KR101787509B1 - Web and mobile-based automated process improvement monitoring system - Google Patents

Abstract

The present invention relates to web and mobile based automated process improvement monitoring systems. More specifically, it is possible to reduce the product defect rate and improve the quality by making it possible to integrate the production management, including the production quantity, the point of change of the tool (cutting tool type), tool cost, quality inspection and lot tracking Web and mobile based automated process improvement monitoring system.
To this end, the invention comprises one or more automated production facilities; In case of abnormality in the production quantity of the automatic production equipment, it is possible to send the data of abnormality to the central controller (PLC) which controls the automatic production equipment, ; A process management server for receiving data on presence or absence of production amount of each automation production facility from a central controller (PLC) and storing the data in a database for each automation production facility; And a terminal used by an administrator to transmit data stored from the process management server and monitor the process status including the operation state of the real-time automated production facility, the work status, and the lot status, And a user terminal including an operator terminal for allowing a user to register a confirmation of the work progress status or the quality abnormality with a terminal used by an operator working in the work center .

Description

Web and mobile based automated process improvement monitoring system {omitted}

The present invention relates to web and mobile based automated process improvement monitoring systems. More specifically, it is possible to reduce the product defect rate and improve the quality by making it possible to integrate the production management, including the production quantity, the point at which the tool (cutting tool) is changed, the tool cost, quality inspection and lot tracking Web and mobile based automated process improvement monitoring system.

In recent years, productivity has improved as factory facilities have become larger. In the conventional production management system, the list of products to be produced on a daily, weekly, monthly and yearly basis for each process is written in the manual and reflected in the production. If an error occurs in the facilities of each production line, Off-line tasks were performed to check the cause and report it to a senior person.

In particular, it is difficult to check whether an abnormality occurs in each facility in real time, even if the person in charge of the process is in charge of each production process.

In addition, it is difficult for the worker in the field to work while maintaining the compliance rate of the tool, because the tool replacement time in the actual production line is difficult to operate. Therefore, when the tool is operated without considering the life of the tool, There is a problem that can fall.

Prior Art Document KR Patent Publication No. 2017-0024262 (published on July 7, 2017)

SUMMARY OF THE INVENTION The present invention has been made in order to solve the above-mentioned problems, and it is an object of the present invention to provide an apparatus and a method for manufacturing a cutting tool, And to provide a web and mobile-based automated process improvement monitoring system that can reduce product defect rate and improve quality.

In order to accomplish the above object, the web and mobile-based automated process improvement monitoring system according to the present invention may include at least one automated production facility; In case of abnormality in the production quantity of the automatic production equipment, it is possible to send the data of abnormality to the central controller (PLC) which controls the automatic production equipment, ; A process management server for receiving data on presence or absence of production amount of each automation production facility from a central controller (PLC) and storing the data in a database for each automation production facility; And a terminal used by an administrator to transmit data stored from the process management server and monitor the process status including the operation state of the real-time automated production facility, the work status, and the lot status, And a user terminal including an operator terminal for allowing a user to register a confirmation of the status of work progress or quality abnormality with a terminal used by an operator working in the work center.

In addition, when the replacement time of a specific tool exceeds the appropriate reference value or the replacement is necessary, the operator's terminal of the user terminal displays a visualized form including warnings or precautions in a specific tool information area requiring replacement On the basis of the error occurrence time, the occurrence code, the processing status, the processing time, and the processing items. If the processing time exceeds the appropriate time, it can send out a call message to the senior person. Occurrence process status register module, inspection before and after tool change performed before and after the tool change, and frequent periodic inspection performed by the operator's self. This module is used to register the results of inspection. It can refer to the inspection method according to the inspection method. And the inspection contents including the tool name, the inspection item, the jig number, the inspection standard, the inspection result, and the color of the lot attached to the spot check box in which the inspection history is outputted are displayed. And a lot classification setting module for outputting a plurality of corresponding colors to the screen and selecting and setting a representative color of the lot.

