JP2012022401A - Defective tracking support system and defective tracking support program - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a defective tracking support system and a defective tracking support program capable of reducing a cost of recalling work by narrowing articles that may be possibly defective.SOLUTION: This defective tracking support system 1 includes: a display 20; a product DB 41 which stores product IDs uniquely identifying products, image information of the products, and sequence information for specifying a sequence when the products are produced, associating them with each other; and a control unit 30 which acquires a product ID corresponding to a product that is defective, specifies other products having a possibility of defective based on the sequence information corresponding to the acquired product ID, and displays the image information corresponding to the specified products on the display 20.

Description

  The present invention relates to a defective product tracking support system and a defective product tracking support program.

  In recent years, tracking methods have been proposed for tracking the shipping destination of a product shipped from a factory, or for identifying the history of a product that has been traced in the factory or in the distribution process after shipment. For example, if a defective product is found after the packing process and there is a possibility that a similar defect has occurred in other products, only the group of products that may have the defect is collected from the market, or There has been proposed a method of tracing a merchandise shipment destination in order to avoid being shipped.

  In this method, the loading start date / time information and the loading end date / time information for each pallet are acquired, the shipping results for each pallet are acquired, and the acquired loading start date / time information, the loading end date information, and the shipping results are obtained. The database is generated by linking and storing the corresponding pallet identification information. Then, the product is loaded by searching the database using the given pallet loading date as a search key or the pallet loading date calculated in consideration of a known delay time from the given manufacturing date as a search key. The shipping destination to which the pallet or the product that has been shipped has been shipped is extracted (for example, see Patent Document 1).

JP 2008-056433 A

  However, in the conventional method as described above, since the date and time when the defective product was loaded on the pallet was used as a search key, the pallet on which the defective product was loaded and the shipping destination were narrowed down, so that a defect may have occurred The minimum range for narrowing down the products that have characteristics was limited to pallet units. Therefore, for example, even when a defect has occurred in only some of the products loaded on the pallet, the presence or absence of the defect is specified unless all the products loaded on the pallet are unpacked. This could increase the cost of collecting defective products. In addition, there is a possibility that defective products will spread further in the market due to delays in collection work.

  The present invention has been made in view of the above, and it is possible to narrow down the products that may have a defect and reduce the collection work cost of the defective product. The purpose is to provide a non-defective tracking support program.

  In order to solve the above-described problems and achieve the object, the defective product tracking support system according to claim 1 includes a display unit, product identification information for uniquely identifying a product, image information of the product, Product information storage means for storing the product information and the order information for specifying the order in which the products are manufactured, and the product identification information corresponding to the product in which the defect has occurred is acquired, and the acquired product identification Control means for identifying another product that may have failed based on the order information corresponding to the information and displaying the image information corresponding to the identified product on the display means.

  Further, the defective product tracking support system according to claim 2 is the defective product tracking support system according to claim 1, wherein the product information storage means specifies whether or not a sampling inspection has been performed on the product. Information is stored, and the control means manufactures the product in which the defect occurs based on the order information corresponding to the product subjected to the sampling inspection and the order information corresponding to the product in which the defect has occurred. The product manufactured after the last sampling inspection before being performed and manufactured before the first sampling inspection after the product in which the defect has occurred is Identify as other said products that may have occurred.

  Also, the defective product tracking support system according to claim 3 is the defective product tracking support system according to claim 1 or 2, wherein the product information storage means uniquely identifies each product in a lower hierarchy constituting the product. The product identification information to be identified and / or the product identification information to uniquely identify a higher-level product including the product are stored, and the control unit specifies that a defect may have occurred The display unit displays the product identification information corresponding to a higher-level product including the other products.

  Further, the defective product tracking support system according to claim 4 is the defective product tracking support system according to claim 3, wherein the control means includes a product in a higher hierarchy including the product in which the defect has occurred. The corresponding product identification information is acquired, and based on the order information corresponding to the acquired product identification information, another product in the upper hierarchy that may include a defective product is identified, and the identified The display unit displays the image information corresponding to the higher-level product.

  Further, the defective product tracking support system according to claim 5 is the defective product tracking support system according to claim 4, wherein the product information storage means is included in the upper layer product from outside the upper layer product. Visual information for specifying whether or not the product can be visually recognized is stored, and the control means can visually recognize the product included in the higher-level product from the outside of the higher-level product based on the visual information. In this case, the display unit displays the image information corresponding to the identified higher-level product.

  In addition, the defective product tracking support system according to claim 6 is the defective product tracking support system according to any one of claims 1 to 5, wherein the product identification information and the packing material in which the product is packed are uniquely identified. A packaging material information storage means for storing the packaging material identification information for identifying and the location information for specifying the history of the storage location of the packaging material and the history of the storage period in association with each other, and the control means is defective The said packaging material identification information corresponding to the packaging material which packed the said product which generate | occur | produced is acquired, Based on the said location information corresponding to the acquired said packaging material identification information, the other said product with which the defect may have generate | occur | produced The packing material in which the packing material is packed is specified, and the packing material identification information corresponding to the specified packing material is displayed on the display means.

