JP2008226037A - Production management system and production management method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To give an incentive to immediately cope with an abnormality when the abnormality occurs in production, and to prevent a staff from overlooking the abnormality when the abnormality occurs in production. <P>SOLUTION: A warning including information which notifies that an abnormality or a possibility of the abnormality occurs and can notify a production facility in which the abnormality of the possibility of the abnormality occurs is used to notify a plurality of management staff of the abnormality of the production facility or the possibility of the abnormality in an area where the plurality of staff who manage a plurality of production facilities are resident on condition that production abnormalities or the possibilities of the abnormalities are detected in the plurality of production facilities (S101 to S109). A warning stop input receiving part provided at the machine side of each of the plurality of production facilities receives an input of a managing staff to stop the warning notified about the production facilities, and the warning notified about the production facilities corresponding to the warning stop input receiving part which has received the input is stopped on condition that the input for stopping the warning is received. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a production management system and a production management method, and more particularly to a production management system and a production management method suitable for comprehensive factory management.

Conventionally, there has been a management system for displaying management information on a large scale using a liquid crystal projector in a factory (for example, Patent Document 1). The screen of the liquid crystal projector is installed at a position where display contents and stored articles can be viewed at the same time. According to this, the work can be efficiently performed while checking the instruction and the current state, and when the instruction and the current state are different, the manager can easily grasp the cause.
JP 2001-344004 A (paragraphs 0008 to 0016)

  According to the management system of Patent Document 1, when a problem occurs, if each person watches the display with caution, the problem can be dealt with. However, there is a problem that the worker overlooks the problem if the worker simply looks at the display.

  Also, even if someone notices a problem in the distribution situation, there is no change in the distribution situation notification even if the person who noticed the problem responds to or does not respond to the problem in the distribution situation. There was a problem that it was impossible to give incentives (motivation stimuli) such as having to deal with

  The present invention has been made to solve the above-described problems, and one of the objects of the present invention is to provide a production management system capable of immediately giving an incentive corresponding to an abnormality when the abnormality occurs in production. Is to provide.

  Another object of the present invention is to provide a production management system capable of preventing personnel from overlooking an abnormality when an abnormality occurs in production.

  In order to achieve the above object, according to an aspect of the present invention, a production management system includes an abnormality detection unit, an abnormality notification unit, an alarm stop input reception unit, and an alarm stop unit. The abnormality detection unit detects a production abnormality or a possibility of abnormality in each of the plurality of production facilities. The anomaly notification unit is in an area where multiple management personnel who manage multiple production facilities are stationed on the condition that the anomaly detection unit has detected an anomaly or an anomaly may occur. A warning including information that can identify the production facility in which the production facility where the abnormality or the abnormality has occurred is notified to a plurality of management personnel. The alarm stop input accepting unit is provided on the machine side of each of the plurality of production facilities, and accepts the input of a manager for stopping the alarm that is notified by the abnormality notifying unit for the production facility. The alarm stop unit is notified by the abnormality notifying unit about the production equipment corresponding to the alarm stop input receiving unit that has received the input, provided that the input for stopping the alarm is received by the alarm stop input receiving unit. Stop the alarm that is.

  According to the present invention, a plurality of management personnel for managing each of the plurality of production facilities are resident on the condition that the production management system detects a production abnormality or a possibility of abnormality in each of the plurality of production facilities. Alarms that include information that can identify the abnormality or the possibility of abnormality in the area and the information that can identify the production facility where the abnormality or abnormality has occurred. An input for stopping the alarm is received by the alarm stop input receiving unit provided on the machine side of each of the plurality of production facilities, and the input of the management personnel for stopping the alarm that is informed about the production facility is accepted. On the condition that the input has been received, the alarm that has been informed about the production facility corresponding to the alarm stop input receiving unit that has received the input is stopped.

  In this way, the production management system issues a warning to the effect that an abnormality or a possibility of abnormality has occurred in a region where management personnel other than the production facility where the abnormality or the possibility of abnormality has occurred are also resident. Further, in order to stop the alarm, it is necessary for an administrator of the production facility to make an input for stopping the alarm at an alarm stop input receiving unit provided on the machine side of the production facility. For this reason, if the alarm is not stopped indefinitely, it is assumed that there is no willingness to respond immediately to the production facility by other personnel in the area where multiple management personnel are stationed. It is regarded. As a result, it is possible to provide a production management system that can immediately provide an incentive to cope with an abnormality when an abnormality occurs in production.

  In addition, the production management system notifies the user of an abnormality or a possibility of abnormality in the production facility with an alarm. As a result, it is possible to provide a production management system capable of preventing personnel from overlooking an abnormality when an abnormality occurs in production.

  Preferably, the abnormality notifying unit is a display device that schematically displays the shape and arrangement of the production facility, and the display corresponding to the production facility in which the abnormality or the possibility of abnormality has occurred is likely to be abnormal or abnormal. By displaying in a mode indicating this, an abnormality or a possibility of abnormality is notified.

  According to the present invention, the display corresponding to the production facility in which the abnormality or the possibility of abnormality occurs is displayed on the display device that schematically displays the shape and arrangement of the production facility by the production management system, and the possibility of the abnormality or abnormality occurring. By displaying it in a mode indicating that it is in progress, an abnormality or a possibility of abnormality is notified. For this reason, the production management system can easily communicate to the management personnel that the production abnormality or the possibility of abnormality in the production facility has been detected.

  Preferably, the production management system displays a display corresponding to the production facility corresponding to the alarm stop input receiving unit that has received the input, on condition that the input for stopping the alarm is received by the alarm stop input receiving unit. Further, an abnormality handling informing means for notifying that the abnormality is being handled is further provided by displaying in a manner indicating that the abnormality or the fear of abnormality is being handled.

  According to the present invention, the production management system corresponds to the production facility corresponding to the alarm stop input receiving unit that has received the input, provided that the input for stopping the alarm is received by the alarm stop input receiving unit. When the display to be performed is displayed in a manner indicating that it is responding to an abnormality or a risk of abnormality, it is notified that the abnormality is being handled. For this reason, it is easy for the management personnel to understand, and it is possible to communicate that the production abnormality or the risk of abnormality in the production facility is being handled.

  Preferably, the abnormality notifying unit notifies the abnormality or the possibility of abnormality with sound of a sound quality corresponding to the content of the abnormality or the possibility of abnormality.

  According to the present invention, the production management system notifies the abnormality or the possibility of abnormality with sound of sound quality corresponding to the content of the abnormality or the possibility of abnormality. For this reason, the production management system makes it easy for the management personnel to communicate, and it is possible to transmit the contents of production abnormality or the possibility of abnormality in the production facility.

  Preferably, the abnormality notifying unit notifies the abnormality or the possibility of abnormality by printing an abnormality countermeasure entry sheet for filling in the countermeasure for the abnormality including information that can identify the production facility in which the abnormality or the abnormality has occurred. To do.

  According to this invention, the production management system prints an abnormality countermeasure entry sheet for entering countermeasures against abnormality including information that can identify the production facility in which abnormality or possibility of abnormality has occurred. The fear of For this reason, the production management system can easily communicate to the management personnel that the production abnormality or the possibility of abnormality in the production facility has been detected. In addition, since it is necessary to fill in a countermeasure against the abnormality on the abnormality countermeasure entry form, it is possible to give an incentive to logically cope with the abnormality.

  Preferably, the production management system further includes a body temperature measurement unit that measures the body temperature of the production personnel of the production facility, and the abnormality detection unit is provided on the condition that the body temperature measured by the body temperature measurement unit is within a predetermined abnormal range. As a result, the possibility of abnormality is detected.

  According to the present invention, the production management system measures the body temperature of the production personnel of the production facility, and detects the possibility of abnormality on the condition that the measured body temperature is within a predetermined abnormal range. For this reason, when the body temperature of the production personnel is in the abnormal range, the production management system can notify the management personnel that there is a possibility of abnormality before the production personnel produce an abnormality. As a result, production abnormalities can be prevented from occurring by the production management system.

  Preferably, the production management system further includes an abnormality occurrence input receiving unit that is provided on each machine side of the plurality of production facilities, and that accepts an input of a production person of the production facility that an abnormality or a possibility of abnormality of the production facility has occurred. The abnormality detection unit detects the abnormality and the possibility of abnormality, respectively, on condition that the input indicating that the abnormality and the possibility of abnormality occurred is received by the abnormality occurrence input receiving unit.

  According to the present invention, the production management system reports that the production facility personnel of the production facility that the production facility abnormality or the possibility of abnormality has occurred in the abnormality occurrence input receiving unit provided on the machine side of each of the plurality of production facilities. On the condition that the input is accepted and the input indicating that the abnormality and the possibility of abnormality has occurred is received by the abnormality occurrence input receiving unit, the abnormality and the possibility of abnormality are detected respectively. For this reason, when the production management system receives an input indicating that an abnormality or a possibility of abnormality has occurred by the production personnel, it is possible to notify the management personnel that there is a possibility of abnormality or abnormality, respectively. As a result, the production management system can promptly respond to the management personnel to the production abnormality or the possibility of abnormality.

  Preferably, the production management system further includes a work pace detection unit that detects a work pace of the production personnel in the production facility, and the abnormality detection unit is within an abnormal range in which the work pace detected by the work pace detection unit is set in advance. If there is, detect the possibility of abnormality.

  According to this invention, the production management system detects the work pace of the production personnel in the production facility, and detects the possibility of abnormality on the condition that the detected work pace is within a preset abnormal range. For this reason, the production management system can inform the management personnel that there is a risk of anomaly before the production personnel produce an abnormality when the work pace of the production personnel in the production facility is in the abnormal range. it can. As a result, production abnormalities can be prevented from occurring by the production management system.

  Preferably, the production management system further includes an inspection unit for inspecting a product produced by the production facility, and the abnormality detection unit detects an abnormality on the condition that the product is inspected as a defective product by the inspection unit. To do.

  According to the present invention, the production management system inspects the product produced in the production facility, and detects an abnormality on the condition that the product is inspected as a defective product. For this reason, when a product is inspected as a defective product by the production management system, the fact that there is an abnormality can be transmitted to management personnel. As a result, the production management system can quickly respond to the management personnel to the production abnormality.

  Preferably, the production management system has a personnel characteristic identifying unit that identifies the characteristics of the production personnel of the production facility, and the production facility in a work environment according to the characteristics identified by the personnel characteristic identification unit of the production personnel of the production facility. And a work environment changing unit to be changed.

  According to this invention, the production management system identifies the characteristics of the production personnel of the production facility, and the production facility is changed to a work environment corresponding to the identified characteristics of the production personnel of the production facility. For this reason, the production management system allows the worker to efficiently produce in the optimum working environment according to the characteristics of the production worker.

  Preferably, the personnel characteristic identification unit identifies the production level of the production personnel as the characteristics of the production personnel, and the work environment change unit determines whether the production facility uses the production level according to the work level identified by the personnel characteristic identification unit. By changing the notification method of the work content, the production facility is changed to a work environment according to the characteristics of the production personnel.

  According to the present invention, the production management system identifies the production level of the production personnel as a characteristic of the production personnel, and changes the method of notifying the work content to the production personnel at the production facility according to the identified work level. As a result, the production facility is changed to a working environment according to the characteristics of the production personnel. For this reason, it is possible to allow the production personnel to efficiently produce the work in the work environment in which the work contents are notified by the optimum notification method according to the production level of the production personnel.

