12 prepares a beverage in advance and supplies it to the filler 3D according to the beverage product to be produced. Are supplied to each material supply means 11 and data such as a production lot number and a preparation lot number are input to the control terminal 4 of each production facility 3.
When the bottling line 1 is operated from this state, the depalletizer 11A takes out the case from the pallet and supplies it to the anchor 3A, and the anchor 3A takes out an empty container from this case and supplies it to the bottle washer 3B. .
Thereafter, the container cleaned by the bottle washing machine 3B is supplied to the empty bottle inspection machine 3C, where the container is inspected for scratches and cracks. When the empty bottle inspection machine 3C detects a crack or a flaw in the container, the container is rejected as a defective product, and the rejection data is stored in the control terminal 4C.

Next, the container supplied from the empty bottle inspection machine 3C to the filler 3D is filled with a beverage in the filler 3D. When, for example, a filling failure occurs in the filler 3D, the container is rejected as a defective product, and the detection result At the same time, the number of the filling nozzle in which the filling failure has occurred is stored in the control terminal 4D as exclusion data.
In the filler 3D, for example, when an abnormality occurs in the liquid temperature of the beverage, the content of the abnormality is stored in the control terminal 4D as alarm data.
In addition, the quality check result of the beverage prepared by the preparation means 12 is input to the control terminal 4 of the filler 3D by the operator as inspection data together with the time when the beverage used for the quality check is extracted.

The container filled with the beverage by the filler 3D is capped by the capper 3E, and when the winding failure or the like occurs in the capper 3E, the container is rejected as a defective product. Is stored in the control terminal 4 as exclusion data.
Next, the capped container is labeled by the labeler 3F. When a labeling failure or the like occurs in the labeler 3F, the container is rejected as a defective product, and the rejection data is stored in the control terminal 4.
The date and time when the container passes through the printing unit 13 and the production lot number are printed on the container supplied from the labeler 3F to the appearance inspection machine 3G by the printing unit 13 provided in the middle of the container.

Further, when the container is transported to the appearance inspection machine 3G, the appearance inspection machine 3G performs an inspection using an optical sensor or the like on the container. Is detected as a defective product, the rejection data is stored in the control terminal 4.
A plurality of containers supplied to the cartner 3H are stored together in a box, and if the box assembly failure or container storage abnormality occurs in the cartner 3H, the container is rejected as a defective product, and the waste data is transferred to the control terminal. 4 is stored.
When the boxes containing the containers are conveyed to the palletizer 3I, the palletizer 3I sequentially stacks the boxes in a predetermined pattern on the pallet, and when a predetermined number of boxes are placed on the pallet, the pallet is moved to a new pallet. It is supposed to be replaced.
In addition, the control terminal 4 of the palletizer 3I obtains the number of non-defective products by adding the number of boxes to the number of containers stored in the box, and the pallet of the pallet on which a predetermined number of boxes are placed and replaced. The quantity is counted, and the pallet number of the pallet is recorded as the shipping data as the final shipping unit number.
The control terminal 4 of each production facility 3 from the answerer 3A to the palletizer 3I counts the number of non-defective products and the number of discharges each time the production facility 3 processes the container, and stores the data.
For the terminal device 4 of the manufacturing facility 3 that does not discharge containers, such as the answerer 3A and the palletizer 3I, the number of discharges may be set to 0 in advance and the number of discharges may not be counted.

Next, the production history management system 2 will be described. The data acquisition means 6 collects various data such as the cumulative number of non-defective products and the cumulative number of discharges every predetermined time from the control terminal 4 of each production facility 3. Are recorded and saved in a data file in time series.
For example, the data acquisition unit 6 collects the cumulative number of non-defective products and the cumulative number of discharged containers processed by each production facility 3 for each predetermined time from the start of the work to the end of the work, and records and stores it in a data file.
In addition to the cumulative number of non-defective products and the cumulative number of emissions, the data acquisition means 6 includes waste data, alarm data, actual value trace data, material data, preparation data, raw material data, equipment set value data, inspection for each production facility 3 Collect various production-related data such as data and exception handling data, and organize and store them in each data file in time series.
Next, the search means 7 performs a search from the data file created by the data acquisition means 6 according to the search conditions input by the operator to the operation terminal 8.
The operation terminal 8 can be a conventionally known personal computer or the like, and includes a monitor for displaying a screen to be described later, a keyboard and a mouse for inputting search conditions and the like.

