Material management system, material management method, and program

Abstract

To manage an inventory of a plurality of materials stored in a material storage area.SOLUTION: Each coil is taken from a coil yard to a blanking press machine, a plurality of products is manufactured from the coils using the blanking press machine, and if the coils are not used up, the coils are returned to the coil yard. A management system 1 acquires inspection information indicating a quality and location of materials received in the coil yard. The management system 1 acquires a coil ID indicating a coil take from the coil yard to the blanking press machine. The management system 1 acquires material return information indicating a consumption quantity and location of the coils returned from the blanking press machine to the coil yard. The management system 1 updates a management DB 14 based on the inspection information, the coil ID, and the material return information, and outputs a remaining quantity and location for each coil stored in the coil yard to a touch panel display 3e of a mobile terminal 3 as needed.SELECTED DRAWING: Figure 13

Description

[Technical field]

[0001] The present invention relates to a material management system, a material management method, and a program. [Background technology]

[0002] Patent Document 1 discloses a product replenishment system that monitors the inflow and outflow of products in each area of ​​a stockyard and each location of a picking shelf, so that workers can efficiently replenish products from a stockyard to a picking shelf, and when the inventory quantity of a product on a picking shelf decreases, displays the area in which that product is stored on a display installed on the picking shelf. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2007-119158 A Summary of the Invention [Problem to be solved by the invention]

[0004] For example, when producing a specified amount of products by blanking from a metal coil, it is rare that the planned production volume matches the production volume that can be produced from a single coil, and coils taken out of the coil yard may be returned to the coil yard after use.

[0005] The configuration of Patent Document 1 does not assume that the coils taken out of the coil yard in this manner would be returned to the coil yard after consumption, and it was not possible to grasp the actual stock of coils in the coil yard.

[0006] The object of the present invention is to provide a technology for managing the inventory of multiple materials stored in a material storage area, with the premise that each material is taken from the material storage area to a material processing device, the material is used to manufacture multiple products from the material, and if the material cannot be used up, the material is returned to the material storage area. [Means for solving the problem]

[0007] According to a first aspect of the present invention, there is provided a material management system comprising a processor and a memory having a program stored therein, which manages a plurality of materials stored in a material storage area, wherein each material is taken out from the material storage area to a material processing device, and a plurality of products are manufactured from the material using the material processing device, and if the material is not used up, the material is returned to the material storage area, and the processor executes the program to obtain material arrival information indicating the amount and storage location of material that has arrived at the material storage area, obtain material take-out information indicating the material that has been taken out from the material storage area to the material processing device, obtain material return information indicating the consumption amount and storage location of material returned from the material processing device to the material storage area, and output the remaining amount and storage location of each material stored in the material storage area based on the material arrival information, material take-out information, and material return information. Obtaining the material return information includes obtaining usage history information indicating a usage history of the material, and calculating a consumption amount of the material based on the usage history information. Obtaining the material return information includes obtaining production plan information for manufacturing the plurality of products, and calculating a consumption amount of the material based on the production plan information. The storage area is a space for temporarily storing only one of the materials. The material is a metal coil and the material processing device is a blanking press. According to a second aspect of the present invention, there is provided a material management method for managing a plurality of materials stored in a material storage site, which comprises taking each material from the material storage site to a material processing device, using the material processing device to manufacture a plurality of products from the material, and returning the material to the material storage site if the material is not used up, and which obtains material arrival information indicating the amount and storage location of the material arrived at the material storage site, obtains material take-out information indicating the material taken out from the material storage site to the material processing device, obtains material return information indicating the consumption amount and storage location of the material returned from the material processing device to the material storage site, and outputs the remaining amount and storage location of each material stored in the material storage site based on the material arrival information, material take-out information, and material return information. A program is provided that causes a computer to execute the above method. Effect of the Invention