  Preferably, the personnel characteristic identifying unit identifies the physical characteristics of the production personnel as the characteristics of the production personnel, and the work environment changing unit determines the shape of the production facility according to the physical characteristics identified by the personnel characteristic identifying unit. Is changed to a work environment according to the characteristics of the production personnel.

  According to this invention, the production management system identifies the physical characteristics of the production personnel as the characteristics of the production personnel, and changes the shape of the production equipment according to the identified physical characteristics, thereby producing the production equipment. However, the working environment is changed according to the characteristics of production personnel. For this reason, the production management system allows the worker to efficiently produce in the work environment having the optimum shape of the production facility in accordance with the physical characteristics of the production worker.

  Preferably, the personnel characteristic identification unit identifies the height and dominant arm of the production personnel as the physical characteristics of the production personnel, and the work environment change unit determines the shape of the production facility according to the height identified by the personnel characteristic identification unit. As a result of changing the height of the workbench and changing the installation position of the tool as the shape of the production equipment according to the dominant arm specified by the personnel characteristics specification unit, the production equipment can be adapted to the characteristics of the production personnel. Change to a working environment.

  According to this invention, the production management system identifies the height and dominant arm of the production personnel as the physical characteristics of the production personnel, and the height of the work table as the shape of the production facility is changed according to the identified height. Then, according to the specified dominant hand, the installation position of the tool as the shape of the production facility is changed, so that the production facility is changed to a work environment according to the characteristics of the production personnel. For this reason, the production management system allows the worker to efficiently produce in the work environment of the optimum work table height and tool installation position according to the height and dominant hand of the production person.

  According to another aspect of the present invention, a production management method includes a step of detecting a possibility of abnormality or abnormality of each of a plurality of production facilities, and a plurality of production facilities on the condition that a possibility of abnormality or abnormality is detected. In an area where multiple management personnel are resident, respectively, an alarm including information indicating that an abnormality or a possibility of abnormality has occurred and identifying the production facility where the abnormality or possibility of abnormality has occurred A step for notifying a plurality of management personnel of an abnormality or a possibility of abnormality, and a control for stopping an alarm that has been informed about the production facility by an alarm stop input receiving device provided on the machine side of each of the plurality of production facilities The alarm stop input reception device that accepts the input, provided that the input of personnel is received and the input for stopping the alarm is accepted. An alarm that is broadcast for the corresponding production equipment to and a step of stopping.

  According to the present invention, it is possible to provide a production management method capable of providing an incentive corresponding to an abnormality immediately when an abnormality occurs in production. Further, it is possible to provide a production management method capable of preventing personnel from overlooking an abnormality when an abnormality occurs in production.

  Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. In addition, about the same or equivalent part in a figure, the same code | symbol is attached | subjected and the description is not repeated.

  In the present embodiment, a production management system 10 in a hand-assembled line in which a person such as a cell production method performs processing and assembly work will be described. However, it is not limited to this, for automatic, semi-automatic and manual assembly, processing and inspection lines of electrical equipment and machinery, and production and inspection lines of manufacturing industries such as steel, pulp, fiber, chemical and foodstuffs, The production management system 10 of this embodiment can be applied.

  FIG. 1 is a schematic diagram showing an outline of a production management system 10 according to an embodiment of the present invention. Referring to FIG. 1, the production line in the present embodiment is a so-called cell production system production line in which a plurality of work tables 300 are arranged in a U shape, as shown in IT ANDON display screen 1410. Note that the production line is not limited to the U-shaped arrangement, and may be a linear arrangement. Andon refers to display lamps and display boards installed at various locations in the production facility in order to notify that an abnormality has occurred.

  In each production line, one or more of the plurality of production processes are assigned to each work table 300. A plurality of workers share the production process on a plurality of worktables 300 for one product, or one worker performs all of the production processes on a plurality of worktables 300 for one product. Assembling and inspecting products.

  FIG. 5 is an external view showing the shape of the work table 300 and the state of attachment of devices to the work table 300 in the present embodiment. Referring to FIG. 5, work table 300 includes a work table personal computer (hereinafter referred to as “PC”) 320 for displaying a work content instruction screen 3240, the worker ID of the worker, the product number of the product to be produced, and the like. A bar code reader 340 for reading a bar code indicating information, an electric jack which is a work table height control actuator 370 for changing the height of the work table to a predetermined height, and an electric motor used for manufacturing a product. An air cylinder that is a tool position control actuator 360 for moving tools such as a screwdriver 380 and an electric screwdriver 380 to a predetermined position on the left and right according to the dominant arm of the worker, and a radiation temperature for measuring the body temperature of the worker A total of 350 is installed.

  A line installation terminal 310 is installed in a production line where a plurality of work tables 300 are installed. The line installation terminal 310 is provided with a completed number count-up switch 311, a signal tower (red) 312 and a signal tower (yellow) 313.

  The radiation thermometer 350 is preferably installed at a position 30 cm away from the forehead of the worker who is working.

  The tool installed on the workbench 300 is not limited to the electric screwdriver 380, and may be a soldering iron or other tools. Further, the apparatus for inputting information such as the worker ID of the worker and the product number of the product to be produced to the worktable PC 320 is not limited to the barcode reader 340, and other information such as a keyboard, a mouse, a camera, and a scanner. It may be an input device.

  In addition, the work table height control actuator 370 is not limited to an electric jack, and may be another device such as a hydraulic jack or an air jack. The tool position control actuator 360 is not limited to an air cylinder, and may be another device such as a hydraulic cylinder or an electric actuator.

  FIG. 9 is a diagram showing an operator information table stored in the database server 200 in the present embodiment. Referring to FIG. 9, the worker information table stores the worker ID, the worker name of the worker, and the department to which the worker belongs in association with each other.

  FIG. 10 is a diagram showing a personal information table stored in the database server 200 in the present embodiment. In the personal information table, the worker ID, the height of the worker, the dominant arm of the worker, the work table height set by the worker as the initial value, and the tool position set by the worker as the initial value The lower limit body temperature that warns when the body temperature of the worker falls below this value, the upper limit body temperature that warns when the body temperature of the worker exceeds this value, and the body temperature of the worker falls below this value The stop lower limit body temperature at which production is stopped and the stop upper limit body temperature at which production is stopped when the worker's body temperature exceeds this value are stored in association with each other. The work table height is the height of the work table top plate from the floor, and its unit is cm. The tool position is indicated by a leftward displacement from the position where the tool is moved to the rightmost by the tool position control actuator 360, and the unit is cm.

  Returning to FIG. 1, first, the worker uses his / her barcode reader 340 to read his / her worker ID into the worktable PC 320. The worktable PC 320 reads the worker name and the department to which the worker belongs corresponding to the read worker ID from the worker information table shown in FIG. 9 of the database server 200, and the personal information shown in FIG. The height, dominant arm, workbench height and tool position corresponding to the read worker ID are read from the table.

  Next, when the work table height and the tool position are set, the work table PC 320 changes the work table height and the tool position to the set work table height and the tool position, respectively. The work table height control actuator 370 and the tool position control actuator 360 are controlled.

  On the other hand, when the work table height and the tool position are not set, the work table PC 320 specifies the work table height and the tool position from the read height and dominant hand, respectively, and the work table height and the tool position. Are changed to the specified work table height and tool position, the work table height control actuator 370 and the tool position control actuator 360 are controlled.

  When the setting of the work table height and the tool position is changed by the operator, the work table PC 320 changes the work table height and the tool position in the personal information table shown in FIG. Update to the new platform height and tool position.

  FIG. 23 is a diagram showing a production history table stored in the database server 200 in the present embodiment. Referring to FIG. 23, the production history table includes an order number. , Part number, type, lot number The worker ID, the total man-hours of the product production process, the soldering man-hours of the product production process, and the production date and time when the product is completed are stored in association with each other.

  FIG. 24 is a diagram showing an item NG table stored in the database server 200 in the present embodiment. Referring to FIG. 24, in the item NG table, the product number, the format, the worker ID of the worker who manufactured the product, and when the worker manufactured the product, the last inspection defect occurred due to manufacturing. The last NG date and time is stored in association with each other.

  FIG. 8 is a diagram showing a product format table stored in the database server 200 in the present embodiment. Referring to FIG. 8, the product format table stores the product number, format, the path of the folder storing the work level display of the basic level of each production process of the product of the format, and the work level display of the intermediate level. And the path of the folder in which the high-level work content display is stored are stored in association with each other.

  Returning to FIG. 1, the worktable PC 320 specifies the worker level and skill level of the worker from the data recorded in the production history table shown in FIG. 23 of the database server 200 and the item NG table shown in FIG. A work content display corresponding to the identified worker level and skill level and product part number is read from the folder of the database server 200 shown in the product format table shown in FIG. As shown in FIG. 38, the read work content display is displayed.

  FIG. 38 is a display screen diagram showing a work content instruction screen 3240 displayed on the screen of worktable PC 320 in the present embodiment. Referring to FIG. 38, the work content display is displayed in the lower left portion of work content instruction screen 3240. In the work content display, for each production process, the work content in the production process is displayed as characters, photos, and videos. As will be described later with reference to FIGS. 38 to 41, the display method of the work content display is changed according to the specified worker level and skill level.

  The work content display is sequentially switched and displayed according to the production process at a speed according to the specified worker level and skill level. That is, the work content display is a production pacemaker, and the worker works in accordance with the pacemaker.

  The work content instruction screen 3240 displays the reference time required for the production process displayed in the work content display and the remaining time obtained by subtracting the time required for the production process from the reference time. By looking at this remaining time, the worker can grasp whether his / her pace is faster or slower than the standard pace.

  The worker clicks the “proceed to the next process” button 3241, the “work start” button 3242, the “suspend” button 3243, or the “pause” button 3244 to display the work content display for the next process, respectively. It is possible to switch to, to resume the work that has been started or paused, or to suspend the work content display or to pause the work content display.

  Returning to FIG. 1, the worktable PC 320 displays the history of the work content display, the “proceed to the next process” button 3241, the “work start” button 3242, the “pause” button 3243, and the “pause” button. The history of operation of 3244 or the like is stored as a work history in the production history table of the database server 200 shown in FIG.

  In addition, when a product is manufactured on the production line, a plurality of management staff that respectively manage the plurality of production lines is resident in the staff area. The IT ANDON display 1410 is projected onto the staff area by the liquid crystal projector 141.

  The IT ANDON display 1410 is not limited to being projected by the liquid crystal projector 141, and may be displayed by other methods such as a large display as long as the management staff in the staff area can visually recognize. .

  FIG. 4 is a display screen diagram showing an IT ANDON display 1410 displayed in the staff area in the present embodiment. With reference to FIG. 4, the shape and arrangement of the production line are schematically displayed in the production line arrangement column at the top of the IT ANDON display 1410. And the display corresponding to the production line in which abnormality or the possibility of abnormality has occurred is displayed in a mode indicating that abnormality or the possibility of abnormality has occurred.

  In the present embodiment, the abnormality includes “inspection defect in the shipping permission line”, “inspection defect in each production line”, and “equipment abnormality”. In addition, the risk of abnormality includes “Q near miss” and “progress abnormality”. The Q near miss is a state in which a defect may occur in terms of quality.