Hereinafter, the production history search procedure by the production history management system 2 will be described with reference to actual examples.
Here, it is assumed that a defective product of a shipped beverage product is found and a production history is searched for the purpose of identifying the cause of the defect. It is assumed that a defective container is printed by the printing means 13 as the date of manufacture, for example, “March 27, 2003, 15:22”.
When the production history management system 2 is started from the above conditions, the “main menu” screen shown in FIG. 2 is first displayed on the operation terminal 8, and two types of search methods are roughly selected on the “main menu” screen. Can do.
“Select from process diagram” at the top of the “Main Menu” screen is used to search the production history from the manufacturing date and time printed on the beverage product, and “Tracking from each element” at the bottom is found to be abnormal Used when the production lot number of the beverage product or the material lot number supplied to the material supply means 11 is known.
In the case of the present embodiment, since the production lot number and the material lot number are unknown under the above conditions, the operator selects “March 27, 2003” from the calendar displayed in the “Select from process diagram” column. Then, the user designates the “to production result process chart” button 21 displayed below the calendar.

By instructing the “to production result process chart” button 21, the search means 7 searches the data file recorded by the data acquisition means 6 for necessary data for the work content of “March 27, 2003” The “production result process chart” of FIG. 3 is displayed on the operation terminal 8.
This “production performance schedule” includes the production lot number of the beverage product produced on the bottling line 1 on “March 27, 2003”, and the materials of the materials supplied to each production facility 3 from each material supply means 11. The lot number and the beverage lot number of the beverage supplied from the preparation means 12 to the filler 3D are displayed as a time-series table for each hour.
In the case of this example, since “March 27, 2003, 15:22” was printed on the container, it can be seen from this “production result process chart” that the manufacturing lot number of the container was “1000A1”. . (A in the figure)

Then, when the part indicated by the production lot number “1000A1” is designated, the search means 7 is the production lot number “1000A1” in which the designated production facility to be searched is the filler 3D and the designated time range is the filler 3D. It is determined that it is the time range when the container was processed.
Next, the search means 7 searches the data file under the above conditions to search the time range in the filler 3D where the beverage product with the production lot number “1000A1” was manufactured, and the entire bottling line 1 in the time range. 4 is retrieved and the “traceability” screen shown in FIG. 4 is displayed on the operation terminal 8.
Above the “traceability” screen, the lot start date and time when the process is started in the filler 3D for the production lot number “1000A1” and the lot end date and time when the process is completed are displayed.
In the lower part, the cumulative number of non-defective products and the cumulative number of discharged products in each production facility 3 constituting the bottling line 1 are displayed every time when the time displayed in the left column elapses. Beverage products related to the production lot number “1000A1” The columns of the number of non-defective products and the number of accumulated discharges corresponding to are all displayed with different background colors.
Here, the time displayed in the left column indicates the current hour, for example, “03/27 15:54” indicates “March 27 15:54:00”. The search results are distinguished by changing the background color of the column. However, the search results may be distinguished by other methods such as shading or bolding.
Depending on the monitor of the terminal device 8, since the time range “15:00” to “18:00” of the production lot number “1000A1” cannot be displayed at a time as shown in FIG. Not all of the parts with different background colors and parts with different background colors are displayed, but by scrolling up and down this table and browsing the entire time range, it has nothing to do with the production lot number “1000A1” It can be distinguished from the part.
Also, in the upper part of FIG. 4, a selection field 42 for changing the time interval displayed on the “traceability” screen is displayed, and an arbitrary interval such as 5 minutes, 10 minutes, 1 hour, etc. is designated. By doing so, the search means 7 can display the cumulative number of non-defective products and the cumulative number of discharges for each interval.
In this embodiment, the processing time corresponding to the production lot number is set to be the same as the processing time in the filler 3D. Therefore, when the production lot number is specified and searched as described above, “Fila” is displayed in the “Trace Target Model” column in the “Traceability” screen of FIG. 4 and the time corresponding to the designated production lot number is displayed. As a range, a time range for the filler 3D is searched.

