JP2008262391A - Work instruction optimization support system and method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To ensure efficient utilization of a production line by conveying to a person in charge selectable work instruction candidate information depending on the quality status of a work-in-process product. <P>SOLUTION: A work instruction optimization support system, as a work instruction management system for providing a work instruction for each production process to a computer terminal connected to a network in a production line, includes: a means for acquiring defect information detected by an inspection device; a means for referencing a database based on the acquired defect information and retrieving line information selectable as a subsequent process from the database; a means for transmitting the retrieved information to a terminal in charge of work instruction through the network; and a means for transmitting a content of instruction determined by a person in charge of work instruction to a terminal in charge of an applicable process. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to a technique for exchanging various information related to production between computer terminals connected to the network in a production line management system constructed on a network.

  In recent years, in order to manage various types of information generated on the production line at the production site, an information system called a manufacturing execution system (MES) has been introduced and used for production performance management, quality management, operation management, etc. (For example, see Patent Document 1 or 2). As computerization progresses, the functions of manufacturing execution systems become more widespread.

As one of basic functions of the manufacturing execution system, there is a work instruction function to the manufacturing line. The work instruction function is mainly a function for transmitting to the person in charge of each production line when and which product should be manufactured. In particular, it can be said that this is an indispensable function for a production line having a plurality of machines of the same production process in order to use each line efficiently.
JP-A-10-301472 JP 2002-304210 A

  However, the work instruction function in the conventional manufacturing execution system may not be effective for a product whose manufacturing process is not stable.

  For example, even if the same type of material and the same manufacturing conditions are used, different types of defects may occur. This is often the case with new products at a stage where stable manufacturing conditions have not been determined, but it is difficult to make an effective production plan because it is not possible to know how much quantity can be passed to the next process unless it is actually manufactured.

  Also, depending on the content of the defect that occurs, it can be diverted to other varieties, or even if the same varieties are used, depending on where the defect occurs, it can be diverted to a smaller size product for effective use of materials. May be possible. Such measures not only lead to cost reduction, but also can prevent the influence on the production plan caused by the occurrence of defects, and are therefore very effective means when the manufacturing conditions are not stable.

  However, when the person in charge of the work instruction to the production line confirms which line can be used as a semi-finished product, the manufacturing conditions and defect information for all products, all processes, and the next process It is necessary to grasp the quality standards that can be passed, and there is a risk that defects will be caused by management mistakes and that the delivery date specified by the customer will not be in time.

  In view of such background art, the present invention has an object to transmit selectable work instruction candidate information according to the quality status of a semi-finished product being produced to a person in charge so that the production line can be used efficiently. To do.

  The present invention solves such a problem, and the invention of claim 1 is a work instruction management system for giving a work instruction to each manufacturing process to a computer terminal connected to a network in a production line, Means for obtaining defect information detected by the inspection apparatus, means for referring to the line information that can be selected as the next process based on the obtained defect information, taking out the information, and instructing the extracted information through the network Is a work instruction optimization support system comprising: means for transmitting to the terminal in charge of the process; and means for transmitting the instruction content determined by the person in charge of the work instruction to the terminal in charge of the process.

  In the work instruction optimization support system according to the first aspect of the invention, when issuing the work instruction to the next process, the semi-finished product name of the corresponding lot and the defect information output from the inspection apparatus are acquired. The acquired information is checked against quality standard information in a database registered in advance by a person in charge, and a choice that can be taken as the next process is obtained by comparison with the registered information. By transmitting the acquired process information that can be selected as the next process to the work instruction person in charge terminal, the person in charge of the work instruction can collaborate with the production plan created by himself and can make an optimum work instruction.

  In the invention of claim 2 of the present invention, means for issuing a work instruction to each process, means for setting and holding setting conditions for extracting selectable processes, and a process to be the next process are determined. The work instruction optimization support system according to claim 1, further comprising means for enabling the updated work instruction immediately after that.

  In the work instruction optimization support system according to the second aspect of the present invention, it immediately responds to a quality standard change request by a person in charge.

  According to a third aspect of the present invention, the work line optimization support system according to the first or second aspect, wherein the production line handles a roll of a long web-shaped product. It is.

  Further, the invention of claim 4 of the present invention is a work instruction management method for giving a work instruction for each manufacturing process to a computer terminal connected to a network in a production line, wherein defect information detected by an inspection device is detected. A step of acquiring, referring to the line information selectable as the next process from the database based on the obtained defect information, a step of extracting the information, and a step of transmitting the extracted information to a terminal in charge of a work instruction through the network And a step of transmitting the instruction content determined by the person in charge of the work instruction to a terminal in charge of the corresponding process.

