JP6425198B2 - Mold control method using mold electronic medical record system - Google Patents

Description

  The present invention relates to a mold electronic medical record system and a mold.

  Conventionally, failures in a series of mold manufacturing processes up to mold design, manufacture and trial (testing) have not often been recorded.

  That is, the quality of molds such as resin molds and press processing, casting, forging, etc. is extremely important in the manufacturing process of parts manufactured by the molds. However, because it is manufactured as a single dish, it is made and finally delivered to the mass production process. For this reason, in many cases, mold defects due to processing problems occurring in the manufacturing process of the mold, defects at the time of assembling the mold, occurrence of defects at the time of molding trial, etc. are not recorded.

  In particular, at the time of mold trial, etc., the deadline for delivery to mass production is approaching, and there is no time for workers at the site to make a record, and even if there is a problem with PC at the site, problems with EXCEL etc. It takes time and is left behind.

Therefore, the same problem occurs repeatedly every time, and improvement does not progress at all. If there is the record, there is no doubt that it is an important material in designing and producing the same mold next time, and the defect correction is a valuable know-how.
Therefore, a simple and accurate record in the field is desired.

  In addition, it has often been unknown whether the cause of the failure during component production is the cause of the mold or its maintenance factor or the failure of the production apparatus that produces components using such a die.

  That is, part defects such as dimensional defects and appearance defects may occur during mass production such as resin molding, in which case it is considered that there is a relationship with the number of parts produced, but the durability of molds during mass production At present, measures against defects have not progressed because the correction records of molds and periodical mold maintenance records have not been matched. Despite special circumstances, molds are generally outsourced in many cases and separated from in-house parts production, so it is difficult for feedback caused by molds during mass production to be fed back. In addition, even when the mold manufacturing department is in-house, there is a division between the mold department and the mass production department, and there is a problem that failure events occurring on the site are not directly fed back to the mold personnel or department. .

  As a major factor, there is a big problem that it is busy during mass production in the field, and it is not possible to obtain a defect maintenance record easily and accurately. In fact, there are many situations in which you do not have time to put in your PC or organize your photos while you are working, and you are stuck in the field.

  Also, in recent years, with the increase in product types due to detailed productization and the demand for new products from consumers, many types of products, small lots, and short-lived products have increased. Inevitably, the mold is in the same situation, and the number of molds and the shortening of production discontinuation are progressing. However, since the consumer continues to use even after sales discontinuation, parts replacement occurs in the case of breakage, etc., and it is necessary to complement the mold for the service parts correspondence. There is a case where it is obliged to save molds for 10 years after mass production discontinuation.

  Furthermore, when global production has recently progressed and production transfer between factories has become frequent, and where storage locations for molds that have increased in number have become unknown or left undiscarded There is a big challenge. Molds are capitalized and waste management is becoming increasingly important.

JP, 2009-184220, A

  Therefore, having a history of defects that occurred in the process of design and manufacture of molds and defects that occur in the mass production process like medical medical records is anticipation of occurrence of defects in the mold design, manufacturing process, and mass production process. , Can help prevent. The effect is said to be the manufacturing loss cost, and it is said that it is 30% in the manufacture of parts where the consumption of molds such as castings is severe from 10% of the manufacturing cost, and a countermeasure has been conventionally desired.

  Moreover, as a series of medical records from the birth of design and manufacture of molds to mass production and disposal, history management and fault record management are important in the manufacturing industry where manufacturing costs are becoming increasingly severer and cost reduction is required in the future, Mold history management of the role of backbone device is the center.

  SUMMARY OF THE INVENTION In view of the above-described circumstances, an object of the present invention is to provide a mold electronic medical record system capable of easily and accurately collecting data on mold defects and easily browsing the history of mold defects. It is.

  According to the findings of the present inventors, there are the following present conditions.

