JPH11156680A - Manufacturing process supporting system - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a quality control device which can reduce worker's load and maintain high quality of workpieces. SOLUTION: A quality control device 20 is equipped with a quality control terminal 30 having a first storage means 32 for storing measuring indication information on workpieces and a second storage means 33 for storing measurement results of workpieces, and one or more workpiece inspection terminals 40 having a measuring operation indicating means 41a for instructing a measuring operation to a worker based on the measuring indication information received from the quality control terminal 30, a measured data reading means 41b for reading measured data of workpieces by a measuring apparatus, a measured value judging means 41c for judging whether this measured value is within a tolerance or not, and a displaying means 43 for displaying judging result of this measured value judging means, and the quality control terminal 30 and the workpiece inspection terminals 40 are interconnected in online.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a quality control device for controlling the quality of a workpiece, a production control device for controlling a processing step, and a manufacturing process support system integrating these.

[0002]

2. Description of the Related Art Quality control at a manufacturing site is performed by an operator using a measuring instrument to determine whether or not the dimensions of a measured portion of a processed workpiece are within an allowable range. However, when measuring a large number of workpieces and measuring the dimensions of a large number of parts to be measured, the measuring instruments must be replaced accordingly, and the determination of whether the measured dimensions are within the allowable range, etc. must be performed. Members must do it. Therefore, the worker performs the inspection while checking it against the inspection sheet,
It is difficult to select a measuring instrument, and it may take time to read the scale of the measuring instrument at the time of measurement, or the scale may be difficult to read.

Immediately after a setup change, that is, after changing a processing line for processing a different type of workpiece, the processed workpiece is measured and inspected. Can not start. Since the judgment of the result of the inspection is not performed by the operator but is asked by the administrator, it takes a long time to start the processing operation.

On the other hand, in production control at a manufacturing site, a plurality of processing lines are provided for each factory, and a processed product is manufactured on the processing lines. In the processing line, workers attach and remove workpieces to and from the processing machine for each processing machine, and as the workpiece flows through the processing machine in sequence, the workers also move along the processing machine to perform work. Do. For example, as shown in FIG.
.. 101h, and when the workpiece flows along the path 102 through the processing machines 101a, 101b... 101h, the worker also moves along the U-shaped path 102.

[0005] Here, the machine time, which is the time required for the processing machine to process the workpiece, is the working time (handling time) required for the worker to attach and detach the workpiece to and from the processing machine, and the time between the worker and the processing machine. If the work time is shorter than the cycle time which is the sum of the moving time (walking time) and two workers are used, when the workpiece flows along the route 102, one of the working machines is an upper and a lower working machine. 10
Route 103 including 1a, 101b, 101g, and 101h
A, and the other worker is a middle-stage processing machine 101c, 101
By moving the route 103B including d, 101e, and 101f, the cycle time can be shortened by the amount that the walking time can be shortened. However, the movement route is complicated for the worker because the movement route is different from the work route.

Further, the processing line is provided with a plurality of processing machines, and the same processing line uses different processing machines in the processing step and the order of the processing machines to be used is different depending on the type of the workpiece. Therefore, for each type of workpiece, the worker must change the route of the working machine,
The movement route of the worker is further complicated.

[0007]

SUMMARY OF THE INVENTION Accordingly, the present invention provides a quality control device and a production control device capable of improving the work efficiency of a worker and maintaining a high quality of a workpiece, and a manufacturing process support system integrating them. The purpose is to do.

[0008]

In order to achieve the above object, a quality control apparatus according to the present invention comprises a first storage means for storing measurement instruction information of a workpiece and a second storage means for storing measurement results of the workpiece. A quality control terminal having a storage means, a measurement operation instruction means for instructing a worker to perform a measurement operation based on the measurement instruction information received from the quality control terminal, and measurement of the workpiece with the measurement instrument. One or more workpieces having measurement data reading means for reading data, measurement value determination means for determining whether or not the measurement value is within an allowable range, and display means for displaying a determination result of the measurement value determination means An inspection terminal, wherein the quality control terminal and the workpiece inspection terminal are connected online.

