Sewing management system and sewing management method

Abstract

To provide data for analyzing causes of defects of a sewing object.SOLUTION: A sewing management system comprises: an input data acquisition part to acquire input data indicating a defect part of each of a plurality of sewing objects having the same design sewn by operators using sewing machines from an input device; and an output part to make a display device display an image of the sewing object by superimposing a first symbol indicating the defect part on the image of the sewing object.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The technology disclosed in this specification relates to a sewing management system and a sewing management method. [Background technology]

[0002] In the technical field related to the stitching management system, a stitching management system such as that disclosed in Patent Document 1 is known. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Publication No. 2020-168056 Summary of the Invention [Problem to be solved by the invention]

[0004] The sewing object sewn in the sewing process is inspected in the inspection process. If the sewing object is determined to be defective in the inspection process, the cause of the defect needs to be analyzed.

[0005] The technology disclosed in this specification aims to provide data for analyzing the cause of defects in a sewing object. [Means for solving the problem]

[0006] This specification discloses a sewing management system that includes an input data acquisition unit that acquires, from an input device, input data indicating defect points in each of a plurality of sewing objects of the same design that have been sewn by an operator using a sewing machine, and an output unit that displays, on a display device, a first symbol indicating the defect point superimposed on an image of the sewing object. [Effects of the Invention]

[0007] According to the technology disclosed in this specification, it is possible to provide data for analyzing the cause of defects in a sewing object. [Brief explanation of the drawings]

[0008] [Figure 1] FIG. 1 is a diagram schematically illustrating a sewing management system according to an embodiment. [Figure 2] FIG. 2 is a hardware configuration diagram showing a management controller according to the embodiment. [Figure 3] FIG. 3 is a functional block diagram showing the management device, sewing machines, and information terminals according to the embodiment. [Figure 4] FIG. 4 is a diagram showing an information terminal in an inspection process according to the embodiment. [Figure 5] FIG. 5 is a flowchart showing an inspection process according to the embodiment. [Figure 6] FIG. 6 is a diagram showing an example of a display device that displays defective locations and the number of defects according to the embodiment. [Figure 7] FIG. 7 is a diagram showing an example of a display device that displays correlation data between defective locations, causes of defects, and evaluation items related to sewing according to the embodiment. [Figure 8] FIG. 8 is a diagram showing an example of a display device that displays the evaluation items and the defect rate according to the embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0009] Hereinafter, embodiments of the present technology will be described with reference to the drawings, but the present technology is not limited to the embodiments. Components of the embodiments described below can be combined as appropriate. In addition, some components may not be used.

[0010] [Sewing management system] FIG. 1 is a diagram schematically illustrating 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 a sewing process in which a sewing object 100 is sewn using a sewing machine 2, and an inspection process in which the sewing object 100 sewn in the sewing process is inspected. The sewing machine 2 is an industrial sewing machine. The sewn product is produced in a production line that includes the sewing machine 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 object 100 is sewn by the sewing machine 2, thereby producing a sewn product. In the embodiment, the management device 3 is installed in the sewing factory. Note that the management device 3 may also be installed outside the sewing factory.

[0011] In the sewing process, a sewing object 100 is sewn by a sewing machine 2 to produce a sewn product. An example of the sewing object is fabric. An example of the sewn product is clothing.

[0012] A sewing factory is equipped with multiple types of sewing machines 2 according to their intended use. A sewing factory is equipped with multiple types of sewing machines 2 corresponding to the multiple sewing processes for producing sewn products. Examples of the types of sewing machines 2 include a lockstitch sewing machine for sewing together body parts, a button sewing machine for attaching buttons to body parts, and a pocket sewing machine for attaching pockets to body parts. A single sewing factory is equipped with many different types of sewing machines 2. For ease of explanation, three sewing machines 2 are shown in FIG. 1. A first sewing machine 2A is used in the first process for producing sewn products. A second sewing machine 2B is used in the second process for producing sewn products. A third sewing machine 2C is used in the third process for producing sewn products. A sewing factory may be equipped with multiple sewing machines 2 of the same type.

