JP2020173753A - Manufacturing process supervising support system - Google Patents

Abstract

To provide a system which permits a management supervisor to extract and record "work state and processing condition" and "the shape and characteristics of a product processed or assembled" for comparison and analysis on a daily basis without any labor.SOLUTION: A manufacturing system has, in a manufacturing line of products: processing means 11 for processing a member; detection means 17 for detecting processing condition; and measurement means 12 for measuring the shape or characteristics of the member processed by the processing means 11, and includes: information processor 26 and an evaluation algorithm 51 for comparing and evaluating detection information provided from the detection means 17 and measurement information provided from the measurement means 12. This system makes it possible to detect "work state and the processing condition" and measure "the shape or characteristics of the processed member" and to compare and evaluate information of the aforementioned detection and measurement in an information display part 22. Consequently, judgment and improvement of management supervision related to production efficiency and quality improvement are supported.SELECTED DRAWING: Figure 1

Description

The present invention is an evaluation algorithm that detects the processing status and compares and evaluates the detection information and the measurement information from the measuring means in the equipment for processing the product or the product manufacturing line in which the worker (40) works. It is a manufacturing system equipped with the above, which provides a system that supports the judgment and improvement of management and supervision regarding production efficiency and quality improvement.

A system that makes it easy to find an image when an abnormal state of equipment such as a chocolate stop occurs from the recorded images (for example, Patent Document 1), or a system that can estimate the state of process work (for example, a patent). Document 2), which did not measure, compare, and evaluate the actual working condition and the shape or characteristics of the product after processing.

[Publication Number] Japanese Patent Application Laid-Open No. 2016-122319 (P2016-122319A) [Publication date] July 7, 2016 [Title of invention] Process monitoring device

[Public Number] 2018-005789 (P2018-005789A) [Publication date] January 11, 2018 (2018.1.11)
Description: A work estimation device, a work estimation method, and a work estimation program.

Among the manufacturing processes, there are a manufacturing process in which all the movements of the worker can be analyzed by process analysis and a process in which the movement of the worker cannot be analyzed. A typical example of a manufacturing process for which process analysis is possible is the assembly process of an automobile or an electric product. These are manufacturing processes called "mass production lines" with a daily production of several hundred units or more than 1,000 units.
In the process of "mass production line", the tact time of one process is several tens of seconds, and the time of one process is short, so that it can be observed repeatedly many times, so it is easy to find waste in the process. It is also easy to find the cause of quality problems for the same reason. As a result, it is analyzed in detail by the process supervisor, and in many cases, activities for improving process efficiency and quality are carried out in detail on a daily basis.

On the other hand, as an example of a manufacturing process that has not been analyzed very much, there is a manufacturing process of equipment and machinery. In such a process, the tact time of one process is several tens of minutes or more. A tact time of several tens of minutes takes a long time, and it takes a lot of time for repeated observation, so it is difficult to find waste and inefficiency in the process. For the same reason, it is difficult to find the cause of quality problems. Therefore, there is a problem that it is difficult for the process supervisor to give instructions for improving the efficiency and quality of the process.

In addition, some of these manufacturing processes may require skill such as welding, and the relationship between the state of detailed work and the accuracy of the finished product is often tacit knowledge of each worker. Furthermore, although NC machine tools are often used, each worker often has his or her own know-how regarding how to attach materials to the machine tool and how to make detailed settings. Since they are tacit knowledge, they are not handed down to other workers, and there is a problem that they cannot contribute to the efficiency of the entire factory.

In the product manufacturing line where the worker works, the parts processed by the processing means (11) for processing the parts, the processing sensor (18) for detecting the operating state of the processing means (11), and the processing means (11). A manufacturing system provided with a measuring means (12) for measuring a shape, and equipped with an evaluation algorithm for comparing and evaluating the processing state information from the machining sensor (18) and the measurement information from the measuring means (12). It supports the activities of the process supervisor.

According to the present invention, the state of the processing means in the production line and the measurement result of the parts produced by the processing can be compared by the information processing means, and the image synchronized with the detection of the processing can be evaluated together with the process supervisor. Instructions for improving production efficiency and quality can be given easily and quickly, and it also has the effect of supporting the evaluation of worker skills.