According to this quality control device, the worker only has to work based on the instruction of the measurement work instructing means, and the measurement data of the workpiece is read by the measurement data reading means, so that the burden on the worker is small. There is no misreading of the scale of the measuring instrument at the time of measurement. Further, a measurement value determination unit that determines whether the measurement value is within an allowable range is provided,
Since the result of the inspection is determined in the terminal, the determination is made in a shorter time than when asking the administrator.

[0010] In a preferred embodiment of the quality control device of the present invention, the measurement operation instructing means displays at least a part of the measurement operation process on a screen of the workpiece inspection terminal as a photograph or a graphic. According to this configuration, at least a part of the measurement operation process is displayed as a photograph or a graphic on the screen of the workpiece inspection terminal, so that the operator can visually select the measuring instrument, and the burden on the operator is further reduced. .

[0011] In a further preferred embodiment of the quality control device of the present invention, when the measured value is out of the allowable range, there is provided a notifying means for notifying to that effect by a voice instruction. According to this configuration, since the notification is made by the voice instruction, it is easy for the worker to understand, and the information is accurately transmitted.

A production management apparatus according to the present invention comprises: a production management terminal having third storage means for storing processing process information; and a processing device having a plurality of processing machines for receiving the processing process information received from the production management terminal. A line production management terminal having editing means for editing for a line, data input means for updating edited machining process information, and fourth storage means for storing machining results of the machining line; A processing step instructing unit for instructing a required processing machine to a worker based on the updated processing step information of the management terminal, wherein the production management terminal, the line production management terminal, and the processing step instruction means And are online.

According to this configuration, the line production management terminal has the editing means for editing the machining process information for the machining line, and the data input means for updating the edited machining process information. Processing step information according to the processing line can be easily obtained. Further, since it has a machining process instructing means for instructing a required machining machine to the worker based on the updated machining process information of the line production management terminal, the worker follows the instruction of the machining process instructing means. What is necessary is just to move between the processing machines, and the worker can smoothly move according to the moving route.

In a preferred embodiment of the production control device of the present invention, the machining process instruction means is a lamp arranged close to the machine. According to this configuration, the machining process is instructed by turning on or blinking the lamp. Therefore, the operator only has to move between the processing machines in accordance with the instruction, and the operator can visually confirm the process. Becomes smooth.

The manufacturing process support system according to the present invention is characterized in that the quality control device, the production control device, a fifth storage means for storing a production plan, and a measurement result of a workpiece received from the quality control device. A production management server having a sixth storage means and a seventh storage means for storing processing results of the processing line received from the production management apparatus, wherein the quality management apparatus, the production management apparatus, the production management server, Is online.

According to the manufacturing process support system of the present invention,
Since the quality management device, the production management device, and the production management server are connected online, and the production management server can manage all information, the information can be managed collectively.

[0017]

Embodiments of the present invention will be described below with reference to the drawings. FIG. 1 shows a manufacturing support system according to an embodiment of the present invention. As shown in FIG. 1, each device of the manufacturing support system 1 is installed in one of the production management unit 2, the receiving inspection factory 3, and the line factory 4, and there are a plurality of line factories 4. The production management unit 2, the receiving inspection factory 3, the line factory 4, and the other line factories are connected online via LANs (Local Area Networks) 5a and 5b, respectively. Each terminal in the acceptance inspection factory 3 is LAN
3a, the terminals are connected online in the line factory 4 via the LAN 4a. In the production management unit 2, the production management server 10 is connected to the LANs 5a and 5b via the hub 6, each terminal is connected to the LAN 5a via the hub 7 in the receiving factory 3, and each terminal is connected to the hub 8 in the line factory 4. Is connected to the LAN 5b.

The acceptance inspection factory 3 is a factory for performing an acceptance inspection of a workpiece, in which a quality management device 20 is installed. The quality management device 20 includes a quality management terminal 30 and a plurality of workpiece inspection terminals 40.

