Sewing management system and sewing management method

Abstract

A sewing management system (1) includes a correlation data storage unit (61) configured to store correlation data indicating a relationship between each of a plurality of sewing steps of sewing a sewing target (100) using a sewing machine (2) and an inspection level related to an inspection step of the sewing target (100) performed after a corresponding one of the sewing steps; and an output unit (62) configured to cause an output device (13) to output the inspection level corresponding to the inspection step.

Description

TECHNICAL FIELD

[0001] The present disclosure relates to a sewing management system and a sewing management method.BACKGROUND ART

[0002] In a technical field related to a sewing management system, a sewing management system as disclosed in Patent Literature 1 is known.CITATION LISTPATENT LITERATURE

[0003] Patent Literature 1: JP2020-168056ASUMMARY OF INVENTIONTECHNICAL PROBLEM

[0004] A sewing target sewn in a sewing step is inspected in an inspection step. In a case where there are a plurality of inspection steps, when an inspection level of each of the plurality of inspection steps is uniformly high or low, there is a possibility that an appropriate inspection cannot be performed.

[0005] An object of the present disclosure is to appropriately inspect a sewing target.SOLUTION TO PROBLEM

[0006] A sewing management system according to the present disclosure includes: a correlation data storage unit configured to store correlation data indicating a relationship between each of a plurality of sewing steps of sewing a sewing target using a sewing machine and an inspection level related to an inspection step of the sewing target performed after a corresponding one of the sewing steps; and an output unit configured to cause an output device to output the inspection level corresponding to the inspection step.ADVANTAGEOUS EFFECTS OF INVENTION

[0007] According to the sewing management system of the present disclosure, the sewing target is appropriately inspected.BRIEF DESCRIPTION OF DRAWINGS

[0008] [Fig. 1] Fig. 1 is a diagram schematically showing a sewing management system according to an embodiment. [Fig. 2] Fig. 2 is a hardware configuration diagram showing a management controller according to the embodiment. [Fig. 3] Fig. 3 is a functional block diagram showing a management device, a sewing machine, and an information terminal according to the embodiment. [Fig. 4] Fig. 4 is a diagram showing an example of correlation data according to the embodiment. [Fig. 5] Fig. 5 is a flowchart showing a sewing management method according to the embodiment. [Fig. 6] Fig. 6 is a diagram showing an example of the correlation data displayed on a display device of a first information terminal according to the embodiment. DESCRIPTION OF EMBODIMENTS

[0009] Hereinafter, embodiments according to the present disclosure will be described with reference to the drawings, but the present disclosure is not limited to the embodiments. The components of the embodiments described below can be appropriately combined. A part of the components may not be used.[Sewing Management System]

[0010] Fig. 1 is a diagram schematically showing a sewing management system 1 according to an embodiment. The sewing management system 1 includes a management device 3 that manages a production process of a sewn product. The production process includes sewing steps of sewing a sewing target 100 using sewing machines 2, and inspection steps of inspecting the sewing target 100 sewn in the sewing steps. Each of the sewing machines 2 is an industrial sewing machine. The sewn product is produced in a production line including the sewing machines 2. A plurality of sewing machines 2 are installed in the production line. The production line is installed in a sewing factory. The sewing machines 2 operate in the sewing factory. The sewing target 100 is sewn by the sewing machines 2 to produce the sewn product. In the embodiment, the management device 3 is installed in the sewing factory. The management device 3 may be installed outside the sewing factory.

[0011] In the sewing steps, the sewing target 100 is sewn by the sewing machines 2 to produce the sewn product. Examples of the sewing target 100 include fabric. Examples of the sewn product include clothes. In the example shown in FIG. 1, the sewing targets 100 include a first sewing target 100A for manufacturing a T-shirt and a second sewing target 100B for manufacturing a Y-shirt.

[0012] In the sewing factory, a plurality of types of sewing machines 2 corresponding to applications are installed. In the sewing factory, a plurality of types of sewing machines 2 are installed to correspond to a plurality of sewing steps for producing the sewn product. Examples of the type of the sewing machine 2 include a lockstitch sewing machine for sewing a body part, a button sewing machine for attaching a button to the body part, and a pocket sewing machine for attaching a pocket to the body part. In one sewing factory, many sewing machines 2 of various types are installed. In order to simplify the description, three sewing machines 2 are shown in Fig. 1. A first sewing machine 2A is used in a first step for producing the sewn product. A second sewing machine 2B is used in a second step for producing the sewn product. A third sewing machine 2C is used in a third step for producing the sewn product. In the sewing factory, a plurality of sewing machines 2 of one type may be installed.

[0013] In the sewing factory, an administrator, workers, and inspectors work. The administrator manages the workers, the inspectors, and the sewing machines 2. The workers sew the sewing target 100 using the sewing machines 2 in the sewing steps. The inspectors inspect the sewing target 100 sewn by the sewing machines 2 in the inspection steps. Each of the administrator, the worker, and the inspector may be regarded as a user of the sewing machine 2. The number of administrators may be one or may be multiple. The number of workers may be multiple or may be one. For example, one worker may operate a plurality of sewing machines 2. The number of inspectors may be multiple or may be one.

[0014] 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 or an organic EL display. The input device 5 is operated by the administrator to generate input data. The input device 5 may be operated by the worker or an operator. The input device 5 includes a touch panel (touch sensor) disposed on a display screen of the display device 4. The input device 5 may be a computer keyboard, a mouse, or a voice input device. The management controller 6 includes a computer system. The management controller 6 includes at least one processor and a main memory that stores a computer program executable by the processor.

[0015] The sewing machine 2 includes a sewing machine controller 8. The sewing machine controller 8 includes a computer system. The sewing machine controller 8 includes at least one processor and a main memory that stores a computer program executable by the processor.

