JP2012133723A - Process control system and method for processed articles - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a process control system and a method for processed article that solves problems of a process skip and two-time processing by securely performing confirmation operation for serial numbers, operation completion flags, etc., of works to be processed at entrances and exits of processing facilities using RFID tags.SOLUTION: The process control system includes an RFID tag 7 attached to a work W; means 15 of determining that processing facilities OP10, OP20, ..., can be actuated based upon information on at least serial numbers of works W, operation completion flags of previous processes, and operation completion flags of current processes read by entrance-side RFID tag readers 5 of the processing facilities OP10, OP20, ...; means 17 of determining that processing operations of the processing facilities are completed based upon at least the serial numbers of the works to be processed read by exit-side (entrance-side) RFID tag readers/writers 5; and write means 19 of writing a completion flag to the RFID tag when it is determined that a processing operation is completed, a next process being started after the writing of the completion flag to the RFID tag 7 is completed.

Description

  The present invention is a processing line in which a plurality of processing facilities for machining a cylinder head and a cylinder block of an engine are arranged side by side. The present invention relates to a process management system and method for a processed article installed in a processing facility.

RFID (Radio Frequency Identification) tags are often used to manage articles being processed in a processing line that processes parts to be processed through a plurality of steps. This RFID tag is equipped with an IC chip and enables reading and writing of recorded information by radio waves and electromagnetic waves in a non-contact manner, and is suitable for data exchange on a production line involving conveyance. .
For example, in Japanese Patent Laid-Open No. 2006-139410 (Patent Document 1), an RFID tag is attached to a processed article, and information such as input / output times to the processing process is acquired, thereby indicating the status of the processed article in the process. An example of a process management system to be managed is shown.

  In JP 2009-75941 A (Patent Document 2), the processing in the processing step is completed in order to manage the location and state of the article being transported without imposing a burden on the transport worker. At that time, the product ID is read from the RFID tag of the processed product that has been processed, and the product ID of the processed product temporarily placed in the processed product storage area is known. Thus, the article ID of the temporarily placed processed article can be associated with the cart ID on which the processed article is placed, and the state of the processed article being conveyed between the processes can be managed. .

JP 2006-139410 A JP 2009-75941 A

  In the case where the processed article is automatically conveyed as in Patent Document 1, the processing history data and the processed article are automatically associated with each other automatically by reading the RFID by automatic conveyance. Process management is easy. Also, as in Patent Document 2, processing history data including transporting by carriage is acquired by associating the carriage ID and the processed article ID. The association with the article is surely performed.

As described above, it is assumed that the process management methods as shown in Patent Document 1 and Patent Document 2 are automatically transported and have a certain regularity in the order and processing order of transported articles.
However, in systems that are not automatically transported, that is, when transporting workpieces between processing facilities or mounting workpieces on processing facilities is handled manually by the operator, the processing order of the processing items and the mounting order are physically enforced. Since there are no workers, that is, the operator is involved in the transport process and mounting, flexibility in the transport order and processing order is likely to occur, and the connection between the processed article and the processing history data becomes uncertain, and the processed article can be reliably connected. There is a problem that processing history tracking (traceability) is difficult to perform.

  In particular, in a processing line that performs machining, a problem of so-called process skipping in which an article that has not been subjected to a previous process is subjected to the process of the process, and furthermore, the process is performed again despite the execution of the process. It is easy to cause a so-called double processing problem that the process is performed.

  Therefore, in view of such problems, workpieces to be processed at the entrance of the processing equipment using RFID tags in processing lines that are not equipped with an automatic transfer system and are manually handled by an operator for transporting processed goods and mounting on processing equipment. It is an object of the present invention to provide a process management system and method for a processed article that can eliminate the problem of skipping the process and processing twice by reliably confirming the serial number and the work completion flag.