When the “traceability” screen of FIG. 4 is displayed and the user wishes to further narrow down the time range by performing a search, the operator instructs the “search” button 41 at the top of the table, and the operation terminal accordingly. 8 displays the “search condition instruction screen” of FIG.
In this search condition instruction screen, the production equipment 3 to be searched and the time range as a reference for the search are specified. Here, the designated production is specified in the “Trace Target” column 51 of the “Search Condition Instruction Screen”. “Labera” is selected as the equipment, and “search date and time” field 52 is entered with “specified date range” as “March 27, 2003 15:20” and “2003 March 27, 15:25”.
This input designated time range is approximately 6 minutes from “15:20:00” to “15:26:00”, centered on “15:22” printed on the container. The range is shown, and this interval can be set long or short.
The reason why “Labera” is selected as the designated production facility is that the time printed on the container by the printing means 13 substantially coincides with the time processed by the labeler 3F, and the position of the printing means 13 is changed. In that case, the production facility 3 adjacent to the printing means 13 may be designated production facility.
If the control unit 4 is connected to the printing unit 13 and the quantity of containers printed is recorded in the data file by the data acquisition unit 6, the time when printing by the printing unit 13 is displayed on the "traceability" screen of FIG. The printing means 13 can be specified in the “Trace Target” column 51.

When the designated production facility and the designated time range are entered in the “Trace Target” field 51 and the “Search Date / Time” field 52 respectively in the “Search Condition Instruction Screen” of FIG. 5 and the “Search” button 53 is designated, the search means 7 The “traceability” screen shown in FIG. 6 is displayed again according to the procedure described below.
In FIG. 6, the background color is varied depending on the search condition input in the “search condition instruction screen”. It should be noted that the columns displayed with different background colors, including this figure, are displayed with the outer columns hatched instead of displaying with different background colors.
To explain the different background colors, the search means 7 first calculates the cumulative number of non-defective products and the cumulative number of emissions corresponding to the designated time range “15:20” to “15:25” for the designated production facility “Labera”. Search for columns and change the background color of these columns. (B in the figure)

Next, the search means 7 determines in which processing time range the containers processed in the specified time range in the labeler 3F are processed in the production facility located upstream of the labeler 3F. Search.
First, the search means 7 calculates the cumulative processing number (670) by adding the cumulative number of non-defective products (640) and the cumulative discharge number (30) at “15:20” in the labeler 3F, and also “15:26”. The cumulative number of non-defective products (946) and the cumulative discharge number (36) are added to obtain the cumulative processing number (982).
Here, the cumulative processing number is calculated based on the numerical value of “15:26” because the displayed cumulative number of non-defective products and the cumulative number of discharges are only the cumulative number at the displayed time and are designated. This is because the final cumulative number in the time range cannot be grasped, and in the present embodiment, the search means 7 performs the following processing on the basis of the cumulative processing number at “15:26”.
The number of accumulated processes (670) at “15:20” and the number of accumulated processes (982) at “15:26” calculated in this way are respectively adjacent to the upstream side adjacent production facilities. As compared with the cumulative number of good products of the capper 3E.
In the case of the present embodiment, the cumulative processing number (670) at “15:20” in the labeler 3F is the cumulative number of non-defective items (652) at “15:19” and the cumulative number of non-defective items at “15:20” (65: 705), and in this case, the search means 7 determines that the (670) -th container that has been processed by the cumulative number of labels 3F has been processed to the "15:19" level by the capper 3E. .
Similarly to this, the search means 7 determines that the (982) -th processed container in the number “15:26” in the labeler 3F has been processed into the “15:25” level in the capper 3E. .
From the above, the search means 7 processes the containers processed in the designated time range “15:20” to “15:25” by the labeler 3F, and processes “15:19” to “15:25” by the capper 3E. It is determined that the processing has been performed within the time range, and the background color of the column of the cumulative non-defective product number and the cumulative discharge number corresponding to “15:19” to “15:25” in the capper 3E is changed.