The line factory 4 is a factory for processing.
A quality control device 20 and a production control device 50 are installed. The quality control device 20 includes a quality control terminal 30 and a workpiece inspection terminal 40 like the acceptance inspection factory 3.
0 includes a production management terminal 60 and a plurality of line production management terminals 70.

FIG. 2 shows an outline of the quality control device 20.
The quality management terminal 30 of the quality management device 20 performs the processing in the processing unit 31 and the measurement instruction information file 32 which is a first storage unit for storing the measurement instruction information and the second storage for storing the measurement result of the workpiece. And a measurement result file 33 as a means. The measurement instruction information file 32 stores information of a photograph or a figure of the measuring instrument, a reference value of the measurement dimension, an allowable range of the measurement dimension, a measurement instruction sequence, and the like. The measurement instruction information file 32 can be updated by input / output using the keyboard 34 and the display 35 of the quality control terminal 30. The quality management terminal 30 further includes a communication control unit 36, and can transmit / receive data to / from another device via the hub 7 (FIG. 1).

The workpiece inspection terminal 40 of the quality control device 20
Receives the contents of the measurement instruction information file 32 of the quality management terminal 30 from the communication control unit 42. The received content is processed by the measurement operation instructing means 41a of the processing section 41, and the measured portion of the workpiece, the measurement method, the measurement instruction sequence, and the like are output to the display 43. The operator uses this display 43
Only the work of measuring the workpiece needs to be performed in accordance with the information output to. For example, when the display 43 displays the characters “calipers” as the name of the measuring instrument and a photograph of the measurement state in which the calipers 44 are brought into contact with the measurement site Wa of the workpiece W as the measurement object, the worker May be obtained by measuring the measurement site Wa of the workpiece W using the caliper 44 according to the photograph. Since the photograph appeals to the worker's vision, the worker may select the measuring instrument displayed in the photograph or the like. In addition, if there are other notes, they are displayed on the display 43.

The processing section 41 also has a measurement data reading means 41b, and can read the measurement value measured by the caliper 44 of the selected measuring instrument via the measuring instrument I / O interface 45. The read measurement value is displayed on the display 43 together with the reference value of the measurement dimension and the allowable range of the measurement dimension. The processing unit 41 further includes a measurement value determination unit 41c, and the measurement data reading unit 41b
It is determined whether or not the measured value read in is within an allowable range.

Specifically, the dimension of the workpiece W is measured by an operator stepping on the foot switch 46 with the vernier caliper 44 in contact with the measured portion Wa of the workpiece W. When the foot switch 46 is depressed, a signal is input to the processing unit 41 via the foot switch I / O interface 47, and at this timing, the size of the measured portion Wa of the workpiece W with which the caliper 44 is in contact is measured by the measuring instrument. The data is input to the processing unit 41 via the I / O interface 45.

The measured value judging means 41c of the processing section 41, which has read the dimensions of the measured portion Wa of the workpiece W, determines that the read measured value is within the allowable range based on the reference value of the measured dimensions and the allowable range of the measured dimensions. It is determined whether or not. The result of this determination is displayed on the display 43 as a display means, and informs the worker whether the operation is normal or abnormal. If not,
Further, the notifying unit 41d of the processing unit 41 notifies by a voice instruction from the speaker 48. This notification alerts the worker to the auditory hearing, which allows the worker to confirm that the measurements are out of tolerance.

The measured value read by the measured data reading means 41b of the workpiece inspection terminal 40 and the result of the determination as to whether or not the measured value is within the allowable range are transmitted to the quality control terminal 30, It is stored in the measurement result file 33. The tendency of the measured dimensions can be grasped from the information of the measurement result file 33, which is useful for preventing the occurrence of trouble.

As shown in FIG. 1, the quality control device 20 is installed in each of the acceptance inspection factory 3 and the line factory 4, and when the quality control device 20 is installed in the acceptance inspection factory 3, the quality of the processed product before packing and shipping is set. Used for sampling inspection. When installed in the line factory 4, it is used for setup change, that is, when a processing line is changed for processing of a different type of workpiece, or when inspecting a workpiece at regular time intervals, for example, every hour. Is measured. This inspection is performed while the processing line is stopped, and when the measured value determining unit 41c (FIG. 2) of the workpiece inspection terminal 40 determines that the measured value is within the allowable range, the processing line is restarted.

