TWI741074B - Product manufacturing method and product manufacturing device - Google Patents

Abstract

A manufacturing method of a product, which is a manufacturing method of manufacturing a product 90 through a plurality of manufacturing steps, and includes the following steps: obtaining equipment data D3 of the manufacturing equipment 40 for manufacturing the above-mentioned product; obtaining product data D1 from the above-mentioned product 90; The equipment data D3 and the above product data D1 are stored in the data collection unit 70; the above equipment data D3 is associated with the above product data D1; the abnormality of the above product data D1 is judged; when the abnormality of the product 90 occurs, the specified output and visual Either or both of the equipment abnormality data D3n and the product abnormality data D1n that are associated with the abnormal product; and by performing a specific step, the manufacturing step that is the cause of the product abnormality is specified.

Description

Product manufacturing method and product manufacturing device

The present invention relates to a manufacturing method and manufacturing apparatus of an absorbent article, a heating element, etc., which are manufactured through a plurality of manufacturing steps.

When an abnormality occurs in a product manufactured on a production line (for example, when a defective product is found in a quality inspection in the manufacturing step, when a consumer complaint, etc.), the cause must be quickly identified. In addition, in addition to abnormal situations in the manufactured products, when a mechanical failure occurs in the production line, it is also required to quickly find out the cause.

Patent Document 1 describes a quality information system in the manufacturing process of manufacturing composite products by successively adding component parts during the production of products. The constituent parts include continuous mesh materials or discontinuous mesh materials. The quality information system includes an inspection system and a quality data subsystem. The inspection system automatically inspects the quality of the sample set of the composite product produced, and provides quality parameters associated with the inspected state. The quality data subsystem obtains and saves a plurality of quality parameters.

Patent Document 2 describes a design method that manages the measurement values based on the product barcode, offline steps, the measurement values of the inline sensors, and the results of the questionnaire (audio or video). Data, redesign products or process parameters. In addition, a quality tracking system is disclosed. The quality tracking system generates quality based on a database storing product identification code (serial number or barcode) information, manufacturing data, a record module of feedback data from consumers, and the association of each. News.

Furthermore, in patent document 3, the manufacturing method of an absorbent article (diaper) is disclosed. The inspection objects in this manufacturing method are the base material and the rear wing. The inspection is performed by the first sensor, the second sensor and the controller respectively connected to the communication network. Moreover, the inspection parameters, process parameters and consumer feedback parameters are correlated. According to this association, the process parameters are adjusted (pressure is applied) based on at least one of the inspection parameters or the customer feedback parameters.

In recent years, the development of high-speed and large-capacity communication networks has also been combined with the improvement of the performance of inspection machines, and a large amount of information about equipment and products is generated in the production line.

[Prior Technical Literature] [Patent Literature]

[Patent Document 1] International Publication No. 2004/015509

[Patent Document 2] International Publication No. 2015/034713

[Patent Document 3] International Publication No. 2015/034891

The present invention provides a manufacturing method of a product, which is a manufacturing method of manufacturing a product through a plurality of manufacturing steps, and includes the following steps: obtaining equipment information of the manufacturing equipment for manufacturing the above-mentioned product; obtaining the product information from the above-mentioned product; And the above product data is stored in the data collection department; the above equipment data is associated with the above product data; the abnormality of the above product data is judged; when the above product is abnormal, the equipment abnormality associated with the abnormal product is identified Both or either of the data and the product abnormality data; and by performing specific steps, the cause of the abnormality of the product can be identified The manufacturing steps.

The present invention provides a product manufacturing device, which is a manufacturing device for manufacturing a product corresponding to a plurality of manufacturing steps, and has a plurality of manufacturing equipment for manufacturing the product and a plurality of inspection devices for inspecting the product, and has: a sensor , Which detects the manufacturing pattern possessed by the manufacturing equipment; and a data collection section, which stores the product data obtained by the inspection device and the manufacturing pattern data detected by the sensor; the above data collection section It has: an auxiliary central processing device that processes the aforementioned product data; a main central processing device that establishes associated equipment data representing the equipment status of the aforementioned manufacturing equipment, and collects data from the auxiliary devices processed by the aforementioned auxiliary central processing device, And the above-mentioned manufacturing pattern data for processing; and a database server, which stores the collected data of the main device processed by the above-mentioned main central processing device.

The above and other features and advantages of the present invention will become more clarified by referring to the accompanying drawings as appropriate and based on the following description.

10: Manufacturing device

20: Production line

21: Production line network

22: Production line central processing device

23: Equipment Central Processing Unit

24: Production line display device

25: Data Collection Network

30: Factory central processing unit

40: Manufacturing equipment

41: Device main control CPU

42, 42A,..., 42M: Equipment auxiliary control CPU

43, 43A, 43B: processing device

44: making patterns

50, 50A, 50B,..., 50Y, 50a, 50b, 50c: inspection device

51: camera device

52: lighting device

53: Displacement sensor

54: Projector

55: Receiver

56: Image processing camera system

57: camera device

58: lighting device

59: Camera

60: Sensor

70: Data Collection Department

71: auxiliary central processing unit

72: main central processing unit

72A: main central processing CPU

72B: main central processing CPU

73: database server

74: display device

74S: Screen

81: Belt conveyor

82: Cutting Machine

83: Belt conveyor

84: camera device

84A: Camera position

85: Manufacturing number assigning device

85A: Manufacturing number assigned position

90: products

91: original sheet

91A: Original film position

92: Sheets sent

93: Cut sheet

100: Absorber forming part

105: Absorber

105A: Overall Department

105B: Middle and high part

105D: recess

106: Absorber image

106A: Overall image

106B: Middle and high image

106D: Defective part image

107: Belt conveyor

109: Coated sheet

110: Manufacturing Device

120: defibrating machine

121: Shell

122: Rotary Knife

123: Opening

124: Opening

130: pipe

130a: one end

130b: the other end

140: Fiber Stacking Machine

141: Recess for fiber accumulation

142: Drum

151: Pulp sheet

152: Pulp Fiber

153: Water-absorbing polymer

154: Absorber material

170: Conveying device

200: Absorber compression part

205: Absorber

205A: Overall Department

205B: Middle and high part

205D: recess

210: pressure roller

220: Anvil Roll

230: Conveying device

231: Conveying belt

232: Conveying belt

300: Embossing processing department

305: Absorber

305N: Part without embossing

305P: Embossing

305T: The part with shallow embossing

306: Absorber image

306A: Embossing surrounding image part

306P: Embossed image section

310: Embossing roller

320: Anvil Roll

330: Conveyor

331: Conveying belt

332: Conveying belt

400: Manufacturing device for heating element

401: The first substrate sheet

401A: Original film roll

402: Paint layer

403: heating body layer

404: Second substrate sheet

405: Heating element continuum

406: heating element

407: The second covering sheet

410: storage tank

420: Liquid delivery pump

430: Coating Department

431: Die Nozzle Coating Machine

432: Paint

433: Coating Roll

440: Electrolyte Addition Department

441: Electrolyte

442: Screw Feeder

443: Electrolyte Quality Sensor

444: slot

445: Electrolyte dispersion sensor

450: Fitting Department

451, 452: Roll

460: Slit and notch processing part

470: The first cutting part

471: Cutting Machine Knife

472: Rotary Die Cutting Machine

473: Anvil Roll

480: Readjustment Department

481: Conveyor

482: Convey Belt

490: discharge part

491: Ladder Conveyor

493: Loop Belt

494: Suction Box

500: Covered Department

501: Conveyor

C1: The first calculation interval

C2: The second calculation interval

D1, D1A, D1B,..., D1Y: product information

D2: Manufacturing pattern data

D3, D3A, D3B, …, D3M: equipment information

D4, D4A, D4B, …, D4M: equipment auxiliary materials

D5: Auxiliary device to collect data

D6: The main device collects data

D7: Database information

LD: recess

L205: line

T1: Scheduled time for receiving paper

W: Window

Fig. 1 is a schematic configuration diagram showing a preferred example of the product manufacturing apparatus of the present invention.

Fig. 2 is a schematic configuration diagram showing a preferred example of manufacturing equipment of the manufacturing apparatus.

Fig. 3 is a schematic configuration diagram showing a preferred example of a production line and a data collection part of the product manufacturing device shown in Fig. 1.

Fig. 4 is a block diagram showing an example of the details of the data collection unit.

Fig. 5 is a schematic diagram showing an example of the establishment of data association.

Fig. 6 is a diagram showing a specific example of the collected data that indicates the establishment of the data association.

Fig. 7 is a diagram showing an example of the start and stop of saving of collected data using triggers.

FIG. 8 is a graph showing an example of the relationship between the diameter of the original film before and after the splicing, the relationship between the splicing and the time, and the relationship between the area value and the time, so that the time axis of each is uniformly shown.

FIG. 9 is a block diagram showing the steps of an example of applying the manufacturing method of the article to the manufacturing method of the absorbent article.

Fig. 10 is a configuration diagram showing an example of a fiber stacking device as an absorbent body forming part.

Figure 11 is a front and back cross-sectional view of the absorbent body of a normal product.

Figure 12 is a front and back sectional view of the absorbent body of the abnormal product.

Fig. 13 is a conceptual diagram showing an example of an image obtained by photographing the surface of an absorbent body of an abnormal product.

Fig. 14 is a plan view showing an example of how to obtain the depth value of the absorber.

Fig. 15 is a graph showing the relationship between the value of the missing area and the suction frequency of fiber accumulation.

Fig. 16 is a schematic configuration diagram showing an example of a press working part of the absorbent body.

Figure 17 is a longitudinal cross-sectional view of the absorbent body of a normal product.

Figure 18 is a longitudinal cross-sectional view of the absorbent body of the abnormal product.

Figure 19 is a diagram showing the relationship between the height of the absorber and the measurement position of the measurement result of the displacement sensor.

Fig. 20 is a schematic configuration diagram showing an example of an embossing portion.

Figure 21 is a top view of the absorbent body of the abnormal product.

Figure 22 is a top view of a normal absorbent body.

Figure 23 is a graph showing the relationship between embossing depth and embossing gap.

Fig. 24 is a plan view showing an example of an image of an absorber with embossing.

Figure 25 is a graph showing the relationship between the value of the indentation depth of the embossing and the value of the missing area (fiber accumulation and suction frequency).