[0008] According to the present invention, it is possible to manage the inventory of multiple materials stored in a material storage area, with each material being taken out from the material storage area to a material processing device, and multiple products being manufactured from the material using the material processing device, and if the material is not used up, the material being returned to the material storage area. [Brief description of the drawings]

[0009] [Figure 1] FIG. 2 is a functional block diagram of a management system. [Diagram 2] FIG. 13 is a diagram showing data contents of an order DB. [Diagram 3] FIG. 13 is a diagram showing data contents of a management DB. [Figure 4] FIG. 13 is a diagram showing data contents of a manufacturing plan DB. [Diagram 5] FIG. 2 is a functional block diagram of a mobile terminal. [Figure 6] 1 is a control flow of a management system. [Figure 7] FIG. 13 is a diagram showing a specific example of an inspection data input screen. [Figure 8]FIG. 13 is a diagram showing a specific example of a coil storage location input screen. [Figure 9] FIG. 13 is a diagram showing a specific example of a coil selection screen. [Figure 10] FIG. 13 is a diagram showing a specific example of a coil transport command screen. [Figure 11] FIG. 13 is a diagram showing a specific example of a coil transport command screen. [Figure 12] FIG. 13 is a diagram showing a specific example of a coil storage location input screen. [Figure 13] FIG. 13 is a diagram showing data contents of a management DB. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0010] Hereinafter, an embodiment of the present invention will be described with reference to FIGS.

[0011] Fig. 1 shows a management system 1 (material management system) that manages an inventory of multiple coils stored in a coil yard. The management system 1 includes a management device 2 and a mobile terminal 3. Although one mobile terminal 3 is depicted in Fig. 1, the management system 1 may include multiple mobile terminals 3. The management device 2 may be realized by distributed processing using multiple devices. The management device 2 and the mobile terminal 3 are capable of two-way communication via a LAN (Local Area Network).

[0012] The coil is a specific example of the material. The material is not limited to the coil, and may be a metal bar. In this embodiment, a plurality of products are taken out of the coil by blanking. Blanking is a processing method in which a blanking press is used to punch out a number of products having a predetermined outer shape from the coil.

[0013] A coil yard is a specific example of a material storage area that stores multiple coils. The coil yard is attached to a blanking press machine that is used for the blanking. Typically, the coil yard can store about 10 to 100 coils at the same time.

[0014] The management device 2 includes a CPU 2a (Central Processing Unit) as a central processing unit, a read / write RAM 2b (Random Access Memory), and a read-only ROM 2c (Read Only Memory). The management device 2 further includes a communication interface 2d for communicating with a mobile terminal 3. The CPU 2a reads and executes a control program stored in the ROM 2c, so that the control program causes hardware such as the CPU 2a to function as an incoming processing unit 10 and a processing unit 12. The management device 2 further includes an order DB 13, a management DB 14, and a manufacturing plan DB 15. The order DB 13, the management DB 14, and the manufacturing plan DB 15 are typically stored in a storage device such as a HDD.

[0015] As shown in FIG. 2, the order DB 13 is a database that associates an order number with a steel type, a coil outer diameter, a coil inner diameter, a coil sheet width, a coil sheet thickness, and a coil weight.

[0016] As shown in FIG. 3, the management DB 14 is a database that associates the coil ID with the steel type, arrival date, outer diameter, inner diameter, plate width, plate thickness, weight at arrival, remaining amount, storage location, and usage history. The coil ID identifies the coil stored in the coil yard. The measured value of the outer diameter means the outer diameter measured at the time of inspection of the coil. The same applies to the measured value of the inner diameter, etc. The weight at arrival means the weight at the time of inspection of the coil. The remaining amount means the current weight of the coil. The storage location means the storage location of the coil in the coil yard. Only one coil can be temporarily stored in one storage location. In other words, two or more coils cannot be temporarily stored in one storage location. However, it may be possible to temporarily store two or more coils in one storage location. The usage history means the usage history from the time of arrival of the coil. The usage history typically consists of the date of use, the name of the manufactured product, the number manufactured, and the consumption amount.

