JP4500876B1 - production management system - Google Patents

Abstract

To provide a production management system that processes data quickly and accurately, displays it to an operator, and realizes stable operation of a production process.
A data aggregation unit aggregates data of post-process items included in a post-process for each device constituting a process prior to the post-process, and obtains data of process items that can be acquired from each process for each process. Aggregate by device to be configured. The tabulated data is displayed so that the post-process item of the post-process and the pre-process item of the pre-process can be compared for each of the lot processed by the specific device and all the lots.
[Selection] Figure 8

Description

  The present invention relates to a production management system that supports the discovery of an abnormality in a production process performed by an operator who manages the production process based on various data obtained from the production process, and the evaluation of a factor analysis result at the time of the abnormality.

  Conventionally, in the production process of products, a production management system that performs processing based on data collected from the production process for the purpose of detecting abnormalities in the production process and monitoring long-term trends has been installed. Data indicating the status of the production process is provided to the operator.

  As a method for providing an operator with the status of a production process, Patent Document 1 displays a graph that shows the progress of an item for a specified item in the production process and character information about supplementary items on a single screen. Thus, a method for providing information to an operator is described. Furthermore, in Patent Document 2, as a data display means in the production management system, each evaluation data is displayed as a list for each item as a graph, and further, a means for enlarging and displaying a specific graph is introduced. Describes techniques used to display data during anomalies and to check daily data.

  On the other hand, there are many production processes for products that are produced by a large number of processes represented by various electronic devices and highly integrated products that are represented by electronic equipment incorporating various electronic devices. Since this process is composed of a large number of production apparatuses, data is acquired for a large number of data items from the production process. These large amounts of data items affect the quality control items of the products produced in a complex manner. For this reason, in order to manage such a production process, when an abnormality occurs in the production process and when an abnormality occurs, an appropriate data item and its data are extracted from a large number of data items. However, it is necessary to monitor or manage data transitions, trends, and distributions.

  Here, in the production process as described above, it is expected that new products will be launched at an early stage, high-efficiency production of products will be realized, etc., which will reduce quality variations, prevent mass defects, improve product yield, etc. There is a strong demand. In such a production process production management system, an operator who selects and determines measures for stable operation of the process is appropriately provided with data indicating the process status on a daily basis. Therefore, it is necessary to narrow down the cause of the failure from the data and provide it to the operator in order to prompt a countermeasure in advance by suggesting a sign of the occurrence of the defect.

JP 2003-122817 A Japanese Patent Laid-Open No. 9-50949

  However, in the conventional production management system, the means for extracting data from a large amount of data items is insufficient for the process of handling a large amount of data items as described above. Since it is not sufficiently considered to clearly indicate the range occupied by the extracted data, the operator cannot promptly determine the next action based on the extracted data. In particular, when one process is composed of a plurality of devices having the same function, means for extracting data while comparing data for each device, checking for abnormalities in the data of the extracted specific device, in one step When there are multiple data items, there is no way to confirm that the extracted items are abnormal compared to the surrounding data items. The work for confirming the above becomes necessary and the work becomes very complicated and the accuracy of the judgment is also lowered.

  SUMMARY OF THE INVENTION An object of the present invention is to provide a production management system that processes data quickly and accurately, displays the data to an operator, and realizes stable operation of the production process.

In order to solve the above problems, the production management system of the present invention is:
A production management system for managing a production process including at least one pre-process and at least one post-process based on data acquired in the production process,
A data collection unit that collects data that can be acquired from each device constituting the production process;
A data aggregation unit that aggregates data collected by the data collection unit;
A data display unit for displaying data aggregated by the data aggregation unit,
The data aggregation part
A first data aggregation device that aggregates data of post-process items included in the post-process for each device constituting the process before the subsequent process;
A second data aggregation device that aggregates the data of process items that can be acquired from each process, for each device constituting each process;
The data display section
A first display unit that displays data of all lots regarding a specific post-process item included in the specific post-process;
A second display unit for displaying the post-process item data by extracting only the data of the lot processed by the specific device from the post-process item data displayed on the first display unit;
A third display unit for displaying data of all lots regarding the previous process items included in the specific previous process;
A fourth display unit for displaying the previous process item data obtained by extracting only the data of the lot processed by the specific device among the previous process item data displayed on the third display unit;
The data display unit is characterized in that the first, second, third and fourth display units are simultaneously displayed on one display surface.

In the production management system of one embodiment,
The production process includes a manufacturing process including at least one individual manufacturing process and an inspection process including at least one individual inspection process.
The post-process is one individual inspection process of the inspection process,
The said pre-process is another production process performed before the one individual test process used as the said post process among the said production processes which consist of the said manufacturing process and the said test | inspection process.

In the production management system of one embodiment,
A processing system for the data display unit to simultaneously display the first, second, third, and fourth display units on one display surface,
A first tabulation process that tabulates the collected post-process data by the previous process in which the product has been processed;
A first display step for displaying a list of the tabulated results tabulated in the first tabulation step;
A first input step of selecting and inputting a previous step from the list display displayed by the first display step;
A second tabulation step of tabulating post-process data for each device constituting the previous step input in the first input step;
A second display step for displaying a list of the tabulated results tabulated in the second tabulation step;
A second input step of selecting and inputting a device from the list display displayed by the second display step;
A third tabulation step of tabulating a list of pre-process item data and post-process item data that can be acquired from the device input in the second input step;
And a third display process for displaying the previous process item data and the subsequent process item data which are aggregated in the third aggregation process.