Fig. 26 is a configuration diagram showing an example of a manufacturing apparatus of a heating element.

Fig. 27 is a diagram showing the relationship between the height and the position of the measurement result of the surface shape of the paint layer.

Fig. 28 is a graph showing the relationship between the position accuracy (standard deviation) of the heating element and the cross-sectional area of the paint layer (the number of pump revolutions).

The present invention relates to a manufacturing method and a manufacturing device for products that effectively utilize data generated by manufacturing equipment to achieve increased productivity. That is, it is related to the following content: the ability to track defective products can be improved, and by achieving rapid cause identification when equipment and products are abnormal, the machine operation rate and the product yield rate can be improved.

In the above-mentioned Patent Documents 1 to 3, there is no record of obtaining the data generated by the manufacturing equipment that constitutes the production line and linking it with the data of the product for storage and effective use. If a large amount of materials related to manufacturing equipment and products can be effectively used, it can be expected to improve productivity and product quality.

That is, it is possible to realize the rapid cause identification when the product manufactured in the manufacturing equipment of the production line is abnormal, and the rapid cause identification when the mechanical failure occurs in the manufacturing equipment. Furthermore, there is a possibility that the occurrence of a mechanical failure can be predicted before the occurrence of the mechanical failure, so that it can be preserved in advance. To this end, a large amount of data must be processed, but the number of data points that can be collected and accumulated by a general-purpose data logger is only a few to dozens of points. Therefore, it is impossible to obtain and keep a large amount of data generated by manufacturing equipment. In addition, the data is not simply stored, but sampling is performed at the same time according to the time series, and the data is correlated with each other and accumulated, thereby expecting its effective use.

The manufacturing method of the product of the present invention can effectively utilize the data generated by the manufacturing equipment to realize the improvement of productivity. That is, by improving the tracking ability of defective products, rapid cause analysis can be performed when abnormalities occur, so that the machine operation rate can be improved, and the product yield rate can be improved.

The manufacturing device manufactured by the present invention can effectively use production-related data to improve the tracking ability of production equipment, thereby enabling rapid cause analysis when abnormalities occur, and realizing the improvement of machine operation rate and product yield rate The improvement.

Regarding a preferred embodiment of the manufacturing method of the product of the present invention, the manufacturing method of an absorbent article is taken as an example, with reference to the drawings and the following description. First, referring to FIG. 1, a preferred example of the manufacturing apparatus will be described.

As shown in FIG. 1, the manufacturing apparatus 10 includes a plurality of production lines 20 and a factory central processing unit 30 that manages the production lines 20. The factory central processing unit 30 determines the "number of pieces produced", "number of good pieces", "operating time", "stop time", "number of stops", "variety number", and "number of pieces per sensor" for each production line 20. Discharge frequency" to process. Each production line 20 is equipped with a production line central processing device 22, which controls the operation, stop, etc. of the production line in a production line network 21 that connects manufacturing equipment (not shown). In addition, it is provided with: an equipment central processing unit 23 that controls each manufacturing facility; a production line display device 24 that displays the operating status of the production line; and the following inspection device 50. Furthermore, although not all the production lines 20 are shown in the figure, in each production line 20, a data collection unit 70 provided with a data collection network 25 is arranged on each production line network 21. In FIG. 1, as a representative, a data collection part 70 of the production line network 21 arranged on the No. XX production line is described. Each production line network 21 is connected to a data collection network 25 of a data collection unit 70 disposed therein. Furthermore, the details of the data collection unit 70 will be described below. The above-mentioned production line network 21 is, for example, a network that connects the following manufacturing equipment to each other.

As shown in FIG. 2, the manufacturing equipment 40 is arranged on the production line, and has a processing device 43 that performs a processing step, an inspection device 50 that performs an inspection step, and the like. The processing device 43 includes, for example, a processing device 43A that processes raw materials, a processing device 43B that processes unfinished products, and the like. Equipment data D3 can be obtained from each processing device 43. For the inspection device 50 on the production line, there are, for example, an inspection device 50a that acquires a raw material number and memorizes it in the product data, an inspection device 50b that performs post-processing inspection, and an inspection device 50c that assigns a product number. On the other hand, under the production line, an inspection device 50 for performing an inspection step under the production line is arranged. This inspection step, for example, inspects the shape, size, quality, etc., as the final inspection of the product. The product data D1 can be obtained from each inspection device 50. The internal system of the manufacturing equipment 40 corresponds to an unfinished product. In the product data D1, not only the product data of the finished product, but also the product data of the unfinished product are included.

As shown in FIG. 3, the manufacturing apparatus 10 has a plurality of production lines 20, and the plurality of production lines 20 have a plurality of manufacturing equipment 40 for manufacturing a product 90 and a plurality of (for example, A~Y) Inspection device 50. That is, the product 90 includes both unfinished products and finished products.

The equipment data D3 (D3A, D3B,..., D3M) obtained from the manufacturing equipment 40 is the equipment main control CPU (Central Processing Unit) 41 and equipment auxiliary control CPU 42 (42A, 42B) that are configured in the manufacturing equipment 40 ,..., 42M) directly sent to the main central processing unit 72 of the data collection unit 70. In addition, the equipment auxiliary data D4 (D4A, D4B, ..., D4M) obtained from the equipment auxiliary control CPU 42 is sent between the equipment auxiliary control CPU 42 (42A, 42B, ..., 42M) and the equipment main control CPU 41. The equipment auxiliary data D4 collected in the equipment main control CPU 41 can be sent to the main central processing unit 72 as the equipment data D3. Furthermore, in each figure, for the sake of convenience, arrows are used to indicate the communication paths of various "data". The following is the same. Also, CPU means central processing unit.

The main central processing unit 72 reads the data of the equipment main control CPU 41 or the equipment auxiliary control CPU 42 arranged in the manufacturing equipment 40, or writes the data of the equipment main control CPU 41 or the equipment auxiliary control CPU 42. Regarding the communication between the equipment main control CPU 41 and the main central processing unit 72, and the equipment auxiliary control CPU 42 and the main central processing unit 72, as a normal communication method, for example, a LAN (Local Area Network) can be used. As the LAN, for example, communication using Ethernet (registered trademark) (Ethernet (registered trademark)) is preferable. In this way, the device data D3 can be collected to the data collection unit 70 without greatly modifying the software and hardware of the device main control CPU 41 or the device auxiliary control CPU 42. In the above manner, the product data D1 and the equipment data D3 are stored in the data collection part 70 (data storage step).

In addition, the manufacturing device 10 has a sensor 60 that detects the manufacturing pattern 44 included in the processing device 43. The sensor 60 includes a proximity sensor and a bump for operating the proximity sensor.

Furthermore, it has a data collection unit 70 that associates the product data D1 (D1A, D1B,..., D1Y) obtained by the inspection device 50 with the manufacturing pattern data D2 detected by the sensor 60 store. Specifically, for example, the product data D1 related to the shape of the product 90 obtained by the inspection device 50 and the manufacturing pattern data D2 of the manufacturing pattern 44 of the processing device 43 that produced the product shape detected by the sensor 60 Establish an association and store it in the data collection unit 70. By establishing the association in this way, when an abnormal situation is found in the work-in-process data D1, the manufacturing pattern data D2 associated with the abnormal product data D1 can be retrieved immediately. Therefore, the abnormality of the processing device 43 can be easily found out.

The data collection unit 70 has an auxiliary central processing unit 71 and a main central processing unit 72. The product data D1 is processed in the auxiliary central processing device 71. Specifically, the data format (for example, communication standard, file format, etc.) of the product data D1 obtained by the inspection device 50 is converted into a main central processing device 72 for processing. Therefore, if it can be obtained from the inspection device 50 The product data D1 is directly input to the main central processing unit 72, and the auxiliary central processing unit 71 can be omitted.

In addition, in the main central processing unit 72, the equipment data D3 indicating the equipment status of the manufacturing equipment 40, the auxiliary equipment collection data D5 processed by the auxiliary central processing unit 71, and the manufacturing pattern data D2 are associated and processed.

Specifically, as shown in FIG. 4, the main central processing unit 72 is equipped with two main central processing CPUs 72A and 72B. The first main central processing CPU 72A is used to acquire the data of the equipment main control CPU 41 or equipment auxiliary control CPU 42 (42A,..., 42M) and the auxiliary central processing unit 71 at a time. The sampling period at this time is set as the time less than the processing period of each piece of product.

The data acquired by the main central processing CPU 72A is sent to the main central processing CPU 72B in a cycle of each piece. In this way, the scattered data for each device can be arranged into the same time series data. At this time, data is saved by two kinds of triggers. The details of data storage will be described below.

In this way, by collecting the data consistent with the time series, the timing of the occurrence of the abnormality can be traced. In the above-mentioned main central processing device 72, the main central processing CPU 72A separately performs data collection at one time for time synchronization.

Specific association establishment can be achieved by comparing data based on the distance between steps (number of processed pieces). The step of associating the equipment data D3 with the product data D1 can be performed based on the distance between the manufacturing steps represented by the number of processed pieces. For example, as shown in FIG. 5, the sheet 92 sent from the original sheet 91 is conveyed by the belt conveyor 81, and is cut by the cutter 82. The cut sheet 93 is re-arranged (repitched) on the belt conveyor 83 by the belt conveyor 83 at a fixed interval. The cut sheet 93 that has been readjusted is photographed by the camera 84. After that, the cut sheet 93 is processed through various processing steps to become the finished product. 品90. The product 90 enters a manufacturing number assigning step, and a manufacturing number is assigned by the manufacturing number assigning device 85. The manufacturing number assignment step will print a different manufacturing number for each piece of product to product 90. In addition, the manufacturing number assigning step may also be printed in a state where the product 90 is in a continuous mesh shape. Furthermore, the manufacturing number assigning step can also print on the package body of the product 90 that packages one or more pieces. The flow direction in the figure refers to the conveying direction of each sheet or product 90.

When establishing associations with other data generated by the manufacturing number, confirm in advance the manufacturing number assigning position 85A of the manufacturing number assigning device 85 and the distance to the position of another step. As the position of another step, in the example of the figure, the imaging position 84A of the imaging device 84 in the imaging step, the position where the sheet 92 of the original sheet 91 is sent out, that is, the original sheet position 91A, etc. . Here, each distance corresponds to the number of cut sheets. As an example, the imaging position 84A is the 50th position from the manufacturing number assignment position 85A. The original sheet position 91A is the 60th sheet from the manufacturing number assigning position 85A. According to the manufacturing apparatus, the number of sheets corresponding to the above-mentioned distance changes. In this way, by corresponding to the number of sheets, the distance from the manufacturing number assigning position 85A to the imaging position 84A or the original film position 91A can be specified.