  For example, when “inspection failure on the shipping permission line” occurs, the display color indicating the shipping permission line is displayed in pink. When “inspection failure in each production line” occurs, the display color indicating the production line is displayed in red. When "equipment abnormality" occurs, the display color indicating the production line where the equipment abnormality has occurred is displayed in yellow.

  When “Q near-miss” occurs, the display color indicating the production line where the Q near-miss has occurred is displayed in gray. When “progress abnormality” occurs, the display color indicating the production line where the progress abnormality has occurred is displayed in purple.

  The display color indicating the production line “in production” is displayed in yellow green. The display color indicating the production line that is “stopped” is displayed in white.

  In the drawings, the display color indicating each production line is indicated by hatching corresponding to each color. Here, the gray color corresponding to “Q near miss” is indicated by the first widest right-up hatching. The pink color corresponding to “inspection failure on the shipping permission line” is indicated by the second widest right-up hatching. The yellow color corresponding to “equipment abnormality” is indicated by the second widest right-down hatching. The yellow-green color corresponding to “in production” is indicated by the third widest right-up hatching. The purple color corresponding to “progress abnormality” is indicated by the third widest right-down hatching. The red color corresponding to “inspection failure in each production line” is indicated by the fourth widest right-downward hatching. The white color corresponding to “stopped” is shown without hatching.

  In the middle icon field at the bottom of the IT ANDON display 1410, a correspondence relationship between each abnormality or a possibility of abnormality and a mode indicating that the abnormality or a possibility of abnormality has occurred is displayed. For example, a schematic diagram of a U-shaped production line to show that inspection defects in each production line correspond to display modes in red indicating that inspection defects in each production line have occurred. The icon is displayed in red, and the characters “inspection failure” are displayed immediately below the icon.

  Further, the number of occurrences of each abnormality or the possibility of abnormality is displayed at a location where the correspondence between each abnormality or the possibility of abnormality and the display mode is displayed. Specifically, the number of cases in which an abnormality or a possibility of abnormality has occurred is displayed in a U-shape of a schematic diagram of a U-shaped production line.

  Further, the line name of the production line is displayed immediately below the display of the shape of each production line on the IT ANDON display 1410. In addition, the number of cumulative abnormalities or the possibility of abnormality occurring in the production line is displayed on the line name in the background color of the color corresponding to the abnormality or the possibility of abnormality. For example, in the production line with the line name “E003”, it is indicated that the cumulative number of inspection failures in the production line is one.

  The numbers displayed in a T-shaped arrangement on the display of the shape of each production line indicate the production status of the product. The meaning indicated by each number is displayed in the middle column at the bottom of the IT ANDON display 1410.

  The number in the lower position of the T-shaped vertical line indicates the expected number of products produced on that production line. The number at the position where the vertical line and the horizontal line of the T-shape intersect indicates the number of products that have been produced on the production line. The number on the right side of the T-shaped horizontal line indicates the elapsed time since the last production was completed. The number on the left side of the T-shaped horizontal line indicates today's average throughput time. The unit of the elapsed time and the average throughput time is “minute” if the background color of the number is green (in the drawing, the first narrowest width of the right-up hatching), and blue (the first narrowest in the drawing). If the width is hatched downward, it is “seconds”.

  Also, the ☆ mark above the position where the vertical line and the horizontal line of the T-shape intersect indicates the operating status of the production line. If there is no ☆ mark, it operates for 8 hours, and there is one ☆ mark. Is 16 hours of operation, and if there are two asterisks, it indicates 24 hours of operation.

  In addition, in the abnormality list in the left column at the bottom of the IT ANDON display 141, a list of abnormalities that are occurring or being dealt with or that may be abnormal is displayed in characters. The list of errors indicates the contents of the error or the possibility of abnormality, information indicating whether the error or the possibility of abnormality occurred, and the line name where the error or the possibility of abnormality occurred, and its status The elapsed time is displayed.

  FIG. 16 is a diagram showing a temperature / humidity history table stored in the database server 200 in the present embodiment. Referring to FIG. 16, in the temperature / humidity history table, measurement date / time, temperature, humidity, and discomfort index are stored in association with each other.

  Returning to FIG. 1, the thermohygrometer 500 measures the temperature, humidity and discomfort index in the area where the production line is installed. Then, the thermohygrometer 500 transmits information indicating the measured temperature, humidity, and discomfort index to the IT ANDON PC 100. The IT ANDON PC 100 stores the received temperature, humidity, and discomfort index in the temperature / humidity history table of the database server 200 shown in FIG.

  FIG. 15 is a diagram showing a cleanliness history table stored in the database server 200 in the present embodiment. Referring to FIG. 15, the cleanliness history table includes the measurement date and time, the sample volume of the air collected at the time of measurement, the number of 3 μm particles, the number of 5 μm particles, the number of 10 μm particles, and the 20 μm particles contained in the sample. The number and the number of particles of 50 μm are stored in association with each other.

  Returning to FIG. 1, the particle counter 600 measures the cleanliness of the air in the area where the production line is installed. Then, the particle counter 600 stores the measured cleanliness in correspondence with the measurement date and time in the cleanliness history table of the database server 200 shown in FIG. The cleanliness is indicated by the volume of air in the collected sample and the number of particles for each size of the particles contained in the collected air. For example, in air with a sample volume of 2.83 L, the number of particles of 3 μm is 2869280, the number of particles of 5 μm is 204110, the number of particles of 10 μm is 10230, the number of particles of 20 μm is 810, the number of particles of 50 μm Is expressed as 10 are included.

  Proceeding to FIG. 4, in the right-hand column at the bottom of the IT ANDON display 1410, temperature, humidity, discomfort index, and cleanliness data are displayed on the database server 200. 16 is acquired and displayed from the temperature / humidity history table shown in FIG. 16 and the cleanliness history table shown in FIG. 15, and is updated as time passes.

  Returning to FIG. 1, a line installation terminal 310 is installed on the machine side of each production line. In the line installation terminal 310, a line installation terminal screen 3140 is displayed.

  FIG. 6 is a display screen diagram showing a line installation terminal screen 3140 displayed on the line installation terminal 310 in the present embodiment. With reference to FIG. 6, line installation terminal screen 3140 displays the line name on the upper left side and the current date and time on the upper right side. In FIG. 6, “E003” is displayed as the line name, and “2006/11/08 (Wednesday) 21:27:09” is displayed as the current date and time.

  On the left side of the middle of the line installation terminal screen 3140, an upper main display section and a lower sub display section are displayed as areas for displaying the line state. In FIG. 6, “stopped” is displayed on the main display section.

  On the right side of the main display section, a completion number display section for displaying the number of completed products that have been produced today is displayed. An increase / decrease button 3147 for increasing / decreasing the number of completions is displayed on the right side of the completion number display section. On the right side of the sub display section, an SPH display section for displaying SPH (Stroke Per Hour) indicating the number of units produced per hour is displayed. On the right side of the SPH display area, a “0 clear” button 3148 for returning SPH to 0 is displayed.

  In addition, since the screen of the line installation terminal 310 is a touch panel, the operator can operate the button by touching the displayed button.

  On the lower left side of the line installation terminal screen 3140, operation buttons in two vertical rows and three horizontal rows are displayed. The operation buttons are “production” button 3141 in the upper left, “stopping” button 3142 in the upper, “watering” button 3143 in the upper right, “inspection defect” button 3144 in the lower left, and “Q near hat” button 3145 in the lower and lower. The lower right is an “equipment abnormality” button 3146.

  On the lower right side of the line installation terminal screen 3140, a “reset” button for resetting the line installation terminal 310 and a “PT setting” button for shifting to the setting mode of the line installation terminal 310 are displayed.

  Returning to FIG. 1, if any of the “production” button 3141, “stopping” button 3142, “inspection failure” button 3144, “Q near miss” button 3145, and “equipment abnormality” button 3146 is operated, The installation terminal 310 transmits information indicating that the state of the production line is the content indicated by the operated operation button to the IT ANDON PC 100.

  When the “water sterling” button is operated, the line installation terminal 310 blinks the signal tower (yellow) 313, and also includes information that the water sterling portable terminal 410 calls the water sterilization and the line name of the caller's production line. Send. When the information is received, the water sterling portable terminal 410 informs the water humor with a display and sound that the water humor is being called on the caller's production line. In response to the notification, the water spouting expresses to the caller's production line.

  FIG. 12 is a diagram showing a line state history table stored in the database server 200 in the present embodiment. Referring to FIG. 12, in the line status history table, the status history ID uniquely assigned to each status history, and the line number of the production line where this status history has occurred are shown. The state ID indicating the generated state, the start date and time of this state, the end date and time of this state, and the required number of seconds in this state are stored in association with each other.

  FIG. 13 is a diagram showing a line state master stored in the database server 200 in the present embodiment. Referring to FIG. 13, the line state master stores the state ID and the state name in association with each other.

  Returning to FIG. 1, the IT ANDON PC 100 changes the contents of the IT ANDON display 1410 projected by the liquid crystal projector 141 according to the information received from the line installation terminal 310. The IT ANDON PC 100 stores the information received from the line installation terminal 310 in the line state history table of the database server 200 shown in FIG.

  If the information received from the line installation terminal 310 indicates an abnormality or a possibility of abnormality, the IT ANDON PC 100 causes the printer 142 to print the quality abnormality countermeasure sheet 1420 shown in FIG.

  FIG. 7 is a diagram showing a quality abnormality countermeasure sheet 1420 printed from the printer 142 connected to the IT ANDON PC 100 in the present embodiment. Referring to FIG. 7, at least the “occurrence date / time”, “line name”, and “abnormal type” at which an abnormality or a possibility of an abnormality has occurred are printed on the quality abnormality countermeasure sheet 1420.

  The quality abnormality countermeasure sheet 1420 is printed with “temperature”, “humidity”, “discomfort index”, and “cleanness (cleanness)” at the time of occurrence of abnormality or a possibility of abnormality.

  In addition, the quality abnormality countermeasure sheet 1420 includes a column of “responder” for entering the name of the management staff corresponding to the abnormality or the possibility of abnormality, and a date and time when the treatment for the possibility of abnormality or abnormality is completed. ”Column,“ Stop time ”column for entering the time the production line was stopped due to an abnormality or the possibility of an abnormality, and“ Symptom confirmation ”for entering a phenomenon that the responder confirmed that there was an abnormality or a possibility of an abnormality. Column, “Temporary measures” column for entering provisional measures against abnormalities or the possibility of abnormalities, “Permanent measures” columns for entering permanent measures against abnormalities or the possibility of abnormalities, and implementing permanent measures A column for “scheduled permanent measure date” for entering the scheduled date is provided.

  The management staff of the production line where the abnormality or the possibility of abnormality has occurred needs to fill in each column of the printed quality abnormality countermeasure sheet 1420, so it must deal with the possibility of abnormality or abnormality exactly logically. .

  FIG. 32 is a diagram showing a body temperature measurement history table stored in the database server 200 in the present embodiment. Referring to FIG. 32, the body temperature measurement history table includes information indicating whether the worker ID, the measured date, the measured body temperature, and the measured body temperature are normal values or abnormal values. Correspondingly stored.