In the production management system of one embodiment,
The data aggregation unit includes a data analysis device,
The data analysis apparatus uses the previous process item data acquired in the previous process and the subsequent process item data acquired in the subsequent process as a cause of failure by statistical analysis for defects generated in the production process. Then, at least one of a specific pre-process device or a pre-process item is extracted, and the data of the extracted defect factor is displayed on the data display unit.

  In the production management system according to an embodiment, the data analysis device extracts items included in a specific device as a failure factor by statistical analysis, and displays the extracted failure factor items on the data display unit. To highlight.

In the production management system of one embodiment,
The data analysis apparatus corresponds to data corresponding to explanatory variables including one or more qualitative variables and one or more quantitative variables corresponding to the qualitative variables, and objective variables described by the explanatory variables. Including an influence factor specifying system for specifying factors that influence the objective variable among the explanatory variables for the analysis target data including a plurality of sets of data by changing these variables,
This influencing factor identification system separates each data set composed of the quantitative variables in the explanatory variables into a plurality of segments according to the levels of the qualitative variables in the explanatory variables. In addition, a pseudo-data set that can be handled as a quantitative variable is obtained for the segment and a blank that complements the segment, and a multivariate analysis method is applied to the explanatory variable and the objective variable that are a set of the pseudo-data sets. Apply to identify influencing factors that affect the objective variable.

In the production management system of one embodiment,
The analysis target data is data relating to the production process of the product acquired in the production process,
The explanatory variable is data that records data items acquired from the previous processes.
The objective variable is data recorded as a qualitative variable or a quantitative variable as a qualitative variable or a quantitative variable in a subsequent process for a product produced by the production process.
The change of each said variable is corresponded to the change for every manufactured product of the said front process item data and the said back process item data.

In the production management system of one embodiment,
The display surface of the data display section is divided into a total of four parts, two vertically and two horizontally,
The first display unit is disposed at an upper left portion of the display surface,
The second display unit is disposed in the upper right part of the display surface,
The third display unit is disposed in the lower left part of the display surface,
The fourth display unit is disposed in the lower right portion of the display surface.

In the production management system of one embodiment,
The first display unit, the second display unit, the third display unit, and the fourth display unit display each data as a graph,
The data displayed by the first display unit and the data displayed by the second display unit are displayed in an overlapping manner,
The data displayed by the third display unit and the data displayed by the fourth display unit are displayed in an overlapping manner,
The data displayed by the second display unit and the data displayed by the fourth display unit are displayed by the data displayed by the first display unit and the third display unit. Displayed with different data and different colors.

  In the production management system of one embodiment, the data displayed by the second display unit and the data displayed by the fourth display unit are further displayed blinking.

In the production management system of one embodiment,
The first display unit, the second display unit, the third display unit, and the fourth display unit display each data as a graph,
With respect to the same item among the data items displayed on the graph, the graph is drawn so that the ranges of the axes of the plurality of graphs are the same.

In the production management system of one embodiment,
The setting system to set the graph axis range for each item is
When drawing the graph of all lots with graph drawing software, then temporarily storing the range of each axis of the drawn graph, and then drawing the graph of the lot processed by the specific device Apply the range of each axis of the stored graph, draw the graph, and the data range of each axis for the graph on the display surface, the graph of all lots and the lot processed by the specific device Match with the graph.

  According to the production management system of the present invention, the data collection unit, the data totaling unit, and the data display unit are provided, and the data totaling unit includes the first data totaling device and the second data. The data display unit includes the first display unit, the second display unit, the third display unit, and the fourth display unit, and the data display unit. Since the display unit displays the first, second, third and fourth display units simultaneously on one display surface, the data is processed quickly and accurately and displayed to the operator. This ensures stable operation of the production process.

It is the schematic of the production process to which the production management system of this invention is applied. 1 is a schematic diagram showing a first embodiment of a production management system of the present invention. It is a flowchart of the 1st arithmetic unit. It is a flowchart of the 2nd arithmetic unit. It is a flowchart of a 3rd arithmetic unit. It is the schematic which shows the 1st display content. It is the schematic which shows the 2nd display content. It is the schematic which shows the 3rd display content. It is the schematic which shows 2nd Embodiment of the production management system of this invention, and shows a 3rd display content. It is a schematic diagram which shows 3rd Embodiment of the production management system of this invention. It is the schematic which shows defect factor analysis object data. It is the schematic which shows the analysis object data divided | segmented for every apparatus number. It is the schematic which shows the 3rd display content.

  Hereinafter, the present invention will be described in detail with reference to the illustrated embodiments.

(First embodiment)
FIG. 1 shows a schematic diagram of a production process to which the production management system of the present invention is applied. This production process includes a manufacturing process 101 for assembling and adjusting the product and an inspection process 104 for inspecting the product after the manufacturing process ends.

  The manufacturing process 101 includes a plurality of individual manufacturing processes 102, and each process 102 includes a plurality of assembly and adjustment manufacturing apparatuses 103 that perform the same operation. The product is managed by a lot number, processed by any of a plurality of assembling and adjusting manufacturing apparatuses 103, and proceeds to the next process.

  The inspection process 104 includes a plurality of individual inspection processes 105. In one inspection process 105, inspection is performed on a plurality of inspection items, and inspection data is acquired. One inspection process 105 includes a plurality of inspection devices 106 that perform the same inspection, and the product is inspected by any one of the inspection devices 106. An allowable range is set for each inspection item, and a product within the allowable range proceeds to the next process, and a product that deviates from the allowable range is processed as a defective product.

  As the characteristics of the process of the present embodiment, the items related to the inspection item of the arbitrary individual inspection process 105 are the items of the individual manufacturing process 102 and the individual inspection process performed before the arbitrary individual inspection process 105. There are 105 items. For this reason, in the analysis of the failure factor, the inspection process 105 performed before the inspection process 105 in which defects frequently occur is also included in the failure factor candidates.