[0016] The inspectors inspect the sewing target 100 in the inspection steps. The inspection for the sewing target 100 includes an intermediate inspection for inspecting the sewing target 100 that has completed a part of the sewing steps, and a final inspection for inspecting the sewing target that has completed all of the sewing steps. Each of the inspectors carries an information terminal 11. Examples of the information terminal 11 include a tablet terminal and a smartphone. The information terminal 11 includes a display, an input device such as a touch panel, and a computer system. In the example shown in Fig. 1, the intermediate inspection is an inspection step of inspecting the sewing target 100 that has completed the second step. The final inspection is an inspection step of inspecting the sewing target 100 that has completed the third step is ended. The information terminals 11 include a first information terminal 11A carried by an inspector who performs the intermediate inspection and a second information terminal 11B carried by an inspector who performs the final inspection.

[0017] The management device 3 is shared by the plurality of sewing machines 2 and the information terminals 11 in the sewing factory. The number of management devices 3 is less than the number of sewing machines 2. The number of management devices 3 is less than the number of information terminals 11. The management device 3 can communicate with the sewing machines 2 and the information terminals 11. 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. The management controller 6, the sewing machine controller 8, and the information terminal 11 wirelessly communicate with each other. The management controller 6, the sewing machine controller 8, and the information terminal 11 wirelessly communicate with each other via a local area network (LAN). Examples of the wireless LAN include Wifi (registered trademark). The management controller 6, the sewing machine controller 8, and the information terminal 11 may wirelessly communicate with each other via a personal area network (PAN). Examples of the wireless PAN include Bluetooth (registered trademark).

[0018] The management controller 6 transmits a control command to the sewing machine controller 8 of the sewing machine 2 based on the input data generated by operating the input device 5.

[0019] The sewing machine controller 8 transmits operation data of the sewing machine 2 to the management controller 6. The operation data of the sewing machine 2 includes operation conditions of the sewing machine 2. The operation conditions of the sewing machine 2 include a seam length, a seam pitch, a seam pattern, a feed speed of the sewing target, the number of stitches, a thread tension, and a pressing pressure on the sewing target. The sewing machine controller 8 monitors the operation conditions of the sewing machine 2. The sewing machine 2 is provided with a sensor that detects each of the operation conditions of the sewing machine 2. Examples of the sensor include a tension sensor that detects the thread tension and a pressing pressure sensor that detects the pressing pressure on the sewing target. The sewing machine controller 8 can monitor the operation conditions of the sewing machine 2 by acquiring detection data of the sensor. The sewing machine 2 includes a sewing machine motor for operating a needle bar and a thread take-up lever. The sewing machine controller 8 can monitor the operation conditions of the sewing machine 2 by acquiring a drive signal of the sewing machine motor. The operation data of the sewing machine 2 indicates an operation history of the sewing machine 2. The operation history of the sewing machine 2 includes at least one of an operation date and time of the sewing machine 2, a continuous operation time of the sewing machine 2, a cumulative operation time of the sewing machine 2, a type of a sewing target sewn by the sewing machine 2, the number of stitches during the sewing, error information generated in the sewing machine 2, or the worker who operates the sewing machine 2.

[0020] In the embodiment, the information terminal 11 includes an identification device 15 that identifies an identification tag 101 attached to the sewing target 100 (see Fig. 3). The identification device 15 outputs identification data indicating an identification result for the identification tag 101. The identification tag 101 is attached to the sewing target 100 to identify the sewing target 100. The identification tag 101 includes a first identification tag 101A for identifying the first sewing target 100A and a second identification tag 101B for identifying the second sewing target 100B. The first identification tag 101A is attached to the first sewing target 100A. The second identification tag 101B is attached to the second sewing target 100B. The identification tag 101 is attachable to and detachable from the sewing target 100. Examples of the identification tag 101 include an RFID tag and a two-dimensional code tag on which a two-dimensional code is printed. Examples of the identification device 15 include an RFID ID reader and a two-dimensional code reader. The two-dimensional code reader includes a camera provided in the information terminal 11. The information terminal 11 transmits the identification data indicating the identification result for the identification tag 101 obtained by the identification device 15 to the management controller 6.

[0021] The management controller 6 collects the operation data of each of the plurality of sewing machines 2. The management controller 6 displays, on the display device 4, the operation data of each of the plurality of sewing machines 2.

[0022] The inspector operates an input device of the information terminal 11 to input an inspection result for the sewing target 100 to the information terminal 11. The information terminal 11 transmits inspection data indicating the inspection result for the sewing target 100 to the management controller 6.

[0023] The management controller 6 transmits guidance data indicating inspection items and inspection methods of the sewing target 100 to the information terminal 11. The guidance data is displayed on a display device 13 (see FIG. 3) of the information terminal 11. The inspector inspects the sewing target 100 while checking the guidance data displayed on the display device 13.[Computer System]

[0024] Fig. 2 is a hardware configuration diagram showing the management controller 6 according to the embodiment. The management controller 6 includes a computer system 1000. The computer system 1000 includes a processor 1001 such as a central processing unit (CPU), a main memory 1002 including a nonvolatile memory such as a read only memory (ROM) and a volatile memory such as a random access memory (RAM), a storage 1003, and an interface 1004 including an input / output circuit. A function of the management controller 6 is stored in the storage 1003 as a computer program. The processor 1001 reads the computer program from the storage 1003, loads the computer program into the main memory 1002, and executes processing according to the computer program. The computer program may be distributed to the computer system 1000 via a network.