  Returning to FIG. 1, the radiation thermometer 350 measures the temperature of the worker. The workbench PC 320 stores the body temperature of the worker measured by the radiation thermometer 350 in the body temperature measurement history table of the database server 200 shown in FIG. 32 in association with the worker ID and the measurement date and time. The body temperature measurement history table also stores information indicating whether the measured body temperature is a normal value or an abnormal value.

  When the data stored in the body temperature measurement history table of the database server 200 indicates that the body temperature is an abnormal value, the IT ANDON PC 100 provides information indicating that a Q near miss has occurred. Send to. When receiving information indicating that a Q near miss has occurred, the line installation terminal 310 performs the same processing as when the “Q near miss” button 3145 is operated.

  FIG. 2 is a block diagram showing the configuration of the production management system 10 in the present embodiment. 2, the production management system 10 includes an IT ANDON PC 100, a liquid crystal projector 141, a printer 142, a database server 200, a work table 300, line installation terminals 310 and 310A, work table PCs 320 and 320A, and a PLC (Programmable Logic). Controller) 330, bar code reader 340, radiation thermometer 350, tool position control actuator 360, worktable height control actuator 370, portable terminal 410 for water hydration, thermohygrometer 500, and particle counter 600. Water-smearing means an operator who supplies necessary parts to the production line.

  The IT ANDON PC 100, the database server 200, the work table PCs 320 and 320A, the thermohygrometer 500, the particle counter 600, and the access point 810 are connected by a LAN (Local Area Network) 900. Further, the line installation terminals 310 and 310 </ b> A and the water sterilization portable terminal 410 are connected to the LAN 900 via the access point 810.

  A barcode reader 340 and a radiation thermometer 350 are connected to the worktable PC 320. A tool position control actuator 360 and a work table height control actuator 370 are connected to the work table PC 320 via the PLC 330. A completion count up switch 311 is connected to the line installation terminal 310.

  FIG. 3 is a block diagram showing an outline of the configuration of the IT ANDON PC 100 in the present embodiment. Referring to FIG. 3, IT ANDON PC 100 includes a CPU (Central Processing Unit) 110, a memory 120, an input unit 130, an output unit 140, an external storage device 150, and a communication unit 160. CPU 110, memory 120, input unit 130, output unit 140, external storage device 150, and communication unit 160 are connected to each other via a bus. The IT ANDON PC 100 can be configured by a general computer such as a PC or a workstation.

  The CPU 110 processes data input from the memory 120, the input unit 130, the external storage device 150, or the communication unit 160 according to the program stored in the memory 120, and the memory 120, the output unit 140, and the external storage device 150. Alternatively, the processed data is output to the communication unit 160.

  The memory 120 includes a RAM (Random Access Memory) and a ROM (Read Only Memory) that perform recording electrically with semiconductor elements. In addition, a part of the recording area of the hard disk of the external storage device 150 may be used as a virtual memory. The memory 120 stores a program executed by the CPU 110, data to be processed by the program, temporary data when the program is executed, and data of the execution result of the program.

  The input unit 130 is an interface that accepts input from a keyboard and mouse input device. The input unit 130 receives data input from the user and outputs the received data to the CPU 110.

  The output unit 140 is an interface for outputting a signal to an output device of a display device such as a display or a liquid crystal projector 141 and a printing device such as the printer 142. The output unit 140 outputs a signal for notifying the user of the information received from the CPU 110, thereby displaying the information as an image by the display device, or printing the information on paper by the printing device. Is output.

  The external storage device 150 includes a storage device such as a hard disk drive, a flexible disk drive, an MO (Magneto-Optical disk) drive, a CD (Compact Disc) drive, a DVD (Digital Versatile Disk) drive, or a memory card drive. .

  The external storage device 150 records predetermined data or programs received from the CPU 110 magnetically, optically, or electrically on the recording medium 151, or reads out from the recording medium 151 and delivers it to the CPU 110. Examples of the recording medium 151 include a flexible disk, MO, CD-ROM, CD-R, CD-RW, DVD-ROM, DVD-R, DVD-RW, DVD-RAM, DVD + R, DVD + RW, and SD memory card.

  The communication unit 160 includes a communication device such as a network adapter, a terminal adapter, a modem, a wireless LAN adapter, or a transceiver. The communication unit 160 transmits data received from the CPU 110 to other computers via the LAN 900, and outputs data received from other computers via the LAN 900 to the CPU 110.

  The configuration of database server 200, line installation terminal 310, and workbench PC 320 is the same as the configuration of IT ANDON PC 100, and therefore, redundant description will not be repeated.

  FIG. 17 is a diagram showing a flow of operations of the production management system 10 when an abnormality or a possibility of abnormality occurs in the production line in the present embodiment. FIG. 18 is a flowchart showing a flow of abnormality processing when abnormality or a possibility of abnormality occurs in the production line in the present embodiment.

  Referring to FIGS. 17 and 18, the operator operates “Inspection failure” button 3144, “Q near miss” button 3145, or “Equipment abnormality” button 3146 on the line installation terminal screen 3140, or the production line When an inspection failure is detected by the inspection device, an abnormality in the body temperature of the operator is detected by the radiation thermometer 350, or an inspection failure occurs due to shipping permission, an abnormality process is executed. In FIG. 17, for example, it is assumed that the “inspection defect” button 3144 is operated.

  When the abnormality process is started, first, the line installation terminal 310 of the production line turns off the “production in progress” button 3141 on the line installation terminal screen 3140 in step S301, and in step S302, the abnormality that has occurred or is likely to occur. The abnormal button (any one of the “inspection failure” button 3144, the “Q near miss” button 3145, and the “equipment abnormality” button 3146) on the line installation terminal screen 3140 corresponding to the screen starts flashing, and in step S303, the signal tower (Red) 312 starts blinking, and the abnormality content is displayed on the main display part of the line installation terminal screen 3140 in step S304, and “occurrence” is displayed on the sub display part of the line installation terminal screen 3140 in step S305. .

  Here, since the “inspection failure” button 3144 is operated, the “production” button 3141 is turned off, the “inspection failure” button 3144 starts blinking, and the signal tower (red) 312 starts blinking. Then, “inspection failure” is displayed on the main display portion, and “occurrence” is displayed on the sub display portion.

  Next, in step S201, the database server 200 issues a state history ID, and in the line state history table shown in FIG. The state ID indicating the state that has occurred and the start date and time of this state are stored in association with each other.

  Here, since the “inspection failure” button 3144 is operated on the production line of the line name “E003”, in addition to the issued state history ID and start date and time, the line number corresponding to the line name “E003”. And the state ID “2” corresponding to the state name “inspection failure occurred” is stored in the line state master of FIG.

  In step S202, the database server 200 acquires the latest data on temperature, humidity, and discomfort index from the temperature / humidity history table in FIG. 16, and in step S203, the database server 200 obtains the latest data on cleanliness from the cleanliness history table in FIG. The latest data of the acquired temperature, humidity, discomfort index, and cleanliness is transmitted to the PC 100 for IT ANDON.

  Next, in step S101, the IT ANDON PC 100 determines the temperature, humidity, discomfort index, and cleanliness transmitted from the database server 200, and the occurrence date and time, line No. stored in the database server 200 in step S201. The status name corresponding to the status ID is reflected in the format of the quality abnormality countermeasure sheet 1420 and printed.

  Here, since the “inspection failure” button 3144 is operated on the production line with the line name “E003”, in addition to the temperature, humidity, discomfort index, cleanliness, occurrence date and time, it corresponds to the line name “E003”. Line No. , And the state name “inspection failure occurred” corresponding to the state ID “2” is printed on the quality abnormality countermeasure sheet 1420.

  In addition, as the IT ANDON display 1410 for the staff area, the IT ANDON PC 100 changes the color of the display corresponding to the production line in which the abnormality or abnormality is likely to occur to a color corresponding to the abnormality or abnormality in step S102. In step S103, the icon in the middle icon field of the IT ANDON display 1410 corresponding to the relevant abnormality or the possibility of abnormality is blinked. In step S104, “(abnormal or Adds a display of “content of possible abnormality) occurrence (line name) (elapsed time)” and blinks.

  Here, since the “inspection failure” button 3144 is operated on the production line with the line name “E003”, the display color corresponding to the production line “E003” is changed to red indicating “inspection failure”. The icon in the icon column corresponding to “defective inspection” is displayed blinking, and “abnormal inspection occurrence_line name: E003 — XX: XX” is added to the abnormality list and displayed flashing.

  Next, in step S105, the IT ANDON PC 100 adds one display of the number of occurrences of the abnormality or the possibility of abnormality of the corresponding production line on the day of the corresponding production line in the production line arrangement column, and in step S106, all the icon fields are displayed. Add one display of the number of occurrences of abnormalities or the possibility of abnormalities on the total production line of the current day.

  In this case, the “inspection failure” button 3144 is operated in the production line with the line name “E003”, and one inspection failure has already occurred in the production line with the line name “E001”. The display of the number of occurrences of “inspection defects” on the day of the line name “E003” in the column is incremented to 1 in total, and the occurrence of “inspection defects” on the total day of all production lines in the icon column The display of the number of cases is added to a total of 2 cases.

  In addition, in the staff area, the IT ANDON PC 100 reproduces a warning sound once as a sound reproduced from the speaker 143 connected to the IT ANDON PC 100 in Step S107. In Step S108, “(Line Name)” is displayed. (Abnormality or contents of fear of abnormality) "is announced, and the warning sound is continuously reproduced in step S109.

  The sound quality of the announcement reproduced in step S108 is switched to male voice or female voice depending on the content of the abnormality. Here, when a defective inspection occurs in the shipping permission, the announcement is reproduced with a female voice, and when an abnormality or other possibility of abnormality occurs, the announcement is reproduced with a male voice.

  The sound quality of the announcement is not limited to two voices, male voice and female voice, for example, high frequency voice and low frequency voice, young voice and old voice, or these voices. A plurality of sound quality sounds that can be discriminated, such as a combination of voices, may be switched according to the content of the abnormality.

  Here, since the “inspection failure” button 3144 is operated on the production line with the line name “E003”, the warning sound is reproduced once, the “inspection failure occurred at E003” is announced, and the warning sound is heard. Continue to play.

  Then, the management staff in charge of the corresponding production line in the staff area rushes to the production line with the quality abnormality countermeasure sheet printed in step S101 in step S701.

  FIG. 19 is a diagram showing an operation flow of the production management system 10 when dealing with an abnormality or a possibility of abnormality in the production line in the present embodiment. FIG. 20 is a flowchart showing the flow of abnormality processing when dealing with an abnormality or a possibility of abnormality in the production line in the present embodiment.

  Referring to FIG. 19 and FIG. 20, following the processing of FIG. 18, the line installation terminal 310 of the production line operates the abnormal button whose blinking display is started in step S302 by the management staff of the production line in step S311. It is judged whether it was done. Note that it may be determined whether or not the operation is actually performed by the management staff of the production line, not by another person, using a technique such as biometric authentication.

  Here, the “inspection failure” button 3144 is operated on the production line with the line name “E003”, and the “inspection failure” button 3144 starts blinking in step S302, so the management of the line name “E003” is performed. It is determined whether or not the “bad inspection” button 3144 has been operated by the staff.

  If it is determined that the blinking abnormal button has been operated, first, the line installation terminal 310 of the production line switches the abnormal button from blinking to lighting display in step S312, and the signal tower (red) 312 in step S313. Is stopped and switched to lighting, and “in response” is displayed on the sub display unit of the line installation terminal screen 3140 in step S314.