  In the work instruction optimization support method according to the fourth aspect of the invention, when issuing a work instruction to the next process, the following procedure is performed. First, the semi-finished product name of the corresponding lot and the defect information output from the inspection device are acquired. The acquired information is collated with information in the database registered in advance by the quality control person in charge, and indicates to the person in charge a work instruction for a process that can be selected as the next process by comparison with the registered information. After the work instruction person finally determines the process for handling the corresponding lot, the work instruction information is displayed on the terminal of the process in charge.

  The invention according to claim 5 of the present invention is the work instruction optimization support method according to claim 4, wherein the production line handles a roll of a long web-like product. .

  Since the present invention is configured as described above, the following effects can be obtained by the present invention.

  According to the first aspect of the present invention, it is possible to provide a work instruction optimization support system that can transmit selectable work instruction candidate information according to the quality status of the semi-finished product being produced to the person in charge and can efficiently use the production line .

  Moreover, according to the invention of claim 2, flexible operation according to the change of quality standards and manufacturing conditions is enabled.

  Moreover, according to the invention of Claim 3, the effect of the invention of Claim 1 or 2 is acquired in the production line which handles what wound the elongate web-shaped product in roll shape.

  According to the invention of claim 4, there is provided a work instruction optimization support method that can transmit selectable work instruction candidate information according to the quality status of the semi-finished product being produced to the person in charge, and can efficiently use the production line. Can be provided.

  According to the invention of claim 5, the effect of the invention of claim 4 can be obtained in a production line that handles a product obtained by winding a long web-like product into a roll.

  The best mode for carrying out the present invention will be described below with reference to the drawings.

  This embodiment relates to a system for managing various data generated by machines and workers in a production line in a factory for manufacturing a new product. This new product is a roll body, and the roll body generally refers to a form in which a long web-like base material or product is wound into a roll shape.

  FIG. 1 is a block diagram showing a manufacturing process of a new product in the present embodiment. The first step A10 is a general-purpose process, and the semi-finished product manufactured by the step A10 becomes the type AB15 by the step B11, becomes the type AC16 by the step C12, and becomes the type ADE17 by the steps D13 and E14. In the process A10 which is the first process in all varieties, an inspection device is attached and quality control based on the inspection conditions is executed. However, it may be a new product and the manufacturing conditions are stable. Absent.

  Although there are several types of defects detected in the process A10, even if the product AB15 having the strictest quality standards is a semi-finished product that cannot be passed to the next process B11, the product AC16 having a relatively low quality standard or If the product is ADE17, the standard may be satisfied.

  However, in all quality standards, the type AB15 does not have a higher quality standard than the other types, and the reverse may occur for a specific defect. In addition, when a new product tends to be in a small lot / multiple product category, the load on the person in charge managing the quality standard for each product type is high, and there is also a risk that a large amount of manufacturing costs may be generated due to an incorrect instruction. Therefore, a mechanism is required to provide work instructions appropriate for the next process by managing quality standards.

  FIG. 2 is a block diagram showing the overall configuration of the work instruction optimization support system in the present embodiment. In the present embodiment, the work instruction optimization support system includes at least one work instruction management server 20, a plurality of process terminals 30 (30A, 30B, 30C, 30D), an inspection apparatus 40 in the process A10, A work instruction terminal 50 is provided. The work instruction management server 20, the process charge terminal 30, the inspection device 40, and the work instruction terminal 50 are connected to the in-factory network 60, respectively, so that two-way information communication can be performed via the in-factory network 60. Yes.

  The work instruction management server 20 has a database function of storing and managing a work instruction database 21, an inspection apparatus defect information database 22, and a quality standard database 23 for each product on a hard disk, etc., searching for data in response to an inquiry, and responding. Further, the defect information storage process 71 for registering the defect information received from the inspection apparatus 40 in the inspection apparatus defect information database 22 and the selectable next process from the quality standard database 23 for each type are extracted and extracted to the person in charge of the work instruction. An application program that can execute each processing routine of the next process candidate extraction process 72 that can transmit the result is installed in the work instruction management server 20.

  The work instruction database 21 stores a process name, product type, quantity, planned date and time, etc. as manufacturing instructions for each process. The worker of each process grasps the priority order of the manufacturing work based on the information in the work instruction database 21.

  In the inspection apparatus defect information database 22, as the defect information detected by the inspection apparatus 40, an occurrence process name, defect type, defect position, defect size, and the like are stored. These data are utilized as original data when extracting the next process that can be manufactured.

  As shown in the table of FIG. 3, the product quality standard database 23 stores product types, processes, acceptance targets, defect types, acceptable quality standards, etc. as quality standards for each defect type. Is done. The process for extracting the next selectable process is executed based on the conditions stored in the quality standard database 23 for each product type.

  Each process terminal 30 (30A, 30B, 30C, 30D) is an information device corresponding to a network such as a personal computer, a PDA (Personal Digital Assistant), or a mobile phone, and is operated by a worker in charge for each process.