[0025] Similarly, each of the sewing machine controller 8 and the information terminal 11 includes a computer system including a processor, a main memory, a storage, and an interface.[Management Device, Sewing Machine, and Information Terminal]

[0026] Fig. 3 is a functional block diagram showing the management device 3, the sewing machine 2, and the information terminal 11 according to the embodiment. As shown in Fig. 3, the information terminal 11 includes a terminal controller 12, the display device 13 such as a flat panel display, and an input device 14 such as a touch panel, and the identification device 15. The input device 14 is operated by the inspector to generate input data. The input device 14 may be operated by the worker or the administrator. The terminal controller 12 transmits the input data generated by operating the input device 14 to the management controller 6. The identification device 15 outputs the identification data indicating the identification result for the identification tag 101. The terminal controller 12 transmits the identification data indicating the identification result for the identification tag 101 obtained by the identification device 15 to the management controller 6. The display device 13 displays the guidance data indicating the inspection items and the inspection methods of the sewing target 100 transmitted from the management controller 6.

[0027] The management controller 6 includes a correlation data storage unit 61 and an output unit 62.

[0028] The correlation data storage unit 61 stores correlation data indicating a relationship between each of a plurality of sewing steps of sewing the sewing target 100 using the sewing machine 2 and an inspection level related to an inspection step of the sewing target 100 performed after a corresponding one of the sewing steps. The correlation data is determined in advance. The correlation data is input from the input device 5 to the management controller 6, for example. For example, the administrator operates the input device 5 to store the correlation data in the correlation data storage unit 61.

[0029] In the embodiment, the correlation data indicates the relationship among the sewing step, the inspection step, the sewing target 100, and the inspection level. As described with reference to Fig. 1, in the embodiment, the sewing steps include the first step, the second step, and the third step. The inspection steps include the intermediate inspection and the final inspection. The intermediate inspection may include, for example, a first intermediate inspection for inspecting the sewing target 100 that has completed the first step, and a second intermediate inspection for inspecting the sewing target 100 that has completed the second step. The sewing target 100 includes the first sewing target 100A and the second sewing target 100B.

[0030] In the embodiment, the inspection level refers to an allowable range for a target value (target state) of the sewing target 100. When the allowable range is small, the inspection level is high (severe). When the allowable range is large, the inspection level is low (loose). For example, when a target position of the seam is set, the inspection level is an allowable value of a deviation amount of the seam with respect to the target position. When the inspection level is high, the allowable value of the deviation amount is small. When the inspection level is low, the allowable value of the deviation amount is large. As an example, when the inspection level is high, the allowable value of the deviation amount is 0.5 mm. When the inspection level is high, if the deviation amount exceeds 0.5 mm, the sewing target 100 is determined to be defective. When the inspection level is low, the allowable value of the deviation amount is 2.0 mm. When the inspection level is low, if the deviation amount exceeds 0.5 mm and is 2.0 mm or less, the sewing target 100 is determined to be good. When the deviation amount exceeds 2.0 mm, the sewing target 100 is determined to be defective.

[0031] The output unit 62 displays the inspection level corresponding to the inspection step on the display device 13 of the information terminal 11. The display device 13 is an example of an output device that outputs the inspection level corresponding to the inspection step. As described above, the identification tag 101 for identifying the sewing target 100 is attached to the sewing target 100. The output unit 62 displays, on the display device 13, the inspection level based on the identification data of the identification tag 101 obtained by the identification device 15 and the correlation data stored in the correlation data storage unit 61.[Correlation Data]

[0032] Fig. 4 is a diagram showing an example of the correlation data according to the embodiment. As shown in FIG. 4, in the embodiment, the correlation data indicates a relationship among the sewing target 100, the inspection step performed after each of the sewing steps, the inspection items in the inspection step, and the inspection levels. The sewing target 100 includes the first sewing target 100A for manufacturing a T-shirt and the second sewing target 100B for manufacturing a Y-shirt. The inspection steps include the first intermediate inspection performed after the first step, the second intermediate inspection performed after the second step, and the final inspection performed after the third step. The inspection items include an item A, an item B, and an item C. As an example, the item A is a deviation amount of the seam with respect to the target position. The item B is an unraveled amount of a thread. The item C is a deviation amount of fabrics overlapping each other. As the inspection levels, Level 1 is lowest, Level 2 is second lowest after Level 1, and Level 3 is highest.

[0033] For example, the inspection level of the final inspection is high. For example, when the first step or the second step of the sewing step is a step of manufacturing a lining, the inspection level of the first intermediate inspection or the second intermediate inspection may be low because the lining is a portion that cannot be seen after completion of the sewn product. The administrator sets the inspection levels according to the inspection steps performed after the sewing steps. As shown in FIG. 4, the administrator creates the correlation data indicating the relationship among the sewing target 100, the inspection step performed after each of the sewing steps, the inspection items in the inspection step, and the inspection levels. The administrator operates the input device 5 to store the created correlation data in the correlation data storage unit 61.[Sewing Management Method]

[0034] Fig. 5 is a flowchart showing a sewing management method according to the embodiment. Hereinafter, a sewing management method performed when the first intermediate inspection is performed on the first sewing target 100A will be described as an example. The inspector who performs the first intermediate inspection carries the first information terminal 11A.

[0035] The first sewing target 100A that has completed the first step is sent to the first intermediate inspection. The inspector reads the first identification tag 101A attached to the first sewing target 100A with the identification device 15 of the first information terminal 11A. The terminal controller 12 transmits the identification data indicating the identification result for the first identification tag 101A obtained by the identification device 15 to the management controller 6. In the embodiment, an identifier (ID) is assigned to each of the plurality of information terminals 11. The terminal controller 12 transmits ID data of the first information terminal 11A to the management controller 6. The management controller 6 acquires the identification data of the first identification tag 101A and the ID data of the first information terminal 11A, which are transmitted from the first information terminal 11A (step S1).