In addition, the manager terminal of the user terminal includes a real-time production management module for checking the current operation status of the real-time facility, the operation status and the lot status, a display device for displaying the past day and night production results for each facility, If you input the production performance management module, search part number and process code to search, and input the period for which search is required, the produced part number and process code result value are displayed on the screen, In order to analyze the production performance management module for each worker that extracts past production results by module and worker and displays them on the screen, the ratio of loading and unloading during the operation time is analyzed to analyze whether the facility is operating at a constant speed Analyzing and outputting tin-milling capacity analysis module, equipment, tool, and worker The tool that calculates and compiles the tool compliance rate and outputs it. Replacement tool The compliance rate detail record retrieval module, the tool cost analysis module for each facility that outputs and compiles the tool cost, and the tool for each worker that compiles and outputs the tool cost for each worker Cost aggregation analysis module, quality inspection result retrieval module that can retrieve the frequent inspection result values by each equipment, inspection items input and output performance management, production lot management by each process, real time production lot management by facility, A lot tracking management module for enabling the production facility and worker tracking of the lot, and a radio identification tag attached to the production part spot box, and by generating the work piece information through the radio identification tag reader, To track the position of the product It can hamhal.

According to the present invention, when the tool of each automatic production facility is changed or an abnormality occurs, it is automatically called to the field worker terminal so that follow-up action can be taken quickly. If the processing time is delayed due to the absence of the person in charge, The message can be transmitted, and the tool can be always managed, thereby reducing the defective rate of the product.

Further, according to the present invention, it is possible to aggregate the production amount for each worker, and it is effective to collectively manage the individual ability values of the worker such as the individual performance payment.

According to the present invention, a tool name, a target replacement cycle, a tool production amount, and a self-inspection actual measurement value are registered on an operator's terminal screen, and the tool life information is displayed on a screen of the operator's terminal So that it is possible to notify the tool replacement timing.

According to the present invention, there is provided a lot classification setting module which can designate the same color as the lot color paper attached to the spot box on a lot basis, thereby making it possible to visually distinguish the lot number without checking the lot number etc., Having that effect.

In addition, according to the present invention, there is an effect of attaching a wireless identification tag to a spot box and generating workpiece information through the wireless identification tag reader, thereby facilitating real time production and tracking of the position of the workpiece in the event of a failure.

1 is a configuration diagram of a web and mobile based automated process improvement monitoring system according to a preferred embodiment of the present invention;
FIG. 2 is a block diagram of a program implemented in an administrator terminal of a web-based and mobile-based automated process improvement monitoring system according to a preferred embodiment of the present invention.
3 is a configuration diagram of a program implemented in an operator terminal of a web and mobile-based automated process improvement monitoring system according to a preferred embodiment of the present invention.
4 is an example screen of a real-time production management module,
5 shows an example screen of the production performance management module for each facility,
6 shows an example screen of a production performance management module for each item and process,
7 shows an example screen of a production performance management module for each worker,
8 is an exemplary screen of the yell activity rate analysis module,
9 is an exemplary screen of the tool replacement compliance rate detailed history search module,
10 shows an example screen of the tool cost aggregation analysis module for each facility,
11 is an example screen of a tool cost aggregation analysis module for each worker,
12 shows an example screen of the quality inspection performance search module,
13 shows an example screen of the lot tracking management module,
14 shows an example screen of an automatic production-processed product tracking module,
15 is an example screen of a tool replacement timing notification sending module,
16 shows an example screen of the abnormality occurrence processing status registration module,
17 shows an example screen of the frequent inspection registration module,
18 is an exemplary screen of the lot classification setting module.

Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings. In the drawings, the same reference numerals are used to designate the same or similar components throughout the drawings. In the following description of the present invention, a detailed description of known functions and configurations incorporated herein will be omitted when it may make the subject matter of the present invention rather unclear. In addition, the preferred embodiments of the present invention will be described below, but it is needless to say that the technical idea of the present invention is not limited thereto and can be variously modified by those skilled in the art.

FIG. 1 is a block diagram of a web-based and mobile-based automated process improvement monitoring system according to a preferred embodiment of the present invention. FIG. 2 is a block diagram of a web- FIG. 3 is a block diagram of a program implemented in an operator terminal of a web and mobile-based automated process improvement monitoring system according to a preferred embodiment of the present invention. FIG. 6 is an exemplary screen of the production performance management module for each item and process, FIG. 7 is an exemplary screen of the production performance management module for each worker, and FIG. 9 is an exemplary screen of the tool replacement compliance rate detailed record retrieving module, and FIG. 10 is an example 12 is an exemplary screen of the quality inspection performance search module, FIG. 13 is an exemplary screen of the lot tracking management module, FIG. 13 is an example screen of the lot tracking management module, 15 is an exemplary screen of a tool replacement timing notification sending module, FIG. 16 is an exemplary screen of an abnormality occurrence processing status registration module, FIG. 17 is an example of a self inspection registration module, Screen, and Fig. 18 is an exemplary screen of the lot classification setting module.