Subsequently, the search means 7 searches for the filler 3D as the upstream separation production facility located further upstream of the capper 3E. The upstream separated production facility refers to a production facility located upstream from the labeler 3F as the designated production facility and not adjacent to the labeler 3F.
The search means 7 refers to the accumulated processing numbers (670) and (982) at “15:20” and “15:26” in the labeler 3F that is the designated production facility, and to this, the processing time range searched by the capper 3E The cumulative discharge numbers (15) and (21) at “15:19” and “15:25” are added to calculate the number of virtual processes (685) (1003) in the filler 3D.
The virtual processing number in the filler 3D is a temporary calculation of the time at which the container processed at the predetermined time in the labeler 3F is processed in the filler 3D. The number of containers discharged by the capper 3E is temporarily calculated. By adding the number to the cumulative processing number in the labeler 3F, the number of containers discharged from the filler 3D until reaching the labeler 3F is corrected, and a more accurate search can be performed.
The number of virtual processes in the capper 3E calculated in this way is compared with the cumulative number of non-defective items in the filler 3D by the search means 7, and the (685) th processed container in the filler 3D is “15:19” units. It is determined that the container processed in (1003) th is processed on the “15:25” level.
From the above, the search means 7 processes the containers processed in the designated time range “15:20” to “15:25” on the labeler 3F, and processes “15:19” to “15:25” on the filler 3D. It is determined that the processing has been performed within the time range, and the background colors in the column of the cumulative non-defective product number and the cumulative discharge number corresponding to “15:19” to “15:25” in the filler 3D are changed.

In this way, the search means 7 also searches for an empty bottle inspection machine 3C, a bottle washing machine 3B, and an anchorer 3A as upstream separation production equipment located further upstream of the filler 3D.
In this case as well, as in the case of the filler 3F, the number of virtual processes is obtained for each production facility, and the accumulated discharge number of the production facility located between each production facility and the labeler 3F is added to make the search result more accurate. It is supposed to be something.
For example, in the case of the above-described bottle washing machine 3B, the accumulated processing numbers (670) and (982) in “15:20” and “15:26” in the labeler 3F are added to “15:19” and “15: Cumulative discharge number (15) (21) at 25 ”, cumulative discharge number (1) (3) at“ 15:19 ”and“ 15:25 ”at filler 3D, and“ 15 ”at empty bottle inspection machine 3C : 17 ”and“ 15:23 ”are added to the cumulative discharge numbers (5) and (5) to obtain the virtual processing numbers (691) and (1011).
The virtual processing numbers (691) and (1011) in the bottle washing machine 3B calculated in this way are determined to have been processed into the “15:16” and “15:23” machines in the bottle washing machine 3B, respectively. The container 7 processed by the labeler 3F in the designated time range of “15:20” to “15:25” is the processing time range of “15:17” to “15:23” in the bottle washing machine 3B. It is determined that it was processed.
Here, the number of virtual processes (1011) and the cumulative number of non-defective products (1011) of “15:23” are the same value. In this example, in this case, the number of virtual processes is the cumulative number of non-defective products. It is supposed to be treated as being included in. However, since the cumulative number of non-defective products of “15:26” in the labeler 3F is not included in the time range of “15:25”, it is not included when the number of virtual processes and the number of non-defective products are the same. You may make it handle.
As described above, the same applies to the answerer 3A and the empty bottle inspection machine 3C not described here, and the specified time range of “15:20” to “15:25” in the labeler 3F. In the answerer 3A, it is determined that the container processed in the processing time range of “15:13” to “15:20”, and in the empty bottle inspection machine 3C, “15:17” to “15:23”. ”Is determined to have been processed within the processing time range of“ ”.

