Production control system and production control program
Patent Information
- Application Number
- JP2025084338
- Authority / Receiving Office
- JP · JP
- Patent Type
- Applications
- Current Assignee / Owner
- Filing Date
- 2025-05-20
- Publication Date
- 2025-10-16
AI Technical Summary
In food factories, label printing, inspection, and production processing are independent and manually managed processes, leading to inefficiencies and uncertain production control due to misprinted labels.
A production management system with imaging, judgment, and prohibition means to ensure accurate label inspection and production processing, integrating labeling devices, inspection devices, and a server for real-time control and communication.
Prevents misprinted label attachment and ensures efficient, reliable production by automating label inspection and production start, reducing labor and human error.
Smart Images
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Abstract
Description
[Technical Field]
[0001] The present invention relates to a production management system and a production management program. [Background technology]
[0002] In food factories that produce rice balls, sandwiches, bento boxes, prepared foods, and other foods, labels are affixed to finished packages before shipping. These labels contain a lot of information that must not be printed incorrectly, such as the product name, ingredients, allergens, and expiration date. Possible causes of printing errors include dirt on the thermal head installed in the printing unit or a broken line on the thermal head. Also, even if there is no abnormality in the printing unit, it is possible that the label loaded into the labeling device is incorrect. Therefore, it is essential to check the printed labels before they are applied. [Prior art documents] [Patent documents]
[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2009-180653 Summary of the Invention [Problem to be solved by the invention]
[0004] In the conventional method, label printing, inspection, and the start of production processing were all independent processes, which took time, and the start of each task was managed manually, resulting in inefficient and uncertain production control.
[0005] Therefore, one of the objects of the present invention is to prevent the attachment of misprinted labels and efficiently ensure the production of reliable products. [Means for solving the problem]
[0006] In order to achieve the above object, the production management system according to the present invention is characterized by comprising an imaging means for imaging an object to be inspected, a judgment means for judging whether the imaging results obtained by the imaging means are good or bad, and a prohibition means for prohibiting production processing relating to the object to be inspected based on the judgment result of the judgment means. The production management system according to the present invention can also be configured as an invention relating to a computer program having a similar configuration. The computer program can be provided by downloading it over a network such as the Internet, or by recording it on various computer-readable recording media such as a CD-ROM. [Brief explanation of the drawings]
[0007] [Figure 1] 1 is a schematic configuration diagram of a production management system according to an embodiment of the present invention, showing functional blocks of each component. FIG. [Figure 2] 2A is a schematic perspective view showing an example of a label application device provided in the production management system, and FIG. 2B is a schematic perspective view showing an example of a label inspection device provided in the production management system. [Figure 3] 3A and 3B are diagrams showing an example of a label attached by the label attachment device and a product to which the label is attached. [Figure 4] FIG. 4 is a diagram showing an example of a worksheet screen displayed on a display unit of the label inspection device. [Figure 5] FIG. 2 is a sequence diagram showing a flow in which the production management system starts production processing. [Figure 6] 10 is a flowchart showing the process in which the production management system determines whether or not production processing can be started. DETAILED DESCRIPTION OF THE INVENTION
[0008] A production management system according to an embodiment of the present invention will be described below with reference to the drawings. ●Outline of the production management system The production management system is a system that prints labels to be affixed to products and starts the label affixing process only if the printed results are appropriate. As shown in FIG. 1, the production management system 1 is configured by connecting a labeling device 10a, an inspection device 20, a vendor terminal 30, and a server 40 to one another via a network NW. The network NW may be entirely connected wirelessly, or part or all of it may be wired. Furthermore, the production management system 1 may include one or more of each component. The figure shows three labeling devices 10a, 10b, and 10c. Each of the labeling devices 10a, 10b, and 10c constitutes part of a production line and is located in a workplace where the actual production of products takes place. The labeling devices 10a, 10b, and 10c may be located on the same production line or on different production lines.
[0009] The vendor terminal 30 is a terminal, such as a personal computer, that displays the status of each component included in the production management system 1. The vendor terminal 30 is located, for example, in a management office separate from the work site, and is viewed and operated by the person in charge of the production management system 1.
