JP5728733B2 - Work procedure management system and work procedure management method - Google Patents

Description

  The present disclosure relates to a work procedure management system and a work procedure management method, and more particularly to a technique that can flexibly manage a worker's work procedure within a prescribed range.

In plant systems, such as pharmaceutical manufacturing plants, in order to ensure product quality, compliance with standard operating provisions (SOP) it is obliged. Hereinafter, the standard work rule and the work procedure according to the standard work rule are referred to as SOP. In order to achieve quality assurance, smooth sharing of work information between workers and managers, measures to eradicate human error, appropriate work instructions to workers, and a mechanism for work transmission are indispensable. It is.

  2. Description of the Related Art Conventionally, a system has been proposed that enables registration of a work procedure for giving an appropriate work instruction and change of the work instruction procedure according to the condition of the work procedure using a menu function (see Patent Document 1). Moreover, the system described in this patent document 1 makes it possible to strictly complement the work procedure by acquiring the result information of the work instruction.

  Further, a system has been proposed that accumulates past work contents as work records, organizes efficient work procedures therefrom, presents them to the worker, and supports the worker's work efficiency improvement (see Patent Document 2). reference).

JP-A-11-265368 JP 2011-2897 A

  However, in the system described in Patent Document 1, even if there is a branch due to a condition, it can be instructed only in a fixed order, and the situation on the actual site cannot be completely handled. . As a result, the worker cannot proceed with the work efficiently, so there is a possibility that the work will be reworked and extra man-hours may be required, and there is a problem that quality cannot be ensured and man-hours cannot be reduced. is there.

  Moreover, since the system described in Patent Document 2 displays an efficient work procedure for the worker, there is a problem in that there is a possibility that the SOP may be missed.

As described above, in the conventional technology, the work procedure can be clearly shown and the execution history can be reliably acquired, but the procedure cannot be changed according to the situation of the site such as the arrangement of the raw materials, and the work efficiency is impaired. There is a fear. That is, in the conventional work procedure management system, extra work has occurred because it is necessary to always follow a predetermined procedure.
For example, when inputting raw materials for pharmaceuticals, in the conventional work procedure management system, the order of the raw materials to be input is determined, and the place where the raw materials are placed is searched for and input. It was over. In addition, there are similar problems in the raw material receiving operation and the weighing operation.

  By the way, in the concept of SOP, it is necessary to observe a predetermined procedure, but there is a case where it is allowed to partially change the order. As an example, input of raw materials in a mixing process without chemical reaction can be mentioned.

  The present disclosure has been made in consideration of the above-described situation, and enables a worker's work procedure to be flexibly changed and managed within a prescribed range.

One aspect of the present disclosure provides a collective work control process that can partially change the work order when it is allowed to partially change the order in the product manufacturing process. Thereby, when a plurality of input operations are continued, it is possible to input in the order of the raw materials arranged in the field, not in the order determined by SOP. However, it also has functions of avoiding work omissions and obtaining work result history that are important as SOP.
First, each process and SOP for a manufactured product are defined in a database. When an operator performs an operation, an execution screen is displayed for each SOP procedure in the order of execution of each process based on the definition information, and indicates the operation that the operator should currently execute. The work contents are stored in the database as manufacturing result data for each work procedure. Further, there is a case where a work capable of performing collective work such as a mixing process is performed in the work of manufacturing a certain product. For example, in the case of a mixing process, the raw materials to be input and the procedure are registered in the SOP in advance, and the SOP for inputting these raw materials is generated in a batch operation SOP in which a plurality of raw materials are input. With this configuration, work included in the collective work can be executed according to the situation at the site during actual work, without being bound in the definition order as in the past.

According to at least one aspect of the present disclosure, by displaying an execution screen for each SOP procedure in the order of execution of each step, the operator can be made to comply with the work procedure, so that human error can be eliminated.
Furthermore, when it is considered that the work procedure may be changed within the specified range according to the situation at the site, work can be performed according to the situation at the site, etc. Time can be reduced.

It is a lineblock diagram showing an outline of a work procedure management system to which one embodiment of this indication is applied. It is explanatory drawing which shows an example of the manufacturing process of a product. A to C are schematic diagrams illustrating examples of work procedure instruction screens. A is a work instruction screen, B is a collective work instruction / result total list screen, and C is an example of a result input screen. It is a flowchart for demonstrating operation | movement of a SOP execution order control processing part. A to C are schematic diagrams showing examples of registered contents of various manufacturing instruction local data storage units, where A is an SOP data table, B is an SOP detailed data table, and C is an SOP definition data table. A and B are schematic diagrams showing examples of various definition screens. A is a collective work execution definition screen, and B is an SOP detail master definition screen. It is a flowchart for demonstrating operation | movement of a collective work control processing part.