Therefore, as shown in FIG. 6, the collected data of the time series of the manufacturing number 1006151 is the measured value of the camera=54pix. (pixels) and the original film diameter=699mm, but the data is not related to the manufacturing number 1006151. The number of products up to the manufacturing number assigning position 85A (refer to FIG. 5) and the imaging position 84A (refer to FIG. 5) is 50 pieces. Therefore, the camera measurement value 52pix. of the imaging position of No. 101 after 50 pieces of data is traced back to the value associated with the manufacturing number 1006151. In addition, the manufacturing number associated with the original film position 91A (refer to FIG. 5) becomes 1006091 of No. 91 after the data is traced back 60 slices. The original sheet diameter value of 759 mm becomes a value associated with the manufacturing number 1006151. Therefore, the measured value of the camera associated with the manufacturing number 1006151 is 52pix., and the original film diameter is 759mm. The above-mentioned camera measurement value is based on the imaging device 84 (refer to FIG. 5) The value of the scratch area on the surface of the material obtained from the captured image data. The so-called scratch area value refers to the total area of scratches visible on the surface of the material (pix.). The unit of the measured value of the camera shown in Figure 6 is pix. (pixel), and the unit of the original film diameter is mm.

The transmission data from the main central processing CPU 72A is temporarily stored by the main central processing CPU 72B, and is sent to the following database server 73 every time it accumulates a fixed time. At this time, the data communication is carried out according to the File Transfer Protocol (FTP), so the data transmission can be carried out without stopping the data recording of the main central processing CPU 72B.

The following shows an example of the transmission interval.

For example, when the processing speed is 300 pieces/min of absorbent articles as the product 90, that is, the processing time per absorbent article is 200 ms, the reading cycle Fw from the main central processing CPU 72A to the device main control CPU 41 is set to, for example, 10ms, 100ms, 1000ms. In addition, the reading from the main central processing CPU 72A to the auxiliary central processing unit 71 is set to, for example, cycle Fsm=20 ms. Furthermore, the transmission cycle Ft from the main central processing CPU 72A to the main central processing CPU 72B is set to, for example, a processing time of 200 ms per chip using a trigger. The trigger interval is set to 200 ms, for example.

The transmission period Fftp from the main central processing CPU 72B to the database server 73 is set to, for example, 1 minute.

In addition, as shown in FIGS. 3 and 4, the data collection unit 70 has a database server 73 that stores the main device collection data D6 processed by the main central processing device 72.

The aforementioned database server 73 is a server that has a database inside and is operated by a database management system. For example, perform the following actions: perform database search and other processing in response to requests from the operator, and send back the processing results. Database management system refers to the Software for database operation and management necessary for database. In addition, the so-called database refers to a file structure that has predefined data formats and can be comprehensively managed.

Furthermore, a display device 74 is provided, and the display device 74 displays the database data D7 stored in the database server 73. The display device 74 can be a normal display such as a liquid crystal display or an organic EL (organic electroluminescence) display.

Next, a preferred example of the manufacturing method of the product will be described with reference to FIG. 3.

The manufacturing method of the product of the present invention is directed to the equipment data D3 and the equipment auxiliary data D4 of the manufacturing equipment 40 constituting the production line 20 (refer to FIG. 1) for manufacturing the product 90, and has a tracking capability for each product 90. Traceability is also called traceability. It means that the self-product 90 is in a traceable state from the production stage to the consumption stage (abandonment stage).

In this manufacturing method, focusing on one of the multiple production lines, the following steps are performed. Furthermore, the following steps can also be performed for each production line of all production lines.

First, for each product 90, the state of the product 90 is checked by the inspection device 50 and the product data D1 is acquired (the product data acquisition step). For example, the product data D1 is acquired during the processing period using the manufacturing equipment 40. Therefore, the manufacturing equipment 40 is associated with the inspection device 50. When there are a plurality of inspection devices 50, the product data D1 (D1A, D1B,..., D1Y) obtained by the inspection by each inspection device 50 (50A, 50B,..., 50Y) is acquired. The state of the product 90 includes shape, thickness, density, and the like. The above-mentioned product data D1 may include position, area, size, density, and the like. As an example of the position, for example, the position where the elastic member of the absorbent article moves, the position where the absorbent body is attached, the position where the product is bent, and the like can be cited. The so-called area refers to the pattern of the product 90 obtained by processing the image acquired by the inspection device 50, for example, the area in a plan view, the area of a cross-section, and the like. The so-called size refers to the product 90 obtained by processing the image obtained by the inspection device 50, such as the length, width, thickness, and angle of the pattern. Degree and so on. In addition, the shape, thickness, and basis weight of the absorber can be cited.

Next, the product data D1 is associated with the equipment data D3 representing the equipment status of the production line 20 (data association establishment step). As the equipment data D3, for example, as the operating status of the manufacturing equipment 40, data such as the number of pieces produced, the operating time, the number of stops, and the operating speed can be cited.

In addition, it can include information such as roller temperature, original film diameter, used shaft, load rate or revolution of servo motor, timing of paper splicing, pattern operation information, image measurement value, pattern position, product counter, etc. As an example, the total data count of these devices is about 1000 to 2000 points.

Examples of the roll temperature include the temperature of each processing roll that performs cutting, embossing, and sealing processing, or the temperature of an anvil roll arranged opposite to each processing roll.

The diameter of the original sheet can be listed as the current roll-out diameter of the original sheet.

The shaft system used is defined as the shaft in use among the multiple shafts performing the same step.

The servo motor uses the product's position data, orientation data, posture data, etc. as the control value, and automatically actuates in a manner consistent with the target value. As the equipment data D3 of the servo motor, data such as the number of revolutions (rotation speed) and the load factor of the shaft can be listed. For example, when the speed of the original film continuously sent from the original film is set to be constant, the number of revolutions varies depending on whether the film is being reeled or not.

The timing of paper splicing can be listed as the timing data of paper splicing immediately before splicing and just after splicing paper.

The pattern operation information can list the position alignment data of the pattern.

The image measurement value can include the position, area, shape, etc. data from the image processing data obtained by image processing of the image obtained by the inspection device by the image processing device not shown in the inspection device .

The position of the pattern can include the fiber stacking drum, cutting machine, and side seal. It is equal to the repetition of each X number of the processing unit in the processing unit that processes the multiple sheets in the manufacturing equipment. material. Set X to be a natural number greater than 2. For example, the information of the page number can be listed.

The product counter may include, for example, the manufacturing year, month, day, time, factory production line number, batch number, manufacturing number, material management number, etc. printed by the printer. The printing of the above items such as the manufacturing number includes not only the printing with colored ink, but also the printing with colorless ink. Examples of colorless inks include UV (ultraviolet) inks that can be visualized by irradiating ultraviolet rays.

The association between the product data D1 and the equipment data D3 is established based on the distance between the manufacturing steps. Specifically, for each product 90, for example, the batch number or manufacturing number of the product 90 corresponds to the equipment data D3 of the manufacturing equipment 40 that processes the product 90. Furthermore, each product data D1 acquired by each inspection device 50 is associated with the equipment data D3 of the product pattern of the manufacturing equipment 40 where each product data D1 is acquired. At this time, there is a difference between the time at which each product data D1 is acquired and the time at which the manufacturing equipment 40 processes and acquires the part of the product 90 of each product data D1. Therefore, it is preferable to adjust the time difference.

Thereafter, the product data D1 and the equipment data D3 that have been associated are stored in the data collection part 70 (the storage step of the associated data).

For the product 90 that is being processed in the production line 20 or the product 90 whose steps implemented by the production line 20 have ended, the product abnormality of the product data D1 is detected (judged). Then, when a product abnormality occurs, the product abnormality data D1n (not shown) associated with the product 90 in which the product abnormality occurs is specified in the product data D1. Tracking is performed based on the specified product abnormality data D1n. Here, it is also possible to track the equipment abnormality data D3n (tracking step of abnormal products) that is associated with the product considered to be abnormal. Alternatively, it is also possible to track both the equipment abnormality data D3n and the product abnormality data D1n that are associated with the product considered to be abnormal. As an example, the tracking mentioned here refers to tracking the production process of the abnormal product 90 based on the product abnormality data D1n. Then, as a result of the tracking, both or either of the product abnormality data D1n and the equipment abnormality data D3n are specified. In this way, the manufacturing steps that are the cause of the abnormality of the product can be identified. The status of the abnormal manufacturing equipment 40 can be investigated based on the equipment abnormality data D3n of the manufacturing equipment of the specified manufacturing step.

For example, by tracking, the abnormal part of the manufacturing pattern 44 of the processing device 43 where the product abnormality occurs is identified, thereby obtaining equipment abnormality data D3n (not shown) (equipment abnormality data acquisition step).

It is preferable to visualize the equipment abnormality data D3n on the screen 74S of the display device 74 (visualization step). The so-called "visualization" refers to one of the management methods in the production site of a product. It refers to the fact that, during the production of the product, the person engaged in the production can specifically grasp the actual situation of various activities such as the production plan, the implementation of the production, the product evaluation, and the verification of the product's problem points. For example, it means that the above-mentioned activity can be seen on the screen of the display device. In addition, the following method has been established: when solving or improving production problems, proactively taking countermeasures based on the level of the production site can seek improvement or improvement. In this way, "visualization" refers to a state in which the judgment criteria for the visible problems are always shared in the production site, and the problems or issues are repeatedly improved. As specific visualized data, for example, there is the time of the sensor data that measures the operating rate of the machine, the yield of the product, the number of stops of the machine, the transition of the number of discharges of defective products, the shape of the product and the defect of the product, etc. Sequence graph, etc.