  Here, since the “inspection failure” button 3144 is operated again, the “inspection failure” button 3144 is switched from blinking to lighting display, the blinking of the signal tower (red) 312 is stopped, and the main display portion is The display on the sub display section is switched from “occurring” to “in response” while the display of “inspection failure” remains.

  Next, in step S204, the database server 200 stores the start date / time from the end date / time and the end date / time in the history of occurrence of an abnormality or the possibility of abnormality in the line state history table shown in FIG. Is added, and a new state history ID is issued. In the line state history table shown in FIG. The state ID indicating the state that has occurred and the start date and time of this state are stored in association with each other.

  Here, since the “inspection failure” button 3144 is operated by the operator on the production line with the line name “E003” and the blinking “inspection failure” button 3144 is operated again by the management staff, step S201 is performed. The end time and the required number of seconds of the history of “inspection failure occurrence” with the line name “E003” saved in the above are saved, and in addition to the newly issued state history ID and start date and time, the line name “E003” Corresponding to the line No. In the line status master of FIG. 13, the status ID “3” corresponding to the status name “inspection failure handling” is stored. That is, in this case, the end time of “occurrence of inspection defect” and the start date and time of “in response to inspection defect” are the same.

  In addition, as the IT ANDON display 1410 of the staff area, the IT ANDON PC 100 switches the display color corresponding to the production line in which an abnormality or a possibility of abnormality has occurred, from blinking display to lighting display in step S111, and in step S112. The icon in the middle of the IT ANDON display 1410 corresponding to the relevant abnormality or the possibility of abnormality is switched from blinking to lighting, and the abnormality list display is changed to “(Abnormality or possibility of abnormality” in step S113. The contents are changed to “Supported” (Line name) (Elapsed time), and the display is lit.

  In this case, the “inspection failure” button 3144 is operated on the production line with the line name “E003”, and the blinking “inspection failure” button 3144 is operated again, so that it corresponds to the production line “E003”. The color of the display to be displayed is lit in red indicating “inspection failure”, the icon in the icon column corresponding to “inspection failure” is lit in, and the display of the abnormality list is “inspection failure handling_line name: E003_ ○ ○: Changed to XX ”and lighted up.

  In addition, as an audio reproduced from the speaker 143 connected to the IT ANDON PC 100 in the staff area, the IT ANDON PC 100 reproduces a warning sound that has been reproduced since the reproduction started in Step S109 in Step S114. Stop.

  Then, the management staff in charge who rushed to the production line from the staff area operates the abnormal button blinking in step S311, and then responds to the abnormality or the possibility of abnormality occurring in the production line in step S702. In step S703, the correspondence contents are recorded on the quality abnormality countermeasure sheet.

  FIG. 21 is a diagram showing a flow of operations of the production management system 10 when a response to an abnormality or a possibility of an abnormality is completed in the present embodiment and a return is made during production. FIG. 22 is a flowchart showing a flow of an abnormality process when a response to an abnormality or a possibility of an abnormality is completed in the present embodiment and a return is made during production.

  Referring to FIG. 21 and FIG. 22, following the processing of FIG. 20, the line installation terminal 310 of the production line determines whether or not the “in production” button 3141 has been operated in step S321.

  If it is determined that the “production in progress” button 3141 has been operated, the line installation terminal 310 of the production line first turns off the abnormal button that is lit and displayed in step S312 in step S322. In step S323, the “production in progress” button is displayed. The button 3141 is turned on, the signal tower (red) 312 is turned off in step S324, and “in production” is displayed on the main display portion of the line installation terminal screen 3140 in step S325. Clear the display.

  Here, since the “in production” button 3141 is operated after the “inspection failure” button 3144 is operated again, the “inspection failure” button 3144 is turned off, and the “in production” button 3141 is lit up. Then, the signal tower (red) 312 is turned off, “production” is displayed on the main display section, and the display on the sub display section is erased.

  Next, in step S205, the database server 200 starts from the end date / time and the end date / time in the history of the start of the response of the abnormality or the possibility of the abnormality stored in step S204 of FIG. 20 of the line state history table shown in FIG. The required number of seconds subtracted from the date and time is added, a new state history ID is issued, and the issued state history ID and line No. are displayed in the line state history table shown in FIG. The state ID “1” indicating “in production” and the start date and time of “in production” are stored in association with each other.

  In addition, as the IT ANDON display 1410 of the staff area, the IT ANDON PC 100 changes the color of the display corresponding to the production line in which the response to the abnormality or the possibility of the abnormality is completed in step S115 to green, and turns it on. In step S116, the display of the abnormality list of the corresponding production line is deleted. After the abnormality process described with reference to FIGS. 18, 20, and 22, the normal production process described with reference to FIGS. 26 and 27 is executed.

  FIG. 26 is a first flowchart showing a flow of production processing executed by the production management system 10 in the present embodiment. Referring to FIG. 26, first, work table PC 320 of the production line determines whether or not the worker ID of the worker is input by bar code reader 340 in step S331.

  If it is determined that the worker ID has been input, the worktable PC 320 of the production line executes processing for setting the worktable height and the tool position. This process will be described later with reference to FIG.

  Next, in step S332, the work table PC 320 of the production line determines whether or not the product number of the product manufactured on the production line is input by the barcode reader 340. When it is determined that the product number has been input, the worktable PC 320 of the production line executes a process of determining whether or not the worker's body temperature is abnormal. This process will be described later with reference to FIG.

  Next, in step S211, the database server 200 searches the item NG table shown in FIG. 24 for the last NG date and time of the product having the product number input in step S332 of the worker with the worker ID input in step S331.

  Next, in step S212, the database server 200 searches the production history table shown in FIG. 23 for the minimum man-hour for the product from a history that is newer than the retrieved history between the last NG date and two days ago. To do. In step S213, the database server 200 determines whether there is no corresponding history as a result of the search in step S212.

  FIG. 25 is a diagram showing a standard man-hour default value table stored in the database server 200 in the present embodiment. In the standard man-hour default value table, the product number, the product type, the standard man-hours of all the processes of the product, and the standard man-hours of the soldering process of the product are stored in association with each other.

  26, when it is determined that there is a corresponding history (NO in step S213), the database server 200 determines in step S214 that the searched minimum man-hour is the standard man-hour default value table shown in FIG. It is determined whether or not it is 1.2 times or more of the standard man-hour of the product stored in. When it is determined that the minimum man-hour is not 1.2 times or more of the standard man-hour (NO in step S214), the database server 200 determines in step S215 that the retrieved minimum man-hour is 0. 0 of the standard man-hour of the product. It is determined whether it is less than 8 times.

  FIG. 11 is a diagram showing a proficiency level table for each product format stored in the database server 200 in the present embodiment. Referring to FIG. 11, information indicating the worker ID, the product number of the product, and the worker level of the worker about the product is stored in the product type-specific proficiency level table in association with each other.

  26, when it is determined that there is no corresponding history (in the case of YES in step S213), and when it is determined that the minimum man-hour is 1.2 times or more of the standard man-hour (YES in step S214). In step S333, the production line worktable PC 320 sets the worker level to beginner. Further, the workbench PC 320 associates the worker ID of the worker with the product ID of the product to be manufactured and the product number of the product to be manufactured in the product type proficiency level table of the database server 200 shown in FIG. Information indicating that the person level is a beginner is stored.

  If it is determined that the minimum man-hour is less than 0.8 times the standard man-hour (YES in step S215), the worktable PC 320 of the production line sets the worker level to an advanced worker in step S334. Further, the workbench PC 320 associates the worker ID of the worker with the product ID of the product to be manufactured and the product number of the product to be manufactured in the product type proficiency level table of the database server 200 shown in FIG. Information indicating that the expert level is advanced.

  If it is determined that the minimum man-hour is not less than 0.8 times the standard man-hour (NO in step S215), the worktable PC 320 of the production line sets the worker level to intermediate in step S335. Further, the workbench PC 320 associates the worker ID of the worker with the product ID of the product to be manufactured and the product number of the product to be manufactured in the product type proficiency level table of the database server 200 shown in FIG. Information indicating that the person level is intermediate is stored.

  FIG. 28 is a graph showing the relationship between the level of workers and the number of work steps. Referring to FIG. 28, statistically, the work man-hours of the beginner level workers are almost equal to the standard work time (Standard Time, ST) calculated on the basis of the company even if the number of products produced increases. It is included in the range of plus 20% or more.

  In addition, the man-hours for intermediate level workers are almost in the range of minus 20% or more plus less than 20% of the standard work hours even if the number of products produced increases. On the other hand, the work man-hours of the senior level workers immediately fall within the range of less than minus 20% of the work standard time as the number of products produced increases.

  Therefore, as described in step S214, step S215 and step S333 to step S335 in FIG. 26, the minimum minimum man-hour of the worker is 1.2 times or less than the standard man-hour, or 0.8. The level of workers was divided into beginners, intermediates, and advanced by over or under double.

  FIG. 29 is a graph showing the forgetting curve of the Ebbing House. Referring to FIG. 29, the forgetting curve of this graph is a curve derived by the psychologist Hermann Ebbinghaus and shows the degree of forgetting of long-term memory.

  Specifically, when the forgetting curve is stored, the forgetting rate is 0%, the forgetting rate is 42% after 20 minutes, the forgetting rate is 56% after 1 hour, and the forgetting rate is 1 day later. The rate is 74%, the forgetting rate is 77% after one week (after 7 days), and the forgetting rate is 79% after one month (after 30 days).

  In this way, the forgetting rate continues to decrease until the second day, and the forgetting rate becomes almost steady after the second day. Therefore, in steps S212 and S222, the work was performed with less man-hours two days ago. Since there is a high possibility of forgetting, if there is no inspection defect, the minimum man-hour is retrieved from the newer history than two days ago in step S212.

  In addition, if the worker has caused an inspection failure within 2 days, there was a possibility that an inspection failure occurred as a result of working with less man-hours. The work man-hours are ignored, and the minimum man-hour is searched from the work man-hours after the occurrence of the inspection failure in step S212.

  Next, in step S221, the database server 200 performs the soldering process of the product having the product number input in step S332 of the worker with the worker ID input in step S331 from the item NG table shown in FIG. Search for the last NG date and time of the product containing.

  Next, in step S222, the database server 200 determines, from the production history table shown in FIG. 23, the minimum soldering of the product from a history that is newer than the history after the last NG date and two days before the search. Search for man-hours. In step S223, the database server 200 determines whether there is no corresponding history as a result of the search in step S222.

  If it is determined that there is a corresponding history (NO in step S223), the database server 200 stores the retrieved minimum soldering man-hour in the standard man-hour default value table shown in FIG. 25 in step S224. It is judged whether or not it is 1.2 times or more of the standard man-hour for soldering of the product. If it is determined that the minimum man-hour for soldering is not 1.2 times or more of the standard man-hour (NO in step S224), the database server 200 determines that the retrieved minimum man-hour for soldering is the product in step S225. It is determined whether or not the standard man-hour for soldering is less than 0.8 times.

  When it is determined that there is no corresponding history (in the case of YES in step S223), and when it is determined that the minimum man-hour for soldering is 1.2 times or more of the standard man-hour (in the case of YES in step S224) The worktable PC 320 of the production line sets the worker's soldering skill level to beginner in step S336.