  That is, as a factor that defects in a series of mold manufacturing processes up to the design, manufacture and trial (testing) of the mold are not recorded, the mold is different from the product, and one item is to make one mold for one product. It is generally produced by a dish, and since it is made and finally delivered to a mass production process, processing defects occurring in the manufacturing process of the mold, defects in assembling the mold, molding trial Mold correction due to a failure has not been recorded and left unchecked.

  In addition, especially at the time of mold trial, etc., it is close to the date of delivery to mass production, and there is no time for workers on site to record, troubles to EXCEL etc. with PC on site, try to record etc. It takes time and is left behind.

  Therefore, the current situation is that the same problem occurs repeatedly each time, and improvement does not progress at all. If there is the record, there is no doubt that it is an important material to design and manufacture the same mold next time, and that the defect correction is a valuable know-how.

  The reason why failure records can not be obtained is that it can not be recorded during mold production and trial operations that are on the due date, and defect records are often summarized after the operation, and there is a circumstance that it can not actually be summarized.

  In view of such circumstances, a mold electronic medical record system according to the present invention is a mold in which an identifier which can be recognized as an image and on which identification data for identifying the mold is recorded is provided at a predetermined position; And an imaging unit capable of imaging the defective portion of the mold; a first input unit capable of inputting the defective data of the mold; and recognition for recognizing the identification data according to the identifier imaged by the imaging unit An electronic device comprising: a transmission unit configured to transmit identification data recognized by the recognition unit, imaging data of a defect location imaged by the imaging unit, and defect data input by the first input unit; A second input unit for inputting identification data, imaging data, and defect data transmitted from the electronic device; identification data, imaging data, and defect data input from the second input unit; A database for storing the imaging data and the defect data for each mold based on the data generation unit, and a generation unit for generating a predetermined defect sheet in which the accumulated imaging data and the defect data for each mold are summarized in time series And a data server.

In the present invention, individual recognition of the mold can be easily performed by, for example, a QR code (registered trademark) provided in the mold, and the moment when the mold manufacturing defect or trial defect occurs, the moment Using the device's photo function, moving image shooting function, and voice recording function, failure events can be recorded easily and accurately, and pull-down selection of failure classification items is made on the first input unit, for example, a predetermined "failure selection / input screen". These data can be easily transmitted to the data server by the communication function of a smartphone, a tablet or the like. In the data server, failure data is automatically accumulated in time series for each mold, and for example, items classified into data in a predetermined failure sheet format can be automatically arranged. Therefore, according to the present invention, data on mold defects can be collected simply and accurately, and the history of mold defects can be easily viewed.
In the mold electronic medical record system according to the present invention, the identifier is a QR code (registered trademark), and the mold is cut at the same time as the manufacture by the cutting process at the time of manufacturing the mold. Is preferred.

  The mold electronic medical record system according to the present invention receives production data from the production apparatus produced using the mold and defect data from the data server, and the mold from the correlation between the production data and the defect data. It is preferable to further comprise a client terminal that predicts a failure of

  In the mold electronic medical record system according to the present invention, the electronic device can input storage place data of the mold and transmit the storage place data, and the data server can receive and store the storage place data. It is preferable that the client terminal is configured to be able to input the storage location data from the data server and grasp the storage location of the mold.

  The mold according to the present invention is provided with a QR code (registered trademark) which is recognizable as an image and in which identification data for identifying the mold is recorded, and which is cut by cutting in the cutting process at the time of manufacturing the mold. Do.

  According to the present invention, data on mold defects can be collected easily and accurately, and the history of mold defects can be easily viewed.

It is a figure showing composition of a mold electronic medical record system concerning one embodiment of the present invention. It is a figure which shows an example of QR Code (trademark) shown in FIG. It is a figure which shows the input example of the defect event of a metal mold | die. It is a figure which shows the example of a display item of a defect selection * input screen. It is a figure which shows the example of the defect data accumulate | stored in the data server. It is a figure which shows the example of the format of a malfunction sheet | seat. It is a graph which shows the example which analyzes what kind of change a malfunction has generate | occur | produced when time-series production data, a die malfunction, and die maintenance data are combined. It is a figure which shows the process flow to prediction and prevention of a metal mold | die defect. It is a figure which shows the example which performs statistical analysis from the defect data collected and accumulate | stored in the database. It is a figure which shows the other example of an identifier.