Based on the identification of the manufacturing process that is the cause of the abnormality of the above-mentioned product, the abnormal part of the manufacturing equipment 40 that is visualized can be repaired (the repairing process of the manufacturing equipment). When the repair is performed, the operation of the manufacturing equipment 40 is temporarily stopped, and the part that becomes the repair target of the manufacturing equipment 40 is repaired. For example, the mechanical parameters related to the abnormal part of the manufacturing equipment 40 are adjusted to repair the abnormal part. At this time, whether to use the production line with the repaired manufacturing equipment The total stoppage of 20 manufacturing equipment is judged according to the repair location and the degree of repair. In this repair, feedback control is not performed, but visualization is used as a repair method of abnormal parts of the manufacturing equipment 40, which means, for example, a method of correcting mechanical parameters. For example, in the embossing process using an embossing roller, it is possible to check the formation of the indentation in the image while adjusting the gap or temperature of the embossing roller.

Moreover, according to the repair object, the repair can also be performed automatically by feedback control. For example, the gap adjustment or temperature adjustment in the embossing process described above can be feedback controlled.

The manufacturing method of the above-mentioned product is preferably performed for each production line 20 (refer to FIG. 1).

According to the manufacturing method of the above-mentioned product, the following functions and effects are exerted.

(1) The product data D1 can be obtained for each product 90, and the product abnormality data D1n indicating the abnormality of the product 90 can be detected to determine the abnormality of the product. The equipment abnormality data D3n of the abnormal manufacturing equipment 40 can be obtained based on the product abnormality data D1n. In this way, the traceability of the production line 20 is improved.

(2) Since the product data D1 is acquired for each product 90, the data collection function can be improved.

(3) Since the abnormality of the manufacturing equipment 40 can be grasped based on the abnormality data of the product 90, that is, the product data D1n, the analysis of the cause of the abnormality becomes quick and easy.

(4) By realizing the visualization of the equipment abnormality data D3n, and displaying the equipment data D3 of the abnormal manufacturing equipment 40 on the display device 74, the response to the abnormal situation at the production site becomes quick.

As described above, the cause of the abnormal product (also referred to as defective product) of the product 90 can be quickly grasped, so that the defective part can be repaired quickly. In addition, since the causes of defects in the production line 20 can be visualized, it is possible to quickly repair defective parts of the manufacturing equipment 40 that have become defective. complex. Therefore, the stop time of the production line 20 is shortened, and the machine operation rate can be improved. In addition, since the identification of the causes of defects becomes quicker, the occurrence of defective products is reduced, and the rate of good products can be improved.

Moreover, even if visualization is not performed, the defective part can be repaired. For example, even if the numerical data or the graph is not displayed on the screen of the display device, the operator can be notified of the occurrence of an abnormality through an audible alarm or an electronic audible alarm. In addition, an abnormality can be notified to staff who are not on the manufacturing site by communication methods such as e-mail.

The product abnormality in the above manufacturing method is to compare the normal product data D1g (not shown) of the normal product with the product data D1 of the product 90 produced by the production line 20, and detect the difference from the normal product data D1g of the normal product As abnormal products (detection steps for abnormal products).

Then, from the product abnormality data D1n of the abnormal product, extract the cause data D8 (not shown) that is the cause of the abnormality (the extraction step of the cause data).

Based on the cause data D8, the manufacturing pattern abnormal data D2n (not shown) of the equipment data D3 associated with the product data D1 is tracked (the abnormal product tracking step). In this way, the occurrence location of the abnormal product of the product is associated with the occurrence equipment.

In the product data D1 stored in the data collection unit 70, in addition to the product data D1 obtained by inspection by each inspection device 50, the manufacturing data DP of each product 90, not shown, is recorded in association with each product 90. As the manufacturing data DP, a factory name, a production line name, a manufacturing implementation date, a manufacturing number, etc. can be listed.

In addition, in the manufacturing method of the above-mentioned product, the statistical value can be calculated through the data collection step. As a statistical value, the average value, standard deviation value, etc. can be obtained.

Calculate the statistical value through each step of the data collection step of the normal product and the data collection step of the abnormal product. At this time, the statistical value may not distinguish between good products (normal products) and defective products (abnormal products). Calculation. As shown in Figure 7, there are two intervals for calculation. The first calculation section C1 is to set only the high-speed data in high-speed operation as the calculation section (data in production). The second calculation interval C2 is set as an interval including low-speed data and high-speed data during low-speed and high-speed operation (also includes data for adjustment operation). For example, when the product 90 is an absorbent article, if the processing speed of the absorbent article is 300 pcs/min, only calculations are performed at a speed of 300 pcs/min during high-speed operation. In low-speed and high-speed operation, Calculate when the speed is 50 pieces/min or more.

In addition, the statistical value is effectively used in the following situations. For example, when the average value fluctuates greatly, it can indicate that the capability of the equipment itself fluctuates greatly (such as failure). In addition, when the standard deviation changes significantly, the occurrence of very few abnormalities can be grasped. The rare occurrence of abnormalities includes, for example, processing defects caused by a small amount of dirt in the equipment, or deterioration of the sensor used for measurement.

The standard deviation controls the behavior that cannot be grasped by the change of the average value. Therefore, by using both the average value and the standard deviation, the possibility of early detection of equipment abnormalities is increased.

Furthermore, in the manufacturing method of the above-mentioned product, it includes the step of confirming the correlation between the image processing data D1IP (not shown) and the equipment data D3 related to the image processing inspector in the product data D1. The image processing inspector is an inspection device that acquires images in the inspection device 50 and performs inspections. It mainly includes: an imaging device that photographs the inspection area; and an image processing device that performs data on the image captured by the imaging device化处理。 Treatment.

The above steps to confirm the related relationship include: the situation of confirming on the production line, that is, the situation of instant confirmation; and the situation of confirming under the production line, that is, the situation of confirming the detailed correlation after data collection.

As shown in Figure 8, the diameter of the original film decreases with the elapse of the operation time. When it becomes the original film diameter that must be spliced, or when the predetermined time T1 for splicing has elapsed since the start of the operation, the splicing is performed Paper. Before the paper splicing, the usual area value was not generated, but after the paper splicing, the area value exceeding the threshold was frequently generated. It can be seen that some abnormalities have occurred due to material changes caused by paper splicing. In addition, based on the correlation between the diameter of the original sheet and the area value, it is also possible to confirm whether the original sheet is abnormal on the inner side or on the outer side.

Furthermore, in addition to the product data D1, the setting values of the manufacturing equipment 40 set in the production line 20 in advance are also registered. For example, the set value can be recorded on paper media under the production line.

Equipment data D3 includes: single piece collection data D31, which is collected in the cycle of each piece of product; long-term collection data D32, which is collected in a longer cycle than single piece collection data D31; and short cycle The collection data D33 is collected in a shorter period than the single collection data D31. The so-called collection in each cycle of one piece of product means acquiring equipment data D3 (single piece collection data D31) for each of the products 90 processed by one of the plurality of manufacturing equipment 40. As the single piece collection data D31, since it is an inspection for each piece of product, for example, inspection data obtained by using an image inspector or the like can be cited. The "single piece" mentioned here refers to each piece of finished product, but it also includes each piece of intermediate product corresponding to one piece of product, and a part of the semi-finished product equivalent to one piece of product.

The long-period collection data D32 is the equipment data D3 collected in a longer period than the single-chip collection data D31, such as temperature data, original film diameter data, etc. The short-period collection data D33 is the equipment data D3 collected in a shorter period than the single-chip collection data D31, such as pressure, the instantaneous load rate of the servo motor, and the heater current value.

In this way, by changing the storage period of the single-chip collection data D31, the long-period collection data D32, and the short-period collection data D33, the processing speed is accelerated and the storage data capacity is suppressed.

The start and stop of the saving of the collected data can be performed by triggers. The so-called trigger refers to one of the functions of the database management system, and refers to the automatic activation of certain operations on the table Start the pre-designated processing function. The so-called table refers to the arrangement of data and other elements vertically and horizontally.

By using the trigger to save, the storage data capacity can be suppressed. Also, for triggers, at least two types of triggers are used. Triggers are set by specifying the content of the processing, the conditions of activation, and the timing of execution. For example, the specified fixed speed or higher, the specified threshold (%) or less, the specified before and after the occurrence of defective products, or the specified before and after the paper splicing in the case of the manufacturing method of the absorbent article.

In addition, by using a plurality of triggers, the data under different conditions can be compared. For example, as shown in Fig. 7 above, collect two types of data: data during high-speed operation (normal production) and data during low-speed operation, and compare the behavior during high-speed operation with the behavior during low-speed operation. The above-mentioned high-speed operation usually refers to the highest-speed operation. The above-mentioned low-speed operation refers to the operation from the start of processing to just before the high-speed operation, and from just after the high-speed operation to the stop of processing. By turning on (ON) the switch of trigger T1, data collection at low speed starts. Data collection during low-speed operation is performed after the trigger T1 is turned on until it is turned off (OFF). In addition, by turning on (turning on) the switch of trigger T2, data collection during high-speed operation is started, and by turning off (off) the switch of trigger T2, data collection during high-speed operation ends.

The manufacturing method of the above-mentioned product described in this embodiment is not limited to the product 90 being an absorbent article, and can also be applied to the manufacturing method of other sheet-like products. For example, it can also be applied to the manufacturing method of heating elements.

Next, an example of the case where the manufacturing method of the above-mentioned product is applied to the manufacturing method of an absorbent article is demonstrated. As shown in FIG. 9, for example, a description will be given below corresponding to the case where the absorbent body forming part 100, the absorbent body pressing part 200, and the embossing part 300 are used. Shaped on the absorbent body In the section 100, an inspection device 50A is used to perform a defect inspection of patterns and the like. In the absorbent body pressurizing part 200, the thickness inspection is performed using the inspection apparatus 50B. In the embossing processing part 300, an indentation inspection is performed to inspect the indentation state of the embossed pattern using the inspection device 50C.

First, referring to FIG. 10 as the absorbent body forming part 100, an example used in the fiber accumulation step will be described below.

As shown in FIG. 10, the absorbent body manufacturing apparatus 110 supplies the absorbent body material 154 containing fiber material and the air flow through the duct 130 together. Then, the absorbent body material 154 is deposited in a recessed portion (hereinafter also referred to as a recessed portion for fiber stacking) 141 arranged on the peripheral surface of the drum 142 of the fiber stacking machine 140.

The front stage of the manufacturing device 110 has: a defibrator 120, which defibrils a pulp sheet 151 drawn from a raw pulp sheet (not shown) to obtain pulp fibers 152; and a pipe 130, which becomes a self-defibrillator 120 The path of the pulp fiber 152 that is sent out along with the air flow.