[0036] The first information terminal 11A is the information terminal 11 used in the first intermediate inspection. It is determined in advance that the first information terminal 11A is used in the first intermediate inspection. By acquiring the ID data of the first information terminal 11A, the management controller 6 can recognize that the first sewing target 100A is subjected to the first intermediate inspection. That is, by acquiring the ID data of the first information terminal 11A, the management controller 6 can recognize that the inspection step of the first sewing target 100A is the first intermediate inspection.

[0037] The output unit 62 transmits the inspection levels corresponding to the inspection step of the first sewing target 100A to the first information terminal 11A based on the identification data of the identification tag obtained by the identification device 15 and the correlation data stored in the correlation data storage unit 61 (step S2). The terminal controller 12 of the first information terminal 11A displays, on the display device 13, the correlation data corresponding to the first sewing target 100A and the first intermediate inspection transmitted from the management controller 6.

[0038] Fig. 6 is a diagram showing an example of the correlation data displayed on the display device 13 of the first information terminal 11A according to the embodiment. As shown in Fig. 6, the display device 13 displays the correlation data corresponding to the first sewing target 100A and the first intermediate inspection among the correlation data shown in Fig. 4. The inspector inspects the first sewing target 100A while checking the correlation data displayed on the display device 13. In the first intermediate inspection, the inspector inspects the first sewing target 100A for inspection items including the item A, the item B, and the item C. An inspection level of the item A is Level 2, an inspection level of the item B is Level 1, and an inspection level of the item C is Level 1. The inspector inspects the first sewing target 100A for each of the item A, the item B, and the item C according to the designated inspection levels.

[0039] The sewing management method performed when the first intermediate inspection is performed on the first sewing target 100A has been described above. The same applies to a case where the first sewing target 100A is subjected to the second intermediate inspection and the final inspection, and the same applies to a case where the second sewing target 100B is subjected to the first intermediate inspection, the second intermediate inspection, and the final inspection.[Advantageous Effects]

[0040] As described above, in the embodiment, the sewing management system 1 includes: the correlation data storage unit 61 configured to store the correlation data indicating the relationship between each of a plurality of sewing steps of sewing the sewing target 100 using the sewing machine 2 and the inspection level related to the inspection step of the sewing target performed after a corresponding one of the sewing steps; and the output unit 62 configured to cause the display device 13 that is the output device to output the inspection level corresponding to the inspection step.

[0041] According to the embodiment, the sewing target 100 is appropriately inspected in each of the plurality of inspection steps. In a case where the inspection level of each of the plurality of inspection steps is uniformly high, when the sewn product is strictly inspected regardless of the inspection step or the inspection item even though the inspection level may be low, productivity of the sewn product decreases. In a case where the inspection level of each of the plurality of inspection steps is uniformly low, when the sewn product is loosely inspected regardless of the inspection step or the inspection item even though the inspection level is required to be high, a defective sewn product may be produced. By determining the inspection level according to each of the plurality of inspection steps and each of the inspection items, an appropriate inspection is performed. Further, since the inspection level is displayed on the display device 13 as the guidance data, variation in the inspection level caused by the inspector is reduced.

[0042] In the embodiment, the correlation data indicates the relationship among the inspection step, the sewing target 100, and the inspection levels. Accordingly, an appropriate inspection corresponding to the sewing target 100 is performed. Further, in the embodiment, the correlation data indicates the relationship among the inspection step, the inspection items in the inspection step, the sewing target 100, and the inspection levels. Accordingly, an appropriate inspection corresponding to the inspection item is performed.

[0043] As described above, the identification tag 101 for identifying the sewing target 100 is attached to the sewing target 100. The output unit 62 outputs the inspection level based on the identification data of the identification tag 101 obtained by the identification device 15 and the correlation data. Accordingly, the correlation data corresponding to the sewing target 100 is displayed on the display device 13.

[0044] The present disclosure includes the following aspects. (1) A sewing management system including: a correlation data storage unit configured to store correlation data indicating a relationship between each of a plurality of sewing steps of sewing a sewing target using a sewing machine and an inspection level related to an inspection step of the sewing target performed after a corresponding one of the sewing steps; and an output unit configured to cause an output device to output the inspection level corresponding to the inspection step. (2) The sewing management system according to claim 1, in which the correlation data indicates a relationship among the inspection step, the sewing target, and the inspection level. (3) The sewing management system according to claim 1, in which an identification tag for identifying the sewing target is attached to the sewing target, and the output unit outputs the inspection level based on identification data of the identification tag obtained by an identification device and the correlation data. (4) A sewing management method including: storing correlation data indicating a relationship between each of a plurality of steps of sewing a sewing target using a sewing machine and an inspection level related to an inspection of the sewing target performed after a corresponding one of the steps; and causing an output device to output the inspection level corresponding to the step.

[0045] The present application is based on Japanese Patent Application No. 2023-187517 filed on November 1, 2023, the contents of which are incorporated herein by reference.

Examples

Embodiment Construction

[0009]Hereinafter, embodiments according to the present disclosure will be described with reference to the drawings, but the present disclosure is not limited to the embodiments. The components of the embodiments described below can be appropriately combined. A part of the components may not be used.

[Sewing Management System]

[0010]Fig. 1 is a diagram schematically showing a sewing management system 1 according to an embodiment. The sewing management system 1 includes a management device 3 that manages a production process of a sewn product. The production process includes sewing steps of sewing a sewing target 100 using sewing machines 2, and inspection steps of inspecting the sewing target 100 sewn in the sewing steps. Each of the sewing machines 2 is an industrial sewing machine. The sewn product is produced in a production line including the sewing machines 2. A plurality of sewing machines 2 are installed in the production line. The production line is installed in a sewing facto...