In order to solve the above-described problem, the first invention is a process management system for a processed article in a processing line that is manually handled by an operator for transporting the processed article or mounting the processing article.
RFID tag attached to the workpiece to be processed, an RFID tag reader for reading information written in the RFID tag provided at the entrance and exit of the processing facility, and a serial number of at least the workpiece to be processed read by the RFID tag reader on the entrance side, Based on the information of the work completion flag of the previous process and the work completion flag of the process, based on the means for determining whether the machining facility can be activated and at least the serial number of the workpiece to be processed read by the RFID tag reader on the outlet side Means for determining completion of the machining operation at the processing facility, and means for writing a completion flag in the RFID tag when the completion of the machining operation is determined, and writing the completion flag to the RFID tag is completed. It progresses to the next process.

  According to the first aspect of the present invention, at least the serial number of the workpiece to be processed among the data written in the RFID tag by the RFID tag reader provided at the entrance of the processing facility, the work completion flag of the previous process, and the work of the process Since it is determined that the machining facility can be activated based on the information of the completion flag, specifically, when the work completion flag of the previous process is set and the work completion flag of the process is not set Then, it is determined that the processing facility can be started.

If the work completion flag for the previous process is not set, it indicates that the work for the previous process has not been completed, so there is a possibility of so-called process skipping.
In addition, when the operation completion flag for the process is not set, it indicates that the processing at the processing facility has not been completed, so there is a possibility of so-called twice processing.
Therefore, when the work completion flag of the previous process is set and the work completion flag of the process is not set, it is determined that the processing equipment can be started and processing by the processing maintenance is started. , It is possible to prevent the skipping of the process and the occurrence of twice processing.

  Further, according to the first invention, since the completion of the machining operation in the machining facility is determined based on at least the serial number of the workpiece to be machined read by the RFID tag reader on the outlet side, that is, specifically, on the outlet side When the serial number of the workpiece to be machined read by the RFID tag reader matches the serial number read by the RFID tag reader on the entrance side, it is determined that the machining operation at the machining facility has been completed.

  In this way, when processing is completed, it can be confirmed whether the processed article is correct by determining whether or not the serial number matches the serial number read on the entrance side, and the completion of the processing work is ensured. Can be judged.

  Preferably, in the first invention, the means for determining the startability and the means for determining the completion of the machining operation are provided for each processing facility, and the activation is possible and the processing operation is completed for each processing facility. The completion flag is preferably written to the RFID tag every time it passes through the process.

  In this way, since it is determined for each processing facility that it can be activated and the completion of the processing operation, installation of storage means and determination means necessary for determination for each processing facility enables equipment changes such as addition or reduction of processing facilities. It is possible to construct a system that is easy to cope with, and it is easy to respond to changes in the criteria for each processing facility.

  Preferably, in the first invention, the RFID tag is assigned with a serial number of a workpiece to be processed and an area for writing a completion flag for each process, and includes a completion flag for each process written in the RFID tag. It is good to provide the means by which data are transmitted and memorize | stored in a process management server via a network.

  In this way, since the RFID tag is assigned with an area for writing the serial number of the workpiece to be machined and the completion flag of the machining operation for each process, history information on completion of machining in each machining facility is accumulated, By reading the RFID tag, the processing history can be easily confirmed. As a result, reliable processing history tracking (traceability) of the processed article can be performed.

  In addition, since the data including the completion flag for each process written in the RFID tag is transmitted to and stored in the process management server via the network, the processing history of the processed article can be obtained by accessing the process management server from the terminal. Can be easily provided to data users such as workers and managers.

In addition, the second invention is an invention relating to a process management method for a processed article, and in the process management method for a processed article in a processing line manually handled by an operator for transporting the processed article or mounting the processing article,
The information written in the RFID tag attached to the workpiece to be processed is read by the RFID tag reader provided at the entrance and exit of the processing equipment, and at least the serial number of the workpiece to be processed read by the RFID tag reader on the entrance side, the work of the previous process Based on the information of the completion flag and the work completion flag of the process, it is determined whether the processing facility can be started, and based on at least the serial number of the workpiece to be processed written in the RFID tag read by the RFID tag reader on the exit side It is characterized in that the completion of the machining operation in the processing facility is determined, and when the completion is determined, a completion flag is written in the RFID tag so that it can be transferred to the next process.