  When it is determined that the minimum man-hour for soldering is less than 0.8 times the standard man-hour (YES in step S225), the work table PC 320 in the production line, in step S337, the operator's soldering skill level Set to advanced.

  When it is determined that the minimum man-hour for soldering is not less than 0.8 times the standard man-hour (NO in step S225), the worktable PC 320 in the production line determines the level of soldering skill of the worker in step S338. Set to intermediate.

  FIG. 30 is a graph showing the relationship between the level of workers and the man-hours for each production process. Referring to FIG. 30, the soldering process is a process from picking up the soldering iron, soldering, and returning the soldering iron, and among the element work common to each product, This is a process in which the proficiency level of the person's skill appears remarkably.

  Therefore, a worker who requires more than 20% of the standard man-hours in the soldering process is designated as a beginner in the skill level of soldering, and a worker who takes less than + 20% and minus 20% or more in the intermediate level of soldering skill. And less than 20% of the workers are advanced soldering skill levels.

  Therefore, as described in Step S224, Step S225 and Step S336 to Step S338 in FIG. 26, the minimum man-hour of the most recent soldering of the worker is 1.2 times or less than the standard man-hour, or The soldering skill level of workers is divided into beginner, intermediate and advanced by 0.8 times or less.

  FIG. 27 is a second flowchart showing the flow of production processing executed by the production management system 10 in the present embodiment. Referring to FIG. 27, in step S341, work table PC 320 of the production line is set in steps S333 to S335, and the level of the worker for the product stored in the proficiency level table for each product type in database server 200 is stored. The work contents are notified in accordance with the soldering skill level of the worker set in steps S336 to S338.

  FIG. 37 is a diagram showing a method for instructing work contents according to the level of the worker notified by worktable PC 320 in the present embodiment. FIG. 39 is a display screen diagram showing a work content instruction screen for beginners displayed on the screen of worktable PC 320 in the present embodiment. FIG. 40 is a display screen diagram showing a work content instruction screen for intermediate persons displayed on the screen of worktable PC 320 in the present embodiment. FIG. 41 is a display screen diagram showing a work content instruction screen for advanced users displayed on the screen of worktable PC 320 in the present embodiment.

  Referring to FIGS. 37 to 41, when the worker level is beginner, visually, worktable PC 320 visually displays characters and 3D data as shown in FIG. 38, or as shown in FIG. The work content is informed by text and video. In addition, audibly, the workbench PC 320 starts production of the product and informs the user of the work contents not only for the first product but also for each time. Then, regarding the feed to the next process, the workbench PC 320 operates the next process when the “proceed to the next process” button 3241 which is a next process feed switch displayed on the work content instruction screen 3240 is operated. Broadcast the contents.

  When the worker level is intermediate, the worktable PC 320 visually notifies the work content with characters and still images as shown in FIG. In addition, audibly, the workbench PC 320 starts production of the product and informs the operation content by voice only for the first product. Then, regarding the feed to the next process, the workbench PC 320 operates the next process when the “proceed to the next process” button 3241 which is a next process feed switch displayed on the work content instruction screen 3240 is operated. Either the method of notifying the content or the method of notifying the operation content of the next process (automatic feed) every time the reference time required for the production process displayed in the operation content display has passed, is selected by the operator Then, the next process feed is executed.

  When the worker level is advanced, the worktable PC 320 visually notifies the work content with characters and still images of the current process and the next process as shown in FIG. In addition, audibly, the workbench PC 320 starts production of the product and informs the operation content by voice only for the first product. And about sending to the next process, worktable PC320 notifies work contents of the next process by automatic feeding.

  Also, when the work level is intermediate or advanced, and the feed to the next process is automatic feed, the time for sending from the soldering process to the next process depends on the soldering skill level. Calculated.

  Returning to FIG. 27, the work table PC 320 of the production line determines whether or not the operator has performed an operation of shifting to the work table adjustment mode in step S342. The case where it is determined that the operation for shifting to the workbench adjustment mode has been performed (YES in step S342) will be described later with reference to FIG.

  If it is determined that the operation for shifting to the workbench adjustment mode has not been performed (NO in step S342), the workbench PC 320 of the production line determines whether or not the current process is an inspection process in step S343. . When it is determined that it is not an inspection process (NO in step S343), in step S348, the worker performs work according to the work content instruction.

  On the other hand, when it is determined that the process is an inspection process (YES in step S343), in step S344, the inspection device or the worker on the production line performs the inspection.

  In step S345, the line installation terminal 310 of the production line determines whether or not an inspection failure has been detected by the inspection device and a signal indicating the inspection failure has been output, or the operator has determined that the inspection has failed and the “inspection failure” button. By determining whether or not 3144 has been operated, it is determined whether or not an inspection failure has occurred.

  If it is determined that an inspection failure has occurred (YES in step S345), the abnormality processing described in FIGS. 18, 20, and 22 is executed in step S346. Next, in step S347, the work table PC 320 of the production line receives an input from the worker as to whether or not the inspection defect is caused by manufacturing.

  When it is input that the inspection defect is due to manufacturing (YES in step S347), the work table PC 320 of the production line displays the operator's information about the product in the item NG table of the database server 200 shown in FIG. Update the last NG date and time.

  After step S348 and step S226, when it is determined that no inspection failure has occurred (NO in step S345), and when it is input that the inspection failure is not due to manufacturing (NO in step S347). In step S349, the line installation terminal 310 of the production line displays an abnormality button (“inspection failure” button 3144, “Q near-miss” on the line installation terminal screen 3140 corresponding to the abnormality or the possibility of abnormality shown in FIG. ”Button 3145 and“ equipment abnormality ”button 3146) are determined.

  If it is determined that the abnormal button has been operated (YES in step S349), the abnormal processing described above with reference to FIGS. 18, 20, and 22 is executed in step S350.

  After step S350 and when it is determined that the abnormal button has not been operated (NO in step S349), the work line PC 320 of the production line determines whether or not the final process is completed in step S351. To do. When it is determined that the process that is not the final process has been completed (NO in step S351), the worktable PC 320 of the production line returns the process to be performed to the process in step S341.

  FIG. 14 is a diagram showing a product completion history table stored in the database server 200 in the present embodiment. Referring to FIG. 14, in the product completion history table, the completion history ID assigned to each production line and the line number of the production line are shown. , The cumulative number of products completed on that day on that production line, the previous completion date and time of the product on that production line, the completion date and time of the manufacture of this product, the required number of seconds that is the throughput of this product, and the completion A flag is associated and stored. When the value of the completion flag is “0”, it indicates that the content of the completion history of the day is reset for the production line, and when it is “1”, the completion date and time is a product due to normal completion. Indicates that the date and time of the manufacturing is completed. When the value is “−1”, it indicates that the correction for adding the cumulative number of completions has been made. When the value is “−2”, the cumulative number of completions is subtracted. Indicates that a correction has been made.

  27, on the other hand, if it is determined that the final process has been completed (YES in step S351), the database server 200 updates the product completion history table shown in FIG. 14 and the production history shown in FIG. Store data about the newly completed product in a table. Then, the worker level and the soldering skill level are updated according to the current man-hour and the soldering man-hour, respectively.

  Next, in step S352, the work table PC 320 of the production line determines whether or not the operation is to be repeated by determining whether or not the production performance has reached the planned production quantity. If it is determined that the work is to be repeated (YES in step S352), the process to be executed is returned to step S211.

  On the other hand, when it is determined that the operation is not repeated (NO in step S352), the worktable PC 320 of the production line determines whether there is no next scheduled production in step S353. It is determined whether to end the work. If it is determined not to end the work (NO in step S353), the process to be executed is returned to step S332. On the other hand, when it is determined that the work is to be ended (YES in step S353), the production process is ended.

  FIG. 31 is a diagram showing a worktable change history table stored in the database server 200 in the present embodiment. Referring to FIG. 31, in the worktable change history table, the worker ID, the date when the worktable height or the tool position is changed, the worktable height after the change, and the tool after the change are made. The position is stored in association with each other.

  FIG. 33 is a flowchart showing a flow of processing for setting the work table height and the tool position, which is executed by the production management system 10 in the present embodiment. Referring to FIG. 33, this process is executed after step S331 in FIG.

  First, in step S231, the database server 200 determines whether or not the worktable height and tool position changed by the worker are stored in the worktable change history table shown in FIG. If stored, the database server 200 reads the worktable height and tool position that were last changed. On the other hand, if not stored, the work table height and the tool position as the initial values stored in association with the worker ID of the worker are read from the personal information table shown in FIG. When the work table height is not stored, a value obtained by subtracting 60 cm from the height of the worker is used as the work table height.

  Next, in step S361, the work table PC 320 of the production line controls the work table height control actuator 370 via the PLC 330 to change the work table height to the work table height read in step S231. In step S362, the tool position control actuator 360 is controlled via the PCC 330 to change the tool position to the tool position read in step S231. Thereafter, the process to be executed is returned to step S332 in FIG.

  FIG. 34 is a flowchart showing a flow of processing for changing the work table height and the tool position, which is executed by the production management system 10 in the present embodiment. Referring to FIG. 34, this process is executed when it is determined in FIG. 27 that the operation for shifting to the workbench adjustment mode has been performed (YES in step S342).

  First, in step S232, the database server 200 obtains the work table height and tool position from the work table change history table shown in FIG. 31 or the personal information table shown in FIG. 10 in the same manner as step S231 in FIG. Read. Then, the worktable PC 320 displays a worktable height and tool position change screen 3250 shown in FIG.

  FIG. 42 is a display screen diagram showing a work table height and tool position change screen 3250 displayed on the work table PC 320 in the work table adjustment mode in the present embodiment. Referring to FIG. 42, on work platform height and tool position change screen 3250, a work table height input field for inputting work table height and a work table height input in the work table height input field are displayed. “Change” button 3251 for changing, tool position input field for inputting the tool position, “change” button 3252 for changing to the tool position input in the tool position input field, and the changed contents are determined. A “decision” button 3253 for performing, and a “cancel” button 3254 for ending the workbench adjustment mode without changing the workbench height and the tool position are displayed.

  Returning to FIG. 34, in step S364, the worktable PC 320 determines whether or not the controllable worktable height is input to the worktable height input field and the “change” button 3251 is operated. When it is determined that the work table height has been input and the “change” button 3251 has been operated (YES in step S364), the work table PC 320, in step S365, the work table height control actuator 370 via the PLC 330. And the work table height is changed to the work table height changed in step S364.

  In step S366, the workbench PC 320 determines whether a controllable tool position is input to the tool position input field and the “change” button 3252 is operated. If it is determined that the tool position has been input and the “change” button 3252 has been operated (YES in step S366), the workbench PC 320 controls the tool position control actuator 360 via the PCC 330 in step S367. The tool position is changed to the tool position changed in step S366.

  In step S368, the worktable PC 320 determines whether the “OK” button 3253 has been operated. Also, it is determined whether or not the “cancel” button 3254 has been operated. When it is determined that the “OK” button 3253 is not operated and the “Cancel” button 3254 is not operated, the worktable PC 320 returns the process to be executed to the process of step S364.