  FIG. 2 is a schematic diagram showing an embodiment of the production management system of the present invention. Each device 103, 106 of the production process 100 is equipped with a data collection unit 204 that collects data, and sequentially stores the product lot number and data collected by the data collection means provided in the data collection unit 204. To the device 207.

  The data totaling unit 205 includes a first arithmetic unit 208, a second arithmetic unit 209, and a third arithmetic unit 210, and the arithmetic units 208 to 210 perform arithmetic operations for extracting data to be described later from the data collection unit 204. Execute the process.

  Further, the data display unit 206 is provided with a display device 211, and displays the results of data aggregation and analysis as a chart for the operator. As specific devices, various monitor devices, printer devices, and the like are provided. In addition, an input device 212 such as a mouse and a keyboard is provided for an operator to instruct and input the production management system 203.

  The first arithmetic unit 208 aggregates the inspection data in the inspection process 105 by the manufacturing process 102 and the apparatuses 103 and 106 constituting the inspection process 105 prior to the inspection process 105.

  The processing steps of the first arithmetic unit 208 will be described. As shown in FIG. 3, the first inspection step is selected (S301), and the first inspection item of the selected inspection step is selected (S302). . The “inspection item” is an item for measuring a product for inspection. For example, an electronic device is an output characteristic or a response characteristic with respect to a certain signal, and a light emitting device is an emission intensity or an emission wavelength.

  Then, the data of the inspection item selected in step S302 is divided for each apparatus in the process prior to the inspection process selected in step S301 (S303). Here, the previous process includes the manufacturing process and the inspection process immediately before the inspection process selected in step S301.

  Then, for the data divided in step S303, the number of passes, the number of failures, and the defect rate (= failure number / (passage number + failure number)) are calculated for each device (S304).

  Thereafter, steps S303 and S304 are repeated for all previous processes (S305), steps S302 to S305 are repeated for all inspection items (S306), and steps S301 to S306 are repeated for all inspection processes (S307). .

  The second arithmetic unit 209 collects the data of the inspection item selected by the operator for each manufacturing apparatus 103 in the arbitrary manufacturing process 102 and the time when the data is acquired.

  The processing steps of the second arithmetic unit 209 will be described. As shown in FIG. 4, an inspection item is selected (S401), and a manufacturing process is selected (S402).

  Then, for the selected manufacturing process, the selected inspection item data and the data of the time when the inspection item was performed in the lot processed by the first manufacturing apparatus are tabulated (S403).

  Thereafter, step S403 is repeated for all the manufacturing apparatuses in the manufacturing process selected in step S401 (S404).

  The third arithmetic unit 210 collects data on lots processed by the manufacturing apparatus with respect to the data items that can be acquired by the manufacturing apparatus with respect to the manufacturing apparatus of an arbitrary previous process, together with the processing time in the manufacturing apparatus.

  The processing steps of the third arithmetic unit 210 will be described. As shown in FIG. 5, the manufacturing device of the previous step is selected (S501), and the first manufacturing item of the selected manufacturing device is selected (S502). Then, the data of the selected manufacturing item in the lot processed by the selected manufacturing apparatus is totaled (S503). The “manufacturing item” is an item included in a specific process for manufacturing a product. For example, in the case of an assembly process, the mounting position and angle of a component, an adjustment amount of a component position, a position after adjustment, and the like.

  Thereafter, steps S502 and S503 are repeated for all the manufacturing items of the selected manufacturing apparatus (S504). For the lots processed by the manufacturing apparatus selected in step S501, the processing time data is aggregated (S505).

  Next, a data processing procedure in the production management system will be described. Here, it is assumed that process data from the production process 100 is sequentially stored in the storage device 207 of the data collection unit 204.

  First, the operator executes the first arithmetic device 208. The execution results are displayed on the data display unit 206 as a list. This display content is the first display content.

  As shown in FIG. 6, in the first display content, the failure occurrence status is displayed as a graph and a table as a list to the operator, so that the problem location of the current process can be identified, and the next step is to the operator. Encourage selection of process problems (high defect rate, high defect quantity). Here, the operator can select an inspection item with a high defect rate and a problematic production process (for example, bias in occurrence of defects). The inspection item selected at this time is defined as an inspection item α, and the selected production process is defined as a production process M.

  When the inspection item and the production process are selected, the second arithmetic unit 209 is automatically executed. The executed results are displayed on the data display unit 206 as a trend graph list. This display content is the second display content.

  As shown in FIG. 7, in the second display content, a trend graph 701 of inspection data of inspection items α of lots processed by each device included in the selected production process M is displayed as a list. Then, as reference data, a trend graph 702 of inspection items α for all lots is displayed, and a failure rate graph 703 for each device is displayed.

  Here, since a list of trend graphs is displayed for the inspection data for each device to the operator, the operator can specify a manufacturing device having an abnormality and selectively input it to the production management system. Prompt. At this time, if the production management system is the same production process (manufacturing process), a plurality of apparatuses (manufacturing apparatuses) can be selected. The device in the production process M selected at this time is set as a device Mi (i = 1,..., N (n is the number of devices)).

  When an apparatus (manufacturing apparatus) is selected, the third arithmetic unit 210 is automatically executed. The executed result is displayed on the data display unit 206 by a trend graph and a correlation diagram. This display content is the third display content.

  As shown in FIG. 8, in the third display content, the data display unit 206 is divided into a range divided into a total of four, two in the vertical and horizontal directions, and the first display unit 801 is located at the upper left of the display unit, respectively. The upper right is the second display unit 802, the lower left is the third display unit 803, and the lower right is the fourth display unit 804.