1, a web and mobile-based automated process improvement monitoring system 1000 according to a preferred embodiment of the present invention includes an automated production facility 100, a central controller (PLC) 200, a process management server 300, , And a user terminal (400).

More specifically, when an abnormality occurs in the amount of production of each automation production facility connected to one or more of the automated production facility 100 and the automated production facility 100 by wired / wireless communication, (PLC) 200, which controls each of the automated production facilities, and a central controller (PLC) 200, which is connected to the automated production facility The manager terminal 420 and the operator terminal 460. The manager terminal 420 transmits the stored data from the process management server 300 to the real time automated production facility And the lot status, and the operator terminal 460 is attached to the machine installed at the work site It is configured to include a user terminal (400) that allows an operator to check the registration details of the work in progress status and the quality abnormality that work in the field.

The user terminal 400 can be divided into an administrator terminal 420 and an operator terminal 460 according to the user of the user. The user terminal 400 can be a desktop, a notebook, a tablet PC, a smart phone, The present invention is not limited thereto.

Hereinafter, programs implemented in the administrator terminal 420 and the operator terminal 460 will be separately described.

The manager terminal 420 is provided with a program for production quantity management, tool cost management, quality inspection management, and lot tracking management, and the program can be implemented on the basis of web and mobile.

2 and 4 to 14, the manager terminal 420 includes a real-time production management module 422, a production performance management module 424 for each facility, a production performance management module 426 for each item and process, A detailed operation history management module 428, a yellowning operation rate analysis module 430, a tool replacement compliance rate detailed history search module 432, a tool cost aggregation analysis module 434 for each facility, a tool cost aggregation analysis module 436 for each worker, A quality inspection performance search module 438, a lot tracking management module 440, and a production processed product automatic tracking module 442.

4 is a diagram showing a real-time production management module 422. The real-time production management module 422 is a module that enables a manager to check the current real-time facility operation state, work status, lot status, Items such as self name, promotional name, U / S, daily target amount, daily performance amount, achievement rate, cumulative monthly production, operation / red, red elapsed time, lot number, lot color,

In particular, the lot color item 423 displays different colors according to lot (production management line), so that the administrator can easily identify the lot information through the lot color without checking the lot number individually, Identification is made possible.

FIG. 5 shows a production result management module 424 for each facility. It can display the past and night production results for each facility, multiply the process unit price, and calculate the production amount for each process.

FIG. 6 shows a production performance management module 426 for each item and each process. The production performance can be analyzed by analyzing items and processes.

The product and process-specific production performance management module 426 inputs the part number and the process code to be searched, and inputs the period required for the search, and the product number and the process code result value produced within the input search period are displayed on the screen. Therefore, even if the same items and processes are produced in various facilities, the production amount and the process amount can be summed up and counted.

FIG. 7 shows a production performance management module 428 for each worker. The production performance of each worker is extracted and displayed on the screen, and the production cost for each process calculated by multiplying the process cost is output. Therefore, it is possible to check the production performance by a certain period of time according to the operator, and it can be utilized as basic data for analyzing the performance by the operator.

FIG. 8 is a module for analyzing the ratio of loading and unloading during operation time in order to analyze whether the facility is stably operating at a constant speed, / T, and then calculates and outputs the operation rate of tinned steel by equipment. Here, C / T is the cycle time, which means the time required to work one process.

The tin operation ratio analysis module 430 can be utilized as an index for improving productivity by improving the loading and unloading time by calculating the tin operation rate.

FIG. 9 illustrates the tool replacement compliance rate detailed record retrieval module 432, which can calculate and comply with the tool tool compliance rate that is performed in compliance with tool replacement by equipment, tool, and worker. Here, the tool refers to a kind of cutting tool used in the present process.

The tool replacement compliance record retrieval module 432 can analyze the tool life by reasonably resetting the tool life, and analyze the cause of excessive tool life degradation, thereby improving facilities and reducing costs.

FIG. 10 shows a tool cost aggregation analysis module 434 for each facility, which compiles and outputs the tool cost for each facility. Typically, there is a target tool cost when using the life cycle, and the actual amount of tool use.

In the tool cost analysis module 434 of the facility, it is possible to grasp the status of how much the utilization rate exceeds the target cost, and if the tool cost is excessive for each facility, the cause can be checked to improve the cost reduction of the tool cost So that they can look for solutions.

FIG. 11 shows a tool cost aggregation analysis module 436 for each worker, which compiles and outputs the tool usage costs for each worker. Therefore, it is possible to reduce the cost of the tool and stabilize the quality by encouraging the worker to use it in compliance with the tool life.