In the embodiment of the present invention, the processing sensor (18), the measuring means (12), the evaluation algorithm (51), and the information processing means (26) for detecting the processing state of the manufacturing line and the processing means (11) of the first example. Schematic configuration diagram The figure which showed the transition of mounting on a jig in an Example The figure which showed the transition of processing in an Example The figure which showed the transition of the measurement in an Example Example of detection information display window Example of accuracy display window Example of evaluation display window Evaluation algorithm Example of video display window display Explanatory diagram of the time axis of the process of the detection information display window Schematic diagram of the production line of Example 2 of the present invention Schematic diagram of the production line of Example 3 of the present invention Diagram of preparatory work in the embodiment of the present invention

The manufacturing system of the present invention is a product manufacturing line in which an operator works, and is a processing means for processing a part, a processing sensor (18) for detecting the processing state of the processing means (11), and a part processed by the processing means. It has a measuring means (12) for measuring the shape or characteristic of the above, and includes an information processing means having an evaluation algorithm for comparing and evaluating the machining information from the machining sensor and the measurement information from the measuring means. ..

A mode for carrying out the invention will be described with reference to the drawings based on the examples of the present invention.
In FIG. 1, (1) is a jig, and a worker (40) is a manufacturing line for assembling and processing a product composed of a member (5), a member (6), a member (9), and the like. The worker (40) holds the processing means (11), which is an electric screwdriver, and performs the work of tightening the bolts (8). This production line is equipped with a jig (1), and a jig sensor (16) that detects the mounting state when the member (5) is mounted on the jig (5) is cured by the cable (4). It is connected to the detection element (3) on the jig (5).

Further, the processing means (11) is connected to the processing sensor (18) by a cable (4a). The jig sensor (16) and the processing sensor (18) are provided with an LED jig sensor display means (15) and an LED processing sensor display means (17), respectively. Further, the jig sensor (16) and the processing sensor (18) are provided with a WIFI transmission function, and can detect the mounting state of the member (5) on the jig (1) or operate the processing means (11). The state is transmitted, and the LEDs (15) and (17) are turned on at the same time.

(12) is a measuring means and is a laser measuring instrument for measuring the processing accuracy or characteristics of the assembly of the member (9). The measuring means (12) is connected to the WIFI transmitter (20) by a cable (38). Further, (14) is a video camera, which is connected to the WIFI transmitter (21) by a cable (39).

The arrows (16a), (18a), (20a), and (21a) of A, B, C, and D in FIG. 1 represent WIFI radio waves. (26) is an information processing means having a computer function, and is an A receiver (27), a B receiver (28), a C receiver (29), and a D receiver (26) that receive radio waves of A, B, C, and D. 30) is provided.

The information received by the A receiver (27), the B receiver (28), and the C receiver (29) is stored in the information storage unit (31) of the information processing means (26). Further, the video of the video camera (14) is received by the D receiver (30) and stored in the video storage unit (33).

(36) is an information / video synchronization means, which will be described later, is a means for motivating the information stored in the information storage unit and the video on the time axis. (51) is an evaluation algorithm, which evaluates the work of the worker (40) from the information and the video synchronized by the synchronization means. (34), (35), (36), and (52) indicate an interface inside the information processing means (26).

(22) is an evaluation information display unit that displays information processed by the information processing means (26) on the interface (52), and (36) is the information / video synchronization means and the evaluation algorithm (51). The information display window (23), the accuracy display window (24), the image display window (25), and the evaluation display window (26) are displayed on the evaluation information display unit (22).

An embodiment of the present invention described with reference to FIG. 1 will be described with reference to FIG. In FIG. 2, the operation of the assembly processing work of the worker (40) will be described in the order of FIGS. 2, 3 and 4. The worker (40) is not shown here for the sake of clarity. First, the structure of the jig (1) is shown on the left side of FIG. (2) is a positioning pin for positioning. The jig sensor (16) is connected to the detection element (3) on the jig (5) by the cable (4).