  The first display unit 801 displays all the data of the selected inspection item α as a trend graph. The second display unit 802 displays the lot data processed by the selected apparatus Mi for the selected inspection item α in a trend graph.

  The third display unit 803 displays all product data in a trend graph for the data items mj of the production process M including the selected device Mi, and further displays the inspection item α and the data items mj of the production process. Display a scatter plot that confirms the correlation. Here, mj (j = 1,..., L (l is the number of items)) is a data item that can be acquired in the production process M.

  In the fourth display unit 804, for the data item mj that can be acquired from the selected production process M, the lot data processed by the selected apparatus Mi is shown in a trend graph, and further processed by the selected apparatus Mi. For the lot data, a scatter diagram for confirming the correlation between the search item α and the data item mj of the production process M is displayed.

  First, the operator compares the entire data with the extracted lot data processed by the apparatus Mi for the inspection item α of interest by comparing the first display unit 801 and the second display unit 802. Then, it can be determined whether the tendency or variation is abnormal.

  Next, by comparing the first display unit 801 and the third display unit 803, and confirming the trend and variation in data from the trend graph of the inspection item α and the production item mj, the inspection item α and the production are confirmed. It is possible to grasp the overall relationship between the items mj, that is, the relationship between the production item mj that affects the inspection item α and the production item mj that is not given.

  Next, by comparing the data of the second display unit 802 and the fourth display unit 804, the graph of the production item mj of the inspection item α of the lot processed by the extracted apparatus Mi is compared. The production item that seems to be At this time, the data of the production item that seems to be abnormal is compared with the whole data of the third display unit 803. The operator can devise measures to improve the process such as adjustment, correction, and review of settings of the production process. Such an inspection result, candidate factor data, data of all devices and data of a specific device can be compared in one screen, so that an operator who is a manager of the production process can easily analyze the data. be able to.

  Here, a method for creating the third display content shown in FIG. 8 will be described. In the trend graph of the third display content, the display ranges of the x-axis (time axis) and the y-axis (examination data axis) of the trend graphs of the first display unit 801 and the second display unit 802 are matched. In addition, the display ranges of the same items are made to coincide on the trend graphs of the third display unit 803 and the fourth display unit 804 and the x and y axes of the scatter diagram.

  Means for automatically setting the axes of such a graph are as follows. The procedure described below is for the first display unit 801 and the third display unit 803. In addition, this system automatically gives an appropriate display range to each axis when graph data is given.

  First, a trend graph of the first display unit 801 is created, and display ranges (x1, x2) and (y1, y2) of the graph created by the first display unit 801 are acquired. Next, a trend graph is created by the second display unit 802, and each axis of the trend graph created by the second display unit 802 is set by (x1, x2), (y1, y2).

  In this processing procedure, since the graph of the first display unit 801 is a graph of all devices, the display range of each axis is the maximum, and a display graph of data processed by a specific device within that range is created. Therefore, when the graph is displayed on the display unit, the comparison is easy. Further, since the axis is automatically given when the graph of the first display unit 801 is created, it changes every time the process is performed. Since there is no need to prepare a calculation part to cope with a change in the display range of each axis, the processing is simple and fast.

  In addition, in the figures referred to in the above explanation, various process data are displayed in graphs, and the numerical values of each graph are normalized for convenience of explanation. Even if it shows by actual numerical value, there is no trouble. Depending on the situation, it is desirable to use real values to present the data to the operator. The same applies to the graphs in the following embodiments.

  In summary, the production management system 203 manages the production process 100 including at least one pre-process and at least one post-process based on the data acquired in the production process 100.

  The production management system 203 includes a data collection unit 204 that collects data that can be acquired from each device constituting the production process 100, a data totaling unit 205 that totals the data collected by the data collection unit 204, and this data totalization. And a data display unit 206 that displays data aggregated by the unit 205.

  The data totaling unit 205 includes a first data totaling device that totals the data of the post-process items included in the post-process for each device constituting the process before the post-process, and the process item data that can be acquired from each process. And a second data totaling device for (automatically) totaling each device constituting each process. The first data totaling device and the second data totaling device constitute a first arithmetic device 208.

  The data display unit 206 includes the first, second, third, and fourth display units 801 to 804.

  The first display unit 801 displays all lot data for a specific post-process item (item c1) included in the specific post-process (process C).

  The second display unit 802 extracts post-process item data from the post-process item data displayed on the first display unit 801 by extracting only the data of the lot processed by the specific device (device B4). indicate.

  The third display unit 803 displays data of all lots regarding the previous process items (items b1 and b2) included in the specific previous process (process B).

  The fourth display unit 804 extracts the previous process item data obtained by extracting only the data of the lot processed by the specific device (device B4) from the previous process item data displayed on the third display unit 803. Is displayed.

  The data display unit 206 simultaneously displays the first, second, third, and fourth display units 801 to 804 on one display surface (confirmed by the operator).

  According to the production management system 203 configured as described above, in the production management system 203 that manages the production process 100 of products that can be divided into a pre-process and a post-process, data necessary for production management is extracted from an enormous amount of data to produce The operator who manages the line, the item data of the post-process managed mainly as quality control items, the data of the pre-process that affects the items, and the above two types of data under specific conditions By displaying the extracted data in such a way that it can be confirmed at a glance, it is possible to quickly confirm the cause of the defect occurring in the production process 100.

  Therefore, it is possible to extract data necessary for process abnormality detection and factor extraction at the time of occurrence of defects from data acquired from the production process 100 having a large number of devices and a large number of management items. Since it is possible to display data necessary to determine the measure, stable operation of the production process 100 is realized.