  In addition, the defective product tracking support program according to claim 7, the computer product identification information for uniquely identifying a product, image information of the product, and order information for specifying the order in which the product is manufactured. And storing the product information in the storage means in association with each other, acquiring the product identification information corresponding to the product in which a defect has occurred, and based on the order information corresponding to the acquired product identification information, A control step of identifying another product that may have a defect and causing the display unit to display the image information corresponding to the identified product.

  According to the defective product tracking support system according to claim 1 and the defective product tracking support program according to claim 7, product identification information corresponding to a product in which a defect has occurred is acquired, and the acquired product identification information is included in the acquired product identification information. Based on the corresponding order information, other products that may have failed are identified, and image information corresponding to the identified products is displayed on the display means. Therefore, based on the order in which the products are manufactured, It is possible to narrow down the range of products that may have occurred, check the occurrence of defects without unpacking packing materials, and reduce the cost of collecting defective products .

  In addition, according to the defective product tracking support system according to claim 2, a product that has been manufactured after the last sampling inspection that has been performed before the product in which the defect has occurred and that has the defect has occurred. Since the product manufactured before the first sampling inspection after manufacturing is identified as another product that may have failed, for example, the sampling inspection is performed before the next sampling inspection. In the event that a defect occurs due to a temporary failure in the production line, the range of products that may have the defect can be narrowed down to the minimum necessary and the collection of defective products The work cost can be reduced.

  In addition, according to the defective product tracking support system according to claim 3, the product identification information corresponding to the higher-level product configured to include other products identified as having the possibility of occurrence of the defect is displayed. Therefore, it is possible to easily grasp the products in the upper hierarchy including the product in which the defect has occurred.

  In addition, according to the defective product tracking support system according to claim 4, product identification information corresponding to a higher-layer product including a product in which a defect has occurred is acquired, and the acquired product identification information is supported. Based on the order information to be identified, other products in the upper hierarchy that may contain the defective product are identified, and the image information corresponding to the identified upper hierarchy product is displayed on the display means. The presence or absence of defects can be confirmed based on the image information along the process. Therefore, for example, in the manufacturing process of a higher-level product, even when a defect occurs in a part constituting the product, it is possible to confirm whether or not the defect has occurred without unpacking the packing material.

  Further, according to the defective product tracking support system according to claim 5, when the product included in the higher-level product is visible from the outside of the higher-level product based on the visual recognition information, Since the image information corresponding to the product is displayed on the display means, the image information can be displayed on the display means only when the operator can confirm the presence or absence of defects based on the image information displayed on the display means.

  In addition, according to the defective product tracking support system according to claim 6, the packaging material identification information corresponding to the packaging material in which the defective product is packed is acquired, and the location information corresponding to the acquired packaging material identification information Based on the location of the packaging material, and the packaging material identification information corresponding to the identified packaging material is displayed on the display means. The range of products that may be defective can be narrowed down, and the cost of collecting defective products can be reduced.

It is the schematic which showed the flow to the process and assembly of parts in a factory, assembly of a finished product, packing, and shipment. It is the block diagram which showed the electrical structure of the defect tracking support system functionally conceptually. It is the table | surface which illustrated the information stored in product DB. It is the table | surface which illustrated the information stored in packing material DB. It is a flowchart of a defective article tracking support process. 6 is a flowchart of defective product tracking support processing following FIG. 5. It is a flowchart of a location tracking process. It is the schematic which illustrated the information displayed on a display in inferior goods tracking assistance processing. It is the schematic which illustrated the information displayed on a display in inferior goods tracking assistance processing. 6 is a table illustrating information stored in a product DB according to the second embodiment. 6 is a flowchart of defective product tracking support processing according to the second embodiment. 12 is a flowchart of defective product tracking support processing following FIG. 11.

  Embodiments of a defective product tracking support system and a defective product tracking support program according to the present invention will be described below in detail with reference to the accompanying drawings. However, the present invention is not limited by these embodiments.

[Embodiment 1]
First, the first embodiment will be described. In the first embodiment, another product that may have a defect is identified, and image information corresponding to the identified product is displayed on the display unit.

(From product manufacture to shipment)
First, the flow from product manufacture to shipment will be described. FIG. 1 is a schematic diagram showing the flow of processing and assembly of parts, assembly of finished products, packing, and shipment in a factory. Here, the “part” indicates a part constituting a higher level part or a finished product (“a-1”, “a-11”, “b-1”, etc. in FIG. 1). The “completed product” indicates a product completed by assembling parts (“A”, “B”, and “C” in FIG. 1). Further, parts and finished products are collectively referred to as “products” as necessary. The “packing material” is used for packing a finished product, and for example, a known packing material such as a cardboard box, a wooden box, a bag material, or the like is used.