  Each process terminal 30 (30A, 30B, 30C, 30D) is equipped with a storage device such as a hard disk as means for storing programs and data. In addition, referring to a work instruction database 21 stored in the work instruction management server 20, a work instruction display process 101 capable of displaying the contents of work instructed in its own process and transmitting it to the worker in charge, and manufacturing work After completion, an application program that can execute each processing routine of the work completion report processing 102 that reports to the work instruction management server 20 that the work has been completed is provided in the process terminal 30 (30A, 30B, 30C, 30D). Installed.

  The inspection apparatus 40 used in the process A acquires the result of processing the obtained image by photographing the characteristic information for each defect registered in advance and the work flowing on the line using a plurality of cameras. Compare with characteristics and classify into several types of defects. The inspection apparatus 40 is installed with an application program capable of executing the processing routine of the defect information output process 81, and transmits the acquired defect information to the work instruction management server 20 together with the size and the occurrence position. be able to.

  The work instruction terminal 50 is an information device corresponding to a network such as a personal computer, a PDA (Personal Digital Assistant), or a mobile phone, and is operated by a person in charge of issuing a work instruction.

  The work instruction terminal 50 is equipped with a storage device such as a hard disk as means for storing programs and data. Further, the work instruction database 21 stored in the work instruction management server 20 is referred to, the information extracted as the next process candidate is extracted, the next process determined to be optimal is determined, and the work instruction management server 20 is determined. An application program that can execute each processing routine of the next process determination process 91 that transmits the determined work instruction content is installed.

  Next, the flow of a series of processes will be described step by step.

  As shown in the flowchart of FIG. 4, first, in step A, the inspection apparatus 40 detects a defect that has occurred on the workpiece flowing through the line and captures an image as step ST11 in the defect information output process 81. Next, as step ST12, the obtained image is processed, and compared with the characteristic value of the defect type registered in advance, the defect type is specified. Finally, as step ST13, the information such as the kind and lot acquired in advance is transmitted as defect information to the work instruction management server 20, and the defect information output processing 81 is terminated.

  As shown in the flowchart of FIG. 5, the work instruction management server 20 stands by until defect information is transmitted from the inspection apparatus 40 as step ST <b> 21 in the defect information accumulation process 71. Next, when the reception of the defect information is confirmed as step ST22, the defect information storage process 71 is terminated as a result of writing into the inspection apparatus defect information database 22 as step ST23. The above processing is executed every time defect information is sent from the inspection device 40.

  When the work in the process A proceeds and the production of a certain lot is completed, the person in charge of the process A reports the work completion using the process A charge terminal 30A. As shown in the flowchart of FIG. 6, the process A charge terminal 30A acquires the type, the semi-finished product name, the lot number, the process name, and the like of the corresponding lot as step ST31 in the work completion report process. Next, in step ST32, the acquired data is transmitted to the work instruction management server 20 as work completion report information, and the process A terminal 30A ends the work management report process.

  As shown in the flowchart of FIG. 7, the work instruction management server 20 stands by until work completion report information is transmitted from the process charge terminal 30 as step ST41 in the next process candidate extraction process 72. When the work instruction management server 20 confirms the reception of the work completion report information in step ST42, the work instruction management server 20 obtains the name of the semi-finished product, the lot number, etc., from the work completion report information in step ST43. Next, as step ST44, from the quality standard database 23 for each product, the product and the determination standard information for the next process for which the semi-finished product has been received are acquired.

  The work instruction management server 20 finally enters a determination process using defect information in the next process candidate extraction process 72. First, as step ST45, the defect information registered when the corresponding semi-finished product is manufactured is acquired from the inspection apparatus defect information database 22. Next, in step ST46, the determination criterion acquired in step ST44 is compared with the manufacturing defect information acquired in step ST45. In step ST47, whether the quality of the corresponding semi-finished product lot satisfies the quality criterion of the corresponding product type. Confirm whether or not. As a result, if the standard is not satisfied, it is determined in step ST48 that the product is a semi-finished product that cannot be accepted. When there are a plurality of quality standards for one product type, it cannot be used for that product type when there is a standard that cannot satisfy one of them. In order to omit unnecessary processing, in this case, in step ST49, the unusable quality data of the unprocessed quality standards is changed to a confirmed state.

  The above processing is performed in step ST50 until the confirmation of all quality standards is completed. Finally, in step ST51, a product satisfying the quality standard is regarded as an applicable product, and work instruction information for the next process is determined as an unconfirmed work instruction. Is written in the work instruction database 21. With the above, the work instruction management server 20 ends the next process candidate extraction process.