  On the other hand, when determining that the “OK” button 3253 has been operated, the database server 200 executes a process of storing the change data in the worktable change history table shown in FIG. 31 in step S233. Then, after the end of step S233 and when it is determined that the “cancel” button 3254 has been operated, the process to be executed is returned to the process of step S341 in FIG.

  FIG. 35 is a flowchart showing a flow of processing for measuring the body temperature of the worker executed in the production management system 10 in the present embodiment. Referring to FIG. 35, this process is executed after step S332 of FIG.

  First, in step S234, the database server 200 reads the warning lower limit body temperature and the warning upper limit body temperature of the worker from the table shown in FIG.

  Next, the work table PC 320 of the production line controls the radiation thermometer 350 to measure the body temperature of the worker in step S371. In step S235, the database server 200 stores the measured body temperature in the body temperature measurement history table in association with the worker ID and the measured date.

  FIG. 36 is a graph showing changes in the body temperature of the worker. Referring to FIG. 36, if the worker's body temperature is not in the range above the warning upper limit body temperature that is the range of fever and is not in the range below the warning upper limit body temperature that is in the low body temperature range, the worker's body temperature is normal. It is judged that there is.

  Next, the worktable PC 320 of the production line determines in step S372 whether or not the body temperature measured in step S371 is outside the range from the warning lower limit body temperature to the warning upper limit body temperature read in step S234. Then, it is determined whether or not the measured body temperature is abnormal. If it is determined that the body temperature is not abnormal (NO in step S372), the process to be executed is returned to the process in step S211 in FIG.

  On the other hand, when it is determined that the body temperature is abnormal (YES in step S372), in step S236, the database server 200 displays the body temperature measurement history stored in the body temperature measurement history table in the state of the worker as the body temperature. Information indicating that there is an abnormality is added and stored, and in step S237, personal information corresponding to the worker in the personal information table is changed to information indicating that the temperature of the worker is abnormal.

  Further, as the IT ANDON display 1410 of the staff area, the IT ANDON PC 100 displays in the step S121 that the operator is prompted to change the operator in the abnormality list. Then, in step S122, the IT ANDON PC 100 transmits to the line installation terminal 310 that the Q near-miss has occurred, assuming that the Q near-miss has occurred because the body temperature of the worker is abnormal.

  When the line installation terminal 310 receives that the Q near miss has occurred, the line installation terminal 310 performs the same process as when the “Q near miss” button 3145 is operated.

  Further, as a sound reproduced from the speaker 143 connected to the IT ANDON PC 100 in the staff area, the IT ANDON PC 100 prompts to stop the production line because the worker's body temperature is abnormal in step S123. Play.

  Thereafter, in step S373, the abnormality process described with reference to FIGS. 18, 20, and 22 is executed. After the abnormal process is executed, the process to be executed is returned to the process of step S211 in FIG.

  As described above, according to the production management system 10 in the present embodiment, step S344, step S345, step S346, step S349 and step S350 in FIG. 27, and step S372 and step S373 in FIG. 35, FIG. As described in Steps S101 to S109, production abnormalities or abnormalities in each of a plurality of production lines, such as operation of abnormal buttons, abnormal body temperature of workers, occurrence of defects in inspection equipment or abnormal work pace, etc. Staff with a plurality of management staff who respectively manage a plurality of production lines on the condition that fear has been detected (YES in step S345, YES in step S349, YES in step S372) LCD projector in the area 141 shows that there is a possibility of abnormality or abnormality and a production line in which there is a possibility of abnormality or abnormality by means of the IT ANDON display 1410 projected at 141, the sound from the speaker 143, and the quality abnormality countermeasure sheet 1420 printed from the printer 142. An alarm including identifiable information notifies a plurality of management staff of an abnormality or a possibility of abnormality of the production line.

  In addition, as described in step S311 of FIG. 20, an abnormal button (“inspection failure” button 3144, flashing) on the line installation terminal screen 3140 of the line installation terminal 310 provided on the machine side of each of the plurality of production lines. Any one of “Q near-miss” button 3145 and “equipment abnormality” button 3146) accepts the input of the management staff for stopping the alarm that has been notified about the production line.

  Further, as described in steps S111 to S114 in FIG. 20, the line color of the IT ANDON display 1410 is provided on condition that an input for stopping the alarm is received (in the case of YES in step S311). The display of the corresponding abnormality icon and abnormality list is switched from blinking to lighting, and the reproduction of the warning sound from the speaker 143 is stopped, so that the production line corresponding to the abnormality button for which the input is accepted is notified. The alarm is stopped.

  In this way, the production management system 10 issues a warning to the effect that an abnormality or a possibility of abnormality has occurred in a staff area where management staff other than the production line where the abnormality or the possibility of an abnormality has occurred also resides. Also, in order to stop the alarm, the production line management staff stops the alarm with an abnormal button blinking on the line installation terminal screen 3140 of the line installation terminal 310 provided on the machine side of the production line. It is necessary to input. For this reason, if the alarm is not stopped indefinitely, other staff in the staff area where multiple management staff are stationed will not be willing to respond immediately to the production line. Is considered. As a result, when an abnormality occurs in production, an incentive to respond to the abnormality can be given immediately.

  In addition, the production management system 10 notifies the user of an abnormality or a possibility of abnormality in production on the production line with an alarm. As a result, it is possible to prevent the management staff from overlooking an abnormality when an abnormality occurs in production.

  Further, as described in steps S102 to S104 in FIG. 18, the production line in which an abnormality or a possibility of abnormality has occurred in the liquid crystal projector 141 that schematically displays the shape and arrangement of the production line by the production management system 10. Is displayed as an IT ANDON display 1410 in a manner indicating that an abnormality or a possibility of an abnormality has occurred by changing the color of the line to the color at the time of abnormality and blinking the display. As a result, an abnormality or a fear of abnormality is notified. For this reason, the production management system 10 can communicate to the management staff that it is easy to understand and that a production abnormality or a possibility of abnormality in the production line has been detected.

  Further, as described in steps S111 to S113 of FIG. 20, the input is made on condition that the input for stopping the alarm is received by the production management system 10 (in the case of YES in step S311). The display corresponding to the production line corresponding to the accepted abnormality button is displayed in a manner indicating that it is responding to the abnormality or the possibility of abnormality by switching the line color from blinking to lighting display, for example. Thus, it is notified that the abnormality is being dealt with. For this reason, it can be easily understood by the management staff, and it can be communicated that the production line in the production line is being dealt with or a risk of abnormality.

  In addition, as described in step S108 in FIG. 18, the production management system 10 notifies the user of the abnormality or the abnormality with the sound quality according to the content of the abnormality or the possibility of the abnormality. For this reason, the production management system 10 makes it easy for the management staff to understand, and it is possible to transmit the contents of the production abnormality or the possibility of abnormality in the production line.

  In addition, as described in step S101 of FIG. 18, the quality management sheet 1420 includes information that can identify a production line in which an abnormality or a possibility of abnormality has occurred, and is used to enter a countermeasure for the abnormality by the production management system 10. By printing with the printer 142, an abnormality or a possibility of abnormality is notified. For this reason, the production management system 10 can communicate to the management staff that it is easy to understand and that a production abnormality or a possibility of abnormality in the production line has been detected. In addition, since it is necessary to write countermeasures for abnormalities in the quality abnormality countermeasure sheet 1420, an incentive for logically responding to abnormalities can be given.

  Further, as described in step S371, step S372, and step S122 of FIG. 35, the production management system 10 measures the body temperature of the worker on the production line, and the measured body temperature is less than the warning lower limit body temperature shown in FIG. Alternatively, the risk of abnormality is detected on the condition that it is within the range of the warning upper limit body temperature abnormality (in the case of YES in step S372). For this reason, when the temperature of the worker is in the abnormal range, the production management system 10 can notify the management staff that there is a possibility of an abnormality before the abnormality occurs in the production by the operator. As a result, the production management system 10 can prevent a production abnormality from occurring.

  Further, as described in S349 of FIG. 18, the abnormality button (“inspection” displayed on the line installation terminal screen 3140 of the line installation terminal 310 provided on the machine side of each of the plurality of production lines by the production management system 10. Any of the “bad” button 3144, “Q near-miss” button 3145, and “equipment abnormality” button 3146) accepts the input of the production line operator to the effect that the production line is abnormal or likely to be abnormal. . Further, as described in step S349 and step S350 in FIG. 18, on the condition that an input indicating that an abnormality and an abnormality may have occurred is received by the abnormality button (when YES in step S349), Abnormality and the possibility of abnormality are detected. For this reason, when an input indicating that an abnormality or a possibility of abnormality has occurred is received by the worker by the production management system 10, it is possible to notify the management staff that there is a possibility of abnormality or abnormality, respectively. As a result, the production management system 10 can promptly respond to the management staff with respect to the production abnormality or the possibility of abnormality.

  Further, the production management system 10 detects the work pace of the worker on the production line, and detects the possibility of abnormality on the condition that the detected work pace is within a preset abnormal range. For this reason, when the work pace of the worker on the production line is in the abnormal range, the production management system 10 notifies the management staff that there is a possibility of abnormality before the production is abnormal. Can do. As a result, the production management system 10 can prevent a production abnormality from occurring.

  In addition, as described in step S345 and step S346 of FIG. 27, the product management system 10 inspects the product produced on the production line, and the abnormality is detected on the condition that the product is inspected as a defective product. Detected. For this reason, when the production management system 10 inspects that the product is defective, it can be notified to the management staff that there is an abnormality. As a result, the production management system 10 can promptly manage the management staff against production abnormalities.

  26, step S211 to step S215, step S333 to step S335, step S221 to step S225, step S336 to step S338, step S341 of FIG. 27, and step S231 of FIG. As described in steps S361 and S362, and steps S232, S233, and S364 to S368 in FIG. 34, the production management system 10 determines the characteristics of workers on the production line (for example, The worker level, skill level, height, and dominant arm) are specified, and the production line has a working environment (for example, work content instruction method, work table height, tool position) according to the specified characteristics of the worker of the production line. ) It is changed. For this reason, the production management system 10 enables the worker to efficiently produce in the optimum working environment according to the characteristics of the worker.

  Also, as described in step S211 to step S215 in FIG. 26, step S333 to step S335, step S221 to step S225, step S336 to step S338, and step S341 in FIG. The system 10 identifies the worker level and skill level of the worker as the characteristics of the worker, and changes the method of instructing the work content to the worker on the production line according to the identified worker level and skill level. Thus, the production line is changed to a work environment according to the characteristics of the worker. For this reason, the production management system 10 can allow the worker to efficiently produce in the work environment in which the work content is notified by the optimum instruction method according to the worker level and skill level of the worker.

  Further, as described in step S231, step S361, and step S362 of FIG. 33 and step S232, step S233, and step S364 to step S368 of FIG. By specifying the physical characteristics of the worker (for example, height and dominant arm) as characteristics, and by changing the shape of the production line (for example, work table height and tool position) according to the specified physical characteristics The production line is changed to a work environment according to the characteristics of the worker. For this reason, the production management system 10 allows the worker to efficiently produce in the work environment having the optimum production line shape according to the physical characteristics of the worker.