  Preferably, in the second invention, when the work completion flag of the previous process is set and the work completion flag of the process is not set, it is determined that the machining equipment can be started and machining is started. In addition, when the serial number of the workpiece to be processed read by the RFID tag reader on the outlet side matches the serial number read by the RFID tag reader on the inlet side, it may be determined that the processing operation at the processing facility has been completed. .

  As described above, according to the second invention related to the process management method for processed articles, as in the first invention related to the process management apparatus for processed articles, when the work completion flag of the previous process is not set, the process skipping is performed. Since there is a possibility, the start by the processing equipment should not be started. Further, when the work completion flag of the process is set, the processing equipment may be started twice, so the start by the processing equipment should not be started. , It is possible to prevent process skipping and occurrence of double processing.

  Furthermore, when the serial number of the workpiece to be processed read by the RFID tag reader on the outlet side matches the serial number read by the RFID tag reader on the inlet side, it is determined that the processing operation in the processing facility has been completed and the completion flag Is written in the RFID tag and can be conveyed to the next process, so that it can be confirmed whether or not the processed article has an error, and the completion of the processing operation can be reliably determined.

  When handling workpieces between processing equipment and mounting on processing equipment is handled manually by an operator, there is no physical compulsory transport of the workpiece, so the operator is involved in the transportation and the order of transportation is flexible. , The connection between the processed article and the processing history data becomes uncertain, and it is difficult to reliably trace the processing history (traceability) of the processed article. .

However, according to the process management apparatus for a processed article of the first invention, based on at least the serial number of the workpiece to be processed, the work completion flag of the previous process, and the work completion flag information of the process read by the RFID tag reader on the entrance side. Means for determining whether the processing facility can be started, means for determining completion of the processing operation in the processing facility based on at least the serial number of the workpiece to be processed read by the RFID tag reader on the outlet side, and the processing operation Means for writing a completion flag to the RFID tag when it is determined that the completion is completed, and when the completion flag is written to the RFID tag, it is possible to proceed to the next step. Can be prevented.
Further, the same operation and effect can be obtained in the process management method for processed articles of the second invention.

1 is an overall configuration diagram of a process management system according to an embodiment. It is a flowchart which shows the process sequence in the process management system of embodiment. Fig. 2 is a continuation flowchart of Fig. 2-1. It is explanatory drawing which shows the example of the data currently written in the RFID tag of embodiment. It is explanatory drawing which shows the example of the process log | history data memorize | stored and accumulated in the process management server.

  Hereinafter, the present invention will be described in detail with reference to embodiments shown in the drawings. However, the dimensions, materials, shapes, relative arrangements, and the like of the component parts described in this embodiment are not intended to limit the scope of the present invention to that unless otherwise specified.

FIG. 1 is an overall system configuration diagram of a process management system according to an embodiment of the present invention.
In this example, the processing facilities OP10, OP20, OP30,... Are installed side by side in series, and the workpiece W, which is an object to be processed, is conveyed to the processing facility OP10, then OP20, and then OP30.
In the present embodiment, the workpiece W is an engine component such as an engine cylinder head or a cylinder block. The processing equipment is constituted by a machining center, and the workpiece W mounted on the machining center is subjected to necessary machining (drilling, cutting, grinding, etc.). A series of machining is performed by sequentially feeding along each processing equipment OP10, OP20, OP30.

  Between the processing facilities OP10, OP20, and OP30, the workpiece W is moved between the processing facilities by a conveyor, a carriage, a carrier, or the like as a conveying means, and the workpiece W is temporarily placed in a workpiece place before processing. Then, when the worker mounts the workpiece on the processing facility, for example, the processing facility OP10, the presence of the workpiece W before processing is confirmed by the workpiece presence sensor 3 before processing.

Further, the presence of the workpiece W before processing is confirmed by the workpiece presence sensor 3 before the facility, and at the same time, the information written in the RFID tag is acquired by the RFID tag reader / writer 5.
That is, a bolt tag (RFID tag) 7 that is a bolt in which an RFID tag is embedded is attached to the work W, and information written in the bolt tag 7 is acquired.
The RFID tag reader / writer 5 is installed opposite to or near the bolt tag 7 when the presence of the workpiece W before processing is confirmed by the workpiece presence sensor 3 in front of the facility.