[0013] A manager, workers, and inspectors work in a sewing factory. The manager manages the workers, other managers, and the sewing machine 2. The workers sew the sewing object 100 using the sewing machine 2 in the sewing process. The inspectors inspect the sewing object 100 sewn by the sewing machine 2 in the inspection process. Each of the manager, workers, and inspectors may be considered to be a user of the sewing machine 2. The manager may be one person or multiple people. The workers may be one person or multiple people. For example, one worker may operate multiple sewing machines 2. The inspectors may be one person or multiple people.

[0014] The management device 3 has 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 generates input data when operated by an administrator. The input device 5 may be operated by a worker or an operator. The input device 5 includes a touch panel (touch sensor) arranged on the 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 has at least one processor and a main memory that stores computer programs executable by the processor.

[0015] The sewing machine 2 has an operation panel 7 and a sewing machine controller 8. The operation panel 7 generates operation data when operated by an operator. The operation panel 7 includes a touch panel (touch sensor) arranged on the display screen of the display. The sewing machine controller 8 includes a computer system. The sewing machine controller 8 has at least one processor and a main memory that stores computer programs executable by the processor.

[0016] The inspector inspects the sewing object 100 in the inspection process. The inspection of the sewing object 100 includes an intermediate inspection in which the sewing object 100 has undergone some of the sewing processes, and a final inspection in which the sewing object 100 has undergone all of the sewing processes. The inspector carries an information terminal 11. Examples of the information terminal 11 include a tablet terminal or a smartphone.

[0017] The management device 3 is shared by a plurality of sewing machines 2 and information terminals 11 in a sewing factory. The number of management devices 3 is smaller than the number of sewing machines 2. The management device 3 is capable of communicating with each of the sewing machines 2 and the information terminals 11. The management controller 6 of the management device 3 communicates with each of the sewing machine controllers 8 of the sewing machines 2 and the information terminals 11. The management controller 6, the sewing machine controller 8, and the information terminals 11 communicate wirelessly. The management controller 6, the sewing machine controller 8, and the information terminals 11 communicate wirelessly via a local area network (LAN). An example of a wireless LAN is Wifi (registered trademark). The management controller 6, the sewing machine controller 8, and the information terminals 11 may also communicate wirelessly via a personal area network (PAN). An example of a wireless PAN is 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 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 operating conditions of the sewing machine 2. The operating conditions of the sewing machine 2 include stitch length, stitch pitch, stitch pattern, feed speed of the sewing object, number of stitches, thread tension, and presser foot pressure on the sewing object. The sewing machine controller 8 monitors the operating conditions of the sewing machine 2. The sewing machine 2 is provided with a sensor that detects the operating conditions of the sewing machine 2. Examples of the sensor include a tension sensor that detects thread tension and a presser foot pressure sensor that detects presser foot pressure on the sewing object. The sewing machine controller 8 can monitor the operating conditions of the sewing machine 2 by acquiring the detection data of the sensor. The sewing machine 2 also has a sewing machine motor for operating the needle bar and thread take-up lever. The sewing machine controller 8 can monitor the operating conditions of the sewing machine 2 by acquiring a drive signal of the sewing machine motor. The operation data of the sewing machine 2 also indicates the operating history of the sewing machine 2. The operation history of the sewing machine 2 includes at least one of the operation date and time of the sewing machine 2, the continuous operation time of the sewing machine 2, the cumulative operation time of the sewing machine 2, the type of sewing object sewn by the sewing machine 2, the number of stitches during sewing, error information that occurred in the sewing machine 2, and the operator who operated the sewing machine 2.

[0020] The management controller 6 collects operation data of each of the plurality of sewing machines 2. The management controller 6 causes the display device 4 to display the operation data of each of the plurality of sewing machines 2.

[0021] The inspector operates the input device of the information terminal 11 to input the inspection results of the sewing object 100 into the information terminal 11. The information terminal 11 transmits inspection data indicating the inspection results of the sewing object 100 to the management controller 6.