FIG. 12 shows a quality inspection performance search module 438, and it is possible to search the values of the frequent inspection performance for each facility and each inspection item. The actual value can be analyzed based on the tool life value at the time of self-inspection registered by the field worker. It is possible to know whether the operator is fully compliant with the tool change period or regular self-inspection activities, so that the quality between processes can be improved.

FIG. 13 shows a lot tracking management module 440. The lot tracking management module 440 manages a lot of input and output records of a lot, a production lot count management by process, a real time production lot management by facility, Production equipment and worker tracking are possible.

For example, when it is assumed that a failure occurs in the H30M lot, the shipment delivery history is confirmed, the current lot for each real-time facility is confirmed, and the shipment lot is minimized by checking the facility, the worker, Emergency measures can be taken.

14 shows a production work piece automatic tracking module 442 in which a production work piece automatic tracking module 444 attaches a radio identification tag to a production workpiece spot box and generates work piece information through a radio identification tag reader, It is possible to track the position of the workpiece in the event of real time production and defects.

The production process automatic tracking module 442 enables real-time product position confirmation, enabling real-time production and quick follow-up in case of failure.

Hereinafter, a module implemented in the operator terminal 460 will be described.

For example, the operator terminal 460 may be a mobile device. The mobile device may be a tablet PC, a PDA (Personal Digital Assistant), a notebook, a cellular phone, a PCS (Personal Communication Service) phone, a handheld PC Hand-Held PCs, GSM (Global System for Mobile) phones, W-CDMA (Wideband CDMA) phones, CDMA-2000 phones and smart phones. have. Here, the type of the operator terminal is not limited to a specific one.

3 and 15 to 18, the worker terminal 460 includes a tool replacement timing notification sending module 462, an abnormality processing status registration module 464, a frequent inspection registration module 466, And a module 468.

FIG. 15 shows a tool change timing notifying / dispatching module 462. When the tool replacement timing notifying / dispatching module 462 determines that the replacement time of a specific tool exceeds the proper reference value or the life time is exceeded, And outputs it in a visualized form including a warning or a precaution in the specific tool information area necessary. Thus, the operator can confirm the life information of the tool and accordingly recognize the exact replacement timing.

In particular, when it is determined that the remaining life of the tool exceeds the appropriate reference value and the remaining life is not left, a color representing a warning such as red is output for an area assigned to the tool item. At this time, when a warning message is generated, it is possible to adjust the transparency on the remaining screen to output a warning color such as red, and to intermittently light the text in the form of "Warning" or "Warning".

In addition, when the remaining life of the tool exceeds the appropriate reference value, but a part of the remaining life is left, it is possible to output a color representing the precaution indication such as green color by the area allocated to the tool item.

Fig. 16 shows an abnormality occurrence processing status registration module 464. The abnormality occurrence processing status registration module 464 outputs items such as an abnormality occurrence time, an occurrence code, a processing status, a processing time, According to the above items, the person in charge of the group can register from the occurrence of abnormality to the process.

Also, if the tool is changed, the worker can arbitrarily send a call message to a senior person in charge. At this time, an operator can arbitrarily send a call message to a senior person in charge. The high-level group manager confirms whether the changed tool and the changed tool are abnormal or not, and registers the confirmation check contents.

For example, the following contents may be registered in the abnormality occurrence processing status registration module 464.

- Abnormal time: May 2, 2015 at 1:44 pm

- Occurrence code: invocation of invocation

- Processing status: Processing

- Processing time: 23 seconds

- Process: T5, T6, T7 OK

At this time, if the processing time exceeds the predetermined time from the abnormality occurrence time, it is determined that the processing time is delayed and a call message can be sent to the higher-level person in charge.

17 shows the self-inspection registering module 466. The self-inspection registering module 466 performs frequent periodical inspections performed before and after the tool change before and after the tool change, A module for registering, a reference photograph for referring to the inspection method is displayed according to the inspection method, and inspection contents including the tool name, the inspection item, the jig number, the inspection standard, and the inspection result and the inspection history are outputted.

Basic equipment and work information are displayed in the frequent inspection registration module 466, and the operator who performs the inspection selects one of inspection before tool replacement, inspection after tool replacement, and frequent periodical inspection to register inspection results . In addition, the test results are stored in the measurement room so that the operator can share the measurement data with each other.

18 shows the lot classification setting module 468. The operator can confirm the color and lot number attached to the box and select the same color to be output on the screen. In addition, lot numbers can be added to production information produced from hereafter and registered.