The defibrator 120 has: a housing 121; and a rotating knife 122, which is disposed in the housing 121 and scrapes the end of the pulp sheet 151. The housing 121 has an opening 123 to take in the pulp sheet 151 and an opening 124 to discharge the pulp fibers 152.

One end 130a of the pipe 130 is connected to the opening 124 of the defibrator 120, and the other end 130b covers a part of the outer circumferential surface of the drum 142.

The drum 142 has, for example, a plurality of fiber stacking recesses 141 formed on the circumferential surface at specific intervals. Towards the peripheral surface of the drum 142, the absorbent material 154 (pulp fiber 152, water-absorbent polymer 153) conveyed in the pipe 130 is supplied (indicated by arrows for convenience), and deposited in the fiber accumulation recess 141 .

The absorber 105 accumulated in the fiber accumulation recess 141 is used, for example, as an absorber for absorbent articles such as menstrual napkins and incontinence pads. Therefore, the shape of the above-mentioned fiber accumulation recess 141 can be It is determined according to the shape of the absorber 105. That is, the shape of the above-mentioned fiber accumulation recessed portion 141 is determined so that the convex portion or the recessed portion is formed in a desired portion of the absorber 105. In addition, the shape of the fiber accumulation recess 141 is not limited to this, and the depth may be fixed, or it may be formed continuously along the outer peripheral surface of the drum 142.

An intake fan (not shown) is connected to the rotating drum 142, and the space B partitioned in the rotating drum 142 is maintained at a negative pressure by the driving of the intake fan. The suction volume of the intake fan can be set by adjusting the frequency of the unillustrated inverter, that is, the fiber accumulation suction frequency. Due to the negative pressure of the space B, an air flow is generated in the duct 130, so that the absorbent material 154 from the defibrating machine 120 is in a scattered state. At least the bottom surface of each fiber accumulation recess 141 is made of a mesh plate or the like as described above, and has a plurality of pores. While each of the fiber accumulation recesses 141 passes through the space B maintained at the negative pressure, the pores of the mesh plate function as suction holes. The space B is located on the back side of the portion covered by the pipe 130 in the rotating drum 142. In the space B, a strong suction force is generated through the fiber accumulation recess 141 of the part covered by the duct 130, thereby causing the absorbent body material 154 to accumulate in the fiber accumulation recess 141, or generate and transport the absorbent body material in the duct 130 The airflow of 154. In order to stably hold the deposit or the absorbent body in the fiber accumulation recess 141 while conveying it, the space C may be maintained at a negative pressure. In this case, the space C is maintained at a level of negative pressure lower than that of the space B. In addition, the air flow of the conveying absorbent material 154 flowing in the duct 130 is guided toward the outer peripheral surface of the drum 142 by suction from the fiber accumulation recess 141 located in the space B.

Furthermore, the manufacturing apparatus 110 includes a conveying device 170 as a transfer conveying mechanism that releases the absorbent body 105 from the fiber accumulation recess 141 and transfers it to a coated sheet 109 made of water-permeable tissue or non-woven fabric. . Furthermore, although not shown, the side of the covering sheet 109 under the absorber 105 may be folded back to cover the upper and lower surfaces of the absorber 105, or it may have A covering mechanism for this kind of action. In addition, a sheet may be supplied in addition to the covering sheet 109 to cover the upper and lower surfaces of the absorber 105.

The above-mentioned absorbent material 154 can use various materials used in absorbent articles such as menstrual sanitary napkins or disposable diapers without limitation, and at least include fiber materials. As the fiber material, for example, in addition to pulp fibers obtained by defibrating a pulp sheet, short fibers of cellulose fibers such as rayon fibers and cotton fibers, or short fibers of synthetic fibers such as polyethylene can be used. These fiber materials can be used individually by 1 type or in combination of 2 or more types. In addition, as the absorber material 154, a water-absorbent polymer can be further used.

In addition to the pulp fiber 152 described above, the fiber material may also include synthetic fiber. The pulp sheet 151 may be mixed with synthetic fibers, and it may be mixed with pulp fibers obtained by defibrating synthetic fibers and supplied. In the manufacturing device 110 shown in FIG. 10, it is directly supplied from the defibrating machine 120 to the pipe 130, but the pulp obtained by defibrating may be stored in a storage tank (not shown) and supplied from the storage tank to the pipe 130 130. Synthetic fibers (short fibers) may also be supplied to the storage tank and mixed.

In the above manner, the fiber stacker 140 performs fiber stacking to form the absorbent body 105. After that, the absorbent body 105 demolded from the fiber stacking recess 141 of the drum 142 of the fiber stacking machine 140 is placed on the belt conveyor 107 and transported. During the transportation process, the inspection device 50 inspects the shape of the absorbent body 105 formed by the accumulation of fibers. The inspection method uses the imaging device 51 and the lighting device 52 in the inspection device 50. The imaging device 51 is arranged above the absorber 105 to be photographed, and the illuminating device 52 is arranged at a position facing the imaging device 51 with the absorber 105 interposed therebetween. The illuminating device 52 illuminates the absorber 105 from the back, and the imaging device 51 captures its shadow. Therefore, the belt conveyor 107 of the area to be photographed is transparent.

For example, as shown in FIG. 11, the absorbent body 105 of a normal product is in a cross-sectional view in the front-to-rear direction. When observing the situation, the cross-sectional rectangular middle-high part 105B is arranged on the cross-sectional rectangular integral part 105A. The front-to-rear direction refers to the side where the absorbent body 105 is placed on the front side of the wearer when the wearer wears the absorbent body 105 as "front", and the side that is placed on the back side of the wearer is referred to as "back". In addition, the front-rear direction means the direction of the mechanical flow of the absorbent body 105.

In the case of the absorber 105, as shown in FIG. 12, when there are concave portions 105D (or convex portions) on the surface of the entire portion 105A and the surface of the mid-high portion 105B, it is regarded as an abnormal product (defective product).

When the absorber 105 has a defect as described above, as shown in FIG. 13, a defective portion 105D (refer to FIG. 12) is captured as a defect portion image 106D in the captured image 106 of the absorber. For example, when the thickness is too thin than the surroundings, the part is photographed brightly, and when the thickness is too thick, the part is photographed darker. The so-called brightly photographed means that the amount of light transmitted by this part is greater than that of the surroundings, which means that the thickness of the absorber 105 is thinner. As such a situation, for example, the clogging of the screen is considered to be the cause. In addition, the so-called darkly imaged means that the amount of light transmitted by the part is less than that of the surroundings, which means that the thickness of the absorber 105 is thicker. As such a situation, for example, it is considered that the mixing of foreign matter or the increase of pulp is one of the reasons.

For the measuring device, for example, an image processing camera system XG-8500L (trade name, manufactured by KEYENCE Co., Ltd.) is used. The measured data is set as the depth value and missing area value of the absorber.

The depth value of the absorber is as shown in FIG. 14 using the captured absorber image 106, and the absorber 105 (refer to FIG. 12) captured in the image is divided into a mesh when viewed from the top. Find out. In the absorber image 106, since the amount of transmitted light in the mid-high portion 105B (see FIG. 12) in the center of the absorber 105 is reduced, it becomes a darker image than the overall portion image 106A around the mid-high portion image 106B. Since the whole part 105A (refer to FIG. 12) is thinner than the middle-high part 105B, the amount of transmitted light becomes larger than that of the middle-high part 105B. As a result, the overall image 106A around the middle and high part becomes It is a brighter image than the mid-to-high image 106B. For such an image, for example, a plurality of windows are arranged in a grid pattern, and the depth (depth) of the absorber portion in the window is obtained for each window.

In addition, the missing area value is shown in the above-mentioned FIG. 14 using the captured absorber image 106, and the absorber 105 (refer to FIG. 12) captured in the image is expanded in a grid when viewed from above. It is determined by setting a plurality of windows W. The absorber image 106 is an image in which the middle and high portion image 106B is darker than the surrounding entire portion image 106A in the same manner as described above. On the other hand, since the amount of transmitted light of the whole part 105A becomes larger than that of the middle and high part 105B, the whole part image 106A becomes a brighter image than the middle and high part image 106B. Furthermore, the defect portion image 106D of the absorber captured in the image becomes the brightest image because the defect portion 105D (refer to FIG. 12) becomes thinner than the mid-high portion 105B or the entire portion 105A, and the amount of transmitted light increases. picture. Based on such an image, binarization is performed for each window W to obtain the area value of the portion corresponding to the defective portion image 106D. The value obtained by adding up the area value is regarded as the missing area value.

Fig. 15 shows the relationship between the missing area value and the fiber accumulation suction frequency in the form of a graph. As shown in Fig. 15, if the missing area becomes larger, the frequency of fiber accumulation and suction becomes lower.

The press processing of the absorber is, for example, processing performed when the thickness of the absorber is reduced to increase the fiber density.

As shown in FIG. 16, the absorber 205 is placed on the conveying belt 231 of the conveying device 230, and is conveyed in the arrow direction. At its transport destination, an absorbent body pressurizing part 200 is provided. The absorbent body pressing portion 200 is provided with a pressing roller 210 which makes the thickness of the absorbent body 205 thinner, and an anvil roller 220 which is spaced apart from the pressing roller 210 at a position opposite to the pressing roller 210. The distance between the opposing roller peripheral surfaces of the pressing roller 210 and the anvil roller 220 is adjusted according to the thickness of the absorbent body 205 that is thinned by pressing. The absorbent body 205 that is sandwiched between the pressure roller 210 and the anvil roller 220 to be pressed becomes thinner, and is placed on the conveying belt 232 to be conveyed toward the next step. Conveying belts 231 and 232 series It is divided by the upstream side and the downstream side of the absorber pressurizing part 200. In this transport step, the height of the absorber 205 is measured by the inspection device 50. The inspection device 50 includes a displacement sensor 53. The displacement sensor 53 is divided into a light projector 54 and a light receiver 55, and is disposed at a position opposed to the absorber 205 via the absorber 205 to be measured, so as not to contact the absorber 205. The displacement sensor 53 uses, for example, LJ-V7300 (controller LJ-V7000) (trade name) manufactured by KEYENCE Co., Ltd. The measurement light is a blue semiconductor laser light with a wavelength of 405nm and a measurement width of 240mm.