TECHNICAL FIELD

[0001] The present disclosure relates to a sewing management system and a sewing management method.BACKGROUND ART

[0002] In a technical field related to a sewing management system, a sewing management system as disclosed in Patent Literature 1 is known.CITATION LISTPATENT LITERATURE

[0003] Patent Literature 1: JP2020-168056ASUMMARY OF INVENTIONTECHNICAL PROBLEM

[0004] A sewing target sewn in a sewing step is inspected in an inspection step. In a case where there are a plurality of inspection steps, when an inspection level of each of the plurality of inspection steps is uniformly high or low, there is a possibility that an appropriate inspection cannot be performed.

[0005] An object of the present disclosure is to appropriately inspect a sewing target.SOLUTION TO PROBLEM

[0006] A sewing management system according to the present disclosure includes: a correlation data storage unit configured to store correlation data indicating a relationship between each of a plurality of sewing steps of sewing a sewing target using a sewing machine and an inspection level related to an inspection step of the sewing target performed after a corresponding one of the sewing steps; and an output unit configured to cause an output device to output the inspection level corresponding to the inspection step.ADVANTAGEOUS EFFECTS OF INVENTION

[0007] According to the sewing management system of the present disclosure, the sewing target is appropriately inspected.BRIEF DESCRIPTION OF DRAWINGS

[0008] [Fig. 1] Fig. 1 is a diagram schematically showing a sewing management system according to an embodiment. [Fig. 2] Fig. 2 is a hardware configuration diagram showing a management controller according to the embodiment. [Fig. 3] Fig. 3 is a functional block diagram showing a management device, a sewing machine, and an information terminal according to the embodiment. [Fig. 4] Fig. 4 is a diagram showing an example of correlation data according to the embodiment. [Fig. 5] Fig. 5 is a flowchart showing a sewing management method according to the embodiment. [Fig. 6] Fig. 6 is a diagram showing an example of the correlation data displayed on a display device of a first information terminal according to the embodiment. DESCRIPTION OF EMBODIMENTS

[0009] Hereinafter, embodiments according to the present disclosure will be described with reference to the drawings, but the present disclosure is not limited to the embodiments. The components of the embodiments described below can be appropriately combined. A part of the components may not be used.[Sewing Management System]

[0010] Fig. 1 is a diagram schematically showing a sewing management system 1 according to an embodiment. The sewing management system 1 includes a management device 3 that manages a production process of a sewn product. The production process includes sewing steps of sewing a sewing target 100 using sewing machines 2, and inspection steps of inspecting the sewing target 100 sewn in the sewing steps. Each of the sewing machines 2 is an industrial sewing machine. The sewn product is produced in a production line including the sewing machines 2. A plurality of sewing machines 2 are installed in the production line. The production line is installed in a sewing factory. The sewing machines 2 operate in the sewing factory. The sewing target 100 is sewn by the sewing machines 2 to produce the sewn product. In the embodiment, the management device 3 is installed in the sewing factory. The management device 3 may be installed outside the sewing factory.

[0011] In the sewing steps, the sewing target 100 is sewn by the sewing machines 2 to produce the sewn product. Examples of the sewing target 100 include fabric. Examples of the sewn product include clothes. In the example shown in FIG. 1, the sewing targets 100 include a first sewing target 100A for manufacturing a T-shirt and a second sewing target 100B for manufacturing a Y-shirt.

[0012] In the sewing factory, a plurality of types of sewing machines 2 corresponding to applications are installed. In the sewing factory, a plurality of types of sewing machines 2 are installed to correspond to a plurality of sewing steps for producing the sewn product. Examples of the type of the sewing machine 2 include a lockstitch sewing machine for sewing a body part, a button sewing machine for attaching a button to the body part, and a pocket sewing machine for attaching a pocket to the body part. In one sewing factory, many sewing machines 2 of various types are installed. In order to simplify the description, three sewing machines 2 are shown in Fig. 1. A first sewing machine 2A is used in a first step for producing the sewn product. A second sewing machine 2B is used in a second step for producing the sewn product. A third sewing machine 2C is used in a third step for producing the sewn product. In the sewing factory, a plurality of sewing machines 2 of one type may be installed.

[0013] In the sewing factory, an administrator, workers, and inspectors work. The administrator manages the workers, the inspectors, and the sewing machines 2. The workers sew the sewing target 100 using the sewing machines 2 in the sewing steps. The inspectors inspect the sewing target 100 sewn by the sewing machines 2 in the inspection steps. Each of the administrator, the worker, and the inspector may be regarded as a user of the sewing machine 2. The number of administrators may be one or may be multiple. The number of workers may be multiple or may be one. For example, one worker may operate a plurality of sewing machines 2. The number of inspectors may be multiple or may be one.

[0014] 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 or an organic EL display. The input device 5 is operated by the administrator to generate input data. The input device 5 may be operated by the worker or an operator. The input device 5 includes a touch panel (touch sensor) disposed on a display screen of the display device 4. The input device 5 may be a computer keyboard, a mouse, or a voice input device. The management controller 6 includes a computer system. The management controller 6 includes at least one processor and a main memory that stores a computer program executable by the processor.

[0015] The sewing machine 2 includes a sewing machine controller 8. The sewing machine controller 8 includes a computer system. The sewing machine controller 8 includes at least one processor and a main memory that stores a computer program executable by the processor.

[0016] The inspectors inspect the sewing target 100 in the inspection steps. The inspection for the sewing target 100 includes an intermediate inspection for inspecting the sewing target 100 that has completed a part of the sewing steps, and a final inspection for inspecting the sewing target that has completed all of the sewing steps. Each of the inspectors carries an information terminal 11. Examples of the information terminal 11 include a tablet terminal and a smartphone. The information terminal 11 includes a display, an input device such as a touch panel, and a computer system. In the example shown in Fig. 1, the intermediate inspection is an inspection step of inspecting the sewing target 100 that has completed the second step. The final inspection is an inspection step of inspecting the sewing target 100 that has completed the third step is ended. The information terminals 11 include a first information terminal 11A carried by an inspector who performs the intermediate inspection and a second information terminal 11B carried by an inspector who performs the final inspection.