A lot color execution window 472 is created so that an operator can select and register a color for each lot. The operator can check the color and lot number attached to the actual box and select the same color as the color attached to the box.

It will be apparent to those skilled in the art that various modifications, substitutions and substitutions are possible, without departing from the scope and spirit of the invention as disclosed in the accompanying claims. will be. Therefore, the embodiments disclosed in the present invention and the accompanying drawings are intended to illustrate and not to limit the technical spirit of the present invention, and the scope of the technical idea of the present invention is not limited by these embodiments and the accompanying drawings . The scope of protection of the present invention should be construed according to the following claims, and all technical ideas within the scope of equivalents should be construed as falling within the scope of the present invention.

100 - Automation production facility
200 - Central controller (PLC)
300 - process management server
400 - User terminal
420 - Manager terminal
422 - Real-time Production Management Module
424 - Production performance management module for each facility
426 - Production performance management module by item and process
428 - Production performance management module for each worker
430 - Yield Analysis Module
432 - Tool Replacement Compliance Record Log Search Module
434 - Tool cost analysis module for each facility
436 - Tool cost analysis module for each worker
438 - Quality inspection performance search module
440 - Lot Tracking Management Module
442 - Production process automatic tracking module
460 - Operator terminal
462 - Notify when to replace tool Delivery module
464 - Abnormal occurrence processing status registration module
466 - Frequently Checked Registration Module
468 - lot separation setting module
1000 - Web and mobile-based automated process improvement monitoring system

Claims (3)

One or more automated production facilities;
It is connected to automation production facility by wired / wireless communication,
A central controller (PLC) for receiving the data of abnormality in production amount to diagnose the cause of abnormality of the automated production facility and controlling each of the automated production facilities;
A process management server for receiving data on presence or absence of production amount of each automation production facility from a central controller (PLC) and storing the data in a database for each automation production facility; And
A terminal used by an administrator to send data stored from the process management server and monitor the process status including the operation status, operation status, and lot status of the real-time automated production facility, A user terminal for use by a working worker, the user terminal including an operator terminal for allowing a user to register a confirmation of the work progress status or the quality abnormality
Lt; / RTI >
The operator terminal of the user terminal
When a replacement time of a specific tool exceeds a predetermined standard value or more, or when it is necessary to replace the tool, a tool replacement time notification is output to the display in a visualized form including a warning or a precaution in a specific tool information area requiring replacement module,
If the check time is registered from the point of occurrence of abnormality according to the items including abnormality occurrence time, occurrence code, processing state, processing time, and processing items, and if the processing time exceeds the proper time from the abnormality occurrence time, An abnormality occurrence processing status registration module for allowing a senior person to send a call message,
This is done by inspection before and after tool change performed before and after tool change and by operator's discretion.
Is a module for frequently registering inspection results after performing regular inspection. A reference picture for referring to the inspection method is displayed according to the inspection method, and the tool name, inspection item, jig number, inspection standard, inspection result And a self-test registration module outputting the test history, and
A plurality of colors corresponding to the colors of the lots attached to the spot boxes are output to the screen, and a lot classification setting module
Based automated process improvement monitoring system. delete The method according to claim 1,
Among the user terminals, the administrator terminal
Real-time production management module that enables to check real-time facility operation status, work status, lot status,
A production performance management module for each facility that displays the past day and night production performance by each facility, calculates and outputs the production amount by each process,
If you enter the part number and process code to be searched and enter the period of time required for the search, the production number and the process result management module for each process,
A production performance management module for each worker extracting past production results by operator and outputting them to the screen,
In order to analyze whether the facility is operating at a stable rate, it is necessary to analyze the ratio of loading and unloading during the operation time,
What is being done to comply with tool change by equipment, tool, and worker? Tool change to calculate and report tool compliance rate.
The tool cost aggregation analysis module for each facility that outputs and compiles the tool cost for each facility,
A tool cost aggregation analysis module for each worker that aggregates and outputs the tool usage cost for each worker,
Quality inspection result retrieval module which can search the frequent inspection result values by equipment and inspection items,
A lot tracking management module that enables the production and management of the lot of the lot, the production lot management of each lot, the real time management of production lot by facility, the production facility of the lot in which quality problems have occurred,
The production process automatic tracking module which enables the wireless identification tag to be affixed to the production workpiece spot box and the workpiece information to be generated through the wireless identification tag reader,
Based automated process improvement monitoring system.

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