  Exemplary embodiments for carrying out the present disclosure will be described below with reference to the accompanying drawings. In addition, in this specification and drawings, about the component which has the substantially same function or structure, the overlapping description is abbreviate | omitted by attaching | subjecting the same code | symbol.

[Work procedure management system as a whole]
FIG. 1 is a configuration diagram illustrating an overview of an entire work procedure management system to which an embodiment of the present disclosure is applied.
As an example, this work procedure management system is a system for supporting that a series of work is performed in accordance with a standard work rule (SOP) designated in advance in a factory where a pharmaceutical manufacturing process is performed. As shown in FIG. 1, there are a plurality of AP / DB servers 1 that have a database that stores manufacturing performance data, various manufacturing instruction masters, etc. and that perform database search and update processing, and are connected via a network 3. The client terminal 2 is configured.

The AP / DB server 1 is a computer installed in the data center in accordance with the number of client terminals 2 and has both functions of an application server and a database server.
The AP / DB server 1 stores a database search / update processing unit (DB search / update processing unit) 15 which is a processing unit for issuing a database search and update command, and recorded data and various manufacturing instruction information. Manufacturing result data database (manufacturing result data DB) 11, various manufacturing order master database (various manufacturing order master DB) 12, on-site inventory data database (on-site inventory data DB) 13, and product master database (product master) DB) 14.

  For example, a table including items such as product ID, instruction ID, SOPID, order, update date / time, and user ID is registered in the manufacturing result data DB 11. The on-site inventory data DB 13 is registered with a table including items such as inventory ID, inventory name, capacity, and storage location. Furthermore, the product master DB 14 is registered with a table including items such as product ID and product name. The contents of the various production instruction master DB 12 will be described later.

  The AP / DB server 1 is divided into an application server including a DB search / update processing unit 15, a manufacturing performance data DB 11, various manufacturing instruction master DBs 12, an on-site inventory data DB 13, and a product master DB 14. May be installed.

The client terminal 2 is for performing work procedure display, work result input, screen display processing, SOP execution order control processing, and collective work control processing. It is a computer provided for each weighing operator.
The client terminal 2 includes various manufacturing instruction local data storage units 21 and on-site inventory local data storage units 22 held in the memory of the client terminal 2, and includes an SOP execution order control processing unit 23 (standard work execution order). An example of a control processing unit), a collective work control processing unit 24 (an example of a collective work control processing unit), and a screen display processing unit 25. Further, a display device 26 such as a liquid crystal display panel and an input device 27 such as a keyboard or a mouse are connected to the client terminal 2 to perform screen display processing and operation input processing.

[SOP execution order control processing]
Next, the operation of the SOP execution order control processing unit 23 of the client terminal 2 will be described with reference to FIGS.
FIG. 2 is an explanatory diagram showing an example of a product manufacturing process.
In the example of FIG. 2, first, raw materials A, B, and C are input in accordance with the instructions in the mixing operation process to generate a process product K30001-001 (mixed product). Next, according to an instruction | indication, the process goods K30001-002 (a granule, a granule state) are produced | generated through a granulation process. Furthermore, according to an instruction | indication, through the tableting process, the process goods K30001-003 (tablet) are produced | generated, and work is completed, and it becomes the product K30001.

3A to 3C are schematic diagrams illustrating examples of work procedure instruction screens, where A is a work instruction screen, B is a collective work instruction and results total list screen, and C is an example of a result input screen.
FIG. 4 is a flowchart for explaining the operation of the SOP execution order control processing unit.
As a premise, the work procedure of each process for the manufactured product is registered in the various manufacturing instruction master DB 12 of the AP / DB server 1 from the client terminal 2.

  First, when the operator operates the input device 27 to select a manufacturing instruction and starts the manufacturing operation, the work instruction of the selected instruction is sent from the SOP execution order control processing unit 23 of the client terminal 2 via the network 3. A request for acquiring information is transmitted to the AP / DB server 1 (step S1). Then, the DB search / update processing unit 15 of the AP / DB server 1 acquires SOP information from the various manufacturing instruction master DBs 12 and transmits it to the SOP execution order control processing unit 23 of the client terminal 2. The SOP execution order control processing unit 23 develops the acquired SOP information in the various production order local data storage unit 21 which is a local table.