  In the production management system 203, the production process 100 includes a manufacturing process 101 including at least one individual manufacturing process 102 and an inspection process 104 including at least one individual inspection process 105. The post-process is one individual inspection process 105 of the inspection process 104. The pre-process is another production process that is performed before one individual inspection process 105 as the post-process among the production processes 100 including the manufacturing process 101 and the inspection process 104.

  According to the production management system 203 having the above-described configuration, in the production process 100 that flows from manufacturing to inspection, it is possible to obtain a factor in the processing content of the manufacturing process 101 from the result of the inspection process 105. By including the inspection process 105 performed before the post-process, the relationship between the inspection processes can be analyzed, and therefore, the data analysis of the production process 100 can be performed more effectively. Depending on the type of the production process 100, there are cases in which the relationship between the inspection processes can be estimated, and if it breaks (for example, the correlation is lost), an abnormality has occurred in the process.

  In the production management system 203, the data display unit 206 displays the first, second, third, and fourth display units 801 to 804 on one display surface at the same time. Has a processing system. The processing system includes a first counting step, a first display step, a first input step, a second counting step, a second display step, a second input step, and a third A counting step and a third display step;

  In the first tabulation step, the collected post-process data is tabulated for each previous process in which the product is processed. The first display step displays a list of the tabulated results tabulated in the first tabulation step. In the first display step, the first display content of FIG. 6 is displayed. The first input step selects and inputs a previous step from the list display displayed by the first display step.

  In the second tabulation step, the post-process data is tabulated for each device constituting the previous step input in the first input step. The second display step displays a list of the tabulation results tabulated in the second tabulation step. In the second display step, the second display content of FIG. 7 is displayed. In the second input step, an apparatus is selected and input from the list display displayed in the second display step.

  The third tabulation step tabulates a list of pre-process item data and post-process item data that can be acquired from the device input in the second input step. The third display step displays the pre-process item data and the post-process item data that have been tabulated (restricted to a specific range) by the third tabulation step. In the third display step, the third display content of FIG. 8 is displayed.

  According to the production management system 203 configured as described above, it is possible to effectively process the data to be displayed. In other words, since it is not easy to select a specific production process 100 from a large amount of production data obtained from many production processes 100, it is automatically selected for the operator in order of process and apparatus in order. By prompting the data display and input, it is possible to smoothly display a portion requested by the operator (for example, data of a device in which a defect has occurred). More specifically, this is a procedure in which important inspection results in the production process 100 are displayed for each process, an overview of the previous process is confirmed, and an apparatus is selected from the next specified previous process. For this reason, since the data range is narrowed down in the order in which the operator can easily understand the enormous data range, the operator can immediately confirm the abnormal part of the process and the data of the factor.

  Further, in the production management system 203, the display surface of the data display unit 206 is divided into a total of four parts, two in each of vertical and horizontal directions, and the first display unit 801 is arranged in the upper left part of the display surface. The second display unit 802 is disposed in the upper right part of the display surface, the third display unit 803 is disposed in the lower left part of the display surface, and the fourth display unit 804 is configured to display the display. Located at the bottom right of the surface.

  According to the production management system 203 of the embodiment having the above configuration, the data can be confirmed more easily. In other words, by displaying the four data contents on one display screen, the data of all devices is displayed on the left side of the screen, the data of the specific device is displayed on the right side, the test result data to be analyzed on the upper side, and the factor data on the lower side Will be displayed. In this way, since data can be compared based on the results and factors, and the relationship between the entire device and the specific device, the data can be confirmed more easily, and the accompanying judgment can be made accurately.

  In the production management system 203, the first, second, third, and fourth display units 801 to 804 display each data as a graph, and items of data displayed on the graph. Among the same items, the graphs are drawn so that the ranges of the axes of the plurality of graphs are the same.

  According to the production management system 203 having the above configuration, a large amount of data is displayed. By graphing the data, it is possible to understand the contents of the data rather than enumeration of numerical values (particularly, the distribution of data distribution, the degree of deviation of abnormal values). Further, by aligning the range of the numerical value axis of each item, when checking the same item in a plurality of graphs, the operator can accurately diagnose the distribution of data on the graph.

  In the production management system 203 of the present invention, the setting system for setting the axis range of the graph according to each item draws the graph of all the lots with the graph drawing software, and then the graph of the drawn graph. Temporarily store the range of each axis, and then draw the graph by applying the range of each axis of the stored graph when drawing the graph of the lot processed by the specific device In this case, the data range of each axis of the graph on the display surface may be matched between the graph of all lots and the graph of lots processed by the specific device.

  According to the production management system 203 configured as described above, when drawing the graph display on the screen, the numerical range is already determined in the processing when drawing other graphs by holding the data range that is the reference of each item. The processing procedure is simplified. Thus, it is necessary to draw a large number of graphs on the screen, and the processing time for screen display can be shortened.

(Second Embodiment)
FIG. 9 shows a second embodiment of the production management system of the present invention. In the second embodiment, the production process, the production management system, the data processing procedure, the first display content in FIG. 6, and the second display content in FIG. 7 are the same in the first embodiment.

  A third display content display method according to the second embodiment will be described. Here, similarly to the first embodiment, the inspection item to be analyzed and examined is the inspection item α, the production process designated by the operator is the production process M, the production process apparatus is Mi, and the production process M is the production process M. Let mj be the data item that can be acquired.

  As shown in FIG. 9, in the third display content, the data display unit 206 is divided into two upper and lower areas, and the upper display unit is area A and the lower display unit is area B, respectively.