[0010] The server 40 is a management device for the production management system 1, and includes an arithmetic unit such as a CPU (Central Processing Unit) for executing information processing, and a storage unit 45 such as RAM (Random Access Memory) and ROM (Read Only Memory), which stores a process management DB 41 and a label information DB 42. The process management DB 41 stores process management information for the production management system 1. The process management information is, for example, information indicating tasks such as which product is to be produced on which production line and when, and information indicating the current status of each task. Examples of information stored in the process management DB will be described later. The label information DB 42 contains information indicating the content of the label to be printed. The label information DB 42 stores at least the product identification information and the content printed on the label to be affixed to the product, in association with each other. In addition, various data serving as the reference for the object to be inspected, such as decorations pre-printed on the label paper, label shape, label affixing position, content printed on the packaging material, and product presentation, may also be stored separately from the printing process. In addition to the process management DB 41 and label information DB 42, the storage unit 45 also stores the results of inspections performed by the inspection device 20. Specifically, the storage unit 45 stores the image capture results of the inspection object and the pass / fail judgment results in association with each other. The storage unit 45 may also store the inspection conditions, such as the inspection date and time and information on the production line where the inspection is performed. The image capture results may be associated with task identification information in the process management information, and the inspection conditions may be retrieved from the process management DB 41. This configuration facilitates post-inspection at a time other than the inspection. The image capture results and judgment results that can be checked post-inspection can be used as evidence that there were no problems during production, for example, when a product that was fine when the label was issued or produced becomes soiled and a misprint or misprint is suspected during distribution, such as during delivery, retail sales, or after customer purchase.
[0011] Labeling device The labeling device 10a is a device that prints labels and affixes them to products. Products are an example of objects to be inspected. The labeling device 10a is an example of a processing device that performs product production processing. In this embodiment, the product production process progresses by printing and affixing labels, so the production processing refers to the printing and affixing of labels. Note that the production processing within the technical scope of the present invention is not limited to the printing and affixing of labels, and may refer to some or all of the processes related to product production. For example, the production processing may be the work of placing food in packaging containers or the work of packaging food.
[0012] As shown in FIG. 2(a), the label application device 10a mainly includes a conveyance table 101a, a label roll holding mechanism 102a, a feed unit 103a, a printing unit 104a, an application unit 105a, and a display unit 106a.
[0013] Conveyor table 101a is a table equipped with a conveying mechanism for conveying products. Label roll holding mechanism 102a, feed unit 103a, printing unit 104a, and application unit 105a are housed below conveyor table 101a and print labels and apply the printed labels to the bottom surfaces of the products on conveyor table 101a. Also, above conveyor table 101a, upper housing 121a supported by arm 120a is located. Inside upper housing 121a, components similar to label roll holding mechanism 102a, feed unit 103a, printing unit 104a, and application unit 105a are housed, and labels are printed and applied to the top surfaces of the products on conveyor table 101a.
[0014] The label roll holding mechanism 102a has the function of holding the label roll 100 so that it can be sent to the printing unit 104a. The label roll 100 is a roll of label paper with labels 110 (see FIG. 3) temporarily attached at regular intervals to a long, strip-shaped backing sheet. One side of the label 110 forms an adhesive surface with an adhesive material attached, and the other side forms a printing surface on which printing is performed, and the adhesive surface is removably adhered to the backing sheet.
[0015] The feed unit 103a is a roller that is driven to rotate by a motor, and pulls out label paper from the label roll 100 and sends the pulled-out label paper to the print unit 104a via a predetermined transport path.
[0016] The printing unit 104a is composed of a thermal head and a pressure roller disposed opposite the thermal head. The thermal head prints on the label 110 on the label paper fed by the feed unit 103a.