Next, the SOP execution order control processing unit 23 searches for the executable instruction order from the various manufacturing order data developed in the various manufacturing order local data storage unit 21 (step S2).
In the instruction content example 56 of the SOP detailed data table 50 (FIG. 5B) to be described later, “batch execution work execution” is executable. The SOP execution order control processing unit 23 executes such an executable SOP (work procedure) (a screen corresponding to an instruction code designated in advance is displayed) (step S3).

When the worker performs the manufacturing work, one line of SOP for each process is shown on the work instruction screen 31 (FIG. 3A) based on the definition information in the SOP detailed data table 50 of the various manufacturing instructions local data storage unit 21. Each one is displayed on the screen, and the current status is displayed (step S5).
For example, on the work instruction screen 31, when “Batch execution work execution” is selected as the content of the work instruction and the “input” button is pressed, the collective work instruction / result total list screen 32 (FIG. 3B) is displayed on the display device 26. Is done.

  Further, the operator inputs the results of each stock item and presses the “Confirm” button. At this time, if the result of each screen processing in step S5 is OK, the next operation is updated to an executable state, and the status (work status) 55 of the SOP detailed data table 50 in the various production order local data storage unit 21 is changed. It is updated from “executable” to “done” (step S7). Further, the DB search / update processing unit 15 of the AP / DB server 1 registers the manufacturing result data in the manufacturing result data DB 11, returns to step S2, and searches again for the next executable instruction order (step S8).

On the work instruction screen 31, when the status of all procedures is “OK”, the work instruction screen 31 ends when the operator presses the “Confirm” button. Further, when a procedure in which the work status is “uncompleted” is displayed on the work instruction screen 31 in step S3, when the “return” button is pressed (step S4), the situation is saved and the work instruction screen 31 ends. To do.
The state at the end is registered in the manufacturing performance data DB 11. When the same manufacturing instruction is opened again on the work instruction screen 31, the previous situation is displayed, and the work can be performed from the previous continuation, so that no work leakage occurs.

  If each screen processing check in step S5 is NG, an error occurs and the process returns to the work instruction screen 31 (step S6).

  In this way, since the worker cannot proceed to the next work unless the work record is input on the displayed screen, the work procedure can be observed. In addition, when the work is interrupted and the screen is terminated, compliance with the work procedure is maintained by starting from the work screen that was interrupted when the work was started again.

[Batch work control processing]
The SOP is basically performed according to work procedures registered in the various manufacturing instruction master DBs 12 of the AP / DB server 1, but there are cases where it is desired to change the procedure depending on the situation at the site. For example, according to the material placement situation of input work site, if you want to change the order of operations, by defining the collective work in advance SOP, change the order while compliance with standard work provisions for SOP predetermined range It becomes possible.

5A to 5C are schematic diagrams showing examples of registered contents in various manufacturing instruction local data storage units, where A is an SOP data table, B is an SOP detail data table, and C is an SOP definition data table.
The SOP data table 40 is an example of a standard work definition table, and includes a product ID 41, a process product ID 42, an instruction name 43, and an SOP ID 44 as items.
The SOP detail data table 50 is an example of a standard work definition detail table, and includes SOPID 51, order 52, instruction name 53, instruction code 54, and status 55 as items.
The SOP definition data table 60 has SOPID 61, order 62, definition name 63, and instruction code 64 as items.
6A and 6B are schematic diagrams showing examples of various definition screens. A is a collective work execution definition screen, and B is an SOP detail master definition screen.

  For example, in the mixing operation 45 of the SOP data table 40 shown in FIG. 5A, an operation of inputting a plurality of raw materials is registered. In this case, the SOPs of the raw material A, the raw material B, and the raw material C (reference numeral 57) are defined in the SOP detailed data table 50 of FIG. 5B, and the batch input operation execution (collective operation) 56 is defined immediately before that. Furthermore, in the SOP definition data table 60 of FIG. 5C, “Fine material code input” is defined (reference numeral 65) as the “FROM instruction code name” value, and “Material C input” is set as the “TO instruction code name” value. It can be defined (reference numeral 66). This definition can be made in the collective work execution definition on the collective work execution definition screen 71 of FIG. 6A, and is registered in various manufacturing instruction master DBs 12.

As an example of a method for defining work, a batch input work execution definition will be described as an example.
First, when the operator operates the input device 27, the collective work control processing unit 24 calls the SOP detail master definition screen 72 of FIG. 6B and displays it on the display device 26. Here, when it is desired to define “batch input work execution” in the work order 2, first, “batch input work execution” is input as the “work content” as the work order 2 between the work order 1 and the work order 3. . Second, “collective work” is selected in the “instruction code”. Third, when the definition button on the SOP detail master definition screen 72 is pressed, the collective work execution definition screen 71 in FIG. 6A is displayed as the fourth.
Fifth, in the collective work execution definition screen 71, “raw material A input” is selected as the “FROM instruction code name” value, “raw material C input” is selected as the “TO instruction code name” value, Finally, press the definition button. By this series of operations, the SOPs of the raw material A, the raw material B, and the raw material C (reference numeral 57) can be defined, and “collective charging operation execution” can be defined.