[0022] The management controller 6 transmits guidance data indicating the inspection items and inspection methods for the sewing object 100 to the information terminal 11. The guidance data is displayed on the display of the information terminal 11. The inspector inspects the sewing object 100 while checking the guidance data displayed on the display.

[0023] [Computer System] FIG. 2 is a hardware configuration diagram showing a management controller 6 according to an embodiment. The management controller 6 includes a computer system 1000. The computer system 1000 includes a processor 1001 such as a CPU (Central Processing Unit), a main memory 1002 including a nonvolatile memory such as a ROM (Read Only Memory) and a volatile memory such as a RAM (Random Access Memory), a storage 1003, and an interface 1004 including an input / output circuit. The functions of the management controller 6 are stored in the storage 1003 as a computer program. The processor 1001 reads the computer program from the storage 1003, loads it into the main memory 1002, and executes processing in accordance with the computer program. The computer program may be distributed to the computer system 1000 via a network.

[0024] Similarly, each of the sewing machine controller 8 and the information terminal 11 includes a computer system having a processor, a main memory, a storage, and an interface.

[0025] [Management device, sewing machine, and information terminal] FIG. 3 is a functional block diagram showing a management device 3, a sewing machine 2, and an information terminal 11 according to an embodiment. As shown in FIG. 3, 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 generates input data when operated by an inspector. The input device 14 may also be operated by a worker or a manager. The terminal controller 12 transmits the input data generated when the input device 14 is operated to the management controller 6.

[0026] The management controller 6 includes a defect cause storage unit 61 , an input data acquisition unit 62 , a processing unit 63 , and an output unit 64 .

[0027] The defect cause storage unit 61 stores a plurality of defect items that are items of defect causes of the sewing object 100 sewn by the worker using the sewing machine 2. The defect items indicating the defect causes are determined in advance. In the embodiment, the defect items include a first item indicating that the sewing machine 2 is the defect cause, a second item indicating that the worker is the defect cause, and a third item indicating that the sewing object 100 is the defect cause. The defect cause related to the first item may be considered to be a mechanical defect cause. The defect cause related to the second item may be considered to be an operation defect cause. The defect cause related to the third item may be considered to be a material defect cause.

[0028] An example of a cause of a defect related to the first item is an abnormality in the stitches formed on the sewing object 100. Examples of stitch abnormalities include an abnormality called a "skipped stitch," in which the length of at least one stitch becomes longer, an abnormality called a "thread break," in which at least a portion of a stitch is lost, and an abnormality called a "lantern thread," in which at least one of the upper thread and the bobbin thread becomes loose on the sewing object. Defects related to the first item are defects caused by the sewing machine 2, such as improper adjustment or setting of the sewing machine 2.

[0029] An example of a cause of a defect related to the second item is an abnormality in the stitches formed on the sewing object 100. Examples of abnormal stitches include meandering stitches, non-existent stitches, and deviation of stitches from the sewing object 100. Also, an example of a cause of a defect related to the second item is a mix-up of the sewing object 100 or a mix-up of threads. A defect related to the second item is a defect caused by an operator, such as a lack of skill or carelessness on the part of the operator.

[0030] The cause of the defect related to the third item is, for example, a defect in the sewing object 100 itself. The defect in the sewing object 100 itself is, for example, a scratch, uneven color, or stain that exists on the sewing object 100. The defect related to the third item is a defect caused by the sewing object 100.

[0031] The input data acquiring unit 62 acquires, from the information terminal 11, input data generated by the input device 14 of the information terminal 11. If a defect exists in the sewing object 100, the inspector operates the input device 14 to input that a defect exists in the sewing object 100. The inspector operates the input device 14 to input the cause of the defect. The inspector operates the input device 14 to input the defective part of the sewing object 100. The input data acquiring unit 62 acquires, from the information terminal 11, input data indicating the presence of a defect in the sewing object 100. The input data acquiring unit 62 acquires, from the information terminal 11, input data indicating the cause of the defect in the sewing object 100. The input data acquiring unit 62 acquires, from the information terminal 11, input data indicating the defective part of the sewing object 100.