[0017] FIG. 3 shows a state in which a label 110 is affixed to a rice ball, an example of a product. The content of the label 110 printed by the printing unit 104a is not particularly limited. However, in the case of a product label for a convenience store, product data such as the product name, price, expiration date, ingredients, and a barcode are printed. The label 110 also has printed thereon product information and label printing time information indicating the time the label was printed. Furthermore, the label 110 also has printed thereon information indicating the label printing position where the label 110 was printed. The information indicating the label printing position is, for example, identification information identifying the production line within a factory. In this embodiment, the label 110 has printed thereon inspection pass / fail information 111, which includes information indicating the label printing time information and the label printing position. In this embodiment, "1111-1" is printed as the inspection pass / fail information 111. This indicates that the label was issued on the first line at 11:11.
[0018] As shown in Figure 2(a), the attachment unit 105a adheres to the printed surface of the label 100a that has been peeled off from the backing sheet, holding the label 100a, and then attaches the label 100a to the object to be attached, such as a product, by pressing the adhesive surface of the held label 100a against the object to be attached.
[0019] The display unit 106a is a device through which an operator inputs and outputs information to the label application device 10a. The display unit 106a is supported by an arm 120a that extends from the end of the conveyance table 101a. The display unit 106a is, for example, a touch panel display. The display unit 106a can input information such as what to print on the label and where to apply the label. The display unit 106a also displays the input information and the work status.
[0020] The labeling device included in the production management system according to the present invention is not limited to the above-described configuration, and may be any device that can affix labels to products.
[0021] As shown in FIG. 1, the label application device 10a includes an arithmetic unit such as a CPU (Central Processing Unit), a computer program executed by the CPU, internal memories such as RAM (Random Access Memory) and ROM (Read Only Memory), and is made up of functional blocks including an input / output unit 11a, a printing control unit 12a, an application control unit 13a, and a communication processing unit 14a.
[0022] The input / output unit 11a is a functional unit that displays information on the display unit 106a and acquires information input to the display unit 106a. The printing control unit 12a is a functional unit that controls the printing unit 104a to print on the label. The affixing control unit 13a is a functional unit that controls the affixing unit 105a to affix the label to the product. The printing control unit 12a and the affixing control unit 13a start printing and affixing based on an operation permission command received by the communication processing unit 14a.
[0023] The communication processing unit 14a is a functional unit that communicates with each component included in the production management system 1 via the network NW, and receives a signal regarding whether the printing control unit 12a or the pasting control unit 13a is operational. In this embodiment, the signal regarding whether the operation is operational is transmitted from the inspection device 20, but it may also be transmitted from the vendor terminal 30 or the server 40 and received by the communication processing unit 14a.
[0024] ●Inspection equipment The inspection device 20 captures an image of an object to be inspected, determines whether the image is acceptable, and then prohibits the labeling devices 10a, 10b, and 10c from carrying out production processing based on the determination result. The object to be inspected may be a label affixed to a product or the label itself. The object to be inspected may also be the product itself. For example, the label may be inspected for printing errors, fading, or potential misreading. Furthermore, the inspection of the label itself may inspect pre-applied decorations on the label paper, rather than the printing. Logos and illustrations of the manufacturing or selling company are pre-printed on the label, separate from the printing process. Labels may also have lines, background colors, and other features that vary from product to product. The inspection device 20 can pre-store these logos, lines, background colors, and other features to determine whether the product is acceptable. Furthermore, if the label is square, rectangular, oval, or another distinctive shape, the label shape can be stored and used for inspection. The inspection device 20 may also inspect the position of the label. Furthermore, the inspection device 20 may inspect the condition of the packaging material that encases the product. Each product has its own unique packaging material. For example, for rice balls, advertising statements such as "Made with seaweed from XX" are printed on the packaging material itself. Also, for products such as sandwiches, the product name is printed on the packaging material itself. Therefore, the inspection device 20 may inspect the printed content of these packaging materials themselves. Furthermore, the inspection of the product may also be carried out by inspecting the state of presentation of the product, for example. As shown in FIG. 2( b ), the inspection device 20 mainly includes a display unit 201 and an imaging unit 202 .
[0025] The display unit 201 is a device that displays information related to the inspection, and is, for example, a touch panel display. The display unit 201 displays the image capture results of the product. The display unit 201 also displays process control information received from the server 40 via the communication processing unit 25 (see FIG. 1). Specific content displayed on the display unit 201 will be described later.