FIG. 7 is a flowchart for explaining the operation of the collective work control processing unit.
Assuming that the various manufacturing instruction data defined in the various manufacturing instruction master DB 12 are acquired and the various manufacturing instruction data are expanded in the various manufacturing instruction local data storage unit 21, the work instruction screen 31 in FIG. A collective work control processing example will be described with reference to the instruction / result total list screen 32, the result input screen 33, and FIG.

  When the operator operates the input device 27 to select the manufacturing instruction “mixed work”, selects “batch execution work execution” on the work instruction screen 31 and presses the “input” button, the batch operation of the client terminal 2 is performed. The control processing unit 24 acquires the definition of the collective work target from the various manufacturing instruction local data storage unit 21 (step S11).

  Next, the collective work control processing unit 24 narrows down the site inventory data from the site inventory data DB 13 of the AP / DB server 1 and acquires it in the site inventory local data storage unit 22 of the client terminal 2 (step S12). Then, a list of the collective work instruction / result total list screen 32 is created in consideration of the raw material A, the raw material B, and the raw material C (reference numeral 57) of the on-site inventory local data storage unit 22 and various manufacturing instruction local data storage units 21. Is displayed on the display device 26 (step 13).

For example, it is assumed that the worker selects the raw material B on the collective work instruction / result total list screen 32 (step S14) and presses the “result input” button (step S15). In this case, FIG. 3 C Actual input screen 33 is displayed (step S16). Next, when the “input” button is pressed to confirm the input of the record data (step S18), the data is added to the memory (various manufacturing data instruction local data) as the record (step S19). Data update of the results total list on the results total list screen 32 is performed (step 20). As a result, a list reflecting the results in the process of step S13 is displayed on the collective work instruction / result total list screen 32.

  Further, when the operator depresses the “return” button at the time of inputting the result on the result input screen 33 in step S16 (step S17), the result input screen 33 is closed and the process of step S13 is executed. In this case, the collective work instruction / result total list screen 32 is redisplayed in a state where the input of the results is not reflected.

  In addition, when all the results are entered on the collective work instruction / actual total list screen 32 and the operator presses the “confirm” button (step S22), the collective work control processing unit 24 checks the data input. Is executed (step S23). It should be noted that the confirmation button is not displayed unless all inputs are completed on the collective work instruction / result total list screen 32 so that the confirmation button cannot be pressed.

After the input check, the performance of the collective work itself is registered in the manufacturing performance data DB 11 of the AP / DB server 1 (step S24).
Next, each performance is registered and reflected in the manufacturing performance data DB 11 of the AP / DB server 1 and the on-site inventory data DB 13 (step S25). Thereafter, the display of the collective work instruction / result total list screen 32 is completed, and the collective input work execution is completed.

  Further, when the operator presses the “Return” button on the collective work instruction / result total list screen 32 in the process of step S13 (step S21), the collective work instruction / actual total list screen 32 regardless of whether or not there is a result. The display of is terminated. In this case, the results of each work are not registered or reflected.

According to the embodiment described above, the work procedure is displayed on the screen (for example, the work instruction screen 31) for each work to be performed by the worker, so that the worker can confirm the progress of the work, It is important to eliminate mistakes.
Furthermore, since a stock item can be selected according to the situation on the site on the collective work instruction screen (for example, collective work instruction / result total list screen 32), the labor of searching for the raw material or moving the raw material is reduced. be able to.
Further, when the worker inputs the result and presses the confirmation button, the screen returns to the collective work instruction screen again. In addition, the confirmation button cannot be pressed unless all inputs are completed on the collective work instruction screen. With this configuration, it is possible to prevent a raw material from being leaked when a batch operation instruction is given. After registering all the results, pressing the confirmation button on the collective work instruction screen stores the work results of the collective work and the results of each stock item in the database.
Further, when the return button is pressed on the collective work instruction screen, the result information is discarded even if a part of the results is input. As a result, work interruptions during batch work can be prevented.

  Note that the batch work method according to the embodiment described above can be applied to other work. For example, the order of raw material input work, raw material input work, weighing work for placing objects close to the work site, etc. can be changed according to the situation at the work site, etc. Man-hours can be reduced in general operation.