Hereinafter, embodiments of the present invention will be described with reference to the drawings.
FIG. 1 is a view showing a mold electronic medical record system according to an embodiment of the present invention.
As shown in FIG. 1, the mold electronic medical record system 1 has a mold 10, an electronic device 20, a data server 30, and a client terminal 40.

  The mold 10 is, for example, a resin mold, or a mold for press processing, casting, forging, etc., and is a QR code that is an identifier that can be recognized as an image and in which identification data for identifying the mold 10 is recorded. A registered trademark 11 is provided at a predetermined position of the mold 10. Here, the mold 10 includes mold parts such as upper mold and lower mold constituting the mold 10, and QR codes (registered trademark) may be applied to the respective mold parts.

  For example, as shown in FIG. 2, the QR code (registered trademark) 11 includes, for example, a customer name, a product name, and a gold in addition to the mold number of the mold 10 as identification data for identifying the mold 10. Data of mold manufacture date, mold designer, and mold maker in the case of external manufacture are recorded. It is preferable that the QR code (registered trademark) be simultaneously incised by cutting in the cutting process at the time of manufacturing the mold 10. Thereby, the QR code (registered trademark) can be applied to the mold 10 without increasing the number of processes, and the durability can be excellent. In addition, as an identifier, it is not limited to QR Code (trademark), You may use a barcode, RFID, etc.

  The electronic device 20 is, for example, a tablet or a smartphone, and the camera 21 as an imaging unit capable of imaging a defective part of the QR code (registered trademark) 11 and the mold 10, a microphone 22 capable of inputting voice, gold Recognize identification data etc. from the touch pad 23 and display 24 as a first input part that can input defect data etc. of the mold 10 by pull-down operation etc. and the QR code (registered trademark) 11 imaged by the camera 21 Microphone 22 such as a QR code (registered trademark) recognition unit 25 as a recognition unit to be recognized, identification data recognized by the QR code (registered trademark) recognition unit 25, etc. Through the network 50, the voice data input by the user, the defect data input by the touch pad 23, and the like. And a WiFi communication unit 26 as a transmission unit that transmits Te.

  The data server 30 performs mold data, defect sheet recording, defect recording, mold maintenance recording, production data, equipment maintenance recording, and the like. The data server 30 receives, for example, identification data, imaging data, defect data, and the like transmitted from the electronic device 20 as mold data, via the network 50, as a second input unit, a data transmission / reception unit 31; Based on these data input by 31, a defect is generated that generates a predetermined failure sheet in which data stored for each mold 10 are accumulated in time series and the database 32 for storing these data in time series for each mold 10 And a sheet generation unit 33.

  The client terminal 40 is constituted by, for example, a PC, and inputs data from the data server 30 via the network 50. The client terminal 40 has a production / mold / maintenance display function, a mold defect management function, an equipment maintenance management function, a mold asset management function, and the like.

  In the electronic device 20, the QR code (registered trademark) recognition unit 25 recognizes the individual mold of the QR code (registered trademark) 11 applied to the mold 10 by a simple operation such as a tablet (see FIG. 2). ).

  Further, in the electronic device 20, the defect event of the mold 10 is recorded at the site where the mold manufacturing defect or trial defect occurs, using the voice recording by the microphone 22 or the still image / moving image photographing by the camera 21 at that moment. Do. This makes it possible to simply and accurately record voice recording and imaging recording relating to a defect event (see FIG. 3).

  Further, the electronic device 20 pulls down and selects the defect classification item on the predetermined “defect selection / input screen” having the display items illustrated in FIG. 4 in the touch pad 23 and the display unit 24, and records the failure event.