  In addition, the workpiece W after processing confirms the presence of the workpiece W by the workpiece presence sensor 3 and reads / writes information written in the bolt tag 7 by the RFID tag reader / writer 5. In the present embodiment, the RFID tag reader / writer 5 serves as both an inlet-side RFID tag reader and an outlet-side RFID tag reader.

The bolt tag 7 has an IC chip embedded therein, and is attached to the cylinder head or cylinder block, which is the workpiece W, at a position where it is not obstructed during processing or at a position where it does not interfere with other parts. At the same time, it flows through each processing equipment OP10, OP20,..., And processing information in each processing equipment is written.
The bolt tag 7 and the IC chip inside the tag are formed of a material that is not affected by cutting oil or the like used in the cutting process.

  The RFID (Radio Frequency Identification) tag exchanges information from an RFID tag in which ID information is embedded by wireless communication at a short distance (several centimeters to several meters depending on a frequency band) using an electromagnetic field or a radio wave. It is suitable for data exchange because it enables reading and writing of recorded information without contact by radio waves or electromagnetic waves.

Each of the processing facilities OP10, OP20, OP30,... Is provided with a facility control device 13 that controls the processing facilities.
A signal from the RFID tag reader / writer 5 installed on the front side of the facility and a signal from the work presence sensor 3 in front of the facility are respectively input to the facility control device 13.
In addition, the equipment control device 13 receives the serial number of the workpiece W written in the bolt tag 7 by the signal from the RFID tag reader / writer 5 installed on the front side of the equipment, the previous process, that is, the machining equipment before OP10 (not shown). Based on the information of the work completion flag and the process, that is, the work completion flag of the machining equipment OP10, activation determination means 15 is provided for determining whether the machining equipment OP10 can be activated.

  Furthermore, the equipment control device 13 includes a processing completion determination means 17 for determining the completion of the processing work in the processing equipment OP10 based on the serial number of the work W read by the RFID tag reader / writer 5 on the front side of the equipment, and When the completion of the work is judged by the processing completion judging means 17, a writing means 19 for writing a completion flag to the bolt tag 7 by the RFID tag reader / writer 5 is provided. When the completion flag is written to the bolt tag 7, the process can proceed to the next step. It is like that.

As shown in FIG. 1, the equipment control devices 13 of the processing equipment OP10, OP20, and OP30 are connected to a process management server 23 via a network 21. The process management server 23 is connected to a user terminal 27 via a network 25.
The process management server 23 stores the machining history of the workpiece W sent from each machining facility, organizes the data, and provides it to the user.

The processing history data from the processing equipment to the process management server 23 is written and accumulated in the bolt tag 7.
For this reason, the equipment control device for the processing equipment that has performed the final processing without sending the processing history data to the process management server 23 and storing it in the storage means on the process management server 23 side with the completion of the processing for each processing equipment. Alternatively, all the processing history data stored in the bolt tag 7 may be transmitted to the process management server 23 via 13 and stored in the storage means on the process management server 23 side.

Next, the processing procedure of the equipment control device 13 will be described with reference to the flowcharts of FIGS.
First, in step S1, whether or not there is a seat is determined by the workpiece presence sensor 3 before processing, and the presence of the workpiece W before processing is confirmed. When the presence is confirmed, in step S2, the data written in the bolt tag 7 is acquired by the RFID tag reader / writer 5 installed on the front side of the facility.

The acquired data includes at least the serial number of the workpiece W to be processed, the work completion flag of the previous process, and the work completion flag information of the process.
FIG. 3 shows an example of data stored in the bolt tag 7. As shown in FIG. 3, information such as “data name”, “loading time”, “line code”, “serial number”, “model code”, “equipment number”, “work flag” is written. .
A work flag is written for each of the processing facilities OP10, OP20, OP30,.

Next, in step S3, it is determined whether or not a work completion flag for the processing equipment has already been set. For example, when the processing facility is the processing facility OP10, it is determined whether or not the work completion flag of the processing facility OP10 is set in the information read from the bolt tag 7.
If the work completion flag is set, the work of the processing equipment OP10 has already been completed, and there is a risk of machining twice. Therefore, the process proceeds to step S5 and the serial number stored in the bolt tag 7 is reached. Is not stored in the storage unit 31 of the equipment control device 13, the process proceeds to step S <b> 6, the work W is removed from the detection position by the work seat sensor 3 in front of the equipment, moved to the next process, and returned to the normal process. .