  As shown in FIG. 1, for example, a part manufactured through processing and assembly in a processing / assembly line is assembled with other parts in a finished product assembly line to become a finished product. The finished product is packed using packing materials, then loaded on a pallet, stored in a warehouse, or transported to a shipping destination using a transportation means such as a truck or a railroad. These parts, finished products, and packaging materials are provided with, for example, RFID (Radio Frequency IDentification) tags, and various information is written to and / or read out from the RFID tags via a known reader / writer. It shall be possible.

  Further, in a part processing / assembly line and a finished product assembly line, in order to guarantee the quality of products, some products are extracted from all manufactured products and inspected (sampling inspection). When this inspection result is determined to be acceptable, it is assumed that a certain range of products (lots) including the product subjected to the sampling inspection have been passed.

  In this way, a defect may occur between the time when the product is manufactured and unpacked at the shipping destination. Here, the term “defective” includes various defects such as defects that are visible from the outside such as product damage, and defects that are not visible from the outside such as electrical failure due to water wetting or impact. It is a concept. For example, as shown in FIG. 1, in a part processing / assembly line, a part that has not been subjected to a sampling inspection may be damaged for some reason. In this case, if no defect is found in the sampling inspection, it is determined that the entire lot is acceptable, and a product with a scratch may be shipped. In addition, after the finished product is packed, there is a possibility that dew condensation may occur during storage in a warehouse, for example, or damage may occur due to vibration during transportation.

(Constitution)
Next, the configuration of the defective product tracking support system will be described. FIG. 2 is a block diagram functionally conceptually showing the electrical configuration of the defective product tracking support system. As shown in FIG. 2, the defective product tracking support system 1 includes an input / output interface 10 (hereinafter, input / output IF 10), a display 20, a control unit 30, and a storage unit 40. The defective product tracking support system 1 is connected to a reader / writer 3 through a network 2 such as the Internet, a LAN (Local Area Network), and a WAN (Wide Area Network).

(Configuration-I / O IF)
The input / output IF 10 is an interface for performing communication with the reader / writer 3 and the input / output terminal via the network 2. For example, communication is performed according to a predetermined communication standard (for example, Ethernet (registered trademark)). Configured as a network board.

(Configuration-Display)
The display 20 is a display unit that displays various types of information according to the control of the control unit 30. As this display 20, for example, a display such as a known liquid crystal display or organic EL display can be used.

(Configuration-control unit)
The control unit 30 is a control unit that controls each unit of the defective product tracking support system 1. Specifically, the control unit 30 includes a CPU, various programs that are interpreted and executed on the CPU (including a basic control program such as an OS and an application program that is activated on the OS and realizes a specific function), and The computer includes an internal memory such as a RAM for storing programs and various data. In particular, the defective product tracking support program according to the first embodiment is installed in the defective product tracking support system 1 via an arbitrary storage medium or network, thereby substantially configuring each function of the control unit 30. .

(Configuration-storage unit)
The storage unit 40 is a recording unit that records a program and various data necessary for the operation of the defective product tracking support system 1, and is configured using, for example, a hard disk (not shown) as an external storage device. However, any other recording medium including a magnetic recording medium such as a magnetic disk or an optical recording medium such as a DVD or a Blu-ray disk can be used instead of or together with the hard disk.

  The storage unit 40 includes a product database 41 (hereinafter, the database is abbreviated as DB) and a packaging material DB 42.

  The product DB 41 is product information storage means for storing product identification information for uniquely identifying a product, product image information, and order information for specifying the order in which the products are manufactured in association with each other. FIG. 3 is a table illustrating information stored in the product DB 41. As shown in FIG. 3, information corresponding to items “product ID”, “image”, “line number”, “order number”, “inspection target”, “upper layer”, and “lower layer” is associated with each other in the product DB 41. Stored. Information stored corresponding to the item “product ID” is product identification information for uniquely identifying a product (for example, “a-1” in FIG. 3). This product identification information is given for each product at the time of manufacture of the product, for example, is written to the RFID tag attached to each product via the reader / writer 3 and is stored in the product DB 41. The information stored corresponding to the item “image” is product image information (for example, “a-1.jpg” in FIG. 3). This image information is acquired by, for example, photographing each product that has been processed or assembled using a camera installed in each production line, and is stored in the product DB 41 together with product identification information. The information stored corresponding to the item “line number” is line identification information for uniquely identifying the line on which the product is manufactured (for example, “41” in FIG. 3). This line identification information is stored in the product DB 41 together with the product identification information when the product is manufactured, for example. The information stored corresponding to the item “order number” is order information for specifying the order in which the products are manufactured (for example, “1325” in FIG. 3). This sequence information is given for each product according to the product production sequence on the production line, for example, at the time of manufacture of the product, and is written to the RFID tag attached to each product via the reader / writer 3 and is combined with the product identification information. Stored in the product DB 41. In the following description, it is assumed that the larger the order number is, the later the product is manufactured. The information stored corresponding to the item “inspection object” is inspection information for specifying whether or not a sampling inspection has been performed on the product (in FIG. 3, “1” for the sampling inspection has been performed. “0” for those that were not tested). For example, “0” is stored in the product DB 41 as an initial value of the inspection information. And about the product which carried out the sampling inspection, the product identification information of the said product is acquired from the RFID tag via the reader / writer 3 at the time of the inspection, and “1” is set as the inspection information corresponding to the acquired product identification information. Overwrite. The information stored corresponding to the item “upper layer” is product identification information for uniquely identifying the upper layer product including the product (in FIG. 3, for example, the product ID “a-1”). "A" etc. as a higher-level product). The product identification information stored corresponding to this item “upper layer” is stored in the product DB 41 when, for example, a product of the upper layer is manufactured. The information stored corresponding to the item “lower hierarchy” is product identification information that uniquely identifies each product in the lower hierarchy constituting the product (in FIG. 3, for example, the lower hierarchy of the product ID “a-1”) "A-11, a-12" etc.). The product identification information stored corresponding to this item “lower layer” is acquired from the RFID tag of each product in the lower layer via the reader / writer 3 and stored in the product DB 41, for example, when the product is manufactured.