In parallel with the above-described search of the processing time range for the production equipment upstream of the labeler 3F, the search means 7 can also process the production equipment located downstream of the labeler 3F in the container that has been processed in the designated time range by the labeler 3F. However, the processing time range in each production facility is searched.
First, between the appearance inspection machine 3G as the downstream side adjacent production facility adjacent to the labeler 3F, the search means 7 is the cumulative number of good products from “15:20” to “15:25” (640) in the labeler 3F. The number of accumulated processes in the appearance inspection machine 3G as included in (895) is searched.
That is, the search means 7 includes the range of the cumulative number of non-defective products (640) to (895) of the labeler 3F in the range of the cumulative number of processes (632 + 8 = 640) to (892 + 8 = 900) in the appearance inspection machine 3G. In the column of the cumulative number of non-defective products and the cumulative number of discharged products in the range of “15:21” to “15:26” corresponding to (632) to (892), Change the background color.

Subsequently, the search means 7 searches for the cartner 3H as the downstream remote production facility located further downstream of the appearance inspection device 3G. The downstream separated production facility is a production facility located downstream of the labeler 3F as the designated production facility and is not adjacent to the labeler 3F.
The search means 7 refers to the cumulative number of non-defective products (640) (946) in “15:20” and “15:26” in the labeler 3F, which is the designated production facility, and to this, the processing searched by the appearance inspection device 3G The cumulative discharge numbers (8) and (8) in the time ranges “15:21” and “15:26” are respectively subtracted to calculate (632) (938) as the virtual processing number in the cartner 3H.
The virtual processing number in the cartner 3H is a provisional calculation of the time at which the container processed at a predetermined time in the labeler 3F was processed in the cartner 3H, and was discharged by the appearance inspection device 3G. By subtracting the number of containers from the number of non-defective items accumulated in the labeler 3F, the number of containers discharged from the labeler 3F until reaching the cartner 3H is corrected, and a more accurate search can be performed.
The calculated virtual processing number in the cartner 3H is compared with the cumulative processing number in the cartner 3H by the search means 7, and the virtual processing numbers (632) to (938) in the cartner 3H are the cumulative processing number (608 + 5). = 613) to (896 + 5 = 901), and it is determined to be included in the processing time range of “15:23” to “15:29”.
From the above, the search means 7 processes the containers processed in the designated time range “15:20” to “15:25” on the labeler 3F, and processes “15:23” to “15:29” on the cartner 3H. It is determined that the processing has been performed within the time range, and the background color of the column of the cumulative non-defective product number and the cumulative discharge number corresponding to “15:23” to “15:29” in the cartner 3H is changed.

Similarly, the search means 7 searches the palletizer 3I for the processing time range. In this case, the number of virtual processes in the palletizer 3I is (640-8-5 = 627) (946-8-5 = 933) and these are included in the range of the cumulative number of good products (599) to (911) of the palletizer 3I.
Therefore, containers processed in the designated time range of “15:20” to “15:25” by the labeler 3F are processed in the processing time range of “15:23” to “15:29” by the cartner 3H. It is judged.
At this time, the column for the palletizer 3I has “number”, “C / S”, and “P / L”. “What is the number” indicates the number of boxes transported from the cartner 3H and the beverage product in the box. “C / S” is the number of boxes processed by the palletizer 3I, and “P / L” indicates the number of pallets processed by the palletizer 3I.
As a result, the containers processed from “15:20” to “15:25” by the labeler 3F are processed from “15:22” to “15:32” by the palletizer 3I. It can be seen that it was placed on the pallet number “2”.

In this way, as a result of the search by the search means 7, it is determined in which time range the containers processed from “15:20” to “15:25” by the labeler 3F were processed in the other production facilities 3. Know exactly.
That is, in the present embodiment, the data acquisition means 6 records the cumulative number of non-defective products and the cumulative number of discharges every predetermined time, and calculates the cumulative processing number by adding the cumulative number of non-defective products and the cumulative number of discharges. It is possible to accurately know in which time range the articles processed in the specified time range in the specified production facility are processed in the other production facilities 3.
For production facilities located upstream from the labeler 3F, the processing time range is searched based on the cumulative number of processes in the designated production facility, and the production facilities located downstream from the designated production facility. For each production facility, the processing time range is searched based on the cumulative number of non-defective products in the specified production facility. It is possible to accurately grasp whether or not the processing has been performed within the time range.
Moreover, for the upstream remote production facility and the downstream remote production facility that are not adjacent to the labeler 3F, the virtual processing number is calculated taking into account the number of containers discharged before reaching the corresponding production facility. So that you can search more accurately.
On the other hand, in the conventional patent document 1, since the safety factor was set for each production facility and the safety factor was integrated into the number of processes, the number of emissions increased uniformly even if the defective product was not actually rejected. We could not say that we were searching for the exact number of processes.