[0026] The image capturing unit 202 is a device that captures an image of an object to be inspected, such as a camera. In this embodiment, the light receiving unit faces downward.
[0027] The inspection device included in the production management system according to the present invention is not limited to the above-described configuration, and may be any device that inspects an object to be inspected.
[0028] As shown in FIG. 1, the inspection device 20 includes an arithmetic unit such as a CPU (Central Processing Unit), a computer program executed by the CPU, internal memories such as a RAM (Random Access Memory) and a ROM (Read Only Memory), and is made up of functional blocks including an input / output unit 21, an imaging control unit 22, a judgment unit 23, a prohibition unit 24, and a communication processing unit 25.
[0029] The input / output unit 21 is a functional unit that displays information on the display unit 201 and acquires information input to the display unit 201. The input / output unit 21 acquires information stored in the process management DB from the server 40 via the network NW, and causes the display unit 201 to display some or all of the information.
[0030] 4 shows an example of a worksheet screen displayed on the display unit 201. As shown in the figure, the display unit 201 displays a process management table 202a and operation buttons 202b such as "barcode," "update," and "close." The process management table 202a displays the production line for each task performed on the production line, the delivery of the produced product, the product number and name, and the production processing status of each task. The production line information corresponds to information about the location where the product is produced, and the delivery information corresponds to information about the time when the product is produced.
[0031] The status of each task includes information that allows a worker to determine whether work is required, and tasks that require work are shown shaded in the process management table 202a. In this embodiment, tasks that require work are "Waiting to print," "Waiting to replace," and "Finished." "Waiting to print" is the state of waiting for label inspection at the start of printing. "Waiting to replace" is the state of waiting for label inspection after the label roll has been replaced. "Finished" is the state of waiting for label inspection at the end of printing. Tasks that do not require work are "Printing" and "Completed." "Printing" is the state in which the label is currently being printed. "Completed" is the state in which inspection at the end of printing has finished and all processes for the task have been completed.
[0032] As shown in FIG. 1, the imaging control unit 22 is a functional unit that controls the imaging unit 202 to capture an image of an object to be inspected.
[0033] The judgment unit 23 is a functional unit that inspects the inspection object based on the data acquired by the imaging unit 202 and judges whether the imaging result is good or bad. The judgment unit 23 judges whether there is a risk of misprinting, faded printing, or misreading of the content of the label 110 (see FIG. 3).
[0034] The determination unit 23 also reads the inspection suitability information 111 to obtain information on when and where the label 110 was printed and determines whether the label 110 is suitable for inspection. Specifically, the determination unit 23 determines whether the label 110 is suitable for inspection based on the label printing time information. For example, the determination unit 23 obtains the inspection request time from the process management DB stored in the server 40. For example, if the printing time included in the label printing time information is before the inspection request time, the label was not printed based on the inspection request. In such a case, the determination unit 23 determines that the label 110 is unsuitable for inspection and that the inspection result is problematic. For example, if label inspection is performed at the end of production processing on the production line and the printing time included in the label printing time information is before the printing time of the label related to the first inspection performed on the production line, the label was not printed at the end of production processing. In such a case, the determination unit 23 also determines that the label 110 is unsuitable for inspection and that the inspection result is problematic.
[0035] Furthermore, the determination unit 23 determines whether the label is good or bad based on the information indicating the label printing position. The determination unit 23 acquires the production line to be inspected from the process management DB. If the production line to be inspected does not match the production line included in the information indicating the label printing position, the determination unit 23 determines that the label is unsuitable for inspection and that there is a problem with the inspection result.
[0036] Label inspection is typically performed at the start and end of printing, and during the first print run after a label roll replacement if it is replaced during printing. If the labels themselves do not contain label printing time information, workers can skip the inspection process by printing multiple labels at the start of printing and reusing those labels at the end of printing or for the first print run after a replacement. Label inspection is also performed for each production line, but if the same product is produced on different production lines, reusing labels printed on other production lines can lead to laziness by skipping inspection printing for that production line. A configuration in which the judgment unit 23 determines the quality of the inspection results based on label printing time information printed on the labels can identify laziness by using labels printed at different times for inspection, thereby improving inspection accuracy. A configuration in which the judgment unit 23 determines the quality of the inspection results based on information indicating the label printing position printed on the labels can identify laziness by using labels printed on different production lines for inspection, thereby improving inspection accuracy.