[0017] As shown in FIG. 4, the manufacturing plan DB 15 is a database that associates date and time with product names, product weights, quantities, steel types, and plate thicknesses.

[0018] The receiving processing unit 10 executes receiving processing of coils on the management device 2 side.

[0019] The processing unit 12 carries out the processes on the management device 2 side among the series of processes related to processing, which includes taking the material from the coil yard to a blanking press machine, using the blanking press machine to manufacture multiple products from the material, and returning the material to the coil yard if the material cannot be used up.

[0020] Fig. 5 shows a functional block diagram of the mobile terminal 3. As shown in Fig. 5, the mobile terminal 3 includes a CPU 3a (Central Processing Unit) as a central processing unit, a readable and writable RAM 3b (Random Access Memory), and a read-only ROM 3c (Read Only Memory). The mobile terminal 3 further includes a communication interface 3d for communicating with the management device 2, and a touch panel display 3e. The CPU 3a reads and executes a control program stored in the ROM 3c, so that the control program causes hardware such as the CPU 3a to function as an incoming processing unit 20 and a processing unit 21.

[0021] The arrival processing unit 20 executes arrival processing of coils on the mobile terminal 3 side.

[0022] The processing unit 21 carries out the processes on the mobile terminal 3 side among the series of processes related to processing, which includes taking the material from the coil yard to a blanking press machine, using the blanking press machine to manufacture multiple products from the material, and returning the material to the coil yard if the material cannot be used up.

[0023] Fig. 6 shows the flow of the management system 1. Hereinafter, the flow of the management system 1 will be described with reference to Fig. 6 etc. As shown in Fig. 6, the flow of the management system 1 mainly includes an inspection step S100 and a processing step S200.

[0024] (Inspection step S100) First, we will explain the flow when coils arrive at the coil yard. A label with a QR code (registered trademark) is attached to the coils that arrive. The information stored in the QR code includes the order number of the coil.

[0025] When a coil arrives at the coil yard, an inspector uses the mobile terminal 3 to read the QR code of the coil (S110). The mobile terminal 3 then transmits order number information for the coil (hereinafter also referred to as the coil to be inspected) to the management device 2 (S120).

[0026] When the receiving processing unit 10 of the management device 2 receives the above-mentioned order number information from the mobile terminal 3, it assigns a coil ID to the coil to be inspected and obtains the order information of the coil to be inspected by referring to the order DB 13 shown in FIG. 2, and transmits the coil ID and the order information to the mobile terminal 3 (S130).

[0027] As shown in Fig. 7, the receiving processing unit 20 of the mobile terminal 3 outputs an inspection input screen d1 to the touch panel display 3e. The inspection input screen d1 displays preset values ​​such as the outer diameter of the coil to be inspected. The inspector measures the outer diameter, etc. of the received coil and inputs the measurement results into the inspection input screen d1 (S140). When this input is complete, the receiving processing unit 20 of the mobile terminal 3 displays a coil yard layout screen d2 on the touch panel display 3e as shown in Fig. 8. The inspector uses the layout screen d2 to input the location of the coil to be inspected (S150). a1 to h4 indicate the locations of the coils.

[0028] At this time, the receiving processing unit 10 of the management device 2 may refer to the management DB 14 and provide the mobile terminal 3 with information regarding the locations where coils are already placed, so that locations where the coil to be inspected cannot be placed are displayed in gray on the layout screen d2 shown in Fig. 8. Here, it is assumed that the inspector has temporarily placed the coil to be inspected in location c7. Here, "temporarily placed" means that the coil is temporarily placed in a location, and does not mean that the coil is installed in that location.

[0029] When the inspector selects a storage location for the coil to be inspected, the receiving processing unit 20 of the mobile terminal 3 transmits inspection information including the inspection data and storage location information for the coil to be inspected to the management device 2 (S160). The receiving processing unit 10 of the management device 2 adds data related to the coil to be inspected to the management DB 14 (S170). The remaining amount of the coil added at this time is the measured weight at the time of arrival itself. In Fig. 3, the coil with the coil ID No. 12115 corresponds to the coil that has just arrived.