The displacement sensor 53 is used to measure the height of the transported absorber 205 in the front and rear directions. For example, when the absorbent body 205 of the normal product shown in FIG. 17 is viewed in the cross section in the longitudinal direction (machine flow direction), the rectangular cross-sectional mid-high portion 205B is arranged on the rectangular cross-sectional entire portion 205A. In addition, in FIGS. 17 and 18, the description of the hatching showing the cross section is omitted. Furthermore, by measuring the height in the longitudinal direction of the absorber 205 provided with the mid-high portion 205B, the surface shape in the longitudinal direction is obtained, and the deformed shape of the absorber is determined. As a result, the concave portion 205D was confirmed by the displacement sensor 53 (refer to FIG. 16) on the surface of the longitudinal direction of the absorber 205 as shown in FIG. 18. The results measured by the displacement sensor 53 are shown in FIG. 19. As shown in FIG. 19, the vertical axis represents the height of the surface of the absorber 205 measured by the displacement sensor 53, and the horizontal axis represents the position of the absorber 205 measured by the displacement sensor 53. By the measurement, the concave part LD corresponding to the concave part 205D (refer to FIG. 18) was confirmed on the surface of the absorber 205 with respect to the line L205 which shows the height of a measured value.

In this way, when the recess 205D is confirmed in the surface shape, it is deemed that an abnormal product (defective product) has occurred, and the production line is stopped. That is, the manufacturing facility 40 where the abnormal product is generated is stopped, and the processing part of the manufacturing facility 40 is cleaned and inspected. In addition, inspection and adjustment of the circumferential area between the pressure roller 210 and the anvil roller 220, the gap between the pressure roller 210, and the pressure of the pressure roller 210 are inspected and adjusted.

Like the manufacturing method of the above-mentioned product, if the suction frequency of the fiber stacker is increased (increasing the suction volume of the absorber), the transferability becomes better, the absorptive area of the absorber decreases, and the processing state becomes better. Therefore, the absorptive area of the absorber is detected, and the suction frequency is adjusted so that the absorptive absorptance does not occur.

The embossing processing of the absorber is processing for the purpose of, for example, improving the leakage resistance and improving the adhesion to the excretory part by promoting the bulge of the opposed part of the excretory part.

As shown in FIG. 20, the absorber 305 is placed on the conveying belt 331 of the conveying device 330, and is conveyed in the arrow direction. The embossing processing part 300 which performs embossing processing on the absorber 305 is provided in the conveyance destination. The embossing part 300 is configured with an embossing roller 310 that embossing the absorber 305 and an anvil roller 320 that is spaced apart from the embossing roller 310 at a position opposite to the embossing roller 310. The interval between the opposite roller peripheral surfaces of the embossing roller 310 and the anvil roller 320 is adjusted in a way that embossing is made on the absorbent body according to the embossing pattern. The absorbent body 305 sandwiched between the embossing roller 310 and the anvil roller 320 and pressurized according to the embossing pattern is placed on the conveying belt 332 to be conveyed toward the next step after the embossing is made. The conveying belts 331 and 332 are divided by the upstream side and the downstream side of the embossing part 300. In this transport step, the image of the absorber 305 is acquired by the inspection device 50. The inspection device 50 is an image processing camera system that photographs the surface of the absorber 305 to obtain a two-dimensional image. According to the obtained two-dimensional image, measure the length, position, depth, etc. of the impression made by embossing. As a result of the measurement, as shown in FIG. 21, a portion 305N without embossing marks was generated on the surface of the absorbent body 305. In addition, there are also cases where the embossing impression is shallower 305T.

In addition, if a normal embossing pattern is formed, as shown in FIG. 22, embossing impressions 305P are arranged clearly and neatly in an oval shape on the surface of the absorber 305 as shown in FIG. 22.

Here, the relationship between the embossing depth value and the embossing gap is shown in FIG. 23. As shown in Fig. 23, it is known that as the embossing gap becomes smaller, the depth of the indentation becomes deeper. That is, if the embossing gap becomes smaller, According to the embossing pattern, the absorber is strongly pressed, so the depth of the indentation becomes deeper.

The depth value of the indentation is obtained by setting a plurality of windows (not shown) in the same manner as in FIG. 14 and measuring the depth of the embossed image in the embossed portion and its surroundings. The window is preferably set to surround the embossed image portion 306P in FIG. 24 described below. Compared with the overall setting of the image window, processing and inspection, the inspection difference time can be shortened.

The image processing camera system 56 of the inspection device 50 for measurement is divided into an imaging device 57 and an illuminating device 58 illuminating the shooting area, both of which are arranged above the absorber 305 to be measured without contacting the absorber 305. As the image processing camera system 56, for example, an image processing camera system CV-X200 (trade name) manufactured by KEYENCE Co., Ltd. can be cited.

As shown in FIG. 24, based on the absorber image 306, the depth of the embossed image portion 306P and the embossed surrounding image portion 306A is measured to obtain the indentation depth value. Specifically, the indentation depth value is obtained from the depth gray scale value in each window. If the embossed image portion 306P is not clear with respect to the embossed surrounding image portion 306A, although it is not shown, it appears whitish and lightly, so the indentation depth value becomes low. In addition, if it is clear, it will appear darker and deeper as shown in the figure, so the indentation depth value will increase. Moreover, the adjustment of the gap of the embossing roll is based on the evaluation of product performance (leakproofness or peeling, appearance, etc.) based on the depth when it is judged that there is no problem. If the gap between the embossing rollers is reduced (increased pressure), the clarity of the embossing becomes better. While sensing the clarity of embossing based on the camera image, adjusting the gap of the embossing roller. Specifically, the gap of the embossing roller is adjusted based on the value of the indentation depth of the reference. Although not shown, the embossing gap is a wedge inserted between the embossing roll and the anvil roll, and the gap is adjusted by the amount of insertion.

According to the manufacturing method of the above-mentioned product, the causal relationship between the inspection data of different steps can be obtained to control different parts. For example, there are cases where the defects of the absorber processing in the upstream step are related to the defects in the embossing processing in the downstream step. For example, there is poor impression of embossing The reason for this affects the processing steps of the absorber. Specifically, as shown in FIG. 25, there is a relationship between the value of the indentation depth and the value of the missing area (fiber accumulation and suction frequency). When the correlation relationship as shown in FIG. 25 can be obtained, one can be controlled while the other can be controlled. For example, in the processing step of the absorbent body, for example, if the suction frequency is controlled, the indentation state can be improved.

In this way, the inspection data of the upstream step of the production line is combined with the inspection data of the downstream step, so that the causal relationship between the inspection data of the downstream step and the inspection data of the upstream step becomes clear. By this, it is possible to control the steps that are different from the steps where the abnormality is found, and establish a connection with the improvement of the steps where the abnormality is found.

In addition, not only the two variables of the area value and the indentation depth value are missing, but also the product data obtained by the inspection of each inspection device can be analyzed in a comprehensive manner. The processed parts other than the absorber can also be used effectively. For example, by obtaining the correlation between the thickness of the product and the product packaging that packs the product, the defective thickness of the product can be detected based on the defective packaging of the product.

Next, referring to FIG. 26, the main parts of the heating element manufacturing apparatus which is better for implementing the heating element manufacturing method will be described.

As shown in FIG. 26, the heating element manufacturing apparatus (hereinafter sometimes referred to simply as the manufacturing apparatus) 400 includes an application part 430, an electrolyte addition part 440, and a bonding part 450. Furthermore, a slit, a notch processing part 460, a first cutting part 470, a re-adjustment part 480, a discharge part 490 (flight conveyor 491), and a covering part 500 are provided.

The paint 432 pre-adjusted by an adjustment device not shown and stored in the storage tank 410 is supplied to the coating part 430 by the liquid feeding pump 420.

In this embodiment, in the coating section 430, the coating 432 is applied to the first substrate sheet 401 of the long strip conveyed in the longitudinal direction successively sent out from the original film reel 401A to coat the heating element layer 403 (coating step).

The coating part 430 includes a die nozzle coating machine 431 for coating the coating material 432. In addition, the first base material sheet 401 of the long strip body successively sent out from the original sheet reel 401A is conveyed by the coating roller 433 to a position opposite to the paint ejection port of the die nozzle coater 431. On one surface of the first substrate sheet 401, the coating material 432 is applied by the die nozzle coater 431 to arrange the coating material layer 402 as the heating element layer 403.

In this way, the cross-sectional area of the paint layer 402 is measured by the inspection device 50 in a state where the paint layer 402 that becomes the heating element layer 403 is applied on the first base sheet 401. The inspection device 50 is an optical surface shape measuring device, and is used for measuring the surface shape of the coating layer 402 in the conveying direction of the first base material sheet 401. The result of the measurement of the paint layer 402 by the inspection device 50 is shown in FIG. 27. As shown in Fig. 27, the vertical axis represents the height of the paint layer 402 measured by the inspection device 50, and the horizontal axis represents the position of the paint layer 402 measured by the inspection device 50 in the direction intersecting the longitudinal direction (width direction). . Based on the measurement result shown in FIG. 27, the cross-sectional area was obtained by integrating the surface shape obtained by the measurement. This cross-sectional area is memorized as the product data D1. In association therewith, the supply amount per unit time of the paint 432 in the liquid feeding pump 420 is memorized as the equipment data D3. The product data D1 and the equipment data D3 are stored in the data collection unit 70 in association with each other.

Moreover, when a product abnormality is detected for a product being processed in the production line or a product whose steps implemented by the production line have ended, the equipment data D3 is tracked based on the product abnormality data D1n of the product where the product abnormality has occurred. For example, based on the product abnormality data D1n, tracking equipment data D3 such as the cutting sequence of the rotary die cutter 472, the conveying speed of the conveying belt 482, and the suction pressure of the suction box 494. By tracking, the abnormal part of the manufacturing pattern of the manufacturing equipment where the product abnormality occurs is identified to obtain the equipment abnormality data D3n. As a result, when it is necessary to adjust the equivalent value, the manufacturing equipment 40 is stopped, and the equipment of the required part is adjusted.

In the electrolyte addition portion 440, the electrolyte 441 is dispersed. For example, the electrolyte 441 is spread on the paint layer 402 from the screw feeder 442 through the tank 444 provided with the electrolyte quality sensor 443. The dispersion amount is measured by the electrolyte dispersion amount sensor 445. Electrolyte 441 uses its powder. In addition, the coated first base material sheet 401 is transported from the coating section 430 to the electrolyte addition section 440 by a transport device including the coating roller 433. Then, toward the coated surface of the first base sheet 401, the electrolyte 441 is spread on the coating layer 402 to become the heating element layer 403.