FIG. 3 shows an outline of the production management device 50.
The production management terminal 60 of the production management device 50 has a processing step information file 62 that is a third storage unit that performs processing in the processing unit 61 and stores processing step information. There is only one production management terminal 60 in the factory 4 (FIG. 1), and the machining process information file 62 receives a daily machining plan from the production management server 10 (FIG. 1) once a month. Updated to content. The contents of the processing step information file 62 are processing step information for a factory based on a processing plan for one day. The production management terminal 60 has a keyboard 63 and a display 64, and the contents of the processing step information file 62 can be updated by input / output using the keyboard 63 and the display 64. The production management terminal 60 further includes a communication control unit 65.
, And can transmit and receive data via the hub 8 (FIG. 1).

The line production management terminal 70 of the production management device 50 receives the contents of the processing step information file 62 of the production management terminal 60 from the communication control unit 72. A sequencer 80 is connected to the line production management terminal 70, and the received contents are edited into an hourly production plan for a processing line by an editing means 71a of a processing unit 71.
0 is stored in the line processing information memory 81, which is a storage means of “0”. A touch panel 82 as an input means is connected to the sequencer 80, and the contents of the line processing information memory 81 are updated by an input from the touch panel 82. A processing step controller 85 of a processing line having a plurality of processing machines is connected to the sequencer 80.
The processing step controller 85 controls lighting or blinking of a lamp 92 as processing step instruction means based on the contents of the line processing information memory 81 of the sequencer 80. A line stop / return panel 94 having a plurality of line stop buttons 95 and a single return button 96 is connected to the processing step controller 85. Lamp 9
2 and a line stop / return panel 94 are arranged for each processing machine in the processing line.

FIG. 4 shows a configuration diagram of the processing line 90. The processing line 90 includes a plurality of processing machines 91a, 91b1, 91
b2, 91c, 91d, 91e, 91f, 91g, 91
h. Reference numerals 91b1 and 91b2 denote processing machines for performing the same processing, and two machines are installed to increase the line speed because the machine time required for the processing is long.

For example, in processing a workpiece, the first workpiece is a processing machine 91a, 91b1, 91d, 91e.
... 92h flows along the route A1 and the second workpiece is a processing machine 91a, 91b2, 91d, 91e ... 92
h along the route A2. The number of workers is two, and one worker alternately moves between the route A11 and the route A12 to cover the upper and lower stages of the processing line 90, and the other worker covers the middle stage of the processing line 90. To the route A20. At this time, the lamps 92a, 92b1, 92b2,... 92h, which are connected to the sequencer 80 (FIG. 3) and are processing process instruction means attached to each processing machine, are provided.
Among them, a lamp to be moved next to each worker lights or flashes, thereby instructing each worker. When the processing is completed, the lamp turns off. Each worker moves according to the instruction of the ramp. The travel route is complicated by shortening the walking time with two workers, but the workers are required to use the ramps 92a and 92a.
What is necessary is just to move along with lighting or blinking of b1 ... 92h.

When changing the processing line 90 for processing different types of workpieces, each worker inputs from the touch panel 82 (FIG. 3) which processing machine to use. As a result, the contents of the line processing information memory 81 (FIG. 3) of the sequencer 80 (FIG. 3) are updated, and subsequent processing step instructions, that is, ramps 92a, 92b1,.
The order of lighting or blinking is changed.