  In the area A, for the inspection item α, the data of all the products and the data of the lot processed by the device Mi designated by the operator are displayed superimposed on one trend graph, and in particular, the lot processed by the device Mi The data display is highlighted in a different color from the overall data.

  In area B, a trend graph of the data item mj of the production process M and a distribution map of the inspection item α and the data item mj of the production process M are created, and the data Mi 902 of all products and the device Mi designated by the operator are created there. The lot data 901 processed in the above is displayed in an overlapping manner. In particular, the display of lot data processed by the apparatus Mi is highlighted in a color different from the whole data.

  In this display means, the entire data and the extracted data are displayed in one graph, so that the comparison between the entire data and the extracted data is easier to understand. Can be performed more accurately.

  In this example, the graph displayed in a superimposed manner is different in color, but in order to further emphasize, the color of the data of the lot processed by the apparatus Mi is changed and further blinked on the graph. Also good.

  In summary, in the production management system, the first, second, third, and fourth display units 801 to 804 (refer to the first embodiment) display each data as a graph.

  The data displayed by the first display unit 801 and the data displayed by the second display unit 802 are displayed in an overlapping manner. The data displayed by the third display unit 803 and the data displayed by the fourth display unit 804 are displayed in an overlapping manner.

  The data displayed by the second display unit 802 and the data displayed by the fourth display unit 804 are the data displayed by the first display unit 801 and the third display unit. The data displayed in 803 is displayed in a different color.

  According to the production management system having the above configuration, four data contents are displayed on one screen. By displaying the entire data and the data of the specific device in the same display section, the inspection result and the previous data are displayed. It becomes two divisions of process item data. Since the data of the entire device and the specific device can be confirmed at one time with one display unit, the data difference between the data of the specific device and other devices becomes clear.

  Note that the data displayed by the second display unit 802 and the data displayed by the fourth display unit 804 may be further blinked.

  According to the production management system having the above configuration, the visibility of data is further improved by blinking the data of the specific device. For example, when it is necessary to check data in a short time, such as actual operation in the production process, and when a warning is given to the operator, the degree of emphasis increases for the operator. Can be overlooked.

(Third embodiment)
FIG. 10 shows a third embodiment of the production management system of the present invention. The difference from the first embodiment will be described. The third embodiment has a data analysis device. In the third embodiment, the same parts as those in the first embodiment are denoted by the same reference numerals, and detailed description thereof is omitted.

  As shown in FIG. 10, the production management system 203A has a data analysis device 1001 in the data totaling unit 205A. The data analysis apparatus 1001 extracts the cause of the defect that has occurred in the production process from the data stored in the data collection unit 204 by using statistical analysis to be described later. Note that the data analysis device 1001 may realize the function using the same arithmetic device as the data totaling unit 205 of the first embodiment.

  Here, an analysis procedure of factor analysis for a defect generated in the production process by the data analysis apparatus 1001 will be described.

  In performing data analysis, qualitative variables include categories such as device numbers, device operators, manufacturing recipes, etc., and quantitative variables include adjustment values, temperature, pressure, gas flow rate, and other operating conditions. , Qualitative variables include device numbers, quantitative variables include assembly parameters in the assembly process, adjustment values in the adjustment process, and inspection measurement values in the inspection process.

  Next, data to be analyzed will be specifically described with reference to FIG. Each product is assigned a product number, and the number of the processed apparatus is associated with each value of assembly, adjustment, and inspection. When performing factor analysis on this data, the objective variable is an inspection measurement item, and the explanatory variable is a quantitative variable of a process prior to the inspection process including the objective variable.

  In FIG. 11, a table is composed of objective variables, that is, data of items to be analyzed such as inspection items in which defects are occurring, and data of items to be explanatory variables.

  Here, looking at the data to be analyzed in detail, the products “Lot01” to “Lot10” are processed by the first machine in the process A, and the products “Lot11” to “Lot20” are processed by the second machine. Has been. Similarly, in the process B, “Lot01” to “Lot05” and “Lot11” to “Lot15” are processed in the first machine, and “Lot06” to “Lot10” and “Lot16” to “Lot20” are processed in the second machine. ”Has been processed.

  In the present embodiment, an explanatory variable having a high influence degree is extracted as a factor for an inspection item that is an objective variable by the following procedure (step 1 to step 3).

  First, as step 1, each data set composed of quantitative variables in the explanatory variables is separated into a plurality of segments according to the levels of the qualitative variables in the explanatory variables.

  For example, as shown in FIG. 12, the data set of the adjustment value “process A_a1” in FIG. 11 is divided into two segments (“process A_a1” depending on the levels of the device numbers “1” and “2” in process A. 10 data in the “(Unit 1)” column and 10 data in the “Process A_a1 (Unit 2)” column. Similarly, the data set of the adjustment value “Process A_a2” in FIG. As shown in the figure, depending on the level of the device numbers “No. 1” and “No. 2” of the process A, there are two segments (“Process A_a2 (No. 1)” column 10 data and “Step A_a2 (No. 2)”). The data is separated into 10 pieces of data in the "" column.

  Next, as step 2, as shown in FIG. 12, a data set composed of a segment of data that is a quantitative variable and a blank space that complements the segment is created.

  Next, as step 3, a multivariate analysis method is applied to the data set created in step 2 to identify influencing factors that affect the objective variable. Here, the multivariate analysis used may be, for example, principal component analysis, regression analysis, PLS, or the like.

  By the above analysis, explanatory variables as factors are extracted. The extracted variables are specific items of specific production apparatuses. Information on the extracted items is sent to the arithmetic device, and the processing of the first, second, and third arithmetic devices 208, 209, and 210 is automatically executed.