[0017] The management device 3 is shared by the plurality of sewing machines 2 and the information terminals 11 in the sewing factory. The number of management devices 3 is less than the number of sewing machines 2. The number of management devices 3 is less than the number of information terminals 11. The management device 3 can communicate with the sewing machines 2 and the information terminals 11. 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. The management controller 6, the sewing machine controller 8, and the information terminal 11 wirelessly communicate with each other. The management controller 6, the sewing machine controller 8, and the information terminal 11 wirelessly communicate with each other via a local area network (LAN). Examples of the wireless LAN include Wifi (registered trademark). The management controller 6, the sewing machine controller 8, and the information terminal 11 may wirelessly communicate with each other via a personal area network (PAN). Examples of the wireless PAN include Bluetooth (registered trademark).

[0018] The management controller 6 transmits a control command to the sewing machine controller 8 of the sewing machine 2 based on the input data generated by operating the input device 5.

[0019] The sewing machine controller 8 transmits operation data of the sewing machine 2 to the management controller 6. The operation data of the sewing machine 2 includes operation conditions of the sewing machine 2. The operation conditions of the sewing machine 2 include a seam length, a seam pitch, a seam pattern, a feed speed of the sewing target, the number of stitches, a thread tension, and a pressing pressure on the sewing target. The sewing machine controller 8 monitors the operation conditions of the sewing machine 2. The sewing machine 2 is provided with a sensor that detects each of the operation conditions of the sewing machine 2. Examples of the sensor include a tension sensor that detects the thread tension and a pressing pressure sensor that detects the pressing pressure on the sewing target. The sewing machine controller 8 can monitor the operation conditions of the sewing machine 2 by acquiring detection data of the sensor. The sewing machine 2 includes a sewing machine motor for operating a needle bar and a thread take-up lever. The sewing machine controller 8 can monitor the operation conditions of the sewing machine 2 by acquiring a drive signal of the sewing machine motor. The operation data of the sewing machine 2 indicates an operation history of the sewing machine 2. The operation history of the sewing machine 2 includes at least one of an operation date and time of the sewing machine 2, a continuous operation time of the sewing machine 2, a cumulative operation time of the sewing machine 2, a type of a sewing target sewn by the sewing machine 2, the number of stitches during the sewing, error information generated in the sewing machine 2, or the worker who operates the sewing machine 2.

[0020] In the embodiment, the information terminal 11 includes an identification device 15 that identifies an identification tag 101 attached to the sewing target 100 (see Fig. 3). The identification device 15 outputs identification data indicating an identification result for the identification tag 101. The identification tag 101 is attached to the sewing target 100 to identify the sewing target 100. The identification tag 101 includes a first identification tag 101A for identifying the first sewing target 100A and a second identification tag 101B for identifying the second sewing target 100B. The first identification tag 101A is attached to the first sewing target 100A. The second identification tag 101B is attached to the second sewing target 100B. The identification tag 101 is attachable to and detachable from the sewing target 100. Examples of the identification tag 101 include an RFID tag and a two-dimensional code tag on which a two-dimensional code is printed. Examples of the identification device 15 include an RFID ID reader and a two-dimensional code reader. The two-dimensional code reader includes a camera provided in the information terminal 11. The information terminal 11 transmits the identification data indicating the identification result for the identification tag 101 obtained by the identification device 15 to the management controller 6.

[0021] The management controller 6 collects the operation data of each of the plurality of sewing machines 2. The management controller 6 displays, on the display device 4, the operation data of each of the plurality of sewing machines 2.

[0022] The inspector operates an input device of the information terminal 11 to input an inspection result for the sewing target 100 to the information terminal 11. The information terminal 11 transmits inspection data indicating the inspection result for the sewing target 100 to the management controller 6.

[0023] The management controller 6 transmits guidance data indicating inspection items and inspection methods of the sewing target 100 to the information terminal 11. The guidance data is displayed on a display device 13 (see FIG. 3) of the information terminal 11. The inspector inspects the sewing target 100 while checking the guidance data displayed on the display device 13.[Computer System]

[0024] Fig. 2 is a hardware configuration diagram showing the management controller 6 according to the embodiment. The management controller 6 includes a computer system 1000. The computer system 1000 includes a processor 1001 such as a central processing unit (CPU), a main memory 1002 including a nonvolatile memory such as a read only memory (ROM) and a volatile memory such as a random access memory (RAM), a storage 1003, and an interface 1004 including an input / output circuit. A function of the management controller 6 is stored in the storage 1003 as a computer program. The processor 1001 reads the computer program from the storage 1003, loads the computer program into the main memory 1002, and executes processing according to the computer program. The computer program may be distributed to the computer system 1000 via a network.

[0025] Similarly, each of the sewing machine controller 8 and the information terminal 11 includes a computer system including a processor, a main memory, a storage, and an interface.[Management Device, Sewing Machine, and Information Terminal]

[0026] Fig. 3 is a functional block diagram showing the management device 3, the sewing machine 2, and the information terminal 11 according to the embodiment. As shown in Fig. 3, the information terminal 11 includes a terminal controller 12, the display device 13 such as a flat panel display, and an input device 14 such as a touch panel, and the identification device 15. The input device 14 is operated by the inspector to generate input data. The input device 14 may be operated by the worker or the administrator. The terminal controller 12 transmits the input data generated by operating the input device 14 to the management controller 6. The identification device 15 outputs the identification data indicating the identification result for the identification tag 101. The terminal controller 12 transmits the identification data indicating the identification result for the identification tag 101 obtained by the identification device 15 to the management controller 6. The display device 13 displays the guidance data indicating the inspection items and the inspection methods of the sewing target 100 transmitted from the management controller 6.