If the work completion flag for the processing facility is not set in step S3, the process proceeds to step S4, and then it is determined whether or not the work completion flag for the previous process is set.
If the work completion flag is not set, there is a risk of machining skipping, so the process proceeds to step S5, where the serial number stored in the bolt tag 7 is stored. Is not stored in the storage unit 31 of the equipment control device 13, the process proceeds to step S <b> 6, the work W is removed from the detection position by the work front seat sensor 3, moved to the previous process, and returned to the normal process. Inform

Next, when the work completion flag of the previous process is set in step S4, the process proceeds to step S7, and the serial number stored in the bolt tag 7 is displayed. Is stored in the storage unit 31 of the equipment control device 13.
Next, in step S8, the operator attaches the workpiece W to the processing facility, for example, the processing facility OP10, and starts automatic operation of machining.

When the processing is completed, in step S9, the processed workpiece W is taken out, the workpiece W is temporarily placed in front of the equipment, and the data stored in the bolt tag 7 is acquired again by the RFID tag reader / writer 5.
In step S10, the serial number of the workpiece W stored in step S7 before machining is obtained. And the serial number read from the bolt tag 7 attached to the workpiece W that has been processed this time. To determine whether or not they match.

If it is determined in step S10 that they do not match, the process proceeds to step S11 to notify that the machined workpiece W has an error.
On the other hand, if they match, it can be confirmed that the machining operation has been completed in the machining facility. As a result, in step S12, the operation completion flag is stored in the storage unit in the bolt tag 7 and the RFID tag reader / writer is set in the bolt tag 7. Write by 5.

  Next, it progresses to step S13 and data, such as "Serial No.", "Equipment No.", "machining date" regarding the processed workpiece W memorize | stored in the memory | storage part 31 of the equipment control apparatus 13, are stored. The data is transmitted to the process management server 23 and stored in the server 23.

  And in step S14, the data memorize | stored in the memory | storage part 31 of the equipment control apparatus 13 are reset in the step transmitted to the process management server 23, and the data with respect to the new workpiece | work W carried in next are memorize | stored. Initialize to. And it ends.

  In step S14, the data stored in the storage unit 31 of each equipment control device 13 is transmitted to the process management server 23 and stored in the storage unit in the process management server 23, whereby the storage of the equipment control device 13 is performed. In the above description, the data stored in the unit 31 is reset. As described above, since the machining history is written in the bolt tag 7, the bolt tag is used when the machining operation by the final machining equipment is completed. 7 may be collectively sent to the process management server 23 via the equipment control device 13.

As described above, when all the processing history data stored in the bolt tag 7 is transmitted to the process management server 23 via the equipment control device 13 of the processing equipment that has performed the final processing, each processing equipment OP10, OP20, OP30. ,... And the reception control device on the process management server 23 side can be simplified, and the system configuration can be simplified.
After the procedure from step S1 to S14, it is transported to the next processing facility and the same processing procedure is repeated.

Further, the processing history data transmitted to the process management server 23 is stored and organized, and stored in a configuration as shown in FIG. 4, for example.
In FIG. 4, “line code” is a processing line number, and “model” is a code number for identifying a model to which a cylinder head or a cylinder block of an object to be processed is applied, and “serial number”. Is a number for identifying the workpiece W, “setting” is an equipment code, “work” is a work flag, for example, flag information such as work completion is described. “No” indicates an abnormal code, and flag information indicating whether or not an abnormality has occurred during the machining process is set.

  As described above, when the workpiece W is put into the processing equipment OP10, OP20,..., The processing operation is completed by the determination in step S3 based on the information read by the RFID tag reader / writer 5 on the front side of the equipment. Forgetting what has been done, it is possible to surely prevent twice machining that causes the same machining process to flow, and further, according to the determination of step S4, the machining process that skips the machining process due to misunderstanding that it has not been machined. Can be reliably prevented.