The member (5) is mounted on the jig (1) on the right side of FIG. 2 in the next step according to the arrow 1a to show the situation. A member (6), which is a rotating turntable, is attached to the member (5), and six screw holes (7) are machined on the upper surface thereof. The assembly and processing of the member (6) and the screw hole (7) have been performed before the process shown on the right side of FIG. 1 or 2, but the process is not shown here.

As shown on the right side of FIG. 2, when the member (5) is mounted on the jig (1), the detection element (5) detects the mounting, and the LED provided on the jig sensor (16). The jig sensor display means (15) lights up. At the same time, the signal whose placement is detected by the WIFI transmission function of the jig sensor (16) is transmitted by WIFI.

Next, FIG. 3 shows a situation in which the member (9) is attached to the member 6. The member (9) has a fan shape, and six holes are formed at positions corresponding to the screw holes (7). The operator (40) (not shown) places the member (9) on the member (6).

Next, as shown by the arrow 1b in FIG. 3, the process proceeds, and as shown on the right side of FIG. 3, the bolt (8) is passed through the member (9) and tightened to the member (6). FIG. 4 shows a state in which the bolt (8) is tightened. In the process from FIG. 3 to FIG. 4, the bolt (8) is tightened by the operator (40) using the processing means (11) which is the electric screwdriver. At this time, the operating state of the processing means (11) is transmitted by the WIFI transmission function of the tool sensor (18), and at the same time, the LED (17) lights up.

In FIG. 4, the measuring means (12) is a laser measuring instrument that measures the distance between the vertical positions of the upper surface of the member (9), and the member (9) is rotated by the member 6 to cause the arrow (9a) in the drawing. By rotating in the direction of, the height is measured by the laser beam (13) emitted from the inspection means (12), and the surface runout of the member (9) is measured. Since the measuring means (12) is connected to the WIFI transmitter (20), the measurement data is transmitted by the oscillator (20). The video captured by the video camera (14) is transmitted as digital data from the WIFI transmitter (21) connected by the cable (39).

FIG. 4 shows these processes. here. The operator (40) and the fixing means of the measuring means (12) or the video camera (14) are not described for clarity in the drawing.

Next, FIG. 6 shows an example of the display contents of the information display window (23). The signals (55), (55a), and (55b) in the J line of 23a indicate the mounted state of the member (5) on the jig, and (55a) or (55b) is not mounted. (55) shows the state of being placed. In other words, in the state of FIG. 2, it is shown by (55a), and then in the state of FIGS. 3 and 4 on which the member (5) is placed, it corresponds to the signal (55).

FIG. 6 shows an example of the display contents of the accuracy display window (24). The WIFI transmitter (20) transmits the result of measuring the surface runout of the member (9) by the measuring means (12), and displays what is received by the C receiver. In the display contents of FIG. 6, the lines (58) and (59) indicate the upper limit (58) and the lower limit (59) of the surface runout, respectively. Further, (60) and (61) are upper management standards (60) and lower management standards (61) before the surface runout reaches the upper limit (58) and the lower limit (59), respectively. The surface runout actually measured by the measuring means (12) is displayed in (62). (64) indicates the rotation angle of the member (9) on the angle axis. According to the example of this display content, it is displayed that the surface runout reaches the upper control standard (60) at around 40 degrees and is close to the limit of accuracy.

FIG. 7 shows an example of the display contents of the evaluation display window. In this display, (65) represents the working speed and (66) represents the working accuracy. (67) represents the evaluation, and in this example, it is represented by a number from 0 to 5.

FIG. 78 is a table showing an example of the algorithm for evaluation, in which the accuracy (69) is evaluated on a 5-point scale, the speed (70) is evaluated on a 5-point scale, and the overall evaluation is a matrix of shaded parts (71). This is an example of an algorithm to evaluate. The 5-step evaluation of accuracy (69) and speed is evaluated by the difference from each target number.

FIG. 9 is an example of the display of the image display window. In this display example, in the image on the left side of FIG. 79, the operator (40) tightens the screws near the jig (1) using the processing means (11). It is determined by the display frame (53) on the image that the user is in the position to be used. This display frame (53) superimposes the display frame (53) displayed by the information processing means (26) and the image of the video camera, and is easily realized by a technique already known. In the example of the image on the right side of FIG. 9 as shown by the arrow 25a, the worker (40) takes the processing means (11) away from his / her hand and carries the member (54) at a position away from the display frame (53). is there.