  The series of processes in the above-described embodiment can be executed by hardware, but can also be executed by software. When a series of processing is executed by software, it can be executed by a computer in which a program constituting the software is incorporated in dedicated hardware or a computer in which programs for executing various functions are installed. is there. For example, a program constituting desired software may be installed on a general-purpose personal computer or the like, developed on a memory, and executed.

  Further, a recording medium in which a program code of software that realizes the function of the above-described embodiment may be supplied to the system or apparatus. It goes without saying that the function is also realized by a computer (or a control device such as a CPU) of the system or apparatus reading and executing the program code stored in the recording medium.

  As a recording medium for supplying the program code in this case, for example, a flexible disk, a hard disk, an optical disk, a magneto-optical disk, a CD-ROM, a CD-R, a magnetic tape, a nonvolatile memory card, a ROM, or the like is used. Can do.

  Further, the functions of the above-described embodiment are realized by executing the program code read by the computer. In addition, based on the instruction of the program code, the OS running on the computer performs part or all of the actual processing. The case where the functions of the above-described embodiment are realized by the processing is also included.

  Further, in this specification, the processing steps describing time-series processing are not limited to processing performed in time series according to the described order, but are not necessarily performed in time series, either in parallel or individually. The processing (for example, parallel processing or object processing) is also included.

As described above, the present disclosure is not limited to each of the above-described embodiments, and various other modifications and application examples can be taken without departing from the gist described in the claims. .
That is, the examples of the above-described embodiments are preferable specific examples of the present disclosure, and thus various technically preferable limitations are given. However, the technical scope of the present disclosure is not limited to these forms unless specifically described in each description to limit the present disclosure. For example, the materials used in the following description, the amounts used, the processing time, the processing order, and the numerical conditions of each parameter are only suitable examples, and the dimensions, shapes, and arrangement relationships in the drawings used for the description are also outline. Is something.

  DESCRIPTION OF SYMBOLS 1 ... AP / DP server, 2 ... Client terminal, 12 ... Various production order master database, 13 ... Site stock data database, 15 ... DB search / update processing part, 21 ... Various production order local data storage part, 22 ... Site stock Local data storage unit, 23 ... SOP execution order control processing unit, 24 ... collective work control processing unit, 25 ... screen display processing unit, 31 ... work instruction screen, 32 ... collective work instruction / result total list screen, 33 ... record input Screen: 40 ... SOP data table, 50 ... SOP detail data table, 60 ... SOP definition data table, 71 ... Batch operation execution definition screen, 72 ... SOP detail master definition screen

Claims (6)

A standard work rule table that defines the work process and sequence of the product manufacturing process based on the standard work rule;
A standard work rule detail table defining the work, sequence and work status in the work process of the standard work rule table;
And the list of possible tasks of working in said work step in the standard work defined detail table, and the standard work execution sequence control processor to be displayed on the screen of the display device and a working status of each task,
When the executable work displayed on the screen of the display device is a work whose order can be changed within the range of the standard work rules, a list of a plurality of work within the changeable range is displayed on the screen of the display device. A collective work control processing unit that displays and displays, on the screen of the display device, work that has been input by a worker among a plurality of work in the changeable range, and displays the work as a work result in the order of input. system. The standard work execution order control processing unit collectively sets a plurality of works that can change the order of works within the work process within the range of the standard work regulations as one work in the work process of the standard work regulation table. The work procedure management system according to claim 1, wherein the work procedure management system is defined and displayed on the screen. Displaying a screen that collectively defines a plurality of operations that can change the order of operations in the operation process of the standard operation rule table within the range of the standard operation rule;
The work procedure management system according to claim 2, wherein the collective work control processing unit collectively defines the plurality of works as one work in a collective work definition table based on an instruction of an operator using an input device. The work procedure management system according to claim 2 or 3, wherein the batched work is executed in an order according to an instruction of an operator using the input device. The work according to any one of claims 2 to 4, wherein the standard work execution order control processing unit changes the work status of the next work to be executable after confirming that the plurality of batched works have been completed. Procedure management system. The work process and order of the manufacturing process of the product based on the standard work rule, the work within the work process of the standard work rule table and the work in the work process in the standard work rule detail table that defines the work status among a list of work that can be done, and displayed on the screen of the display device and a working status of each work,
When the executable work displayed on the screen of the display device is a work whose order can be changed within the range of the standard work rules, a list of a plurality of work within the changeable range is displayed on the screen of the display device. display and,
A work procedure management method for displaying work on which a worker has input a record among a plurality of work in the changeable range as a work record in the order of input and displaying on the screen of the display device.

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