  Then, the data is transmitted to the data server 30 via the WiFi communication unit 26 of the electronic device 20, and the data server 30 automatically accumulates failure data in time series for each mold 10 as illustrated in FIG. 5. Ru. The data server 30 stores data groups related to defects such as mold data, defect sheet records, defect records, mold maintenance records, production data, and equipment maintenance records.

  In addition, the data server 30 automatically arranges the items classified in the format of the predetermined failure sheet illustrated in FIG. The reporter may also be recognized by, for example, the QR code (registered trademark) of the employee plate. The defect sheet created by the data server 30 is received by the electronic device 20 via the network 50, and the data of the defect sheet can be viewed at the molding / mold site.

  By the way, component defects such as dimensional defects and appearance defects occur during mass production such as resin molding. According to the findings of the present inventors, it is considered that there is a relation between the number of parts produced and the mold, but for the cause elucidation, maintenance information related to the failure event and the mold failure parts and the durability of the mold I think that data analysis is necessary. However, conventionally, such related information has not been captured centrally. Therefore, in the client terminal 40 according to the present embodiment, the malfunction data stored in the data server 30 described above and the control device counter of the molding apparatus for molding parts using the mold 10 or the PLC for controlling the molding line A configuration is adopted in which the data server 30 processes it as batch data in conjunction with the production data of the program / logic / controller), and displays and analyzes it at the client terminal 40. Although these molding apparatuses are not shown, they can exchange data with the data server 30 through the network 50, for example.

For example, by combining time-series production data accumulated in the data server 30, mold defects, and mold maintenance data, it is possible to analyze what change is causing a defect. An example is shown in the graph of FIG. From such a graph, the defect cause of the dimensional defect B occurring in the production line A is found to be a defect caused by the increase in the clearance and the widening of the gap due to the slide D wear in the mold maintenance C. The number of production shots at that time was 650. Then, about one month later, when the number of products reached 1000, the same dimensional defect E occurred again, and the same slide D was worn out in the mold maintenance F. From this, the same dimensional defects are predicted for reaching the next production of 1400 pieces. The cause of the repeated failure was identified as insufficient holding distance of slide D, and mold modification was carried out to extend the slide holding distance for prevention, and the mold design manual was changed.
The process flow until the prediction / prevention of the above mold defects is as shown in FIG.

In addition, as shown in FIG. 9, it is possible to produce medical products, and then to carry out mass production, service parts, and medical records (history) up to disposal. As a result, the weak point of the mold is highlighted, and it is possible to eliminate the defect from the upstream side so that the defect will not be repeated at the time of manufacturing the mold of the next similar product.
Furthermore, in the client terminal 40, statistical analysis can be performed as shown in FIG. 9 from the defect data collected and accumulated in the data server 30.

  As described above, having a history of defects occurring in the process of design and manufacture of molds and defects occurring in the mass production process like medical medical records means that defects in the mold design, manufacturing process, and mass production process occur. Can be used to predict and prevent The effect is said to be the manufacturing loss cost, and it is said that from 10% of the manufacturing cost to 30% in the manufacture of parts where the consumption of molds such as castings is severe, such measures have been desired from the past. It is.

  Also, in recent years, with the increase in product types due to detailed productization and the demand for new products from consumers, many types of products, small lots, and short-lived products have increased. Inevitably, the mold is in the same situation, and the number of molds and the shortening of production discontinuation are progressing. However, since the consumer continues to use even after the sales discontinuation, parts replacement occurs in the case of breakage, etc., and it is necessary to complement the mold in order to correspond to the service parts. There is a case where it is obliged to save molds for 10 years after mass production discontinuation. Furthermore, when global production has recently progressed and production transfer between factories has become frequent, and where storage locations for molds that have increased in number have become unknown or left undiscarded There is a big challenge. Molds are capitalized and waste management is becoming increasingly important. Therefore, in the present invention, individual recognition is performed by the QR code (registered trademark) 11 provided in the mold 10, the storage place is input on the input screen prepared in the electronic device 20, transmission of the data server 30, history May be stored in the mold asset management function so that the location of the mold 10 can be grasped on the client terminal 40, and asset management such as disposal of the mold 10 can be performed.