The processing line 90 includes a processing machine 91a,
91b1... 91h are provided with a plurality of stop buttons 95a.
..95h (FIG. 3) and single return button 96a... 9
6h (FIG. 3) stop / return panels 94a, 94
b1... 94h are arranged, and the sequencer 80
(FIG. 3). This stop / return panel 94
The stop buttons of a, 94b1,..., 94h are used when the machining line 90 is broken due to a failure of the machining line 90, replacement of a cutting tool of a machining machine, setup change, that is, when the machining line is changed for machining a different type of workpiece. When stopping, the operator presses the corresponding stop button among the plurality of stop buttons according to the reason for the stop. Stop / return panels 94a, 94b1
The operator presses the 94h return button when the processing line 90 returns. The event of the stop / return is stored in the performance data memory 83 which is a storage means of the sequencer 80, and is stored in the processing performance data file 73 of the line production management terminal 70.
(FIG. 1). In the production management server 10 (FIG. 1), the history of the stop / return of the processing line is stored.

Stop / return panel 94 due to setup change
a, 94b1... 94h, when the stop button is pressed, the stop event is sent to the quality control device 20 in the line factory 4.
(FIG. 1) is also transmitted to inspect the workpiece. If there is no abnormality in this inspection, the fact that there is no abnormality is transmitted to the line production management terminal 70 (FIG. 3), and processing of the processing line 90 starts. Since the measured value determining means 41c (FIG. 2) of the workpiece inspection terminal 40 determines that there is no abnormality, the time is shorter than when asking the administrator for the determination, and further, the workpiece inspection and the processing line 90 are performed. Since the instruction to start the processing is performed online via the LAN 4a (FIG. 1), the time for inspecting the workpiece is reduced.

Further, the processing line 90 is provided with a number of gauges for checking the quality of the workpiece during the processing. Although not shown, the quality control terminal 30 of the quality control device 20 of FIG.
Is a terminal similar to the workpiece inspection terminal 40 connected to the processing machine 9 and does not read measurement data.
1a, 91b2, 91d, 91e... 92h. Therefore, the worker performs an inspection according to the measurement instruction output on the display of the terminal. The operator only has to select the gauge by looking at the picture or the graphic of the gauge displayed on the screen, and the burden on the operator is reduced. When the worker detects an abnormality, the stop / return panels 94a and 94b1 connected to the sequencer 80 are detected.
... Press the stop button at 94h. As a result, the number of defective products is counted in the result data memory 83 (FIG. 3), which is the storage means of the sequencer 80 (FIG. 3), and the number of defective products is also processed by the line production management terminal 70 (FIG. 3). After being stored in the performance data file 73 (FIG. 3), it is transmitted to the production management server 10 (FIG. 1).

As shown in FIG. 3, the actual result of the workpiece in the machining line 90, that is, the number of completed workpieces, is stored in an actual data memory 83 as a storage means of the sequencer 80.
Is stored in The result data is stored in the processing result data file 73, which is the fourth storage means of the line production management terminal 70, as the total processing time and the completed number for each of the different types of workpieces. Is transmitted to the production management server 10 (FIG. 1) of the production management unit 2. The processing result data file 73 is then overwritten.

FIG. 5 shows an outline of the production management section 2. A production management server 10 is installed in the production management unit 2.
The production management server 10 performs processing in the processing unit 11 and has a production plan information file 12a as a fifth storage unit.
The content of the production plan information file 12a is an annual processing plan, and the processing unit 11 creates a daily processing plan of each factory based on the processing plan and transmits it to each production management device every month.

Further, the production management server 10 has a work measurement result storage file 12b as a sixth storage means received from each quality management device 20 (FIG. 1). Since the histories of all the workpiece measurement results can be centrally managed by the production management server 10, storing the histories for a certain period can enhance the quality assurance system of the workpiece.

Further, the production management server 10 has a processing result storage file 12c of the processing line as the seventh storage means received from the production management device 50. Since the processing results of all the processing lines can be centrally managed by the production management server 10, the progress management of all the processing lines can be easily performed.

The contents of the workpiece measurement result storage file 12b and the processing result storage file 12c of the processing line can be monitored using the keyboard 13 and the display 14 of the production management server 10, but can be communicated via the communication control unit 15. Monitoring from a remote location using a terminal or the like is also possible.