  The packaging material DB 42 correlates the product identification information, the packaging material identification information that uniquely identifies the packaging material in which the product is packed, and the location information that specifies the history of the storage location and the storage period of the packaging material. Packing material information storage means for storing. FIG. 4 is a table illustrating information stored in the packaging material DB 42. As illustrated in FIG. 4, information corresponding to items “product ID”, “packaging material ID”, and “location” is stored in the packing material DB 42 in association with each other. The information stored corresponding to the item “product ID” is the same product identification information as the item “product ID” of the product DB 41 (for example, “A” in FIG. 4). For example, when packing a finished product, the product identification information is acquired from the RFID tag of the finished product via the reader / writer 3 and stored in the packing material DB 42. The information stored corresponding to the item “packing material ID” is packing material identification information for uniquely identifying the packing material in which the product is packed (for example, “K-01” in FIG. 4). The packaging material identification information is acquired from the RFID tag attached to the packaging material in advance via the reader / writer 3 when packaging the finished product, for example, and stored in the packaging material DB 42 together with the product identification information. The information stored corresponding to the item “location” is location information that specifies the history of the storage location of the packing material and the history of the storage period. For example, as shown in FIG. 4, storage location information for specifying the storage location is stored corresponding to the small item “storage location” (for example, “pallet A” in FIG. 4) and the small item “storage period”. Corresponding to the storage period, storage period information for specifying a storage period in each storage location is stored (for example, “2010/02/01 to 2010/02/05” in FIG. 4). This location information is written into the RFID tag of the packing material via the reader / writer 3 and stored in the packing material DB 42 at the timing when the packing material packing the product enters and exits each storage location, for example.

(Processing-Support for tracking defective products)
Next, processing performed in the defective product tracking support system 1 configured as described above will be described. FIG. 5 is a flowchart of defective product tracking support processing, and FIG. 6 is a flowchart of defective product tracking support processing following FIG. 8 and 9 are schematic diagrams illustrating information displayed on the display 20 in the defective product tracking support process. In this defective product tracking support process, for example, when the presence of a defective product is confirmed based on a complaint from the shipping destination, the operator gives an instruction to execute the defective product tracking support process via an operation unit (not shown). As a result, the defective product tracking support process is started.

  When the defective product tracking support process is activated by the operator's operation, the control unit 30 acquires the product ID of the finished product in which the defect is confirmed (SA1). For example, as shown in FIG. 8A, the product ID of the finished product in which the defect is confirmed is acquired from the RFID tag of the finished product via the reader / writer 3.

  Returning to FIG. 5, the control unit 30 causes the display 20 to display a tree diagram of the parts constituting the finished product in which the defect is confirmed (SA2). For example, when the product ID is stored in association with the product ID acquired in SA1 in the item “lower hierarchy” of the product DB 41, the control unit 30 acquires the product ID. Similarly, when the product ID of a part in a lower hierarchy constituting the product identified by the acquired product ID is stored, the product ID is acquired. In this way, by sequentially obtaining the product IDs of the lower-layer parts, the tree structure of the products is specified and displayed on the display 20 as a tree diagram as shown in FIG. 8B.

  Returning to FIG. 5, the control unit 30 waits until a defective part is selected from the tree diagram displayed on the display 20 via the operation means (SA3, No), and the defective part is When selected (SA3, Yes), the order information of the part is acquired from the product DB 41 (SA4). For example, as shown in FIG. 8A, a failure has occurred in the component “a-2” of the finished product “A”, and the component “a-2” is defective as shown in FIG. 8B. 3 is selected through the operation means, the control unit 30 acquires the line number “42” and the sequence number “5576” of the component “a-2” from the product DB 41 of FIG.