With the addition of the electrolyte 441, it is possible to ensure a better electrolyte concentration in the heating body layer 403 for heating. In addition, the electrolyte 441 of the powder is dissolved by the moisture contained in the coating layer 402 and the first substrate sheet 401. Furthermore, the second base material sheet 404 is supplied so as to be next to the heating body layer 403 side, and is conveyed to the bonding part 450. Furthermore, the electrolyte may be a powder or an aqueous solution.

Thereby, the moisture in the heating element layer 403 is absorbed and held by the second base sheet 404, and the moisture content and electrolyte concentration of the heating element layer 403 become better.

In the present embodiment, in the bonding part 450, the first base material sheet 401 and the second base material sheet 404 are bonded to each other with the heating element layer 403 sandwiched therebetween (bonding step).

The bonding part 450 is sandwiched between the rollers 451 and 452 to bond the heating element layer 403 made on the first base material sheet 401 to the first base material sheet 401 and the second base material sheet 404 .

Then, in the slit and notch processing portion 460, a notch processing step of forming a plurality of notches and joining the first base material sheet 401 and the above-mentioned second base material sheet 404 is performed.

The slit and slit processing part 460 is a slit (perforation) and slit not shown in the drawing in the longitudinal direction of the first base sheet 401, that is, in the conveying direction of the first base sheet 401.

In this way, a heating element continuum 405 composed of a continuous strip is produced. After that, the heating element continuum 405 is cut across the direction (width direction) intersecting the longitudinal direction in the first cutting portion 470 (cutting step). The first cutting part 470 is equipped with a rotary die with a knife 471 of a cutting machine on the peripheral surface Cutting machine 472 and anvil roll 473. The heating element continuum 405 is cut by passing it between the rotary die cutter 472 and the anvil roll 473, so that a single heating element 406 is obtained. The cut heating element 406 is transferred to the re-adjusting part 480 and received by the conveyor 481.

The cutting of the heating element continuum 405 is performed in the width direction of the heating element continuum 405. For example, the heating element continuum 405 can be cut linearly in the width direction. Alternatively, it can be cut in such a way that the cutting line draws a curve.

The heating element 406 as a single piece is placed on the conveying belt 482 of the conveyor 481 arranged in the readjusting part 480. The conveying speed of the conveying belt 482 is faster than the circumferential speed of the anvil roller 473 provided in the first cutting part 470. As a result, the distance between the heating elements 406 that are adjacent to each other in the forward and backward directions in the conveying direction is enlarged, and the heating elements 406 are rearranged at a certain distance.

Generally, in the conveyor 481, the heating element 406 is transported while being sucked toward the conveyor 481 side. During the transportation of the heating element 406 in the next stair conveyor 491, in order to prevent the heating element 406 in the front stage of the stair conveyor 491 from falling, the suction in the subsequent stage of the conveyor 481 can also be stopped. In addition, in the conveyor 481, the interval in the width direction of the heating element 406 is also widened. As a mechanism for such readjustment, those previously known can be used without particular limitation. In addition, the term "front and back in the conveying direction" means the upstream and downstream sides of the conveying direction.

The heating element 406 that has been re-adjusted and expanded in the width direction is conveyed to the discharge part 490. A ladder conveyor 491 is provided in the discharge part 490. The heating element 406 is transported in a state of being hung on the ladder conveyor 491. In order to realize the transportation in this state, a suction box 494 is installed inside the circular track at a position facing downward. By activating the suction box 494, the heating element 406, which is the object to be conveyed, is conveyed at the above-mentioned position in a state of being sucked and supported on the supporting surface of the endless belt 493 by suction.

The heating element 406 that has passed through the discharge part 490 is delivered to the conveyor 501 of the covering part 500. The covering part 500 covers the entire heating element 406 with a first covering sheet and a second covering sheet 407 not shown.

An inspection device 50 is arranged, and the inspection device 50 detects the position of the heating element 406 before being coated with the first coating sheet. The inspection device 50 includes an imaging device 59 and an image processing unit (not shown). The image of the heating element captured by the imaging device 59 is image-processed by the image processing unit, and the position of the heating element 406 is detected to obtain the product data D1. In association with it, the cutting sequence of the manufacturing device 400, such as the rotary die cutter 472, the conveying speed of the conveying belt 482, the suction pressure of the suction box 494, etc., as the manufacturing equipment, is stored as the equipment data D3 to the equipment main processing device 41 (Refer to Figure 3). The product data D1 and the equipment data D3 are associated and stored in the data collection unit 70 in the same manner as described with reference to FIG. 3 above.

Moreover, when a product abnormality is detected for a product being processed in the production line or a product whose steps implemented by the production line have ended, the equipment data D3 is tracked based on the product data D1 of the product where the product abnormality has occurred. For example, based on the product data D1, track the cutting timing of the rotary die cutting machine 472, the conveying speed of the conveying belt 482, and the suction pressure of the suction box 494 and other equipment data D3, and establish associations. By tracking, the abnormal part of the manufacturing pattern of the manufacturing equipment where the product abnormality occurs is identified to obtain the equipment abnormality data D3n. As a result, when it is necessary to adjust the equivalent value, the manufacturing equipment (equivalent to the manufacturing equipment 40 in FIG. 3) is stopped, and the equipment of the required part is adjusted.

When no adjustment is required, the side of the heating element 406 where the heating element layer 403 is not arranged is covered by the second covering sheet 407. Then, while maintaining the state of being covered by the first covering sheet and the second covering sheet 407, the covered heating element 406 is conveyed by the conveyor 501 to a sealing part not shown.

By the sealing portion, each heating element 406 is continuously formed by the first covering sheet and the second covering sheet 407 It is covered to obtain a continuum of heating elements in a state where a plurality of heating elements are connected in one direction. For the first coating sheet and the second coating sheet 407, for example, the same ones described in Japanese Patent Laid-Open No. 2012-000344 and Japanese Patent Laid-Open No. 2012-000345 can be used. In the second cutting part (not shown), the heating element continuum is cut across the width direction between adjacent heating elements. The second cutting part is provided with a rotary die cutter and an anvil roll opposite to the rotary die cutter. By cutting the heating element continuum through between the two members, the target heating element (not shown) can be obtained.

In this way, the heating element is sealed in a packaging bag with oxygen barrier properties in the next step (not shown).

An oxidizable metal is used in the raw material of the paint 432. Examples of the oxidizable metal include powders of iron, aluminum, zinc, manganese, magnesium, calcium, and the like. Preferably, iron powder is used.

In the manufacturing method of the heating element described above, the coating material 432 is supplied to the coating part 430 by the liquid feeding pump 420. The supply amount of the coating material 432 and the rotation speed of the liquid feeding pump 420 have a roughly proportional correlation. If the pump rotation speed is increased, the cutting performance of the heating element continuum 405 is improved. However, if the number of pump revolutions is excessively increased, the thickness of the coating layer 402 becomes thicker, and therefore the cutting property of the heating element continuum 405 becomes poor. The relationship between the cross-sectional area of the paint layer 402 measured by the inspection device 50 and the position accuracy of the heating element measured by the imaging device 59 is as shown in FIG. 28. Therefore, by controlling the pump revolution of the liquid feeding pump 420 within the specification range of the coating amount of the paint 432, the position accuracy of the heating element can be improved. The so-called heating element position accuracy refers to the standard deviation of the distance between the heating element and the heating element, and means the cutting accuracy of the heating element continuum 405.

Regarding the above-mentioned embodiment, the present invention further discloses the following aspects.

<1>

A manufacturing method of a product, which is a manufacturing method of manufacturing a product through a plurality of manufacturing steps, and includes the following steps: Obtain the equipment data of the manufacturing equipment that manufactures the above-mentioned products; obtain the product data from the above-mentioned products; store the above-mentioned equipment data and the above-mentioned product data in the data collection department; associate the above-mentioned equipment data with the above-mentioned product data; determine the abnormality of the above-mentioned product data; When the above-mentioned product is abnormal, identify both or either of the equipment abnormality data and the product abnormality data associated with the product deemed to be abnormal; and by performing specific steps, the product will be identified as the above-mentioned product The above manufacturing steps of the cause of the abnormality.

<2>

For example, the manufacturing method of the product in <1> includes the following steps: after the manufacture of the above product, the abnormality of the above product is judged; when the above product is abnormal, the above mentioned product that is related to the product considered to be abnormal is identified Either or both of the equipment abnormality data and the aforementioned product abnormality data; and by performing a specific step, the aforementioned manufacturing step that is the cause of the aforementioned product abnormality is identified.

<3>

For example, the manufacturing method of the product of <1> or <2>, which includes the following steps: obtaining the above-mentioned equipment abnormality data related to the manufacturing equipment that is the cause of the above-mentioned product abnormality; and making the above-mentioned abnormal product The product abnormal data and the above-mentioned equipment abnormal data are visualized on the screen of the display device.

<4>

Such as the manufacturing method of any one of <1> to <3>, wherein the above-mentioned product enters the manufacturing number assignment step, and the manufacturing number assignment device is assigned the manufacturing number.

<5>

Such as the manufacturing method of a product in <4>, wherein the above-mentioned manufacturing number assignment step is to print a different manufacturing number for each piece of product to the above-mentioned product.

<6>

Such as the manufacturing method of the product of <4>, wherein the above-mentioned manufacturing number assigning step is to perform printing when the above-mentioned product is in a continuous mesh state.

<7>

Such as the manufacturing method of the product of <4>, wherein the above-mentioned manufacturing number assignment step is to print the package body of the above-mentioned product that packs more than one piece of the above-mentioned product.

<8>

Such as the manufacturing method of any one of <1> to <7>, wherein the step of associating the above-mentioned equipment data with the above-mentioned product data is performed based on the distance between the above-mentioned manufacturing steps.

<9>

Such as the manufacturing method of any one of <1> to <8>, which includes the following steps: repairing the manufacturing equipment of the manufacturing step specified by further specifying the steps of the above manufacturing step.

<10>

Such as the manufacturing method of the product of <9>, wherein the above-mentioned step of repairing the manufacturing equipment is to automatically repair the abnormal part of the above-mentioned manufacturing equipment through feedback control.