As shown in the flowchart of FIG. 8, the work instruction terminal 50 subsequently creates a list of unconfirmed work instructions from the work instruction database 21 existing in the work instruction management server 20 as step ST61 in the next process determination process 91. indicate. In step ST62, the work instruction person in charge compares the obtained unconfirmed work instruction list with the production plan at that time and selects one unconfirmed work instruction that seems to be most effective. Finally, in step ST63, the work instruction terminal 50 updates the unconfirmed work instruction selected by the work instruction person in charge as a confirmed work instruction, and deletes the remaining unconfirmed work instructions. 91 is ended.

  Based on the determined work instruction, the process charge terminal 30 performs the following process in the work instruction display process 101.

  As shown in the flowchart of FIG. 9, first, as step ST71, information on a process in charge is acquired from a database or a local file. Next, in step ST72, the work instruction database 21 of the work instruction management server 20 is searched, and in step ST73, work instruction information corresponding to the own process is acquired. Finally, as step ST74, screen display is performed in a list format based on the priority order information that the work instruction information has, and the process terminal 30 ends the work instruction display processing 101.

  Through the above processing, even if the product has unstable manufacturing conditions, depending on the content of defect information, it can be applied as a semi-finished product of other products, not only reducing costs but also adjusting with customers. Can be an advantage.

  Therefore, the person in charge of work including the production management of the factory can carry out the production plan according to the quality.

  The present invention is not limited to the one embodiment.

  For example, in the above-described embodiment, the work instruction management server 20 executes the next process candidate extraction process 72 based on the work completion report 102 of the process charge terminal 30. Since it is reported to the work instruction management server 20 at any time by the information output processing 81, it is possible to carry out prompt risk management by confirming whether the quality standards are satisfied in advance before the lot production is completed. .

  Note that the method described in the above-described embodiment is provided as a program that can be executed by a computer, written on a magnetic disk such as a hard disk, an optical disk such as a CD-ROM, and other recording media such as a semiconductor memory and provided to various apparatuses. be able to. It can also be transmitted by communication means and provided to various devices. A computer that implements this apparatus reads the program recorded on the recording medium or receives the program through communication means, and the operation is controlled by this program, thereby executing the above-described processing.

The block diagram which shows the manufacturing process of new goods in this Embodiment. The block diagram showing the whole structure of the work instruction optimization support system in this Embodiment. The table | surface which shows the data sample which the quality standard database for every kind has stored in this Embodiment. The flowchart which shows the principal part of the defect information output process which the test | inspection apparatus performs in this Embodiment. The flowchart which shows the principal part of the defect information storage process which the work instruction management server performs in this Embodiment. The flowchart which shows the principal part of the work completion report process which a process charge terminal performs in this Embodiment. The flowchart which shows the principal part of the next process candidate extraction process which the work instruction management server performs in this Embodiment. The flowchart which shows the principal part of the next process determination process which a work instruction terminal performs in this Embodiment. The flowchart which shows the principal part of the work instruction display process which a process charge terminal performs in this Embodiment.

Explanation of symbols

10 ... Process A
11 ... Process B
12 ... Process C
13 ... Process D
14 ... Process E
15 ... Variety AB
16 ... Variety AC
17 ... Variety ADE
20 ... Work instruction management server 21 ... Work instruction database 22 ... Inspection device failure information database 23 ... Quality standard parameter database 30 for each product type (30A, 30B, 30C, 30D) ... Process charge terminal 40 ... Process A inspection device 50 ... Work instruction Terminal 60 ... Factory network 71 ... Defect information accumulation process 72 ... Next process candidate extraction process 81 ... Defect information output process 91 ... Next process decision process 101 ... Work instruction display process 102 ... Work completion report process

Claims (5)

  A work instruction management system for giving a work instruction for each manufacturing process to a computer terminal connected to a network in a production line, a means for obtaining defect information detected by an inspection device, and the obtained defect information Originally, means for referring to and selecting line information that can be selected as the next process from the database, means for transmitting the extracted information to a terminal in charge of work instructions through the network, and instruction contents determined by the person in charge of work instructions And a means for transmitting the information to a terminal in charge of the corresponding process.   A means for issuing work instructions for each process, a means for setting and maintaining setting conditions for extracting selectable processes, and a process to be the next process are determined, and an updated work instruction is immediately followed. The work instruction optimization support system according to claim 1, further comprising a valid means.   The work instruction optimization support system according to claim 1 or 2, wherein the production line handles a long web-shaped product wound in a roll shape.   A work instruction management method for giving a work instruction for each manufacturing process to a computer terminal connected to a network in a production line, the step of acquiring defect information detected by an inspection device, and the obtained defect information Originally, a step of referring to the line information that can be selected as the next process from the database and taking it out, a step of sending the taken out information to the terminal in charge of the work instruction through the network, and the instruction content determined by the person in charge of the work instruction Transmitting to a terminal in charge of the corresponding process.   5. The work instruction optimization support method according to claim 4, wherein the production line handles a long web-shaped product wound in a roll shape.

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