[0040]

As described above, according to the quality control device of the present invention, the worker only has to work based on the instruction of the measurement operation instructing means, and the measurement data of the workpiece is read by the measurement data reading means. Therefore, the burden on the operator is small, and it is not necessary to read the scale of the measuring instrument at the time of measurement.
In addition, a measurement value determination unit that determines whether the measurement value is within the allowable range is provided, and the result of the inspection is determined in the terminal. Therefore, the determination is made in a shorter time than when asking the administrator.

Further, according to the production management apparatus of the present invention, the line production management terminal includes editing means for editing the machining process information for the machining line and data input means for updating the edited machining process information. As a result, machining process information corresponding to the machining line can be easily created. In addition, since there is provided processing step instructing means for instructing a required processing machine to the worker based on the updated processing step information of the line production management terminal, the worker performs the processing according to the instruction of the processing step instructing means. What is necessary is just to move between aircrafts, and it is possible to move smoothly on the movement route.

Further, according to the manufacturing process support system of the present invention, the quality management device, the production management device, and the production management server are connected online, and the production management server can manage all the information. It is.

[Brief description of the drawings]

FIG. 1 is a system configuration diagram of a manufacturing support system according to an embodiment of the present invention.

FIG. 2 is a block diagram of a quality management device according to the embodiment of the present invention.

FIG. 3 is a block diagram of a production management device according to the embodiment of the present invention.

FIG. 4 is a configuration diagram of a processing line according to the embodiment of the present invention.

FIG. 5 is a block diagram of a production management server according to the embodiment of the present invention.

FIG. 6 is an explanatory view showing a conventional processing method.

[Explanation of symbols]

1: Manufacturing support system, 10: Production management server, 12a
... Fifth storage means, 12b ... Sixth storage means, 12c ...
Seventh storage means, 20: quality control device, 30: quality control terminal, 32: first storage means, 33: second storage means, 40: workpiece inspection terminal, 41a: measurement work instruction means, 41b ... Measurement data reading means, 41c ... Measurement value judgment means, 41d ... Information means, 43 ... Display means, 44 ...
Measuring instrument, 50: production management device, 60: production management terminal, 62: third storage means, 70: line production management terminal, 71: editing means, 73: fourth storage means, 82: input means, 90 ... processing line, 91a, 91b1, 91b
2,91c, 91d, 91e, 91f, 91g, 91h
... Processing machine, 92 ... Processing process instruction means.

Claims (6)

[Claims] 1. A quality control terminal having first storage means for storing workpiece measurement instruction information and second storage means for storing workpiece measurement results, and received from the quality management terminal. A measurement work instructing means for instructing a worker to perform a measurement work based on the measurement instruction information, a measurement data reading means for reading measurement data of a workpiece with a measuring instrument, and a measurement data reading means for determining whether or not the measured value is within an allowable range. It is provided with one or more workpiece inspection terminals having a measured value determining means to be determined and a display means for displaying a determination result of the measured value determining means, wherein the quality control terminal and the workpiece inspection terminal are online. Connected quality control device. 2. The quality control device according to claim 1, wherein the measurement operation instruction means displays at least a part of the measurement operation process on a screen of the workpiece inspection terminal as a photograph or a graphic. 3. The quality control device according to claim 1, further comprising a notifying unit for notifying by voice when the measured value is out of an allowable range. 4. A production management terminal having third storage means for storing machining process information, and editing for editing the machining process information received from the production management terminal for a machining line having a plurality of machining machines. A line production management terminal having means, data input means for updating edited machining process information, and fourth storage means for storing machining results of the machining line; and updating of the line production management terminal. Machining process instruction means for instructing a required machining machine to an operator based on the machining process information obtained, wherein the production management terminal, the line production management terminal, and the machining process instruction means are connected online. Production management equipment. 5. The production management apparatus according to claim 4, wherein said processing step instruction means is a lamp arranged close to a processing machine. 6. A quality management device according to claim 1, a production management device according to claim 4, a fifth storage unit for storing a production plan, and the quality. A sixth storage unit for storing a measurement result of the workpiece received from the management device, and a production management server having a seventh storage unit for storing the processing results of the processing line received from the production management device, A manufacturing process support system in which a quality management device, the production management device, and the production management server are connected online.