  Returning to FIG. 5, based on the order information acquired in SA4, the control unit 30 determines the product ID of the part that has been subjected to a sampling inspection last before the defective part is manufactured, and the product in which the defect has occurred. The product ID of the part that was first subjected to the sampling inspection after being manufactured is acquired (SA5). That is, the control unit 30 has the same line number as the line number acquired in SA4 among the parts having the inspection information “1” stored corresponding to the item “inspection object” in the product DB 41 of FIG. In addition, the product ID of the component having the largest sequence number less than the sequence number acquired in SA4 is acquired as the product ID of the component that was finally subjected to the sampling inspection before the defective component was manufactured. . Further, among the parts whose inspection information stored in the product DB 41 of FIG. 3 corresponding to the item “inspection object” is “1”, the part has the same line number as the line number acquired in SA4, and SA4 The product ID of the component having the smallest sequence number larger than the sequence number acquired in step S1 is acquired as the product ID of the component that was first subjected to the sampling inspection after the product in which the defect occurred.

  Subsequently, the control unit 30 acquires product IDs of other parts that may have failed (SA6). For example, the control unit 30 is manufactured after the sampling inspection that was performed last before the defective part is manufactured, and the sampling inspection that was first performed after the defective part was manufactured. A part manufactured before is identified as another part that may have failed. That is, based on the product ID acquired in SA5, a product having a defect that is larger than the sequence number corresponding to the product ID of the component that was last subjected to the sampling inspection before the defective component is manufactured is manufactured. After that, the product ID of the part having the order number smaller than the order number corresponding to the product ID of the part first subjected to the sampling inspection is acquired as the product ID of another part that may have failed.

  Subsequently, the control unit 30 acquires image information of a component in which a failure has occurred and other components in which a failure may have occurred (SA7). That is, the control unit 30 acquires image information associated with the product ID acquired in SA6 from the product DB 41.

  Furthermore, the control unit 30 acquires a product ID of a finished product that includes other parts that may have failed (SA8). For example, the control unit 30 acquires the product ID of the higher-level product associated with the product ID acquired in SA6, and acquires the product ID of the finished product by sequentially acquiring the higher-level product ID. .

  Subsequently, the control unit 30 acquires the packing material ID and the current storage location information of the packing material in which the finished product including the other parts that may have failed is packed (SA9). For example, the control unit 30 acquires the packing material ID and the current storage location information associated with the product ID of the finished product acquired in SA8 from the packing material DB 42.

  And the control part 30 displays the information acquired by each process of said SA6 to SA9 on the display 20 (SA10). For example, as shown in FIG. 8C, the control unit 30 obtains the product ID of each finished product acquired in SA8, the image information of each part acquired in SA7, the product ID of each part acquired in SA6, and SA9. The acquired packing material ID and the current storage location information are displayed on the display 20.

  Returning to FIG. 5, whether or not the control unit 30 has been able to confirm that a defect has actually occurred in another component that may have failed based on the image information displayed on the display 20 in SA10. Is determined (SA11). For example, when the defect generated in the part is a scratch, the operator who has confirmed the image information displayed on the display 20 may cause another defect as shown in FIG. When it is found that a part is also attached and an input to that effect is made via the operation means, the control unit 30 determines that it has been confirmed that a defect has actually occurred in another part. On the other hand, as shown in FIG. 9C, for example, any part displayed on the display 20 as another part that may have a defect is not damaged, and the operator does not damage the other part. When the input indicating that the presence or absence of scratches cannot be confirmed from the image information is made via the operation means, or because there is a scratch at a position where photographing is not possible, the presence or absence of scratches on other parts cannot be confirmed from the image information When the input is performed via the operation unit, the control unit 30 determines that it cannot be confirmed that another component actually has a defect. Or you may make it determine whether the same defect as the produced | generated defect has generate | occur | produced also in other components by analyzing image information using a well-known image analysis method.

  Returning to FIG. 6, as a result of the determination at SA11, based on the image information displayed on the display 20 at SA10, it is confirmed that a defect has actually occurred in another component that may have failed. When the unit 30 determines (SA11, Yes), that is, for example, an input to the effect that an image indicating that another part has the same damage as that of the defective part has been found through the operation means If the control unit 30 determines that the same defect as the generated defect has occurred in other parts, the control unit 30 determines that the image information is analyzed using a known image analysis method. The system waits until a product collection instruction is issued via the operation means (SA12, No). At this time, the worker, for example, based on the image information displayed on the display 20 as shown in FIG. 8C, the finished products “B” and “C” including the parts with the same scratches as the defective parts. Can be instructed via the operating means. In this case, the control unit 30 determines that an instruction to collect the finished products “B” and “C” has been issued.

  Returning to FIG. 6, when a product collection instruction is given via the operation means (SA12, Yes), the control unit 30 outputs a collection instruction (SA13), and ends the defective product tracking support process. For example, the control unit 30 identifies a terminal device (not shown) installed in the current storage location of the packaging material in which the finished product that is the target of the collection instruction is packed, and connects the terminal device to the terminal device via the network 2. A collection instruction is output. Note that the address information of the terminal device and the storage location information are associated with each other and stored in the storage unit 40, so that the control unit 30 allows the current state of the packaging material in which the finished product targeted for the collection instruction is packed. Based on the storage location information corresponding to the storage location, the terminal device installed in the storage location can be identified.