[0037] The prohibition unit 24 is a functional unit that prohibits production processing by the labeling apparatuses 10a, 10b, and 10c included in the production line being inspected when the judgment unit 23 judges that there is a problem with the inspection results. The prohibition unit 24 transmits a command prohibiting the production processing to the labeling apparatuses 10a, 10b, and 10c via the network NW. The prohibition unit 24 may also transmit a message to the labeling apparatuses 10a, 10b, and 10c, the inspection device 20, and the vendor terminal 30 that the production processing is prohibited and the reason for the prohibition, and display the message on each input / output unit or display unit. When the judgment unit 23 judges that there is no problem with the inspection results, the prohibition unit 24 transmits a command permitting the production processing to the labeling apparatuses 10a, 10b, and 10c via the network NW.
[0038] In this embodiment, the judgment unit 23 and the prohibition unit 24 are included in the inspection device 20, but these functions may be included in the label application devices 10a, 10b, and 10c, the vendor terminal 30, or the server 40. In addition, although the storage unit 45 is included in the server 40, these functions may be included in the label application devices 10a, 10b, and 10c, the inspection device 20, or the vendor terminal 30.
[0039] ● Flow to start production processing Using Figure 5, the flow of when the production management system 1 starts production processing will be explained. Note that the solid arrows in the figure indicate the flow of information within the system, and the dashed arrows indicate the flow of work by workers. As shown in the figure, first, the inspection device 20 requests process control information from the server 40 (step S1). The server 40 transmits the process control information stored in the process control DB to the inspection device 20 (step S2). Based on the process control information, the inspection device 20 displays a request for label inspection together with information about the production line that requires inspection (step S3). Based on the request, the worker operates the label application device 10a and prints a label for inspection (step S4).
[0040] The operator places a label below the imaging unit 202 of the inspection device 20 and instructs the inspection device 20 to start inspection. The inspection device 20 captures an image of the label using the imaging unit 202 (step S5). The inspection device 20 requests information from the label information DB along with information about the production line to be inspected from the server 40 (step S6), and the server 40 transmits the label information based on the information about the production line to be inspected (step S7). Next, the judgment unit 23 judges whether the imaging result is acceptable based on the imaging result and the label information (step S8). If there is no problem with the imaging result, it transmits a command to the label application device 10a to permit production processing (step S9). Upon receiving the command to permit production processing, the label application device 10a starts production processing (step S10).
[0041] Based on the inspection results, the inspection device 20 transmits change information for the process management information and a request to edit the process management DB to the server 40 (step S11). The change information for the process management information is, for example, information about the "status" of the task. If there are no problems with the inspection results, the status of the task is changed and the task proceeds to the next status. The server 40 updates the process management DB based on the change information (step S12).
[0042] ● Flow to determine whether production processing can be started or not Using Figure 6, the flow in which the production management system 1 determines whether or not production processing can be started will be described. First, the inspection device 20 takes an image of the inspection object (step S101). Next, the determination unit 23 determines whether the image capture result is appropriate (step S102). If the image capture result is appropriate, the inspection device 20 sends a command to the label application device 10a to permit production processing (step S103). Next, the label application device 10a starts production processing (step S104).
[0043] If it is determined in step S102 that the imaging result is inappropriate, the determination unit 23 sends a command to the label application device 10a to prohibit production (step S105), and notifies the device 10a of this via the display unit 106a, the display unit 201, the vendor terminal 30, etc. (step S106).
[0044] The display unit 106a or the display unit 201 displays the imaging results and whether the judgment result is OK or NG. Furthermore, the display unit 106a or the display unit 201 may also display information such as the need to replace the label roll. Therefore, each display unit 106a, 201 can output the status of the production line, allowing workers to easily grasp the situation wherever they are and take appropriate measures.