Further, the history information from the design and manufacture of molds to the production of parts and removal obtained from the present invention can also be used for traceability of products that automakers are working on serious problems such as recalls. By collecting production data, defect data, and equipment maintenance data required for traceability by the data server 30, and processing the data in the data server 30 on the client terminal 40, data of specific defects is recognized, analyzed and analyzed. It can be used to
Furthermore, although the present invention is proposed in consideration of the effects on a mold and a part production site using the mold, the present invention is also applicable to equipment maintenance charts and production charts.
The present invention is not limited to the above-described embodiment, and can be variously modified and implemented.

  For example, a plate member having a QR code (registered trademark) and predetermined data imprinted thereon as shown in FIG. 10 may be attached to the mold. Thereby, information on the mold can be known visually, and individual recognition of the mold can be performed by predetermined data even if the QR code (registered trademark) becomes unrecognizable.

  Further, in the above embodiment, the QR code (registered trademark) is applied to the mold, but the QR code (registered trademark) is applied to the mold management shelf, the production facility, the tool management shelf, the worker, etc. It may be applied and used to manage data in the same way as a mold.

1 Mold electronic medical record system 10 Mold 11 QR code (registered trademark)
Reference Signs List 20 electronic device 21 camera 22 microphone 23 touch pad 25 QR code (registered trademark) recognition unit 26 WiFi communication unit 30 data server 31 data transmission / reception unit 32 database 33 malfunction sheet generation unit 40 client terminal

Claims (3)

A mold provided at a predetermined position with a QR code (registered trademark) in which identification data for identifying the mold is recorded;
Capable of inputting the defect data of the mold including the QR code (registered trademark) and an imaging unit capable of imaging the defect portion of the mold, and data specifying the mold component causing the defect of the mold A first input unit, a recognition unit for recognizing the identification data corresponding to the QR code (registered trademark) picked up by the imaging unit, identification data recognized by the recognition unit, and the image pickup unit An electronic device comprising: a transmission unit for transmitting imaging data of a defective portion, defect data inputted by the first input unit, and product defect data of a product molded by the mold;
Second input unit for inputting identification data, image pickup data and defect data, and product defect data transmitted from the electronic device, identification data, image pickup data and defect data, product defect data inputted by the second input unit And a database for storing the image pickup data and the defect data and the product defect data for each mold, and a generation unit for generating a predetermined defect sheet in which the image data and the defect data accumulated for each mold are summarized in time series And a data server comprising: a mold management method using a mold electronic medical record system,
The client terminal receives the defect data and the product defect data from the data server, and graphs and displays them in time series,
The operator identifies the defective part which has become a defect of the mold by the analysis based on the display, and reflects the data concerning the identified defective part on the defective sheet using the mold electronic medical record system Management method. A method of managing a mold using the mold electronic medical record system according to claim 1;
Assign QR code (registered trademark) to a mold management shelf for storing the mold,
In the mold storage place for storing the mold, the electronic device captures and recognizes the QR code (registered trademark) provided on the mold and the QR code (registered trademark) on the mold management shelf, and recognizes it Data stored in the database to make it possible to grasp the location of the mold. A mold management method using a mold electronic medical record system. A mold management method using the mold electronic medical record system according to claim 1 or 2,
The mold, together with the QR code (registered trademark), is a mold number of the mold that enables at least individual recognition of the mold, a customer name, a product name, and a mold manufacture of a product molded by the mold. A plate member on which a predetermined data including a mold designer is engraved is provided at a predetermined position. A method of managing a mold using a mold electronic medical record system.