  The result of the processing is displayed to the operator by the third display content method in the first embodiment or the second embodiment. An example of the display result is shown in FIG. Assuming that the analysis item to be analyzed, which is the objective variable, is the inspection item α, and the extracted items are the process X, the device Xa, and the item x, the upper left part of the display surface (first display unit 1301) A trend graph of all products is displayed, and in the upper right part (second display part 1302) of the display surface, a trend graph of the inspection item α of the lot processed by the production apparatus Xa is displayed, and the lower left part (the second display part) 3 display section 1303), a trend graph of all products of items included in process X and a distribution chart of inspection items α are displayed. In the lower right part of the display surface (fourth display section 1304), process X is displayed. For the included items, a trend graph of lots processed by the production apparatus Xa and a distribution map of inspection items α are displayed. Further, at this time, since the specific production item x is extracted in the analysis of the present embodiment, the graphs 1305 and 1306 of the item are highlighted.

  With such a display method, the operator confirms on the fourth display unit 1304 what kind of tendency, distribution, and variation the cause of the failure extracted in the factor analysis shows in the actual production data. The degree of influence on the inspection item can be confirmed on the second display unit 1302 and the comparison with the whole data can be confirmed by comparing with the first and third display units 1301 and 1303. And since it can be judged whether it is abnormal extracted based on the data, the result of an analysis can be quickly fed back to a production process. Furthermore, evaluation of the results of the analysis method used in this embodiment requires a certain level of proficiency, but since the analysis results are shown as data that can be acquired in the production process as in this embodiment, the analysis results are evaluated. It is easier and the accuracy of measures to stabilize the production process based on the analysis results is improved.

  In summary, in the production management system 203A, the data totaling unit 205A has a data analysis device 1001. The data analysis apparatus 1001 uses the previous process item data acquired in the previous process and the subsequent process item data acquired in the subsequent process for the defects generated in the production process to perform a failure factor by statistical analysis. As described above, at least one of a specific pre-process apparatus or a pre-process item is extracted, and the data of the extracted defect factor is displayed on the data display unit 206.

  According to the production management system 203A having the above-described configuration, the analysis result is displayed on the data display unit 206, so that the analysis result that requires skill to understand is displayed on the screen displaying the normal process state. And the analysis results can be clearly shown.

  In the production management system 203A, the data analysis apparatus 1001 extracts items included in a specific apparatus as a failure factor by statistical analysis, and displays the extracted failure factor items on the data display unit 206. To highlight (automatically).

  According to the production management system 203A having the above configuration, it is possible to automatically display the display contents clearly. This is because the first, second, third, and fourth display units 1301 to 1304 display a plurality of items in the previous process, and thus highlight the items extracted in the analysis. Therefore, it is possible to clearly indicate to the operator, and it is possible to more accurately determine the difference in data.

  In the production management system 203A, the data analysis apparatus 1001 includes data corresponding to explanatory variables including one or more qualitative variables and one or more quantitative variables corresponding to the qualitative variables, and the description. Including an influence factor identification system for identifying factors affecting the objective variable among the explanatory variables for the analysis target data including a plurality of sets of data corresponding to the objective variable explained by the variable by changing these variables . This influencing factor identification system separates each data set composed of the quantitative variables in the explanatory variables into a plurality of segments according to the levels of the qualitative variables in the explanatory variables. In addition, a pseudo-data set that can be handled as a quantitative variable is obtained for the segment and a blank that complements the segment, and a multivariate analysis method is applied to the explanatory variable and the objective variable that are a set of the pseudo-data sets. Apply to identify influencing factors that affect the objective variable.

  According to the production management system 203A having the above-described configuration, it is possible to analyze a qualitative variable by converting the qualitative variable into a quantitative variable. That is, the data obtained from the production process includes numerical data (quantitative variables) and qualitative data such as device numbers. When multivariate analysis is performed on such data, the influence of qualitative data can be analyzed.

  In the production management system 203A, the analysis target data is data related to a product production process acquired in the production process. The explanatory variable is data in which data items acquired from the previous processes are recorded. The objective variable is data obtained by recording a processing result in a subsequent process for a product by the production process as a qualitative variable or a quantitative variable. The change of each said variable is corresponded to the change for every manufactured product of the said front process item data and the said back process item data.

  According to the production management system 203A having the above-described configuration, it is possible to accurately systematize the method by clearly indicating to which part of the production process the explanatory variable and the objective variable are applied. In particular, in the analysis, when the explanatory variable is a pre-process and the target variable is a post-process, the pre-process is always extracted as an item that affects the target variable. Since the explanatory variable does not include the post-process, the post-process items that seem to have an influence are not extracted, and disturbance to the analysis can be reduced.

DESCRIPTION OF SYMBOLS 100 Production process 101 Manufacturing process 102 Individual manufacturing process 103 Manufacturing apparatus 104 Inspection process 105 Individual inspection process 106 Inspection apparatus 203,203A Production management system 204 Data collection part 205,205A Data totaling part 206 Data display part 207 Data storage apparatus 208 1st 209 Second arithmetic device 210 Third arithmetic device 211 Display device 212 Input device 701 Trend graph of inspection data α of lots processed by each device 702 Trend graph of inspection items α of all lots 703 Graph of defect rate for each apparatus 801, 1301 First display unit 802, 1302 Second display unit 803, 1303 Third display unit 804, 1304 Fourth display unit 901 Extracted lot data 902 All product data 1001 Analysis device 130 5,1306 Highlighted graph

Claims (12)