[0030] (Processing step S200) Next, a flow for manufacturing a plurality of products using one or more coils stored in the coil yard will be described.

[0031] First, the processing unit 21 of the mobile terminal 3 displays the layout screen d3 on the touch panel display 3e as shown in FIG. 9. At this time, the processing unit 21 of the mobile terminal 3 acquires manufacturing plan information to be executed from the manufacturing plan DB 15, and searches the management DB 14 for a coil that matches the manufacturing plan. Then, the processing unit 21 of the mobile terminal 3 highlights the storage area where the coil hit as a result of the search is temporarily stored. For example, when a coil whose steel type is SUS4 and whose plate thickness is 3 mm is used in the manufacturing plan, the coil temporarily stored in the storage areas a5-a7, b6, and b7 is hit during the above search. Therefore, in this case, as shown in FIG. 9, the processing unit 21 of the mobile terminal 3 highlights the storage areas a5-a7, b6, and b7. The processing worker selects the coil to be used by tapping any of the storage areas a5-a7, b6, and b7 on the touch panel display 3e (S210). Then, the processor 21 of the mobile terminal 3 transmits the coil ID of the selected coil to the management device 2 (S220).

[0032] The processing unit 12 of the management device 2 refers to the management DB 14 and determines whether the amount of the coil corresponding to the coil ID is sufficient (S230). Specifically, the processing unit 12 obtains the weight of the product to be manufactured by the blanking to be executed and the number of manufactured products from the manufacturing plan DB 15, and calculates the required weight of the coil by multiplying them together. Then, if the amount of the coil selected by the processing worker exceeds the required weight, the processing unit 12 of the management device 2 determines that the amount of the coil selected by the processing worker is sufficient (S230: YES). If the amount of the coil selected by the processing worker is below the required weight (S230: NO), the processing unit 12 of the management device 2 transmits an additional selection command to the mobile terminal 3 (S235). Then, if the total value of the amounts of the multiple coils selected by the processing worker exceeds the required weight, the processing unit 12 of the management device 2 determines that the total value of the amounts of the multiple coils selected by the processing worker is sufficient (S230: YES).

[0033] In addition, since a processing worker typically preferentially selects a coil with an older arrival date, the processing unit 12 of the management device 2 may automatically select one or more coils in ascending order of arrival date based on the arrival date information in the management DB 14.

[0034] The processing unit 12 of the management device 2 also determines whether the selected coil or coils will be used up in the blanking to be executed (S240), and if not (S240: NO), calculates the remaining amount of the coil to be used last (S250). The remaining amount of the coil can be calculated by subtracting the required weight from the total amount of the selected coil or coils.

[0035] When the processor 21 of the mobile terminal 3 receives an additional selection command from the management device 2 (S235), it continues to display the coil yard layout screen d3 and receives coil selection by the processor (S210).

[0036] Thereafter, the processing unit 12 of the management device 2 transmits a transport command to the mobile terminal 3 (S260). The transport command is a command to instruct a processing worker to transport the coils temporarily placed in the storage areas a5 and a6 to the blanking press device in order as shown in Figs. 10 and 11.

[0037] A hoist or a crane is used to transport the coil to be processed from the coil yard to a coil car attached to the uncoiler of the blanking press device. When the coil is transported by a crane, the coil cannot be seen up close, but since the specific location of the coil to be transported is specified, the coil to be transported can be identified from a distance.