  On the other hand, when it is determined in SA11 of FIG. 5 that it is not possible to confirm that a defect has actually occurred in another component that may have failed based on the image information displayed on the display 20 in SA10 ( SA11, No), that is, for example, when an input indicating that it is impossible to find and confirm from the image information that the same flaw as the flaw of the defective part is attached to other parts is performed, When there is a flaw at a position where the image cannot be taken, the input to the effect that the presence or absence of flaws in other parts cannot be confirmed from the image information, or the image information is obtained using a known image analysis technique. If the control unit 30 determines that the same defect as the generated defect has not occurred in any of the other components, the control unit 30 executes a location tracking process (SA14).

(Processing-Location tracking process)
Here, the location tracking process will be described. This location tracking process is a process for identifying the packaging material that has packed other products that may have failed, based on the storage location and storage period history of the packaging material that has packed the defective product. is there. FIG. 7 is a flowchart of the location tracking process.

  When the location tracking process is activated, the control unit 30 acquires the packing material ID of the packing material in which the finished product including the defective part is packed (SB1). That is, the control unit 30 acquires the packaging material ID associated with the product ID of the finished product acquired in SA1 of FIG.

  Returning to FIG. 7, the control unit 30 acquires the location information corresponding to the packaging material ID acquired in SB1 and displays it on the display 20 (SB2). For example, when the product ID “A” of the finished product is acquired in SA1, and “K-01” is acquired as the packing material ID associated with the product ID “A” in SB1, the packing material DB 42 in FIG. According to this, the storage location “pallet A” and its storage period “2010/02/01 to 2010/02/05” as the location information, the storage location “warehouse X” and its storage period “2010/02/06 to 2010/03” / 15 ", storage location" transportation vehicle Y "and its storage period" 2010/03/16 to 2010/03/16 ", storage location" customer Q "and its storage period" 2010/03/17-" 9D is displayed on the display 20 as shown in FIG.

  Returning to FIG. 7, the control unit 30 stands by until an instruction for the location to be tracked is given via the operation means (SB3, No). For example, when it is considered that the failure occurred in the “pallet A” while the packing material “K-01” packed with the finished product “A” is loaded on the “pallet A”. In the location information displayed on the display 20 as shown in FIG. 9D, the worker tracks the storage location “pallet A” and the storage period “2010/02/01 to 2010/02/05”. Can be selected as a location.

  Returning to FIG. 7, when the location of the tracking target is instructed via the operation unit (SB3, Yes), the control unit 30 packs the packing material in which other products that may have failed are packed. As the material ID, the packing material ID corresponding to the storage location and storage period designated as the tracking target is acquired (SB4). That is, when the storage location “pallet A” and the storage period “2010/02/01 to 2010/02/05” are selected as the tracking target location, the control unit 30 refers to the packing material DB 42 and stores it. The packing material ID of the packing material loaded on the storage location “pallet A” during the period “2010/02/01 to 2010/02/05” is acquired.

  Subsequently, the control unit 30 displays the packaging material ID acquired in SB4 on the display 20 (SB5). For example, in SB4, “K-02” and “K-03” are used as the packing material IDs of the packing materials loaded on the storage place “pallet A” during the storage period “2010/02/01 to 2010/02/05”. When “K-04”, “K-05”, and “K-06” are acquired, these acquired packing material IDs are displayed on the display 20 as shown in FIG. After the process of SB5, the control unit 30 returns to the main routine. The operator packs the packing material ID of the packing material that packs the finished product including the part that may have the same scratch as the defective part from the packing material ID displayed on the display 20 in SB5. And a packing material recovery instruction corresponding to the selected packing material ID can be issued via the operation means. In this case, the control unit 30 determines that an instruction to collect the selected packing material (that is, the product packed in the packing material) has been given (SA12, Yes).

(effect)
As described above, according to the first embodiment, the product ID corresponding to the product in which the defect has occurred is acquired, and the other product in which the defect may have occurred may be based on the order information corresponding to the acquired product ID. Since the image information corresponding to the identified product is displayed on the display 20, it is possible to narrow down the range of products that may be defective based on the order in which the products are manufactured, The presence or absence of defects can be confirmed without unpacking the packing material, and the cost of collecting defective products can be reduced.

  In particular, it is manufactured after the last sampling inspection that was performed before the product in which the defect occurred was manufactured, and before the first sampling inspection that was performed after the product in which the defect occurred was manufactured. Because the manufactured product is identified as another product that may have failed, for example, due to a temporary failure of the manufacturing line between the sampling inspection and the next sampling inspection. When a defect occurs, the range of products that may have the defect can be narrowed to the minimum necessary, and the cost of collecting defective products can be reduced.

  In addition, since the product ID corresponding to the higher-level product configured to include other products identified as having the possibility that a defect has occurred is displayed on the display 20, the higher-level product including the product in which the failure has occurred Can be easily grasped.