A production management system for managing a production process including at least one pre-process and at least one post-process based on data acquired in the production process,
A data collection unit that collects data that can be acquired from each device constituting the production process;
A data aggregation unit that aggregates data collected by the data collection unit;
A data display unit for displaying data aggregated by the data aggregation unit,
The data aggregation part
A first data aggregation device that aggregates data of post-process items included in the post-process for each device constituting the process before the subsequent process;
A second data aggregation device that aggregates the data of process items that can be acquired from each process, for each device constituting each process;
The data display section
A first display unit that displays data of all lots regarding a specific post-process item included in the specific post-process;
A second display unit for displaying the post-process item data by extracting only the data of the lot processed by the specific device from the post-process item data displayed on the first display unit;
A third display unit for displaying data of all lots regarding the previous process items included in the specific previous process;
A fourth display unit for displaying the previous process item data obtained by extracting only the data of the lot processed by the specific device among the previous process item data displayed on the third display unit;
The production control system, wherein the data display unit simultaneously displays the first, second, third and fourth display units on one display surface. The production management system according to claim 1,
The production process includes a manufacturing process including at least one individual manufacturing process and an inspection process including at least one individual inspection process.
The post-process is one individual inspection process of the inspection process,
The said pre-process is another production process performed before one individual inspection process used as the said back process among the said production processes consisting of the said manufacturing process and the said inspection process, The production management system characterized by the above-mentioned . In the production management system according to claim 1 or 2,
A processing system for the data display unit to simultaneously display the first, second, third, and fourth display units on one display surface,
A first tabulation process that tabulates the collected post-process data by the previous process in which the product has been processed;
A first display step for displaying a list of the tabulated results tabulated in the first tabulation step;
A first input step of selecting and inputting a previous step from the list display displayed by the first display step;
A second tabulation step of tabulating post-process data for each device constituting the previous step input in the first input step;
A second display step for displaying a list of the tabulated results tabulated in the second tabulation step;
A second input step of selecting and inputting a device from the list display displayed by the second display step;
A third tabulation step of tabulating a list of pre-process item data and post-process item data that can be acquired from the device input in the second input step;
A production management system comprising: a third display process for displaying the previous process item data and the subsequent process item data aggregated in the third aggregation process. In the production management system according to any one of claims 1 to 3,
The data aggregation unit includes a data analysis device,
The data analysis apparatus uses the previous process item data acquired in the previous process and the subsequent process item data acquired in the subsequent process as a cause of failure by statistical analysis for defects generated in the production process. A production management system characterized by extracting at least one of a specific pre-process device or a pre-process item, and displaying the extracted defect factor data on the data display unit. In the production management system according to claim 4,
The data analysis device extracts an item included in a specific device as a failure factor by statistical analysis, and causes the display of the extracted failure factor item to be highlighted on the data display unit. system. In the production management system according to claim 4 or 5,
The data analysis apparatus corresponds to data corresponding to explanatory variables including one or more qualitative variables and one or more quantitative variables corresponding to the qualitative variables, and objective variables described by the explanatory variables. Including an influence factor specifying system for specifying factors that influence the objective variable among the explanatory variables for the analysis target data including a plurality of sets of data by changing these variables,
This influencing factor identification system separates each data set composed of the quantitative variables in the explanatory variables into a plurality of segments according to the levels of the qualitative variables in the explanatory variables. In addition, a pseudo-data set that can be handled as a quantitative variable is obtained for the segment and a blank that complements the segment, and a multivariate analysis method is applied to the explanatory variable and the objective variable that are a set of the pseudo-data sets. A production management system characterized by being applied to identify influential factors that affect the objective variable. The production management system according to claim 6,
The analysis target data is data relating to the production process of the product acquired in the production process,
The explanatory variable is data that records data items acquired from the previous processes.
The objective variable is data recorded as a qualitative variable or a quantitative variable as a qualitative variable or a quantitative variable in a subsequent process for a product produced by the production process.
The change of each said variable is corresponded to the change for every manufactured goods of the said front process item data and the said back process item data, The production management system characterized by the above-mentioned. The production management system according to claim 1,
The display surface of the data display section is divided into a total of four parts, two vertically and two horizontally,
The first display unit is disposed at an upper left portion of the display surface,
The second display unit is disposed in the upper right part of the display surface,
The third display unit is disposed in the lower left part of the display surface,
The production management system according to claim 4, wherein the fourth display unit is arranged at a lower right portion of the display surface. The production management system according to claim 1,
The first display unit, the second display unit, the third display unit, and the fourth display unit display each data as a graph,
The data displayed by the first display unit and the data displayed by the second display unit are displayed in an overlapping manner,
The data displayed by the third display unit and the data displayed by the fourth display unit are displayed in an overlapping manner,
The data displayed by the second display unit and the data displayed by the fourth display unit are displayed by the data displayed by the first display unit and the third display unit. Production management system, characterized by being displayed in different colors with different data. The production management system according to claim 9,
The data displayed by the second display unit and the data displayed by the fourth display unit are further displayed blinking. In the production management system according to any one of claims 1 to 7,
The first display unit, the second display unit, the third display unit, and the fourth display unit display each data as a graph,
A production management system, wherein a graph is drawn for the same item among data items displayed on the graph such that the ranges of the axes of the plurality of graphs are the same. The production management system according to claim 11,
The setting system to set the graph axis range for each item is
When drawing the graph of all lots with graph drawing software, then temporarily storing the range of each axis of the drawn graph, and then drawing the graph of the lot processed by the specific device Apply the range of each axis of the stored graph, draw the graph, and the data range of each axis for the graph on the display surface, the graph of all lots and the lot processed by the specific device Production management system characterized by matching with graphs.