[0045] Conventionally, label printing and application devices are located in production line work areas, while label inspection devices that check labels are located in administrative offices. Workers transport printed labels to the administrative office for inspection, receive instructions to start work, and then return to the office to instruct the label application device to start production processing. In contrast, the production management system 1 according to the present invention allows the inspection device 20 to be installed in the work area and transmits the approval or disapproval of production processing to the label application devices 10a, 10b, and 10c connected via the network NW. This eliminates the need for workers to issue instructions to start production processing, thereby saving labor and reducing human error. Furthermore, the administrative office can also monitor the inspection status using the vendor terminal 30.
[0046] According to the production management system 1 according to the present embodiment, it is possible to prevent affixing of erroneously printed labels and efficiently ensure accurate production of products.
[0047] ● Overview of implementation The present invention relates to a production management system.
[0048] In food factories that produce rice balls, sandwiches, bento boxes, prepared foods, and other foods, labels are affixed to finished packages before shipping. These labels contain a lot of information that must not be printed incorrectly, such as the product name, ingredients, allergens, and expiration date. Possible causes of printing errors include dirt on the thermal head installed in the printing unit or a broken line on the thermal head. Also, even if there is no abnormality in the printing unit, it is possible that the label loaded into the labeling device is incorrect. Therefore, it is essential to check the printed labels before they are applied.
[0049] In the conventional method, label printing, inspection, and the start of production processing were all independent processes, which took time, and the start of each task was managed manually, resulting in inefficient and uncertain production control.
[0050] For example, Japanese Patent Application Laid-Open No. 2009-180653 is a prior art document.
[0051] Therefore, one of the objects of the present invention is to prevent the attachment of misprinted labels and efficiently ensure the production of reliable products.
[0052] In order to achieve the above object, the production management system according to the present invention is characterized by comprising an imaging means for imaging an object to be inspected, a judgment means for judging whether the imaging results obtained by the imaging means are good or bad, and a prohibition means for prohibiting production processing relating to the object to be inspected based on the judgment result of the judgment means.
[0053] The apparatus may further comprise a display means for displaying the status of the production process.
[0054] The object to be inspected may be a label affixed to a product, and the device may include a printing means for printing product information and label printing time information indicating the time the label was printed on the label, and the judgment means may judge whether the imaging result is good or bad based on the label printing time information.
[0055] The printing means may print, on the label, information indicating a label printing position at which the label is printed, and the determination means may print, on the label, information indicating the label printing position.
[0056] In order to achieve the above object, a production management system according to another aspect of the present invention executes, by a computer, an imaging command to image an object to be inspected, a judgment command to judge whether the imaging results obtained by the imaging command are good or bad, and a prohibition command to prohibit production processing related to the object to be inspected based on the judgment result of the judgment command.
[0057] According to the present invention, it is possible to prevent the attachment of erroneously printed labels and efficiently ensure accurate production of products. [Explanation of symbols]
[0058] 1 Production management system 10a Labeling device 104a Print section 12a Printing control unit 13a Pasting control section 20 Inspection equipment 201 Display section 202 Imaging unit 23 Judgment Department 24 Prohibited part
Claims
1. A production management system including a labeling device that affixes a label to a product and an imaging device that captures an image of the label. A stem, a printing means for printing label printing time information indicating the printing time on the label; an imaging means for imaging the label printing time information; a display means for displaying a list of products for which the label printing time information should be captured, The display means The products that have been photographed by the imaging means are displayed in a manner that distinguishes between the products that have not yet been photographed. A production management system characterized by:
2. The display means The printing state of each product in the list display is displayed in a manner that distinguishes between the state before printing and the state after printing. The production management system according to claim 1.
3. The display means The printing status of each product in the list display is displayed in a manner that indicates that the printing device has replaced the label roll.
3. The production management system according to claim 1 or 2.
4. Label printing time information indicating the printing time is printed on the label attached to the product by the attaching device. Printing instructions and an imaging command for an imaging device that images the label to capture the label printing time information; a display command for displaying a list of products for which the label printing time information should be captured; is executed by a computer, The display command: and displaying the products whose images have been captured in accordance with the image capturing command in a manner that distinguishes between the products whose images have not been captured and the products whose images have not been captured. A production management program characterized by: