Sewing management system and sewing management method

Abstract

A sewing management system (1) includes: a defect cause storage section (61) that stores items of defect causes, i.e., a plurality of defect items, of a sewing object (100) sewn by an operator using a sewing machine (2); an input data acquisition section (62) that acquires input data indicating the defect causes from an input device (14); a processing section (63) that classifies the input data by each defect item; and an output section (64) that outputs the classified input data.

Description

Technical Field

[0001] This invention relates to a sewing management system and a sewing management method. Background Technology

[0002] In the technical field of sewing management systems, sewing management systems such as those disclosed in Patent Document 1 are known.

[0003] Patent Document 1: Japanese Patent Application Publication No. 2020-168056 Summary of the Invention

[0004] The sewn items produced during the sewing process are then inspected during the inspection process. If an item is determined to be defective during the inspection process, the reasons for the defect must be analyzed.

[0005] The purpose of this invention is to provide data for analyzing the reasons for defects in sewn objects.

[0006] The sewing management system of the present invention includes: a defect cause storage unit that stores multiple items of defect causes for sewn objects sewn by an operator using a sewing machine; an input data acquisition unit that acquires input data representing defect causes from an input device; a processing unit that classifies the input data according to each defect item; and an output unit that outputs the classified input data.

[0007] The effects of the invention

[0008] The sewing management system according to the present invention can provide data for analyzing the reasons for defects in sewn objects. Attached Figure Description

[0009] Figure 1 This is a schematic diagram illustrating the sewing management system involved in the implementation method.

[0010] Figure 2 This is a hardware structure diagram illustrating the management controller involved in the implementation method.

[0011] Figure 3 This is a functional block diagram representing the management device, sewing machine, and information terminal involved in the implementation method.

[0012] Figure 4 This is a diagram showing the information terminal in the inspection process involved in the implementation method.

[0013] Figure 5 This is a flowchart illustrating the inspection procedures involved in the implementation method.

[0014] Figure 6This is a diagram showing an example of a display device that displays the defective parts and the number of defects involved in the implementation method.

[0015] Figure 7 This is a diagram illustrating an example of a display device that displays relevant data regarding the non-conforming parts, causes of non-conformity, and evaluation items related to sewing in the implementation method.

[0016] Figure 8 This is a diagram illustrating an example of a display device that displays the evaluation items and failure rates involved in the implementation method. Detailed Implementation

[0017] The embodiments of the present invention will now be described with reference to the accompanying drawings, but the present invention is not limited to these embodiments. The structural elements of the embodiments described below can be appropriately combined. In addition, sometimes some structural elements are not used.

[0018] [Sewing Management System]

[0019] Figure 1 This diagram schematically illustrates a sewing management system 1 according to an embodiment. The sewing management system 1 includes a management device 3 that manages the production process of sewn products. The production process includes: a sewing process, in which a sewing machine 2 is used to sew a sewing object 100; and an inspection process, in which the sewing object 100 produced in the sewing process is inspected. The sewing machine 2 is an industrial sewing machine. Sewn products are produced in a production line that includes the sewing machines 2. Multiple sewing machines 2 are installed on the production line. The production line is located in a sewing factory. The sewing machines 2 operate in the sewing factory. Sewn products are produced by sewing the sewing object 100 using the sewing machines 2. In this embodiment, the management device 3 is installed in the sewing factory. Alternatively, the management device 3 may be installed outside the sewing factory.

[0020] In the sewing process, the object to be sewn 100 is sewn by sewing machine 2, thereby producing a sewn product. Fabric is shown as the object to be sewn. Garment is shown as the sewn product.

[0021] In a sewing factory, multiple types of sewing machines 2 are provided, each corresponding to a specific purpose. In the sewing factory, multiple types of sewing machines 2 are provided so that they can each handle multiple sewing processes for producing sewn products. Examples of types of sewing machines 2 include a flat sewing machine for sewing garment bodies, a button sewing machine for sewing buttons onto garment bodies, and a pocket sewing machine for sewing pockets onto garment bodies. Multiple types and numerous industrial sewing machines 2 are provided in a single sewing factory. Furthermore, for the sake of simplicity, in… Figure 1Three sewing machines 2 are shown. Sewing machine 2A is used in the first process of producing sewn products. Sewing machine 2B is used in the second process of producing sewn products. Sewing machine 2C is used in the third process of producing sewn products. Furthermore, multiple sewing machines 2 of one type can be installed in a sewing factory.

[0022] In the sewing factory, managers, operators, and inspectors work. The manager oversees the operators, inspectors, and sewing machines 2. Operators use sewing machines 2 to sew object 100 during the sewing process. Inspectors inspect the sewn object 100 produced by sewing machines 2 during the inspection process. Managers, operators, and inspectors can each be considered users of sewing machines 2. There can be one or more managers. There can be one or more operators. For example, one operator can operate multiple sewing machines 2. There can be one or more inspectors.

[0023] The management device 3 includes a display device 4, an input device 5, and a management controller 6. The display device 4 displays display data. The display device 4 includes a flat panel display such as a liquid crystal display (LCD) or an organic EL display. The input device 5 is operated by the manager, thereby generating input data. Alternatively, the input device 5 can also be operated by an operator. The input device 5 includes a touch panel (touch sensor) configured on the display screen of the display device 4. Furthermore, the input device 5 can also be a computer keyboard, a mouse, or a voice input device. The management controller 6 includes a computer system. The management controller 6 has at least one processor and main memory for storing computer programs executable by the processor.

[0024] The sewing machine 2 has an operation panel 7 and a sewing machine controller 8. The operation panel 7 is operated by the operator, thereby generating operation data. The operation panel 7 includes a touch panel (touch sensor) configured to display a screen on the monitor. The sewing machine controller 8 includes a computer system. The sewing machine controller 8 has at least one processor and a main memory for storing computer programs executable by the processor.

[0025] The inspector inspects the sewn object 100 during the inspection process. The inspection of the sewn object 100 includes: intermediate inspection, which examines the sewn object 100 after completing a portion of the sewing process; and final inspection, which examines the sewn object after completing all the sewing processes. The inspector holds an information terminal 11. An example of an information terminal 11 is a tablet terminal or a smartphone.

[0026] The management device 3 is shared by multiple sewing machines 2 and information terminals 11 in the sewing factory. The number of management devices 3 is less than the number of sewing machines 2. The management device 3 can communicate with each of the sewing machines 2 and the information terminal 11 separately. The management controller 6 of the management device 3 communicates with the sewing machine controller 8 of the sewing machine 2 and the information terminal 11 separately. The management controller 6, the sewing machine controller 8, and the information terminal 11 communicate wirelessly. The management controller 6, the sewing machine controller 8, and the information terminal 11 communicate wirelessly via a local area network (LAN). Wifi (registered trademark) is an example of a wireless LAN. In addition, the management controller 6, the sewing machine controller 8, and the information terminal 11 can also communicate wirelessly via a personal area network (PAN). Bluetooth (registered trademark) is an example of a wireless PAN.

[0027] The management controller 6 sends control commands to the sewing machine controller 8 of the sewing machine 2 based on the input data generated by operating the input device 5.

[0028] The sewing machine controller 8 sends the operating data of the sewing machine 2 to the management controller 6. The operating data of the sewing machine 2 includes the operating conditions of the sewing machine 2. These operating conditions include at least one of the following: stitch length, stitch spacing, stitch pattern, feed speed of the workpiece, number of stitches, thread tension, and presser foot pressure of the workpiece. The sewing machine controller 8 monitors the operating conditions of the sewing machine 2. Sensors for detecting the operating conditions of the sewing machine 2 are provided in the sewing machine 2. Examples of these sensors include a tension sensor for detecting thread tension and a presser foot pressure sensor for detecting presser foot pressure of the workpiece. By acquiring the sensor detection data, the sewing machine controller 8 can monitor the operating conditions of the sewing machine 2. Furthermore, the sewing machine 2 has a sewing machine motor for actuating the needle bar and take-up lever. By acquiring the drive signal of the sewing machine motor, the sewing machine controller 8 can monitor the operating conditions of the sewing machine 2. Additionally, the operating data of the sewing machine 2 represents the operating history of the sewing machine 2. The operation history of sewing machine 2 includes the date and time of operation of sewing machine 2, continuous operation time of sewing machine 2, cumulative operation time of sewing machine 2, type of sewing object sewn by sewing machine 2, number of stitches during sewing, error messages that occurred on sewing machine 2, and at least one operator who operated sewing machine 2.

[0029] The management controller 6 collects the operating data of each of the multiple sewing machines 2. The management controller 6 then displays the operating data of each of the multiple sewing machines 2 on the display device 4.

[0030] The inspector operates the input device of the information terminal 11 to input the inspection results of the sewn object 100 into the information terminal 11. The information terminal 11 sends the inspection data representing the inspection results of the sewn object 100 to the management controller 6.

[0031] The management controller 6 sends guidance data indicating the inspection items and methods for the sewn object 100 to the information terminal 11. The guidance data is displayed on the screen of the information terminal 11. The inspector checks the sewn object 100 while confirming the guidance data displayed on the screen.

[0032] [Computer System]

[0033] Figure 2 This is a hardware structure diagram illustrating the management controller 6 according to the implementation method. The management controller 6 includes a computer system 1000. The computer system 1000 has: a processor 1001 such as a CPU (Central Processing Unit); a main memory 1002, which includes non-volatile memory such as ROM (Read Only Memory) and volatile memory such as RAM (Random Access Memory); a storage device 1003; and an interface 1004 including input / output circuitry. The functions of the management controller 6 are stored as a computer program in the storage device 1003. The processor 1001 reads the computer program from the storage device 1003 and expands it into the main memory 1002, and executes the processing according to the computer program. In addition, the computer program can also be transmitted to the computer system 1000 via a network.

[0034] Similarly, the sewing machine controller 8 and the information terminal 11 each include a computer system with a processor, main memory, storage, and interface.

[0035] [Management devices, sewing machines, and information terminals]

[0036] Figure 3 This is a functional block diagram illustrating the management device 3, sewing machine 2, and information terminal 11 involved in the implementation method. For example... Figure 3 As shown, the information terminal 11 includes a terminal controller 12, a display device 13 such as a flat panel display, and an input device 14 such as a touch panel. The input device 14 is operated by the inspector, thereby generating input data. In addition, the input device 14 can also be operated by the operator or the manager. The terminal controller 12 sends the input data generated by operating the input device 14 to the management controller 6.

[0037] The management controller 6 has a non-conformity reason storage unit 61, an input data acquisition unit 62, a processing unit 63, and an output unit 64.

[0038] The non-conformity storage unit 61 stores multiple non-conformity items for non-conformity reasons of the sewn object 100 sewn by the operator using the sewing machine 2. The non-conformity items indicating non-conformity reasons are predetermined. In this embodiment, the non-conformity items include a first item indicating a non-conformity reason related to the sewing machine 2, a second item indicating a non-conformity reason related to the operator, and a third item indicating a non-conformity reason related to the sewn object 100. The non-conformity reason related to the first item can also be considered a mechanical non-conformity reason. The non-conformity reason related to the second item can also be considered an operational non-conformity reason. The non-conformity reason related to the third item can also be considered a material non-conformity reason.

[0039] As examples of nonconformities covered in Item 1, anomalies in the stitches formed on the sewn object 100 are shown. Examples of stitch anomalies include an anomaly called "skipped stitch" where at least one stitch becomes longer, an anomaly called "broken thread" where at least a portion of the stitch disappears, and an anomaly called "lantern" where at least one of the upper or lower thread is loose in the sewn object. Nonconformities covered in Item 1 are, for example, nonconformities caused by the sewing machine 2, such as improper adjustment or incorrect settings.

[0040] Examples of nonconformities covered in Item 2 include abnormalities in the stitches formed on the sewn object 100. Examples of stitch abnormalities include serpentine stitches, absence of stitches, and stitches detaching from the sewn object 100. Additionally, examples of nonconformities covered in Item 2 include confusion of the sewn object 100 or confusion of the thread. Nonconformities covered in Item 2 are those caused by the operator, such as insufficient operator skill or negligence.

[0041] As examples of nonconformities related to Item 3, nonconformities of the sewn object 100 itself are shown. Examples of nonconformities of the sewn object 100 itself include scratches, uneven coloring, and dirt present on the sewn object 100. Nonconformities related to Item 3 are nonconformities caused by the sewn object 100.

[0042] The input data acquisition unit 62 acquires input data generated by the input device 14 of the information terminal 11 from the information terminal 11. If the sewn object 100 is defective, the inspector operates the input device 14 to input that the sewn object 100 is defective. The inspector operates the input device 14 to input the reason for the defect. The inspector operates the input device 14 to input the defective part of the sewn object 100. The input data acquisition unit 62 acquires input data from the information terminal 11 indicating that the sewn object 100 is defective. The input data acquisition unit 62 acquires input data from the information terminal 11 indicating the reason for the defect in the sewn object 100. The input data acquisition unit 62 acquires input data from the information terminal 11 indicating the defective part of the sewn object 100.

[0043] Based on the input data obtained by the input data acquisition unit 62, the processing unit 63 calculates the non-conformance rate for each of the multiple evaluation items involved in the sewing process. The evaluation items include at least one of the following: the product number of the sewn object 100, the sewing process, the sewing time (sewing moment, sewing time period), and the operator.

[0044] In addition, the processing unit 63 classifies the input data indicating the reasons for non-conformity based on the input data obtained by the input data acquisition unit 62, according to multiple non-conformity items.

[0045] In addition, the processing unit 63 counts the number of defects at the same location of multiple sewn objects of the same design based on the input data indicating defective parts obtained by the input data acquisition unit 62.

[0046] The output unit 64 outputs the defect rate calculated by the processing unit 63 to the display device 4. The output unit 64 also displays the input data indicating the reasons for defection, categorized by the processing unit 63, on the display device 4. Based on the input data indicating the defective parts acquired by the input data acquisition unit 62, the output unit 64 displays the defective parts on the display device 4. Furthermore, the output unit 64 can also output the input data indicating the reasons for defection, categorized by the processing unit 63, to the defective reason storage unit 61 for storage.

[0047] [Sewing Management Methods]

[0048] Next, the sewing management method involved in the implementation will be described. As described above, in a sewing factory, multiple workers each use multiple sewing machines 2 to sew multiple sewing objects 100. In a sewing factory, sometimes multiple sewing objects 100 of the same design are sewn sequentially using sewing machines 2. In the following description, an example will be given in which multiple sewing objects 100 of the same design are inspected sequentially during the inspection process. In the following description, the sewing object 100 is assumed to be fabric used to manufacture T-shirts.

[0049] Figure 4 This diagram illustrates the information terminal 11 in the inspection process according to the embodiment. In the inspection process, the inspector uses the information terminal 11 to inspect the sewn object 100. If the sewn object 100 is found to be defective, the inspector operates the input device 14 to input the defective condition of the sewn object 100. Figure 4 As shown, the display device 13 of the information terminal 11 displays a first display screen, which is used to input the defective parts of the sewn object 100. The first display screen contains an image of the sewn object 100. The inspector operates the input device 14 to input the defective parts of the sewn object 100. The input device 14 includes a touch panel. For example, if there is a defect in the shoulder portion of the sewn object 100, the inspector clicks on the shoulder portion of the image of the sewn object 100 displayed on the display device 13.

[0050] After the defective parts of the sewn object 100 are entered, the display screen of the display device 13 changes from the first display screen for entering the defective parts to the second display screen for entering the reason for the defect. The inspector operates the input device 14 to enter the reason for the defect of the sewn object 100. Multiple defective items are displayed on the display device 13. For example... Figure 4 As shown, the display device 13 displays the text representing the first item "sewing machine", the second item "operator" and the third item "sewing object".

[0051] If the inspector determines that at least one of the following defects—"skipped stitches," "broken thread," or "lantern"—is present on the shoulder portion of the sewing object 100, the defect is determined to be due to the sewing machine, and the inspector clicks on the "Sewing Machine" display on the display device 13. This sends the input data indicating that the defect is due to the sewing machine 2 from the terminal controller 12 to the management controller 6.

[0052] If the inspector determines that at least one of the following conditions exists on the shoulder portion of the sewn object 100: serpentine stitching, absence of stitching, or stitching detachment from the sewn object 100, the inspector determines the cause of non-compliance to be the operator and clicks on the "Operator" display on the display device 13. This sends the input data indicating the operator as the cause of non-compliance from the terminal controller 12 to the management controller 6.

[0053] If the inspector determines that at least one of the following defects exists on the shoulder portion of the sewn object 100: a scratch, uneven color, or dirt, the defective object is deemed to be of substandard quality, and the inspector clicks on the "Sewn Object" display on the display device 13. This sends the input data indicating the defective object as the cause of substandard quality to the management controller 6 from the terminal controller 12.

[0054] Figure 5 This is a flowchart illustrating the inspection process involved in the implementation method. The inspector operates the input device 14, inputting the product number of the sewn object 100 to be inspected, the sewing process that the sewn object 100 has undergone, the sewing time (sewing moment, sewing time period) during which the sewn object 100 was sewn, and the operator who sewn the sewn object 100. If the inspection process is performed after the first process, the sewing process that the sewn object 100 has undergone is the first process. If the inspection process is performed after the second or third process, the sewing process that the sewn object 100 has undergone is the second or third process. The input data representing the product number of the sewn object 100, the sewing process, the sewing time, and the operator are sent from the terminal controller 12 to the management controller 6. The input data acquisition unit 62 acquires the input data representing the product number of the sewn object 100, the sewing process, the sewing time, and the operator (step S1).

[0055] Next, as referred to Figure 4 As explained, the operator inputs the defective parts of the sewing object 100. The input data indicating the defective parts of the sewing object 100 is sent from the terminal controller 12 to the management controller 6. The input data acquisition unit 62 acquires the input data indicating the defective parts of the sewing object 100 (step S2).

[0056] In this embodiment, the input data acquisition unit 62 acquires input data from the input device 14, which represents the defective parts of multiple sewn objects 100 of the same design sewn by the operator using the sewing machine 2. Based on the input data representing the defective parts, the processing unit 63 counts the number of defects at the same location on the multiple sewn objects 100 (step S3).

[0057] Next, as referred to Figure 4As explained, the operator inputs the reason for the defect of the sewn object 100. The input data indicating the reason for the defect of the sewn object 100 is sent from the terminal controller 12 to the management controller 6. The input data acquisition unit 62 acquires the input data indicating the reason for the defect of the sewn object 100 (step S4).

[0058] The processing unit 63 classifies the input data representing the cause of non-conformity according to each non-conformity item stored in the non-conformity cause storage unit 61 (step S5).

[0059] Based on the input data representing the defective parts, the processing unit 63 calculates the defect rate for each of the multiple evaluation items involved in the sewing process (step S6).

[0060] The output unit 64 outputs the defective parts obtained in step S2, the number of defective parts counted in step S3, the reasons for defective parts classified in step S5, and the defective rate calculated in step S6 to the display device 4 (step S7).

[0061] Figure 6 This diagram illustrates an example of a display device 4 that displays the defective parts and quantities involved in the embodiment. (See diagram for example.) Figure 6 As shown, the display device 4 displays an image of the sewn object 100. The output unit 64 overlays a first symbol representing a defective part onto the image of the sewn object 100 and displays it on the display device. Figure 6 In the example shown, the first symbol is a circle. Figure 6 Examples of defective parts found in the shoulder, armpit, and hem sections of the sewn object 100 are shown.

[0062] Additionally, the output unit 64 overlays a second symbol indicating the number of defects at the same location onto an image of the sewn object 100 and displays it on the display device 4. Figure 6 In the example shown, the second symbol is the numerical data superimposed on the first symbol. Figure 6 The example shown is that the number of defects in the shoulder section of the sewn object 100 is "1", the number of defects in the underarm section is "3", and the number of defects in the hem section is "4".

[0063] Figure 7 This is a diagram illustrating an example of a display device 4 that displays relevant data regarding the non-conforming parts, causes of non-conformity, and evaluation items related to sewing in the implementation method. For example... Figure 7As shown, the output unit 64 displays the input data indicating the reason for non-conformity on the display device 4 for each of the multiple non-conformity items. For example, when input data indicating that the reason for non-conformity is sewing machine 2 is sent from the terminal controller 12 to the management controller 6, the output unit 64 displays this information on the display device 4. Furthermore, as... Figure 7 As shown, the output unit 64 displays relevant data on the display device 4 regarding the defective parts, the reasons for the defect, and the evaluation items involved in the sewing process. As described above, the evaluation items include at least one of the product number of the sewn object 100, the sewing process, the sewing time, and the operator.

[0064] Figure 8 This diagram illustrates an example of a display device 4 that displays the evaluation items and defect rates involved in the implementation method. The processing unit 63 calculates the defect rate for each evaluation item related to the sewing process based on input data representing the defects of multiple sewn objects 100 sewn by multiple operators using multiple sewing machines 2. The output unit 64 displays the relationship between the evaluation items and the defect rate on the display device 4. Figure 8 This is a graph showing the relationship between sewing time (sewing period) and defect rate. Furthermore, the output unit 64 can also output the relationship between multiple product numbers and the defect rate associated with each product number, the relationship between multiple sewing processes and the defect rate associated with each sewing process, and the relationship between multiple operators and the defect rate associated with each operator.

[0065] [Effect]

[0066] As explained above, according to the embodiment, the sewing management system 1 includes: a defect reason storage unit 61, which stores multiple defect reasons for the sewn object 100 sewn by the operator using the sewing machine 2; an input data acquisition unit 62, which acquires input data indicating defect reasons from the input device 14; a processing unit 63, which classifies the input data indicating defect reasons according to each defect item; and an output unit 64, which outputs the classified input data indicating defect reasons.

[0067] According to the implementation method, after the reasons for non-conformities discovered during the inspection process are determined by the inspector, these reasons are categorized into predetermined non-conformity items. Because the reasons for non-conformities are categorized, for example, a manager can analyze the non-conformities of the sewn object based on the categorized reasons. The non-conformities categorized into multiple non-conformity items are effectively used as useful data when analyzing the non-conformities of the sewn object.

[0068] The input data related to the reasons for non-conformity are displayed separately on display device 4 according to multiple non-conformity items. Managers can analyze the reasons for non-conformity of the sewn object based on the reasons for non-conformity displayed separately for multiple non-conformity items.

[0069] The non-conformance items include item 1 indicating the reason for non-conformance for sewing machine 2, item 2 indicating the reason for non-conformance for operator, and item 3 indicating the reason for non-conformance for sewn object 100. This allows managers to efficiently determine the reasons for non-conformance.

[0070] According to the embodiment, the sewing management system 1 includes: an input data acquisition unit 62, which acquires input data from an input device 14, the input data representing the defects of multiple sewing objects 100 sewn by multiple operators using multiple sewing machines 2; a processing unit 63, which calculates the defect rate for multiple evaluation items related to sewing based on the input data representing defects; and an output unit 64, which outputs the defect rate.

[0071] According to the implementation method, when a defect is found during the inspection process, a defect rate is calculated for each of the multiple evaluation items and displayed on the display device 4. Since the defect rate, which represents the proportion of defective sewn objects 100 out of the multiple sewn objects 100, is calculated, the manager can analyze the reasons for the defects of the sewn objects 100 based on the calculated defect rate. The defect rate is effectively used as useful data when analyzing the reasons for the defects of the sewn objects 100.

[0072] The evaluation items include at least one of the following: the product number of the sewn object 100, the sewing process, the sewing time, and the operator. This allows managers to easily determine the reasons for non-compliance.

[0073] According to the embodiment, the sewing management system 1 includes: an input data acquisition unit 62, which acquires input data from the input device 14, the input data representing the defective parts of each of the multiple sewing objects 100 of the same design sewn by the operator using the sewing machine 2; and an output unit 64, which displays a first symbol representing the defective part superimposed on an image of the sewing object 100 on the display device 4.

[0074] According to the embodiment, after the inspector identifies the defective parts found during the inspection process, a first symbol indicating the defective parts identified by the inspector is displayed on the display device 4 as an overlay on the image of the sewn object 100. Since the defective parts are identified, the manager can analyze the reasons for the defects in the sewn object 100 based on the identified defects. The defective parts of the sewn object 100 are effectively used as useful data when analyzing the reasons for the defects in the sewn object 100. Furthermore, since the first symbol indicating the defective parts is displayed on the display device 4 as an overlay on the image of the sewn object 100, the manager can visually identify the defective parts.

[0075] The processing unit 63 counts the number of defects at the same location on multiple sewn objects 100 based on the input data indicating defective areas. This allows the manager to easily determine the cause of the defects. For example, if there are many defects in the hem section, there may be a problem with the sewing machine 2 used to sew the hem section, or the operator's skill level may be lacking. The manager can then maintain the sewing machine 2 used to sew the hem section or take measures to improve the operator's skill level. Furthermore, since the second symbol indicating the number of defects is displayed on the display device 4 superimposed on the image of the sewn object 100, the manager can visually identify defective areas with a high number of defects.

[0076] Since the relevant data between the defective parts and the evaluation items involved in the sewing are displayed on the display device 4, for example, a manager can analyze the reasons for the defect of the sewn object 100 based on the relevant data.

[0077] The relevant data includes the sewing time and the operator using sewing machine 2. This allows managers to easily identify the reasons for non-compliance.

[0078] [Other Implementation Methods]

[0079] In the above embodiment, the sewing machine controller 8 sends the operation data of the sewing machine 2 to the management controller 6. The processing unit 63 can also collect the operation data of each of the multiple sewing machines 2. As described above, the operation data of the sewing machine 2 includes the operating conditions and operation history of the sewing machine 2. The output unit 64 can also output the input data indicating the cause of failure, which has been classified by the processing unit 63, in association with the operation data of the sewing machine 2, to the display device 4 for display. (See reference...) Figure 7As explained, the display device 4 can also display data relating the cause of defect to the operating conditions of the sewing machine 2 (e.g., presser foot pressure), and it can also display data relating the cause of defect to the operating history of the sewing machine 2 (e.g., the type of object being sewn or the operator of the sewing machine 2). By outputting the categorized causes of defect in relation to the operating conditions of the sewing machine 2, for example, a manager can analyze the causes of defect in the sewing object. Similarly, by outputting the categorized causes of defect in relation to the operating history of the sewing machine 2, for example, a manager can analyze the causes of defect in the sewing object. Furthermore, the output unit 64 can also output the input data representing the causes of defect, categorized by the processing unit 63, in relation to the operating data of the sewing machine 2, to the defect cause storage unit 61 for storage.

[0080] The present invention includes the following methods. (1)

[0082] A sewing management system, which has: The non-conformance reason storage department stores multiple non-conformance items, which are items indicating the reasons for non-conformance of the sewn objects made by the operator using a sewing machine. The input data acquisition unit acquires input data indicating the reason for the failure from the input device; The processing unit categorizes the input data according to each of the non-conforming items; and The output unit outputs the categorized input data. (2)

[0084] According to the sewing management system described in (1), in which, The output unit causes the input data to be displayed on the display device or stored in the non-compliance reason storage unit according to each of the plurality of non-compliance items. (3)

[0086] According to the sewing management system described in (1), in which, The non-conforming items include a first item indicating that the sewing machine is non-conforming, a second item indicating that the operator is non-conforming, and a third item indicating that the sewn object is non-conforming. (4)

[0088] According to the sewing management system described in (1), in which, The input data acquisition unit collects the operating data of the sewing machine. The output unit outputs the classified input data in association with the operation data. (5)

[0090] According to the sewing management system described in (4), The output unit displays the input data in association with the operation data on the display device or stores it in the failure reason storage unit. (6)

[0092] According to the sewing management system described in (4), The operational data includes the operating conditions of the sewing machine and the operating history of the sewing machine. (7)

[0094] According to the sewing management system described in (6), in which, The operating conditions of the sewing machine include at least one of the following: stitch length, stitch spacing, stitch pattern, feed speed of the workpiece, number of stitches, thread tension, and presser foot pressure of the workpiece. (8)

[0096] According to the sewing management system described in (6), in which, The sewing machine's operating history includes at least one of the following: the date and time of the sewing machine's operation, the continuous operating time of the sewing machine, the cumulative operating time of the sewing machine, the type of object sewn by the sewing machine, the number of stitches during sewing, error messages that occurred on the sewing machine, and the operators who operated the sewing machine. (9)

[0098] A sewing management method comprising the following steps: Store the items that are defective due to the sewing machine used by the operator, i.e., multiple defective items; Obtain input data indicating the reason for the non-compliance from the input device; The input data is categorized according to each of the non-compliant items; and Output the categorized input data. (10)

[0100] A sewing management system, which has: The input data acquisition unit acquires input data from the input device, which represents the defects of multiple sewn objects produced by multiple operators using multiple sewing machines. The processing unit, based on the input data, calculates the defect rate for each of the multiple evaluation items involved in the sewing; and The output section outputs the aforementioned non-conforming rate. (11)

[0102] According to the sewing management system described in (10), in which, The evaluation items include at least one of the following: the product number of the sewn object, the sewing process, the sewing time, and the operator. (12)

[0104] A sewing management method comprising the following steps: Input data is obtained from the input device, which represents the defects of multiple sewn objects produced by multiple operators using multiple sewing machines. Based on the input data, the non-conformity rate is calculated for each of the multiple evaluation items involved in the sewing; and Output the aforementioned non-conformance rate. (13)

[0106] A sewing management system, which has: The input data acquisition unit acquires input data from the input device, which represents the defective parts of multiple sewn objects of the same design produced by the operator using a sewing machine; and The output section displays the first symbol representing the defective part superimposed on the image of the sewn object on the display device. (14)

[0108] According to the sewing management system described in (13), The system includes a processing unit that, based on the input data, counts the number of defects at the same location on multiple sewn objects. The output unit displays a second symbol representing the number of defects superimposed on an image of the sewn object on a display device. (15)

[0110] According to the sewing management system described in (13), It has a processing unit that generates relevant data between the defective parts and the evaluation items involved in the sewing. The output unit enables the relevant data to be displayed on the display device. (16)

[0112] According to the sewing management system described in (15), The relevant data includes the sewing time using the sewing machine and the operator. (17)

[0114] A sewing management method comprising the following steps: Input data is obtained from the input device, which represents the defective parts of multiple sewn objects of the same design produced by the operator using a sewing machine; and The first symbol representing the defective part is superimposed on the image of the sewn object and displayed on the display device.

[0115] This application is based on Japanese Patent Application No. 2023-187515, filed on November 1, 2023; Japanese Patent Application No. 2023-187516, filed on November 1, 2023; and Japanese Patent Application No. 2023-195366, filed on November 16, 2023, the contents of which are incorporated herein by reference.

Claims

1. A sewing management system, comprising: The non-conformance reason storage department stores multiple non-conformance items, which are items indicating the reasons for non-conformance of the sewn objects made by the operator using a sewing machine. The input data acquisition unit acquires input data indicating the reason for the failure from the input device; The processing unit categorizes the input data according to each of the non-conforming items; and The output unit outputs the categorized input data.

2. The sewing management system according to claim 1, wherein, The output unit causes the input data to be displayed on the display device or stored in the non-compliance reason storage unit according to each of the plurality of non-compliance items.

3. The sewing management system according to claim 1, wherein, The non-conforming items include a first item indicating that the sewing machine is non-conforming, a second item indicating that the operator is non-conforming, and a third item indicating that the sewn object is non-conforming.

4. The sewing management system according to claim 1, wherein, The input data acquisition unit collects the operating data of the sewing machine. The output unit outputs the classified input data in association with the operation data.

5. The sewing management system according to claim 4, wherein, The output unit displays the input data in association with the operation data on the display device or stores it in the failure reason storage unit.

6. The sewing management system according to claim 4, wherein, The operational data includes the operating conditions of the sewing machine and the operating history of the sewing machine.

7. The sewing management system according to claim 6, wherein, The operating conditions of the sewing machine include at least one of the following: stitch length, stitch spacing, stitch pattern, feed speed of the workpiece, number of stitches, thread tension, and presser foot pressure of the workpiece.

8. The sewing management system according to claim 6, wherein, The sewing machine's operating history includes at least one of the following: the date and time of the sewing machine's operation, the continuous operating time of the sewing machine, the cumulative operating time of the sewing machine, the type of object sewn by the sewing machine, the number of stitches during sewing, error messages that occurred on the sewing machine, and the operators who operated the sewing machine.

9. A sewing management method, comprising the following steps: Store the items that are defective due to the sewing machine used by the operator, i.e., multiple defective items; Obtain input data indicating the reason for the non-compliance from the input device; The input data is categorized according to each of the non-compliant items; and Output the categorized input data.

10. A sewing management system, comprising: The input data acquisition unit acquires input data from the input device, which represents the defects of multiple sewn objects produced by multiple operators using multiple sewing machines. The processing unit, based on the input data, calculates the defect rate for each of the multiple evaluation items involved in the sewing; and The output section outputs the aforementioned non-conforming rate.

11. The sewing management system according to claim 10, wherein, The evaluation items include at least one of the following: the product number of the sewn object, the sewing process, the sewing time, and the operator.

12. A sewing management method, comprising the following steps: Input data is obtained from the input device, which represents the defects of multiple sewn objects produced by multiple operators using multiple sewing machines. Based on the input data, the failure rate is calculated for each of the multiple evaluation items involved in the sewing process; as well as Output the aforementioned non-conformance rate.

13. A sewing management system, comprising: The input data acquisition unit acquires input data from the input device, which represents the defective parts of multiple sewn objects of the same design produced by the operator using a sewing machine; and The output section displays the first symbol representing the defective part superimposed on the image of the sewn object on the display device.

14. The sewing management system according to claim 13, wherein, The system includes a processing unit that, based on the input data, counts the number of defects at the same location on multiple sewn objects. The output unit displays a second symbol representing the number of defects superimposed on an image of the sewn object on a display device.

15. The sewing management system according to claim 13, wherein, It has a processing unit that generates relevant data between the defective parts and the evaluation items involved in the sewing. The output unit enables the relevant data to be displayed on the display device.

16. The sewing management system according to claim 15, wherein, The relevant data includes the sewing time using the sewing machine and the operator.

17. A sewing management method comprising the following steps: Input data is obtained from the input device, which represents the defective parts of multiple sewn objects of the same design produced by the operator using a sewing machine; and The first symbol representing the defective part is superimposed on the image of the sewn object and displayed on the display device.

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