[0032] The processing unit 63 calculates the defect rate for each of a plurality of evaluation items related to sewing based on the input data acquired by the input data acquisition unit 62. The evaluation items include at least one of the product number of the sewing object 100, the sewing process, the sewing time (sewing time, sewing time zone), and the worker.

[0033] Furthermore, the processing unit 63 classifies the input data indicating the cause of the defect into a plurality of defect items based on the input data indicating the cause of the defect acquired by the input data acquiring unit 62 .

[0034] Furthermore, the processing unit 63 counts the number of defects in the same part of a plurality of sewing objects of the same design based on the input data indicating the defective parts acquired by the input data acquisition unit 62.

[0035] The output unit 64 outputs the defect rate calculated by the processing unit 63 to the display device 4. The output unit 64 outputs input data indicating the causes of defects classified by the processing unit 63 to the display device 4. The output unit 64 outputs the defective parts to the display device 4 based on the input data indicating the defective parts acquired by the input data acquisition unit 62.

[0036] [Sewing management method] Next, a sewing management method according to an embodiment will be described. As described above, in a sewing factory, a plurality of workers each sew a plurality of sewing objects 100 using a plurality of sewing machines 2. In a sewing factory, a plurality of sewing objects 100 having the same design may be sewn sequentially using the sewing machines 2. In the following description, an example will be described in which a plurality of sewing objects 100 having the same design are inspected sequentially in an inspection process. In the following description, the sewing objects 100 are assumed to be fabric for manufacturing T-shirts.

[0037] FIG. 4 is a diagram showing an information terminal 11 in an inspection process according to an embodiment. In the inspection process, an inspector uses the information terminal 11 to inspect the sewing object 100. If a defect is found in the sewing object 100, the inspector operates the input device 14 to input that a defect is found in the sewing object 100. As shown in FIG. 4, a first display screen that prompts the inspector to input the defective portion of the sewing object 100 is displayed on the display device 13 of the information terminal 11. The first display screen includes an image of the sewing object 100. The inspector operates the input device 14 to input the defective portion of the sewing object 100. The input device 14 includes a touch panel. For example, if a defect is found in the shoulder portion of the sewing object 100, the inspector taps the shoulder portion of the image of the sewing object 100 that is displayed on the display device 13.

[0038] After the defective parts of the sewing object 100 are input, the display screen of the display device 13 transitions from the first display screen for inputting the defective parts to a second display screen for inputting the cause of the defect. The inspector operates the input device 14 to input the cause of the defect of the sewing object 100. A plurality of defect items are displayed on the display device 13. As shown in FIG. 4, the display device 13 displays the characters "sewing machine" indicating the first item, "operator" indicating the second item, and "sewing object" indicating the third item.

[0039] If the inspector determines that at least one of the following is present in the shoulder portion of the sewing object 100: a skipped stitch, a broken thread, or a loose thread, the inspector determines that the cause of the defect is the sewing machine and taps "sewing machine" on the display device 13. As a result, input data indicating that the cause of the defect is the sewing machine 2 is sent from the terminal controller 12 to the management controller 6.

[0040] If the inspector determines that at least one of the following is present in the shoulder portion of the sewing object 100: meandering of a seam, absence of a seam, and deviation of a seam from the sewing object 100, the inspector determines that the cause of the defect is the worker and taps "Worker" on the display device 13. As a result, input data indicating that the cause of the defect is the worker is sent from the terminal controller 12 to the management controller 6.

[0041] When the inspector determines that at least one of scratches, color unevenness, and stains of the sewing object 100 exists in the shoulder portion of the sewing object 100, he determines that the cause of the defect is the sewing object and taps "sewing object" on the display device 13. As a result, input data indicating that the cause of the defect is the sewing object is sent from the terminal controller 12 to the management controller 6.