In addition to the above search results, if the defective product has a liquid leak from between the container and the cap, for example, and the cause is a defective molding or poor accuracy of the cap, from the information on the cap as a material product, Furthermore, the search object can be narrowed down.
In the state where the “traceability” screen of FIG. 6 is displayed, when the operator designates the “trace information” button 61 at the top of the table, the “selection screen” of FIG. The “information” button 71 is selected.
Then, the search means 7 has already searched in which time range the containers processed from “15:20” to “15:25” in the labeler 3F were processed in the other production facilities 3, and By detecting the lot number of various materials supplied to the material supply means 11 in the time range, the “material lot information screen” of FIG. 8 is displayed.
Specifically, the search means 7 processes the container processed from “15:20” to “15:25” by the labeler 3F from the “15:19” to “15:25” by the capper 3E by the above-described method. And the material lot number of the cap supplied from the cap supply means 11E to the capper 3E in this time range is detected.
As a result, it was found that the container with the material lot number “AAAA2” was used in the container processed from “15:20” to “15:25” with the labeler 3F (C in the figure). It is also possible to know the time range from the start of supply of the cap from the cap supply means 11E to the end of supply, and the manufacturer code indicating the manufacturer of the material.

In addition, when it can be determined in advance that there is a problem with the cap, which is a material, as a defective product, it is possible to pursue from the information on the cap. In that case, the operator displays the main menu of FIG. 2 and designates the “material lot” button 23 of “tracking from each element”, whereby the search means 7 displays the “material lot selection screen” of FIG. To do.
Below this “material lot selection screen”, a list of materials supplied to the bottling line 1 on “March 27, 2003” is displayed, together with the supply start date and time, supply end date and time, manufacturer code, etc. Data is displayed.
Then, when the worker designates the material lot number “AAAAA2” of the cap from this table, information on the material lot number is displayed in the “selected lot” column 91 at the top of the screen, and then the “Lot selection decision” button is further displayed. 92 is indicated.

Then, the search means 7 displays the “traceability” screen shown in FIG. This “traceability” screen has the same contents as those in FIGS. 4 and 6, but the range in which the background color is changed by the search means 7 is different.
Specifically, since the target material is a cap, the capper 3E is designated as the designated production facility, and the cap of the material lot number “AAAAA2” is supplied to the capper 3E “15: By setting “15” to “15:30” as the designated time range, the search means 7 changes the background colors in the columns of the number of non-defective products and the number of accumulated discharges corresponding to the designated time range. (D in the figure)
That is, here, the search is performed under the condition of the capper 3E as the production facility to be searched and the specified time range of the search reference from “15:15 on March 27, 2003” to “15:30 on March 27, 2003”. Is going.
After that, as described in the “traceability” screen of FIG. 6, the search means 7 performs the cumulative number of non-defective products and the cumulative number of discharged products for each of the production equipment located on the upstream side and the production equipment located on the downstream side of the capper 3E. Change the background color of the column.
For example, in the case of the filler 3D, which is an upstream adjacent production facility of the capper 3E, the cumulative processing numbers (440 + 12 = 452) and (1288 + 21 = 1301) of “15:15” and “15:31” in the capper 3E are respectively Since it is included in the 3D accumulated number of non-defective products (425) to (1258), the container capped with the material lot number “AAAA2” is the processing time range of “15:14” to “15:31” in the filler 3D. It turns out that it was processed by.
Further, for example, in the case of the bottle washing machine 3B which is the upstream side separation production facility of the capper 3E, the virtual processing numbers of “15:15” and “15:31” of the capper 3E are (452 + 1 + 3 = 456) and (1301 + 3 + 5 = 1309), respectively. Since this is included in the range of the cumulative number of non-defective products (423) to (1305) of the bottle washer 3B, the container with the cap of the material lot number “AAAAA2” is “15:11” in the bottle washer 3B. ”To“ 15:29 ”is found to have been processed.