[0027] The management controller 6 includes a correlation data storage unit 61 and an output unit 62.

[0028] The correlation data storage unit 61 stores correlation data indicating a relationship between each of a plurality of sewing steps of sewing the sewing target 100 using the sewing machine 2 and an inspection level related to an inspection step of the sewing target 100 performed after a corresponding one of the sewing steps. The correlation data is determined in advance. The correlation data is input from the input device 5 to the management controller 6, for example. For example, the administrator operates the input device 5 to store the correlation data in the correlation data storage unit 61.

[0029] In the embodiment, the correlation data indicates the relationship among the sewing step, the inspection step, the sewing target 100, and the inspection level. As described with reference to Fig. 1, in the embodiment, the sewing steps include the first step, the second step, and the third step. The inspection steps include the intermediate inspection and the final inspection. The intermediate inspection may include, for example, a first intermediate inspection for inspecting the sewing target 100 that has completed the first step, and a second intermediate inspection for inspecting the sewing target 100 that has completed the second step. The sewing target 100 includes the first sewing target 100A and the second sewing target 100B.

[0030] In the embodiment, the inspection level refers to an allowable range for a target value (target state) of the sewing target 100. When the allowable range is small, the inspection level is high (severe). When the allowable range is large, the inspection level is low (loose). For example, when a target position of the seam is set, the inspection level is an allowable value of a deviation amount of the seam with respect to the target position. When the inspection level is high, the allowable value of the deviation amount is small. When the inspection level is low, the allowable value of the deviation amount is large. As an example, when the inspection level is high, the allowable value of the deviation amount is 0.5 mm. When the inspection level is high, if the deviation amount exceeds 0.5 mm, the sewing target 100 is determined to be defective. When the inspection level is low, the allowable value of the deviation amount is 2.0 mm. When the inspection level is low, if the deviation amount exceeds 0.5 mm and is 2.0 mm or less, the sewing target 100 is determined to be good. When the deviation amount exceeds 2.0 mm, the sewing target 100 is determined to be defective.

[0031] The output unit 62 displays the inspection level corresponding to the inspection step on the display device 13 of the information terminal 11. The display device 13 is an example of an output device that outputs the inspection level corresponding to the inspection step. As described above, the identification tag 101 for identifying the sewing target 100 is attached to the sewing target 100. The output unit 62 displays, on the display device 13, the inspection level based on the identification data of the identification tag 101 obtained by the identification device 15 and the correlation data stored in the correlation data storage unit 61.[Correlation Data]

[0032] Fig. 4 is a diagram showing an example of the correlation data according to the embodiment. As shown in FIG. 4, in the embodiment, the correlation data indicates a relationship among the sewing target 100, the inspection step performed after each of the sewing steps, the inspection items in the inspection step, and the inspection levels. The sewing target 100 includes the first sewing target 100A for manufacturing a T-shirt and the second sewing target 100B for manufacturing a Y-shirt. The inspection steps include the first intermediate inspection performed after the first step, the second intermediate inspection performed after the second step, and the final inspection performed after the third step. The inspection items include an item A, an item B, and an item C. As an example, the item A is a deviation amount of the seam with respect to the target position. The item B is an unraveled amount of a thread. The item C is a deviation amount of fabrics overlapping each other. As the inspection levels, Level 1 is lowest, Level 2 is second lowest after Level 1, and Level 3 is highest.

[0033] For example, the inspection level of the final inspection is high. For example, when the first step or the second step of the sewing step is a step of manufacturing a lining, the inspection level of the first intermediate inspection or the second intermediate inspection may be low because the lining is a portion that cannot be seen after completion of the sewn product. The administrator sets the inspection levels according to the inspection steps performed after the sewing steps. As shown in FIG. 4, the administrator creates the correlation data indicating the relationship among the sewing target 100, the inspection step performed after each of the sewing steps, the inspection items in the inspection step, and the inspection levels. The administrator operates the input device 5 to store the created correlation data in the correlation data storage unit 61.[Sewing Management Method]

[0034] Fig. 5 is a flowchart showing a sewing management method according to the embodiment. Hereinafter, a sewing management method performed when the first intermediate inspection is performed on the first sewing target 100A will be described as an example. The inspector who performs the first intermediate inspection carries the first information terminal 11A.

[0035] The first sewing target 100A that has completed the first step is sent to the first intermediate inspection. The inspector reads the first identification tag 101A attached to the first sewing target 100A with the identification device 15 of the first information terminal 11A. The terminal controller 12 transmits the identification data indicating the identification result for the first identification tag 101A obtained by the identification device 15 to the management controller 6. In the embodiment, an identifier (ID) is assigned to each of the plurality of information terminals 11. The terminal controller 12 transmits ID data of the first information terminal 11A to the management controller 6. The management controller 6 acquires the identification data of the first identification tag 101A and the ID data of the first information terminal 11A, which are transmitted from the first information terminal 11A (step S1).

[0036] The first information terminal 11A is the information terminal 11 used in the first intermediate inspection. It is determined in advance that the first information terminal 11A is used in the first intermediate inspection. By acquiring the ID data of the first information terminal 11A, the management controller 6 can recognize that the first sewing target 100A is subjected to the first intermediate inspection. That is, by acquiring the ID data of the first information terminal 11A, the management controller 6 can recognize that the inspection step of the first sewing target 100A is the first intermediate inspection.

[0037] The output unit 62 transmits the inspection levels corresponding to the inspection step of the first sewing target 100A to the first information terminal 11A based on the identification data of the identification tag obtained by the identification device 15 and the correlation data stored in the correlation data storage unit 61 (step S2). The terminal controller 12 of the first information terminal 11A displays, on the display device 13, the correlation data corresponding to the first sewing target 100A and the first intermediate inspection transmitted from the management controller 6.

[0038] Fig. 6 is a diagram showing an example of the correlation data displayed on the display device 13 of the first information terminal 11A according to the embodiment. As shown in Fig. 6, the display device 13 displays the correlation data corresponding to the first sewing target 100A and the first intermediate inspection among the correlation data shown in Fig. 4. The inspector inspects the first sewing target 100A while checking the correlation data displayed on the display device 13. In the first intermediate inspection, the inspector inspects the first sewing target 100A for inspection items including the item A, the item B, and the item C. An inspection level of the item A is Level 2, an inspection level of the item B is Level 1, and an inspection level of the item C is Level 1. The inspector inspects the first sewing target 100A for each of the item A, the item B, and the item C according to the designated inspection levels.

[0039] The sewing management method performed when the first intermediate inspection is performed on the first sewing target 100A has been described above. The same applies to a case where the first sewing target 100A is subjected to the second intermediate inspection and the final inspection, and the same applies to a case where the second sewing target 100B is subjected to the first intermediate inspection, the second intermediate inspection, and the final inspection.[Advantageous Effects]

[0040] As described above, in the embodiment, the sewing management system 1 includes: the correlation data storage unit 61 configured to store the correlation data indicating the relationship between each of a plurality of sewing steps of sewing the sewing target 100 using the sewing machine 2 and the inspection level related to the inspection step of the sewing target performed after a corresponding one of the sewing steps; and the output unit 62 configured to cause the display device 13 that is the output device to output the inspection level corresponding to the inspection step.

[0041] According to the embodiment, the sewing target 100 is appropriately inspected in each of the plurality of inspection steps. In a case where the inspection level of each of the plurality of inspection steps is uniformly high, when the sewn product is strictly inspected regardless of the inspection step or the inspection item even though the inspection level may be low, productivity of the sewn product decreases. In a case where the inspection level of each of the plurality of inspection steps is uniformly low, when the sewn product is loosely inspected regardless of the inspection step or the inspection item even though the inspection level is required to be high, a defective sewn product may be produced. By determining the inspection level according to each of the plurality of inspection steps and each of the inspection items, an appropriate inspection is performed. Further, since the inspection level is displayed on the display device 13 as the guidance data, variation in the inspection level caused by the inspector is reduced.

[0042] In the embodiment, the correlation data indicates the relationship among the inspection step, the sewing target 100, and the inspection levels. Accordingly, an appropriate inspection corresponding to the sewing target 100 is performed. Further, in the embodiment, the correlation data indicates the relationship among the inspection step, the inspection items in the inspection step, the sewing target 100, and the inspection levels. Accordingly, an appropriate inspection corresponding to the inspection item is performed.

[0043] As described above, the identification tag 101 for identifying the sewing target 100 is attached to the sewing target 100. The output unit 62 outputs the inspection level based on the identification data of the identification tag 101 obtained by the identification device 15 and the correlation data. Accordingly, the correlation data corresponding to the sewing target 100 is displayed on the display device 13.

[0044] The present disclosure includes the following aspects. (1) A sewing management system including: a correlation data storage unit configured to store correlation data indicating a relationship between each of a plurality of sewing steps of sewing a sewing target using a sewing machine and an inspection level related to an inspection step of the sewing target performed after a corresponding one of the sewing steps; and an output unit configured to cause an output device to output the inspection level corresponding to the inspection step. (2) The sewing management system according to claim 1, in which the correlation data indicates a relationship among the inspection step, the sewing target, and the inspection level. (3) The sewing management system according to claim 1, in which an identification tag for identifying the sewing target is attached to the sewing target, and the output unit outputs the inspection level based on identification data of the identification tag obtained by an identification device and the correlation data. (4) A sewing management method including: storing correlation data indicating a relationship between each of a plurality of steps of sewing a sewing target using a sewing machine and an inspection level related to an inspection of the sewing target performed after a corresponding one of the steps; and causing an output device to output the inspection level corresponding to the step.

[0045] The present application is based on Japanese Patent Application No. 2023-187517 filed on November 1, 2023, the contents of which are incorporated herein by reference.

Examples

Embodiment Construction

[0009]Hereinafter, embodiments according to the present disclosure will be described with reference to the drawings, but the present disclosure is not limited to the embodiments. The components of the embodiments described below can be appropriately combined. A part of the components may not be used.

[Sewing Management System]

[0010]Fig. 1 is a diagram schematically showing a sewing management system 1 according to an embodiment. The sewing management system 1 includes a management device 3 that manages a production process of a sewn product. The production process includes sewing steps of sewing a sewing target 100 using sewing machines 2, and inspection steps of inspecting the sewing target 100 sewn in the sewing steps. Each of the sewing machines 2 is an industrial sewing machine. The sewn product is produced in a production line including the sewing machines 2. A plurality of sewing machines 2 are installed in the production line. The production line is installed in a sewing facto...

Claims

1. A sewing management system comprising: a correlation data storage unit configured to store correlation data indicating a relationship between each of a plurality of sewing steps of sewing a sewing target using a sewing machine and an inspection level related to an inspection step of the sewing target performed after a corresponding one of the sewing steps; and an output unit configured to cause an output device to output the inspection level corresponding to the inspection step.

2. The sewing management system according to claim 1, wherein the correlation data indicates a relationship among the inspection step, the sewing target, and the inspection level.

3. The sewing management system according to claim 1, wherein an identification tag for identifying the sewing target is attached to the sewing target, and the output unit outputs the inspection level based on identification data of the identification tag obtained by an identification device and the correlation data.

4. A sewing management method comprising: storing correlation data indicating a relationship between each of a plurality of steps of sewing a sewing target using a sewing machine and an inspection level related to an inspection of the sewing target performed after a corresponding one of the steps; and causing an output device to output the inspection level corresponding to the step.

Images