  Further, as described in step S231, step S361, and step S362 of FIG. 33 and step S232, step S233, and step S364 to step S368 of FIG. As the physical characteristics, the height and dominant arm of the worker are identified, and the work table height as the shape of the production line is changed according to the identified height, and as the shape of the production line according to the identified dominant arm By changing the tool position, the production line is changed to a work environment according to the characteristics of the worker. For this reason, the production management system 10 allows the worker to efficiently produce in the work environment having the optimum work table height and tool position according to the height and dominant hand of the worker.

  Next, a modification of the above-described embodiment will be described. In the present embodiment, the invention has been described as the production management system 10. However, the present invention is not limited to this, and the invention can be understood as a production management method executed by the production management system 10. Further, the invention can be understood as a production management program executed by each computer included in the production management system 10.

  In the present embodiment, the case where the IT ANDON PC 100 and the database server 200 are configured by different computers has been described. However, the present invention is not limited to this, and the IT ANDON PC 100 and the database server 200 may be configured by one computer.

  In the present embodiment, the case where the line installation terminal 310 and the workbench PC 320 are configured by different computers has been described. However, the present invention is not limited to this, and the line installation terminal 310 and the work table PC 320 may be configured by one computer.

  When the worker's work pace is slower or faster than a predetermined range with respect to the standard man-hour, it is determined that the work pace is abnormal and the IT ANDON display 1410 or the line installation terminal screen 3140 is warned. May be displayed.

  The embodiment disclosed this time should be considered as illustrative in all points and not restrictive. The scope of the present invention is defined by the terms of the claims, rather than the description above, and is intended to include any modifications within the scope and meaning equivalent to the terms of the claims.

It is the schematic which shows the outline of the production management system in embodiment of this invention. It is a block diagram which shows the structure of the production management system in this Embodiment. It is a block diagram which shows the outline of a structure of PC for IT ANDON in this Embodiment. It is a display screen figure which shows the IT ANDON display displayed on a staff area in this Embodiment. It is an external view which shows the shape of the worktable in this Embodiment, and the attachment condition of the apparatus to a worktable. It is a display screen figure which shows the line installation terminal screen displayed on a line installation terminal in this Embodiment. It is a figure which shows the quality abnormality countermeasure sheet | seat printed from the printer connected to PC for IT ANDON in this Embodiment. It is a figure which shows the product format table memorize | stored in the database server in this Embodiment. It is a figure which shows the worker information table memorize | stored in the database server in this Embodiment. It is a figure which shows the personal information table memorize | stored in the database server in this Embodiment. It is a figure which shows the proficiency degree table classified by product format memorize | stored in the database server in this Embodiment. It is a figure which shows the line state log | history table memorize | stored in the database server in this Embodiment. It is a figure which shows the line state master memorize | stored in the database server in this Embodiment. It is a figure which shows the product completion log | history table memorize | stored in the database server in this Embodiment. It is a figure which shows the cleanliness history table memorize | stored in the database server in this Embodiment. It is a figure which shows the temperature / humidity history table memorize | stored in the database server in this Embodiment. It is a figure which shows the flow of operation | movement of a production management system when abnormality or the possibility of abnormality generate | occur | produces in a production line in this Embodiment. It is a flowchart which shows the flow of the abnormality process when abnormality or the possibility of abnormality generate | occur | produces in the production line in this Embodiment. It is a figure which shows the flow of operation | movement of a production management system when it respond | corresponds to abnormality or a possibility of abnormality in a production line in this Embodiment. It is a flowchart which shows the flow of the abnormality process when it respond | corresponds to abnormality or a possibility of abnormality in a production line in this Embodiment. It is a figure which shows the flow of operation | movement of a production management system when the response | compatibility to abnormality or the possibility of abnormality is completed in this Embodiment and it returns during production. It is a flowchart which shows the flow of the abnormality process when the response | compatibility to abnormality or a possibility of abnormality is completed in this Embodiment and it returns during production. It is a figure which shows the production history table memorize | stored in the database server in this Embodiment. It is a figure which shows the item NG table memorize | stored in the database server in this Embodiment. It is a figure which shows the standard manhour default value table memorize | stored in the database server in this Embodiment. It is a 1st flowchart which shows the flow of the production process performed with a production management system in this Embodiment. It is a 2nd flowchart which shows the flow of the production process performed with a production management system in this Embodiment. It is a graph which shows the relationship between a worker's level and work man-hours. It is a graph which shows the forgetting curve of Ebbinghouse. It is a graph which shows the relationship between the level of the worker according to production process, and work man-hours. It is a figure which shows the worktable change log | history table memorize | stored in the database server in this Embodiment. It is a figure which shows the body temperature measurement log | history table memorize | stored in the database server in this Embodiment. It is a flowchart which shows the flow of the process which sets the work-table height and tool position which are performed with a production management system in this Embodiment. It is a flowchart which shows the flow of the process which changes the work-table height and tool position which are performed with a production management system in this Embodiment. It is a flowchart which shows the flow of the process which measures the body temperature of the operator performed with a production management system in this Embodiment. It is a graph which shows the change of a worker's body temperature. It is a figure which shows the instruction | indication method of the work content according to the level of the operator alert | reported by worktable PC in this Embodiment. It is a display screen figure which shows the work content instruction | indication screen displayed on the screen of worktable PC in this Embodiment. It is a display screen figure which shows the work content instruction | indication screen for beginners displayed on the screen of work bench PC in this Embodiment. It is a display screen figure which shows the work content instruction | indication screen for intermediate persons displayed on the screen of work bench PC in this Embodiment. It is a display screen figure which shows the work content instruction | indication screen for advanced users displayed on the screen of work bench PC in this Embodiment. It is a display screen figure which shows the work-table height and tool position change screen displayed on work-table PC in work-table adjustment mode in this Embodiment.

Explanation of symbols

  10 Production management system, 100 IT ANDON PC, 141 LCD projector, 142 Printer, 143 Speaker, 200 Database server, 310, 310A Line installation terminal, 311 Completion count up switch, 320, 320A Worktable PC, 330 PLC, 340 Barcode reader, 350 Radiation thermometer, 360 Tool position control actuator, 370 Work table height control actuator, 410 Water-smoothing portable terminal, 500 Thermohygrometer, 600 Particle counter, 810 Access point, 900 LAN.

Claims (14)

An abnormality detecting means for detecting an abnormality or a possibility of abnormality in production in each of a plurality of production facilities;
On the condition that an abnormality or a possibility of abnormality is detected by the abnormality detection means, in a region where a plurality of management personnel who respectively manage the plurality of production facilities are resident, the fact that an abnormality or a possibility of abnormality has occurred and An abnormality notification means for notifying a plurality of the management personnel of an abnormality or a possibility of abnormality of the production facility with an alarm including information capable of specifying the abnormality or the possibility of abnormality of the production facility;
An alarm stop input accepting means for accepting an input of the manager for stopping an alarm that is provided on the machine side of each of the plurality of production facilities and is informed by the abnormality notifying means for the production equipment;
An alarm that is informed by the abnormality notifying means about the production equipment corresponding to the alarm stop input receiving means that has received the input, provided that an input for stopping the alarm is accepted by the alarm stop input accepting means. A production management system comprising alarm stop means for stopping the operation.   The abnormality notifying means is a display device that schematically displays the shape and arrangement of the production equipment, and that the display corresponding to the production equipment in which the abnormality or abnormality has occurred has occurred. The production management system according to claim 1, wherein an abnormality or a risk of abnormality is notified by displaying in a mode shown.   The display corresponding to the production facility corresponding to the alarm stop input accepting unit that has accepted the input may be abnormal or abnormal, provided that an input for stopping the alarm is accepted by the alarm stop input accepting unit. The production management system according to claim 2, further comprising an abnormality handling informing means for notifying that an abnormality is being handled by displaying in a mode indicating that the system is responding to.   The production management system according to any one of claims 1 to 3, wherein the abnormality notification means notifies the abnormality or the possibility of abnormality with sound of a sound quality corresponding to the content of the abnormality or the possibility of abnormality.   The abnormality notifying means notifies the abnormality or the possibility of abnormality by printing the abnormality countermeasure entry sheet for filling in the countermeasure against the abnormality including information that can identify the production facility where the abnormality or the possibility of abnormality has occurred, The production management system according to any one of claims 1 to 4. Further comprising body temperature measuring means for measuring the body temperature of production personnel of the production facility,
6. The abnormality detection unit according to any one of claims 1 to 5, wherein the abnormality detection unit detects a possibility of abnormality on the condition that the body temperature measured by the body temperature measurement unit is in a predetermined abnormality range. production management system. Provided on the machine side of each of the plurality of production facilities, further comprising an abnormality occurrence input receiving means for accepting an input of a production person of the production facility that an abnormality or a risk of abnormality has occurred in the production facility,
The abnormality detection unit detects an abnormality and a possibility of abnormality, respectively, on condition that the abnormality occurrence input reception unit receives an input indicating that an abnormality and a possibility of abnormality have occurred. The production management system according to any one of 5 to 5. A work pace detecting means for detecting a work pace of a production person in the production facility;
6. The abnormality detection unit according to claim 1, wherein the abnormality detection unit detects a possibility of abnormality on the condition that the work pace detected by the work pace detection unit is within a preset abnormality range. The production management system described. An inspection means for inspecting a product produced in the production facility;
6. The production management system according to claim 1, wherein the abnormality detection unit detects an abnormality on the condition that the inspection unit inspects that the product is defective. Personnel characteristic specifying means for specifying characteristics of production personnel of the production facility;
The work environment changing means for changing the production facility to a work environment corresponding to the characteristic specified by the personnel characteristic specifying means of the production personnel of the production equipment. The production management system described in. The personnel characteristic specifying means specifies the work level of the production personnel as the characteristics of the production personnel,
The work environment changing means changes the notification method of work contents for the production personnel in the production equipment according to the work level specified by the personnel characteristic specifying means, thereby changing the production equipment to the production personnel. The production management system according to claim 10, wherein the production environment is changed to a work environment according to characteristics. The personnel characteristic identification means identifies the physical characteristics of the production personnel as the characteristics of the production personnel,
The work environment changing means changes the shape of the production equipment according to the physical characteristics specified by the personnel characteristic specifying means, thereby changing the production equipment to a work environment according to the characteristics of the production personnel. The production management system according to claim 10 to be changed. The personnel characteristic specifying means specifies the height and dominant arm of the production person as a physical characteristic of the production person,
The work environment changing means changes the height of the work table as the shape of the production facility according to the height specified by the personnel characteristic specifying means, and according to the dominant arm specified by the personnel characteristic specifying means The production management system according to claim 12, wherein the production facility is changed to a work environment in accordance with characteristics of the production personnel by changing an installation position of a tool as a shape of the production facility. Detecting an abnormality or a risk of abnormality in each of a plurality of production facilities;
On the condition that an abnormality or a possibility of abnormality is detected, the fact that an abnormality or a possibility of abnormality has occurred and that there is a possibility of an abnormality or an abnormality in an area where a plurality of management personnel managing each of the plurality of production facilities is resident A warning including information that can identify the production facility where the occurrence occurred, and notifying a plurality of the management personnel of an abnormality or a possibility of abnormality of the production facility;
A step of accepting the input of the manager for stopping an alarm that has been informed about the production facility in an alarm stop input receiving device provided on the machine side of each of the plurality of production facilities;
And a step of stopping an alarm that has been informed about a production facility corresponding to the alarm stop input receiving device that has received the input, on condition that an input for stopping the alarm has been received.

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