If the cause of liquid leakage is to be further pursued, the search means 7 displays the “related information” screen shown in FIG. 11 by designating a column with a different background color for the number of non-defective products or the number of accumulated discharges of the capper 3E. .
In the “related information” screen, various information collected for the capper 3E in the time range in which the cap of the material lot number “AAAA2” is processed is shown.
Specifically, production-related data such as the production lot number of the beverage product in the designated time range, the preparation lot number of the beverage filled at that time, and the material lot number of the cap supplied to the cap supply means 11E are stored. Is displayed.
Further, on the right side of this screen, buttons of “inspection data”, “exclusion data”, and “alarm data” are displayed. For example, when the operator designates the “exclusion data” button 111, the search means 7 displays FIG. 12 “capper evacuation data” screen is displayed.

This “capper evacuation data” screen displays a list of containers rejected by the capper 3E between “15:15” and “15:30” when the cap of the material lot number “AAAA2” is supplied. It is supposed to be.
Further, on this “capper evacuation data” screen, the evacuation data recorded in the data file of the data acquisition means 6 is displayed, the cumulative number of processes in the capper 3E at the time of rejection, and the capping that capped the container The head number is displayed.
As shown in this table, if it is clear that the rejected container has been processed by the capping head number 5, the cap is not abnormal, and there is a cause of liquid leakage in the capping head 5. It can also be judged that.
In addition, if the “inspection data” button 112 is pointed out among the buttons of the “related information” screen in FIG. 11 described above, the search means 7 is performed between “15:15” and “15:30” with the capper 3E. When the inspection results are displayed in time series and the “alarm data” button 113 is pressed, the retrieval means 7 displays the contents of the alarm generated between “15:15” and “15:30” by the capper 3E in time series. Is displayed.
In addition, when a column with a different background color of another production facility 3 is designated on the “traceability” screen of FIG. 10, the “related information” screen in the designated time range of the production facility 3 is displayed in the same manner as the column of the capper 3E. Furthermore, when each button of inspection data, exclusion data, and alarm data is designated, various production-related data in the designated time range in the production facility 3 are displayed in time series.
In the “related information” screen of FIG. 11, only the buttons for inspection data, exclusion data, and alarm data are displayed, but other productions such as actual value trace data, facility setting value data, exception processing data, and work data are displayed. You may make it search by providing the button of related data.

On the other hand, if it is found that there is a cause for the defect in the cap of the material lot number “AAAAA2” and it is determined that the beverage product is to be collected, on which pallet the beverage product in which the cap is used is loaded. It is necessary to specify whether it was attached and distributed to the market.
In this case, in the state where the “traceability” screen shown in FIG. 10 showing the search result related to the cap of the material lot number “AAAA2” is displayed, the “trace information” button 101 at the upper part of this figure is instructed. 7 “selection screen” is displayed.
Here, when the operator selects the “shipment information” button 72, the search means 7 searches the pallet on which the beverage product with the cap of the material lot number “AAAAA2” is loaded. Display the "shipping information" screen.
Here, if the beverage product with the cap of the material lot number “AAAA2” is stored in one box among the boxes stacked on the pallet by the palletizer 3I, the search means 7 detects the pallet. It is supposed to be displayed as.
As a result, it was found that the beverage product with the cap of the material lot number “AAAA2” was loaded on the pallets with the pallet numbers “1” to “3”. And “end date and time of loading” are also found.
Then, if an arbitrary pallet number displayed here is designated, the search means 7 detects shipping data such as the date and time when the pallet was shipped and the supplier name of the shipping destination, and displays this on the operation terminal 8. The worker can contact a business partner or the like from the display result.

In the above-described embodiment, the production history of the bottling line 1 is searched. However, a production system including a plurality of other production facilities 3 may be used, and the contents and search of the table displayed on the operation terminal 8 may be used. The order in which they are performed is not limited to this.
Further, the position at which the printing unit 13 is installed is not particularly limited, and if the printing unit 13 prints the production lot number in addition to the production date and time, the production lot number can be quickly obtained. It is possible to search for defects and the like.