[0042] 5 is a flowchart showing an inspection process according to an embodiment. An inspector operates the input device 14 to input the product number of the sewing object 100 to be inspected, the sewing process through which the sewing object 100 passed, the sewing time (sewing time, sewing time period) during which the sewing object 100 was sewn, and the worker who sewed the sewing object 100. If the inspection process is carried out after the first process, the sewing process through which the sewing object 100 passed is the first process. If the inspection process is carried out after the second process or the third process, the sewing process through which the sewing object 100 passed is the second process or the third process. Input data indicating the product number, sewing process, sewing time, and worker of the sewing object 100 are transmitted from the terminal controller 12 to the management controller 6. The input data acquisition unit 62 acquires input data indicating the product number, sewing process, sewing time, and worker of the sewing object 100 (step S1).

[0043] Next, as described with reference to Fig. 4, the worker inputs the defective parts of the sewing object 100. The input data indicating the defective parts of the sewing object 100 is transmitted 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).

[0044] In the embodiment, the input data acquisition unit 62 acquires, from the input device 14, input data indicating defective portions of each of a plurality of sewing objects 100 of the same design that have been sewn by an operator using the sewing machine 2. The processing unit 63 counts the number of defects in the same portion of the plurality of sewing objects 100 based on the input data indicating the defective portions (step S3).

[0045] Next, as described with reference to Fig. 4, the worker inputs the cause of the defect of the sewing object 100. The input data indicating the cause of the defect of the sewing object 100 is transmitted from the terminal controller 12 to the management controller 6. The input data acquisition unit 62 acquires the input data indicating the cause of the defect of the sewing object 100 (step S4).

[0046] The processing unit 63 classifies the input data indicating the cause of defect into each defect item stored in the defect cause storage unit 61 (step S5).

[0047] The processing unit 63 calculates the defect rate for each of a plurality of evaluation items related to sewing based on the input data indicating the defective portions (step S6).

[0048] The output unit 64 outputs the defective locations acquired in step S2, the number of defects counted in step S3, the causes of defects classified in step S5, and the defect rate calculated in step S6 to the display device 4 (step S7).

[0049] Fig. 6 is a diagram showing an example of a display device 4 that displays defective locations and the number of defects according to an embodiment. As shown in Fig. 6, an image of the sewing object 100 is displayed on the display device 4. The output unit 64 causes the display device to display a first symbol indicating the defective location superimposed on the image of the sewing object 100. In the example shown in Fig. 6, the first symbol is a circular mark. Fig. 6 shows an example in which defective locations have been found in each of the shoulder portions, side portions, and hem portions of the sewing object 100.

[0050] Furthermore, the output unit 64 superimposes a second symbol indicating the number of defects in the same portion on the image of the sewing object 100 and displays it on the display device 4. In the example shown in Fig. 6, the second symbol is numerical data that is superimposed on the first symbol. Fig. 6 shows an example in which the number of defects in the shoulder portion of the sewing object 100 is "1", the number of defects in the side portion is "3", and the number of defects in the hem portion is "4".

[0051] 7 is a diagram showing an example of the display device 4 displaying correlation data between defect locations, causes of the defect, and evaluation items related to sewing according to the embodiment. As shown in FIG. 7, the output unit 64 causes the display device 4 to display input data indicating the cause of the defect for each of a plurality of defect items. For example, when input data indicating that the cause of the defect is the sewing machine 2 is transmitted from the terminal controller 12 to the management controller 6, the output unit 64 causes the display device 4 to display that the cause of the defect is the sewing machine 2. Also, as shown in FIG. 7, the output unit 64 causes the display device 4 to display correlation data between the defect locations, causes of the defect, and evaluation items related to sewing. As described above, the evaluation items include at least one of the product number of the sewing object 100, the sewing process, the sewing time, and the worker.