<11>

Such as <9> or <10> the manufacturing method of the product, in which the above steps of repairing the manufacturing equipment The above-mentioned manufacturing equipment is stopped, and the mechanical parameters related to the abnormal part of the above-mentioned manufacturing equipment are adjusted to repair the above-mentioned abnormal part.

<12>

Such as the manufacturing method of any one of <1> to <11>, wherein the abnormality of the above-mentioned product is to compare the product data of the normal product with the product data of the product produced by the above-mentioned manufacturing steps, and the detection is If the product data is different, it is regarded as an abnormal product. The cause data of the abnormal cause is extracted from the product data of the above abnormal product. Based on the above cause data, the manufacturing pattern data of the above equipment data associated with the above product data is tracked.

<13>

For example, the manufacturing method of the product in any one of <1> to <12>, wherein the above-mentioned product is an absorbent article, and the above-mentioned product data stored in the above-mentioned data collection part is associated with the above-mentioned absorbent article. Manufacturing data of the above-mentioned absorbent articles.

<14>

For example, in the manufacturing method of any one of <1> to <13>, the statistical value is calculated in each step of the data collection step of the normal product and the data collection step of the abnormal product.

<15>

For example, the manufacturing method of a product in any one of <1> to <14> includes the following steps: confirming the correlation between the image processing data related to the image processing checker in the product data and the equipment data.

<16>

For example, the manufacturing method of the product in <15>, in which the above steps to confirm the related relationship are in the production Confirm on the production line.

<17>

For example, the manufacturing method of the product in <15>, in which the above steps of confirming the related relationship are confirmed under the production line.

<18>

Such as the manufacturing method of any one of <1> to <17>, wherein the data collection part has a main central processing device and an auxiliary central processing device.

<19>

For example, in the manufacturing method of any one of <1> to <18>, in addition to the above-mentioned product data, the preset values of the above-mentioned manufacturing equipment are also registered.

<20>

Such as the manufacturing method of any one of <1> to <19>, wherein the above-mentioned equipment data includes: single piece collection data, which is collected in the cycle of each piece of product; long-period collection data, which is The data is collected in a longer period than the monolithic collection of data; and the data is collected in a short period, which is collected in a shorter period than the monolithic collection of data.

<21>

Such as the manufacturing method of any one of <1> to <20>, wherein the printing specifying the manufacturing number of the above product is based on printing using colored ink or colorless ink.

<22>

Such as the manufacturing method of any one of <1> to <21>, wherein in the manufacturing method of the above-mentioned article, the above-mentioned article is an absorbent article.

<23>

Such as the manufacturing method of any one of <1> to <22>, wherein the manufacturing of the above-mentioned products In the method, the above-mentioned product is a sheet product.

<24>

A manufacturing device for a product, which corresponds to a plurality of manufacturing steps to manufacture a product, and has a plurality of manufacturing equipment for manufacturing the product and a plurality of inspection devices for inspecting the product, and has: a sensor, which detects The manufacturing pattern possessed by the above-mentioned manufacturing equipment; and a data collection unit that stores related product data obtained by using the above-mentioned inspection device and manufacturing pattern data detected by the above-mentioned sensor; the above-mentioned data collection unit has: auxiliary The central processing device, which processes the above-mentioned product data; the main central processing device, which establishes the associated equipment data representing the equipment status of the above-mentioned manufacturing equipment, the collection data of the auxiliary equipment processed by the above-mentioned auxiliary central processing unit, and the above-mentioned manufacturing The pattern data is processed; and the database server, which stores the data collected by the main device that has been processed by the main central processing device.

<25>

For example, the product manufacturing device of <24>, wherein the auxiliary central processing device converts the data form of the product data obtained by the inspection device into a data format that can be processed by the main central processing device.

The present invention has been described while describing its embodiments and examples. However, as long as the inventors have not specified otherwise, any details of the description are not intended to limit the invention of the inventors, and it is considered that Should not violate the spirit and spirit of the invention shown in the attached patent application scope The scope is explained in a broad manner before mentioning.

This application is based on Japanese Patent Application No. 2016-229251 filed in Japan on November 25, 2016, Japanese Patent Application No. 2017-021494 filed in Japan on February 8, 2017 and November 14, 2017 For the priority of Japanese Patent Application No. 2017-219350 filed in Japan, the content is incorporated herein by reference as part of the description of this specification.

40: Manufacturing equipment

43: processing device

43A: Processing device

43B: Processing device

50: check device

50a: Inspection device

50b: Inspection device

50c: Inspection device

D1: Product information

D3: Equipment information

Claims (24)

A manufacturing method of a product, which is a manufacturing method of manufacturing a product through a plurality of manufacturing steps, and includes the following steps: obtaining equipment information of the manufacturing equipment for manufacturing the above-mentioned product; obtaining the product information from the above-mentioned product; combining the above-mentioned equipment information and the above-mentioned product The data is stored in the data collection department; the above-mentioned equipment data is associated with the above-mentioned product data; the abnormality of the above-mentioned product data is judged; when the above-mentioned product is abnormal, the equipment abnormality data and the product that are associated with the product deemed to be abnormal are identified Two or either of the abnormal data; and by performing a specific step, the manufacturing step that is the cause of the abnormality of the product is identified; wherein the step of associating the equipment data with the product data is based on the manufacturing The distance between the steps. For example, the manufacturing method of the product of claim 1, which includes the following steps: after the manufacture of the product, the product of the product is judged to be abnormal; when the product is abnormal, the product that is regarded as abnormal is identified Both or either of the above-mentioned equipment abnormality data and the above-mentioned product abnormality data; and by performing a specific step, the above-mentioned manufacturing step that is the cause of the above-mentioned product abnormality is specified. For example, the method of manufacturing a product of claim 1 or 2, which includes the following steps: obtaining the above-mentioned equipment abnormality data related to the manufacturing equipment of the manufacturing step that is the cause of the above-mentioned product abnormality; and making the above-mentioned product of the above-mentioned product regarded as abnormal The abnormal data and the above-mentioned equipment abnormal data are visualized on the screen of the display device. For example, the method of manufacturing a product of claim 1 or 2, wherein the above-mentioned product enters the manufacturing number assigning step, and the manufacturing number assigning device assigns a manufacturing number. For example, the method for manufacturing a product of claim 4, wherein the above-mentioned manufacturing number assignment step is to print a different manufacturing number for each piece of product to the above-mentioned product. Such as the method of manufacturing a product of claim 4, wherein the manufacturing number assignment step is to perform printing in a state where the product is a continuous mesh. For example, the method of manufacturing a product of claim 4, wherein the above-mentioned manufacturing number assignment step is to print the package body that packs more than one piece of the above-mentioned product. For example, the manufacturing method of the product of claim 1 or 2, which includes the following steps: repairing the manufacturing equipment of the manufacturing step specified by further specifying the steps of the above-mentioned manufacturing step. Such as the method of manufacturing a product of claim 8, wherein the step of repairing the manufacturing equipment is to automatically repair the abnormal part of the manufacturing equipment by feedback control. For example, the method of manufacturing a product of claim 8, wherein the step of repairing the manufacturing equipment is to stop the manufacturing equipment and adjust the mechanical parameters related to the abnormal part of the manufacturing equipment to repair the abnormal part. For example, the manufacturing method of the product of claim 1 or 2, wherein the above-mentioned product abnormality is to compare the product data of the normal product with the product data of the product produced by the above-mentioned manufacturing steps, and detect the difference from the product data of the normal product as For abnormal products, extract the cause data of the abnormality from the product data of the above abnormal products, and track the manufacturing pattern data of the above equipment data associated with the above product data based on the above cause data. For example, the manufacturing method of the article of claim 1 or 2, wherein the article is an absorbent article, and in the article data stored in the data collection part, the manufacturing of the absorbent article is recorded in association with the absorbent article material. For example, the manufacturing method of the product of claim 1 or 2, in which the statistical value is calculated in each step of the data collection step of the normal product and the data collection step of the abnormal product. For example, the manufacturing method of the product of claim 1 or 2, which includes the following steps: confirming the image processing data related to the image processing checker in the product data and the correlation with the equipment data. For example, the manufacturing method of the product in claim 14, in which the above-mentioned steps of confirming the related relationship are confirmed on the production line. For example, the manufacturing method of the product in claim 14, wherein the above-mentioned steps of confirming the related relationship are confirmed under the production line. For example, the method for manufacturing a product of claim 1 or 2, wherein the data collection unit has a main central processing device and an auxiliary central processing device. For example, the manufacturing method of the product of claim 1 or 2, in which, in addition to the above product data, the preset value set in the above manufacturing equipment is also registered. For example, the manufacturing method of the product of claim 1 or 2, wherein the above-mentioned equipment data includes: single-chip collection data, which is collected in the cycle of each product; long-period collection data, which is more than single-chip collection data Collecting data in a long period; and collecting data in a short period, which is collected in a shorter period than the single-chip collection of data. For example, the manufacturing method of the product of claim 1 or 2, wherein the printing specifying the manufacturing number of the above product is based on printing using colored ink or colorless ink. The manufacturing method of the article of claim 1 or 2, wherein in the manufacturing method of the above-mentioned article, the above-mentioned article is an absorbent article. The method of manufacturing a product of claim 1 or 2, wherein in the method of manufacturing the product, the product is a sheet-shaped product. A manufacturing device for a product, which is a manufacturing device for manufacturing a product corresponding to a plurality of manufacturing steps, and has a plurality of manufacturing equipment for manufacturing the product and a plurality of inspection devices for inspecting the product, and has: a sensor, which detects The manufacturing pattern possessed by the above-mentioned manufacturing equipment; and a data collection unit that stores related product data obtained by using the above-mentioned inspection device and manufacturing pattern data detected by the above-mentioned sensor; the above-mentioned data collection unit has: auxiliary The central processing device, which processes the above-mentioned product data; the main central processing device, which establishes the associated equipment data representing the equipment status of the above-mentioned manufacturing equipment, the collection data of the auxiliary equipment processed by the above-mentioned auxiliary central processing unit, and the above-mentioned manufacturing The pattern data is processed; and a database server that stores the collected data of the main device processed by the main central processing device; wherein the device data and the product data are associated based on the distance between the manufacturing steps. For example, the product manufacturing device of claim 23, wherein the auxiliary central processing device converts the data form of the product data obtained by the inspection device into a data format that can be processed by the main central processing device.

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