The block diagram about the bottling line and production history management system of a present Example. The figure which shows the "main menu" screen displayed on the operation terminal. The figure which shows the "production performance process schedule" screen displayed on the operation terminal. The figure which shows the "traceability" screen displayed on the operation terminal. The figure which shows the "search condition instruction | indication screen" screen displayed on the operating terminal. The figure which shows the "traceability" screen displayed on the operation terminal. The figure which shows the "selection screen" screen displayed on the operation terminal. The figure which shows the "material lot information" screen displayed on the operation terminal. The figure which shows the "material lot selection screen" screen displayed on the operation terminal. The figure which shows the "traceability" screen displayed on the operation terminal. The figure which shows the "related information" screen displayed on the operation terminal. The figure which shows the "capper exclusion data" screen displayed on the operation terminal. The figure which shows the "shipment information" screen displayed on the operation terminal.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Bottling line 2 Production history management system 3 Production equipment 4 Control terminal 6 Data acquisition means 7 Search means 8 Operation terminal 11 Material supply means 12 Preparation means 13 Printing means

Claims (3)

A production history management system for a production system that manufactures products by sequentially processing articles in a plurality of production facilities,
The production history management system specifies a data acquisition unit that acquires, for each production facility, the cumulative number of articles processed by each production facility every predetermined time, and a data file created by the data acquisition unit. Search means for performing a search according to the specified search conditions,
When a designated production facility and a designated time range as a reference for the search are designated, the retrieval means obtains a processing time range in which an article processed in the designated time range by the designated production facility is processed in another production facility. In the production history system to search,
The data acquisition means creates a data file that records, for each production facility, the cumulative number of non-defective items processed by each production facility and the cumulative number of rejected items rejected as defective by each production facility. And
For the upstream adjacent production facility adjacent to the designated production facility, the search means is configured such that the cumulative number of non-defective products in the upstream adjacent production facility is the sum of the cumulative number of non-defective products and the cumulative discharge number in the designated production facility. Search for a time range that includes the processing time range at the upstream adjacent production facility,
When there is an upstream remote production facility further upstream than the upstream adjacent production facility, the search means is located between the designated production facility and the upstream remote production facility in the cumulative processing number of the designated production facility. Calculate the number of virtual processes by adding the cumulative number of emissions in the processing time range for each production facility, and set the time range such that the virtual processing number is included in the cumulative number of non-defective products of the upstream remote production facility Production history management system characterized by searching as. A production history management system for a production system that manufactures products by sequentially processing articles in a plurality of production facilities,
The production history management system specifies a data acquisition unit that acquires, for each production facility, the cumulative number of articles processed by each production facility every predetermined time, and a data file created by the data acquisition unit. Search means for performing a search according to the specified search conditions,
When a designated production facility and a designated time range as a reference for the search are designated, the retrieval means obtains a processing time range in which an article processed in the designated time range by the designated production facility is processed in another production facility. In the production history system to search,
The data acquisition means creates a data file that records, for each production facility, the cumulative number of non-defective items processed by each production facility and the cumulative number of rejected items rejected as defective by each production facility. And
The search means, for the downstream side adjacent production facility adjacent to the designated production facility, the cumulative number of processed products, which is the sum of the cumulative number of non-defective products and the cumulative discharge number of the downstream side adjacent production facility, is the designated time range in the designated production facility. The time range that includes the cumulative number of non-defective products at is searched as the processing time range at the downstream adjacent production facility,
When there is a downstream remote production facility further downstream than the downstream adjacent production facility, the search means is located between the designated production facility and the downstream remote production facility based on the cumulative number of non-defective products of the designated production facility. The number of virtual processes is calculated by subtracting the cumulative number of emissions in the above processing time range for each production facility, and the time range in which the virtual processing number is included in the cumulative number of processes in the downstream remote production facility is the processing time range. Production history management system characterized by searching as.   3. The production history management system according to claim 1, wherein the production system is a bottling line for filling a container as an article with a liquid.

Images