[0052] FIG. 8 is a diagram showing an example of a display device 4 that displays evaluation items and defect rates according to an embodiment. The processing unit 63 calculates the defect rate for each evaluation item related to sewing based on input data indicating defects in each of a plurality of sewing objects 100 sewn by a plurality of workers using a plurality of sewing machines 2. The output unit 64 causes the display device 4 to display the relationship between the evaluation items and the defect rate. FIG. 8 is a diagram showing the relationship between sewing time (sewing time period) and the defect rate. The output unit 64 may output the relationship between a plurality of product numbers and the defect rate for each of the plurality of product numbers, may output the relationship between a plurality of sewing processes and the defect rate for each of the plurality of sewing processes, or may output the relationship between a plurality of workers and the defect rate for each of the plurality of workers.

[0053] [effect] As described above, according to the embodiment, the sewing management system 1 includes an input data acquisition unit 62 that acquires, from the input device 14, input data indicating defective areas of each of a plurality of sewing objects 100 of the same design that have been sewn by an operator using the sewing machine 2, and an output unit 64 that superimposes a first symbol indicating the defective area on an image of the sewing object 100 and displays it on the display device 4.

[0054] According to the embodiment, after a defective portion found in the inspection process is identified by an inspector, a first symbol indicating the defective portion identified by the inspector is displayed on the display device 4 while being superimposed on the image of the sewing object 100. Since the defective portion is identified, the manager can analyze the cause of the defect in the sewing object 100 based on the identified defective portion. The defective portion in the sewing object 100 is utilized as useful data when analyzing the cause of the defect in the sewing object 100. Furthermore, since the first symbol indicating the defective portion is displayed on the display device 4 while being superimposed on the image of the sewing object 100, the manager can intuitively recognize the defective portion.

[0055] The processing unit 63 counts the number of defects in the same portion of the multiple sewing objects 100 based on the input data indicating the defective portions. This makes it easier for the manager to identify the cause of the defects. For example, if there are a large number of defects in the hem portion, there is a possibility that there is a problem with the sewing machine 2 that sews the hem portion or that there is a problem with the skill of the worker who sews the hem portion. The manager can perform maintenance on the sewing machine 2 that sews the hem portion or take measures to improve the skill of the worker who sews the hem portion. In addition, since the second symbol indicating the number of defects is displayed on the display device 4 superimposed on the image of the sewing object 100, the manager can intuitively recognize the defective portion with a large number of defects.

[0056] Since the correlation data between the defective portion and the evaluation items related to sewing is displayed on the display device 4, for example, the manager can analyze the cause of the defect in the sewing object 100 based on the correlation data.

[0057] The correlation data includes the sewing time and the worker using the sewing machine 2. This makes it easier for the manager to identify the cause of the defect. [Explanation of symbols]

[0058] 1...sewing management system, 2...sewing machine, 2A...first sewing machine, 2B...second sewing machine, 2C...third sewing machine, 3...management device, 4...display device, 5...input device, 6...management controller, 7...operation panel, 8...sewing machine controller, 11...information terminal, 12...terminal controller, 13...display device, 14...input device, 61...defect cause memory unit, input data acquisition unit 62...input data acquisition unit, 63...processing unit, 64...output unit, 100...sewing object, 1000...computer system, 1001...processor, 1002...main memory, 1003...storage, 1004...interface.

Claims

1. an input data acquisition unit that acquires, from an input device, input data indicating defect locations of each of a plurality of sewing objects of the same design sewn by an operator using a sewing machine; and an output unit that displays a first symbol indicating the defective portion on the image of the sewing object on a display device. Sewing management system.

2. a processing unit that counts the number of defects in the same portion of the plurality of sewing objects based on the input data, the output unit causes a display device to display a second symbol indicating the number of defects superimposed on the image of the sewing object. The sewing management system according to claim 1 .

3. a processing unit that generates correlation data between the defective portion and an evaluation item related to sewing, The output unit causes a display device to display the correlation data. The sewing management system according to claim 1 .

4. The correlation data includes a sewing time using the sewing machine and the worker. The sewing management system according to claim 3 .

5. acquiring, from an input device, input data indicating defect locations of each of a plurality of sewing objects of the same design sewn by an operator using a sewing machine; and displaying, on a display device, a first symbol indicating the defective portion on the image of the sewing object. Sewing management method.

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