From the definition of general process work, it can be distinguished that the worker (40) is performing the processing work in the image on the left side of FIG. 9 and the worker (40) is performing the transportation work in the image on the right side of FIG. It is the basis of work analysis. In order to improve the efficiency of this process work, it is important to reduce the rate of transportation work. Therefore, being able to make such a distinction from the video image helps the management supervisor to give instructions for process improvement.
It is possible with existing video software technology to detect whether a specific person's video is included or out of the frame on the video.

FIG. 10 is an explanatory diagram of the time axis of the process of the detection information display window. (78) shows the time axis of the process, B1 is the length B1 minute of the time axis, and represents the length of time for the above-mentioned worker (40) to perform the first process work. The time (72) represented by A1 minute in B1 minute is cured from the time (79) when the jig sensor detects the loading price of the component on the jig as shown by the dotted lines in (76) and (77) in the figure. It represents the time A1 minute until the time 78 when the part is moved from the jig.

The worker (40) holds the processing means (11) which is an electric screwdriver during the time 55 when the member (5) is detected by the jig sensor during the A1 minute of the first working time B1 minute. Work to tighten the bolt (8). This is as shown in FIG. Further, in the second working time B2, during the time (73) of A2, the work of tightening the bolt (8) is performed by similarly holding the processing means (11). Further, at the time (74) of A3, the work of tightening the bolt (8) is performed with the processing means (11) in the same manner. These are repeated, and in the nth operation as well, during the time (75) of A2 within the work time Bn, the work of tightening the bolt (8) is performed with the processing means (11) in the same manner.

In the work of B1, B2, B3 ... Bn, the times of A1, A2, A3 are not always the same. However, if the time detected by the jig sensor (16) is known, it can be displayed on the detection information display window (23). Further, A2, A3, ... An can also be displayed in sequence, and the same work can be repeated and evaluated. This is a great support for managers and supervisors in analyzing process improvements.

For example, even if the process is called a "medium-volume production line" with a tact time of several tens of minutes or more and it is difficult to find a problem within the tact time of several tens of minutes, if necessary. A jig sensor, a tool sensor, and a video camera are arranged, and by detecting these, it becomes easy to find waste and inefficiency in the process by extracting and analyzing the same work in the process on the time axis.

Similarly, since it is possible to discover variations in work, the possibility of discovering the cause of quality problems is expanded. It provides a means for solving a problem that it is difficult for a conventional process supervisor to give instructions for improving process efficiency and quality regarding the process.

FIG. 11 is a diagram showing only the steps of the examples. Unlike the steps of the previous examples, the worker (43) is a worker who performs welding. Reference numeral (41) is a member, and the worker (43) is welding the upper surface of the member (41). (40) indicates a jig, and the member (41) is placed on the upper surface of the jig (40). The jig (40) is provided with the jig sensor (16) shown in the embodiment of FIG. 1, and is provided with a display means (16) as in FIG. 1. (44) is a detection means for detecting the placement of the jig.

Reference numeral (42) is the main body of the electric welding machine, to which the torch indicated by the processing tool (42a) held by the operator (43) is connected. The main body (42) is provided with a tool sensor (18) and a display means (17). Similar to FIG. 1, (14) is a video camera, which is connected to the WIFI transmitter (21) by a cable (39). (45) The inspection means measures the shape of the member (41) with a three-dimensional scanner using a laser. The alternate long and short dash line (46) in the figure indicates the measurement range by the laser. Since (45) is connected to the WIFI transmitter (20) as in the embodiment of FIG. 1, the measurement data is transmitted by the oscillator (20).

In the embodiment of FIG. 9, similarly to the embodiment of FIG. 1, the jig sensor (16) detects that the member (41) is placed on the jig (40), and then the tool sensor detects the power supply unit ( A signal is transmitted by WIFI according to the operation of 42). Further, the processing state of the member (41) is measured by the three-dimensional scanner (45), and the transmitter (20) transmits a signal of the measurement result. At the same time, the image of the TV camera (14) is also transmitted as a WIFI signal by the transmitter (21).