  In addition, the packing material ID corresponding to the packing material in which the defective product is packed is acquired, and other products that may have failed are packed based on the location information corresponding to the acquired packing material ID. Since the packaging material is identified and the packaging material ID corresponding to the identified packaging material is displayed on the display 20, the range of products that may be defective can be narrowed down based on the location of the packaging material. In addition, the cost of collecting defective products can be reduced.

[Embodiment 2]
Next, a second embodiment will be described. In the second embodiment, another product in a higher hierarchy that may include a product in which a defect has occurred is specified. The configuration of the second embodiment is substantially the same as the configuration of the first embodiment unless otherwise specified, and the configuration substantially the same as the configuration of the first embodiment is the same as that of the first embodiment. The same reference numerals and / or names as used are attached as necessary, and the description thereof is omitted.

(Configuration-storage unit)
First, the configuration of the defective product tracking support system 1 according to the second embodiment will be described. FIG. 10 is a table illustrating information stored in the product DB 41 according to the second embodiment. As illustrated in FIG. 10, the product DB 41 stores information corresponding to the item “visual information” in addition to the same information as the product DB 41 illustrated in FIG. 3. The information stored corresponding to this item “visual information” is visual information that specifies whether or not a product included in the higher-level product is visible from the outside of the higher-level product (in FIG. 10, “1” when visible, “0” when not visible). For example, in FIG. 10, since the visual information corresponding to the product ID “a-1” is “1”, the product “a-1” from the outside of the product “A” in the upper hierarchy of the product “a-1” is displayed. It is specified that it is visible. On the other hand, since the visual information corresponding to the product ID “a-2” is “0”, the product “a-2” cannot be visually recognized from outside the product “A” in the upper hierarchy of the product “a-2”. Is identified.

(Processing-Support for tracking defective products)
Next, processing performed in the defective product tracking support system 1 according to the second embodiment will be described. FIG. 11 is a flowchart of defective product tracking support processing according to the second embodiment, and FIG. 12 is a flowchart of defective product tracking support processing following FIG. Note that SC1 to SC13 of the defective product tracking support process in the second embodiment are the same as SA1 to SA13 in FIGS. 5 and 6 described in the first embodiment, and thus description thereof is omitted.

  As a result of the determination at SC11, when it is determined based on the image information displayed on the display 20 at SC10 that it is not possible to confirm that a defect has actually occurred in another component that may have failed (SC11, No), the control unit 30 acquires visual information corresponding to the component whose image information is displayed on the display 20 in SC10 (SC14).

  Subsequently, based on the visual recognition information acquired in SC14, the control unit 30 determines whether or not a component that may have failed can be visually recognized from the outside of a product in a higher hierarchy of the component whose image information is displayed on the display 20. Is determined (SC15).

  As a result, when it is determined that a component that may have failed is not visible from the outside of the product in the upper hierarchy of the component whose image information is displayed on the display 20 (SC15, No), the control unit 30 A location tracking process is executed (SC16). Since the location tracking process is the same as the location tracking process of FIG. 7 described in the first embodiment, the description thereof is omitted.

  On the other hand, if it is determined that a component that may have failed can be visually recognized from the outside of the product in a higher hierarchy of the component whose image information is displayed on the display 20 (SC15, Yes), the control unit 30 determines in SC10. The product ID of a product that is a higher-level product of the part displayed on the display 20 and that includes the part in which the defect has occurred is acquired (SC17).

  Subsequently, the control unit 30 acquires the order information of the products identified by the product ID acquired in SC17 from the product DB 41 (SC18).

  Next, based on the order information acquired at SC18, the control unit 30 determines the product ID of the part that was lastly inspected before the product with the product ID acquired at SC17 is manufactured, and the product ID acquired at SC17. The product ID of the part that was first subjected to the sampling inspection after the product is manufactured is acquired (SC19).

  Subsequently, the control unit 30 acquires a product ID of a higher-level product including other parts that may have failed (SC20). For example, the control unit 30 is manufactured after the last sampling inspection performed before the product with the product ID acquired in SC17 is manufactured, and first after the product with the product ID acquired in SC17 is manufactured. A product manufactured before the sampling inspection that has been performed is identified as a higher-level product including other parts that may have failed, and the product ID is acquired. That is, based on the product ID acquired in SC17, the defect is larger than the sequence number corresponding to the product ID of the product that was last subjected to the sampling inspection before the higher-level product including the defective part is manufactured. The product ID of a part having a sequence number smaller than the sequence number corresponding to the product ID of the product first subjected to the sampling inspection after the higher-level product including the generated part is manufactured may be defective. Acquired as a product ID of a higher-level product including some other part.

  Subsequently, the control unit 30 acquires image information associated with the product ID acquired in SC20 from the product DB 41 (SC21).

  Furthermore, the control unit 30 acquires a product ID of a finished product including the product identified by the product ID acquired in SC20 (SC22).

  Subsequently, the control unit 30 acquires the packing material ID and the current storage location information of the packing material in which the finished product including the product identified by the product ID acquired in SC20 is packed (SC23).

  And the control part 30 displays the information acquired by each process of said SC20 to SC23 on the display 20 (SC24). Thereafter, the control unit 30 returns to SC11.