  Further, as a result of the determination in step S10, the serial number of the workpiece to be processed read by the RFID tag reader / writer 5 on the front side of the facility is displayed. However, serial No. read before processing. When it is coincident with, it is determined that the processing work in the processing equipment is completed, and a completion flag is written in the bolt tag 7 so that it can be transported to the next process. The completion of the machining operation can be reliably determined.

  In addition, as described above, machining skipping and twice-working workpiece W are prevented, so that the connection between the workpiece flowing through the machining line and the machining history data is ensured, and the workpiece W is reliably traced (traceability). ) Is performed.

  According to the present invention, it is possible to eliminate the problem of skipping the process and the twice machining by surely confirming the serial number of the workpiece to be machined and the work completion flag at the entrance of the machining facility using the RFID tag. It is suitable for a process management system and process management method for a processed article in a processing line that is not equipped with an automatic transfer system and is manually handled by an operator for transporting the processed article or mounting it on a processing facility.

3 Work presence sensor before processing 5 RFID tag reader / writer 7 Bolt tag (RFID tag)
DESCRIPTION OF SYMBOLS 13 Equipment control apparatus 15 Starting | judging determination means 17 Processing completion determination means 19 Writing means 21, 25 Network 23 Process management server 27 Terminal 31 Memory | storage part OP10, OP20, OP30 Processing equipment W Work (work to be processed)

Claims (8)

In the process management system for processed articles in a processing line that transports processed articles between processing facilities by the handling of workers,
An RFID tag attached to the workpiece to be machined;
An RFID tag reader that reads information written on the RFID tag provided at the entrance and exit of the processing facility;
Based on at least the serial number of the workpiece to be machined read by the RFID tag reader on the entrance side, the work completion flag of the previous process, and the information on the work completion flag of the process, a means for determining whether the machining facility can be activated,
Means for determining completion of the processing operation in the processing facility based on at least the serial number of the workpiece to be processed read by the RFID tag reader on the exit side;
Means for writing a completion flag to the RFID tag when the completion of the machining operation is determined;
A process management system for a processed article, wherein the process proceeds to the next process after the completion flag is written to the RFID tag.   The processed article according to claim 1, wherein when the work completion flag for the previous process is set and the work completion flag for the process is not set, it is determined that the processing equipment can be started. Process management system.   When the serial number of the workpiece to be processed read by the RFID tag reader on the outlet side matches the serial number read by the RFID tag reader on the inlet side, it is determined that the machining operation in the processing facility is completed A process management system for a processed article according to claim 1.   The means for determining the startability and the means for determining the completion of the machining operation are provided for each processing facility, the activation is possible for each processing facility and the completion of the processing operation is determined, and the completion flag passes the process. 2. The process management system for a processed article according to claim 1, wherein the process tag is written in an RFID tag each time.   An area for writing a serial number of a workpiece to be processed and a completion flag for each process is allocated to the RFID tag, and the data is transmitted to a process management apparatus via a network and stored therein. The process management system for a processed article according to any one of claims 1 to 4. In the process management method for processed articles in a processing line that transports processed articles between processing facilities by the operator's hand,
Read the information written in the RFID tag attached to the workpiece to be processed by the RFID tag reader provided at the entrance and exit of the processing equipment,
Based on at least the serial number of the workpiece to be machined read by the RFID tag reader on the entrance side, the work completion flag of the previous process, and the information of the work completion flag of the process, it is determined whether the machining facility can be activated,
Based on at least the serial number of the workpiece to be processed written in the RFID tag read by the RFID tag reader on the outlet side, the completion of the processing operation in the processing facility is determined,
A process management method for a processed article, wherein when the completion is determined, a completion flag is written in the RFID tag and conveyed to the next process.   The machining is started by determining that the machining facility can be activated when the work completion flag for the previous process is set and the work completion flag for the process is not set. The process management method of the processed article of 6.   When the serial number of the workpiece to be processed read by the RFID tag reader on the outlet side matches the serial number read by the RFID tag reader on the inlet side, it is determined that the machining operation in the processing facility is completed The process management method of the processed article of Claim 6.

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