The information received by the A receiver (27), the B receiver (28), and the C receiver (29) is transmitted by the information processing means (26) to the evaluation information display unit (22) with the information display window (23) and accuracy. The display window (24), the image display window (25), and the evaluation display window (26) are displayed. All of these displays correspond to processing at the same time. By using this, it is possible to discover variations in work as in the embodiment of FIG. 1, so that the possibility of improving the process and discovering the cause of quality problems is expanded. Provide a means for a conventional process supervisor to solve a problem that it is difficult to give instructions for improving process efficiency and quality for the process.

FIG. 10 is a diagram showing only the steps of the embodiment different from those of FIGS. 1 and 9. (42) is an NC lathe. Unlike the steps of the previous examples, the worker (47) is an NC lathe. A worker who handles (50). A tool sensor (18) is provided and a display means (17) is provided. Similar to FIG. 1, (14) is a video camera, which is connected to the WIFI transmitter (21) by a cable (39). (45) The inspection means measures the shape of the member (41) with a three-dimensional scanner using a laser. The alternate long and short dash line (46) in the figure indicates the measurement range by the laser. Since (45) is connected to the WIFI transmitter (20) as in the embodiment of FIG. 1, the measurement data is transmitted by the oscillator (20).

In the embodiment of FIG. 10, the tool sensor transmits a signal by WIFI according to the operation of the NC lathe (50). (48) shows a situation in which the worker (47) is measuring the processing state of the member (49) with the three-dimensional scanner (45). In this embodiment, the transmitter (20) transmits a signal of the measurement result. At the same time, the image of the TV camera (14) is also transmitted as a WIFI signal by the transmitter (21).

Also in the embodiment of FIG. 10, the information received by the A receiver (27), the B receiver (28), and the C receiver (29) is displayed on the evaluation information display unit (22) by the information processing means (26). The information display window (23), the accuracy display window (24), the image display window (25), and the evaluation display window (26) are displayed. By using these displays, it is possible to discover variations in work as in the embodiment of FIG. 1, so that it is possible to improve the process and discover the cause of quality problems. Provide a means for a conventional process supervisor to solve a problem that it is difficult to give instructions for improving process efficiency and quality for the process.

FIG. 13 shows a state in which the operator (40) lifts the semi-finished product composed of the member 5 and the member 6 from the stand (80) in order to carry it to the jig 1 shown in FIG. 1 and place it on the jig 1. There is. Detection elements (3a), (3b), and (3c) are attached to the pedestal (80), and the mounting sensors (16a), (16b), and (16b) are attached with cables (4a), (4b), and (4c), respectively. It is connected to (16c). The mounting sensors (16a), (16b), and (16c) are provided with LED display units (15a), (15b), and (15c).

FIG. 13 shows the preparatory work for the embodiment of FIG. When the worker (40) lifts the product in the process of assembly including the member 5 and the member (6) from the stand (80) for carrying it to the jig (1) shown in FIG. 1 and mounting it, the mounting sensor (16C) ) Changes from the mounting ON state (81) shown by J in FIG. 10 to the mounting OFF state (82), and the worker (40) carries the semi-finished product to the jig (1) shown in FIG. When mounted, the jig OFF state (55a) shown in K of (23a) changes to the jig ON state (55) as described above. This makes it possible to detect that the worker (40) has carried the semi-finished product to the jig. The process supervisor can analyze the working time by the information processing means (26).

Next, the operation of the jig sensor display means (15) or the processing sensor display means (17) in cooperation with the information processing means (26) will be described. When the LED lights on the jig sensor display means (15) or the processing sensor display means (17), the jig (1) and the processing means (11) in FIG. 1 mount the members on the jig (11). The operation of the jig or processing means (11) is displayed. These displays are captured by the video camera (14), sent as images to the D receiver (30) through the WIFI oscillator (21), and stored in the image storage unit (33). At this time, when the jig sensor display means (15) or the processing sensor display means (17) is turned on, the “time 1” captured as an image is also stored at the same time. These operations can be realized by existing technology.