(effect)
As described above, according to the second embodiment, a product ID corresponding to a higher-level product configured to include a product in which a defect has occurred is acquired, and a defect is determined based on the order information corresponding to the acquired product ID. Since other products in the upper hierarchy that may include the product in which the occurrence of the error occurred are identified and the image information corresponding to the identified upper hierarchy product is displayed on the display 20, the image information is displayed along the manufacturing process of the product. Based on this, the presence or absence of defects can be confirmed. Therefore, for example, in the manufacturing process of a higher-level product, even when a defect occurs in a part constituting the product, it is possible to confirm whether or not the defect has occurred without unpacking the packing material.

  In particular, based on the visual recognition information, when a product included in the upper-layer product is visible from the outside of the upper-layer product, image information corresponding to the identified upper-layer product is displayed on the display 20. The image information can be displayed on the display 20 only when the person can confirm the presence or absence of a defect based on the image information displayed on the display 20.

[Modifications to Embodiment]
Although the embodiments of the present invention have been described above, the specific configuration and means of the present invention can be arbitrarily modified and improved within the scope of the technical idea of each invention described in the claims. Can do. Hereinafter, such a modification will be described.

(About problems to be solved and effects of the invention)
First, the problems to be solved by the invention and the effects of the invention are not limited to the above-described contents, and the present invention solves the problems not described above or has the effects not described above. There are also cases where only some of the described problems are solved or only some of the described effects are achieved.

(About distribution and integration)
Further, each of the electrical components described above is functionally conceptual and does not necessarily need to be physically configured as illustrated. In other words, the specific form of distribution / integration of each part is not limited to the one shown in the figure, and all or a part thereof may be functionally or physically distributed / integrated in arbitrary units according to various loads and usage conditions. Can be configured. For example, the display 20 and the storage unit 40 in the defective product tracking support system 1 may be external devices of the defective product tracking support system 1.

1 Defective Product Tracking Support System 2 Network 3 Reader / Writer 10 Input / Output IF
20 Display 30 Control unit 40 Storage unit 41 Product DB
42 Packing material DB

Claims (7)

Display means;
Product information storage means for storing product identification information for uniquely identifying a product, image information of the product, and order information for specifying the order in which the products are manufactured, in association with each other;
The product identification information corresponding to the product in which the defect has occurred is acquired, the other product that may have failed is identified based on the order information corresponding to the acquired product identification information, and the identification is performed. Control means for causing the display means to display the image information corresponding to the finished product;
A defective product tracking support system. The product information storage means stores inspection information for specifying whether a sampling inspection has been performed on the product,
Based on the order information corresponding to the product on which the sampling inspection has been performed and the order information corresponding to the product on which the defect has occurred, the control means may perform a final check before the product on which the defect has occurred is manufactured. There is a possibility that a defect has occurred in the product manufactured after the sampling inspection performed before the sampling inspection performed first after the product in which the defect has occurred is manufactured. Identify as some other said product,
The defective product tracking support system according to claim 1. The product information storage means uniquely identifies each product in a lower hierarchy that constitutes the product, and / or the product identification that uniquely identifies an upper hierarchy product that includes the product. Store information,
The control means causes the display means to display the product identification information corresponding to a higher-level product including the other products identified as having a possibility of occurrence of a defect;
The defective product tracking support system according to claim 1 or 2. The control means acquires the product identification information corresponding to a higher-layer product configured to include the product in which a defect has occurred, and a defect has occurred based on the order information corresponding to the acquired product identification information. Identifying other products in the upper hierarchy that may include the product, and causing the display unit to display the image information corresponding to the identified upper hierarchy product,
The defective product tracking support system according to claim 3. The product information storage means stores visual information for specifying whether or not the product included in the upper layer product is visible from outside the upper layer product,
The control means, based on the visual recognition information, when the product included in the higher-layer product is visible from the outside of the upper-layer product, the image information corresponding to the identified upper-layer product is displayed. Displaying on the display means;
The defective product tracking support system according to claim 4. The product identification information, the packaging material identification information that uniquely identifies the packaging material that packed the product, and the location information that specifies the history of the storage location and the storage period of the packaging material are stored in association with each other. Packaging material information storage means to
The control means acquires the packaging material identification information corresponding to the packaging material in which the product in which the defect has occurred is packed, and the possibility that the defect has occurred is based on the location information corresponding to the acquired packaging material identification information. Identifying the packaging material in which the other product is packed and displaying the packaging material identification information corresponding to the identified packaging material on the display means,
The defective product tracking support system according to any one of claims 1 to 5. On the computer,
A product information storage step for storing product identification information for uniquely identifying a product, image information of the product, and order information for specifying the order in which the products are manufactured, in association with each other in a storage unit;
The product identification information corresponding to the product in which the defect has occurred is acquired, the other product that may have failed is identified based on the order information corresponding to the acquired product identification information, and the identification is performed. A control step of causing the display means to display the image information corresponding to the finished product;
This is a defective product tracking support program.

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