On the other hand, regarding the placement of the member on the jig detected by the jig sensor (16) or the processing sensor (18) or the operation of the processing means (11), the jig sensor (16) or the processing sensor (18) WIFI. Is transmitted to the A receiver (27) and the B receiver (28) and stored in the information storage unit (31) of the information processing means (26). At the same time, the "time 2" of the operation of the pre-described or processing means is also stored.

The means for correcting the time difference between the "time 1" and the "time 2" is the information / video synchronization means (36), and this operation adds or adds the difference between the "time 1" and the "time 2" of the operation. It is performed by subtracting, correcting, and displaying on the information display unit (22). This is achieved by displaying the information in the information recording unit and the information in the video recording unit at the same time. These operations can be realized by existing technology and can be realized.

It can be used for equipment for processing products or for product manufacturing processes in which workers work.

1 Jig 3 Detection element 5 Member, 6 Member, 9 Member 11 Processing means, 12 Measuring means 13 Laser light, 14 Video camera 15 Jig sensor display means 16 Jig sensor 17 Processing sensor display means 18 Processing sensor 20, 21 WIFI Transmitter 22 Information display 24 Precision display window,
25 Video display window, 26 Information processing means 27 A receiver, 28 B receiver, 29 C receiver,
30 D receiver, 31 information storage unit, 33 video storage unit,
36 Information / video synchronization means 40 Worker 42 Power supply unit of electric welding machine, 42a Processing tool 45 Inspection means 51 Evaluation algorithm 22 Evaluation information display unit 23 Information display window 60 Upper management standard, 61 Lower management standard

Claims (5)

A processing sensor (18) that detects the operating state of the processing means (11) for processing the member of the product and the processing means (11) in the product manufacturing line where the equipment for processing the product or the worker (40) works. ) And the measuring means (12) for measuring the shape or characteristic of the member machined by the machining means, the operating state detected by the machining sensor (18) and the measurement information from the measuring means (12). A manufacturing system equipped with an information display unit (22) that displays related items. Equipment for processing products or product production lines operated by workers, having one or more jigs (1) or one or more processing means (11) arranged in the product production line. A jig sensor (16) for detecting the mounting state of the component on the jig (1) or a processing sensor (18) and a video camera unit (14) for detecting the operating state of the addition means are provided. Acquire and calculate the data of A receiver (27) B receiver (28) and A receiver (27) B receiver (28) that receive the information of the jig sensor (16) or the processing sensor (18). The jig sensor (16) or the jig sensor (16) indicates that the information processing means (26) is provided and the worker (40) places the part on the jig (1) or processes it by the processing means (11). In the "detected time" detected by the processing sensor (18) and the image recorded by the video camera unit (14), the part is placed on the jig or the processing means (11) by the processing work of the operator. A manufacturing system provided with a synchronization means (36) that synchronizes the time difference with the "time determined from the image" determined in () by the information processing means (26). In the product manufacturing line according to claim 1 or 2, the jig sensor (16) or the processing sensor (18) is provided with a jig sensor display means (15) or a processing sensor display means (17), respectively. The jig sensor display means (15) or the processing sensor display means (17) is a manufacturing system that displays a mounting state on a jig or an operating state of the processing means, respectively. The product manufacturing line is provided with a jig (1) or a processing means (11), and has a jig sensor (16) or a processing sensor (18) for detecting each state, and the jig sensor (16). It has a detection information storage unit (31) that stores the mounting state detected by the above or the operating state detected by the processing sensor (18) and the measurement data measured by the measurement means (12), and is a jig. A manufacturing system provided with an evaluation algorithm (51) for evaluating the production efficiency and measurement results of an operator by comparing the measurement data with the mounted state or the operating state of the tool (11). One or more jigs (1) or one or more processing means (11) and a video camera unit (14) arranged in the product manufacturing line, which is a product manufacturing line in which equipment for processing products or workers work. ) Is provided, and the video camera unit (14) is equipped with a recognition algorithm (72) that recognizes the position of the worker (40) in the image captured by the video camera unit (14). A manufacturing system that recognizes whether it is near the jig (1) or the processing means (11) or away from the jig (1) or the processing means (11).