[0038] When the blanking is completed (S270: YES), the processing unit 12 of the management device 2 transmits a place selection command to the mobile terminal 3 (S280). As shown in FIG. 12, the mobile terminal 3 outputs a layout screen d4 of the coil yard on the touch panel display 3e. The processing worker returns the last used coil to the desired place in the coil yard and selects the place where the coil was temporarily placed on the layout screen d4 (S290). The processing unit 21 of the mobile terminal 3 transmits the place information of the coil to the management device 2 (S300). The processing unit 12 of the management device 2 updates the management DB 14 using the place information received from the mobile terminal 3 and the remaining amount of the coil calculated in advance (S310). FIG. 13 shows the management DB 14 after the update. 13, the coil with coil ID No. 12108 was used up during the current blanking, so the remaining amount of that coil is zero, the location is left blank, and "completely consumed" is entered in the usage history field. On the other hand, the coil with coil ID No. 12109 was not used up during the current blanking, so the processor 12 of the management device 2 enters a new location indicated by the location information received from the mobile terminal 3 into the location field, and enters the remaining amount calculated in advance into the remaining amount field. The processor 12 of the management device 2 also enters the processing date, product name, manufactured quantity, and consumption amount into the usage history of that coil.

[0039] As shown in Figure 13, the coil with the coil ID No. 12109 has been returned to location a6, but it may be returned to location d9, for example, which is closer to the blanking press. One advantage of the free location system is that the location for temporarily storing the coil can be freely decided each time.

[0040] The processing unit 12 of the mobile terminal 3 can output the data contents of the management DB 14 to the touch panel display 3e of the mobile terminal 3 by acquiring the management DB 14 from the management device 2 at any time. Therefore, the processing worker can easily check the presence or absence of coils in each storage area and obtain information about the coils temporarily stored in each storage area, typically the remaining amount of coils and their usage history. In addition, the processing worker can check the data contents of the order DB 13 output to the touch panel display 3e to confirm the number of coils for each steel type and the amount (remaining amount) of each coil.

[0041] The preferred embodiment of the present invention has been described above, and the above embodiment has the following features.

[0042] The management system 1 manages the inventory of multiple coils (materials) stored in a coil yard (material storage area). Each coil is taken out from the coil yard to a blanking press (material processing device), and multiple products are manufactured from the coil using the blanking press. If the coil is not used up, the coil is returned to the coil yard. The management system 1 acquires inspection information (material arrival information) indicating the amount of material that has arrived at the coil yard and the storage location (S160). The management system 1 acquires a coil ID (material take-out information) indicating the coil that has been taken out from the oil yard to the blanking press (S220). The management system 1 acquires material return information indicating the consumption amount and storage location of the coil that has been returned from the blanking press to the coil yard (S250, S300). The management system 1 updates the management DB 14 based on the inspection information, coil ID, and material return information, and outputs the remaining amount and storage location of each coil stored in the coil yard to the touch panel display 3e of the mobile terminal 3 as needed. According to the above configuration, it is possible to manage the inventory of multiple coils stored in the coil yard.

[0043] When obtaining the material return information (S250), usage history information indicating the usage history of the material may be obtained from the management DB 14, and the consumption amount of the material may be calculated based on the usage history information. The current remaining amount of the coil can be calculated by subtracting the consumption amount from the weight of the coil when it arrived. If multiple uses are recorded in the usage history, the current remaining amount of the coil can be calculated by subtracting the total consumption amount over multiple uses from the weight of the coil when it arrived.

[0044] When obtaining the material return information (S250), production plan information for producing a plurality of products may be obtained from the production plan DB 15, and the consumption amount of the material may be calculated based on the production plan information.

[0045] Also, the remaining amount of the material may be measured each time using a weighing scale.

[0046] In the above embodiment, the processing worker acquires information about the coil using the mobile terminal 3, but a stationary personal computer may be used instead of the mobile terminal 3.

[0047] In addition, although it was stated that inspection of incoming coils is to be performed by inspectors, if the coil is received with its outer diameter, etc., already measured, and the measurement results are included in the information held by the QR code, inspection by inspectors may be omitted. [Explanation of symbols]

[0048] 1 Management System 2 Management device 2d Communication Interface 3. Mobile devices 3d communication interface 3e Touch panel display 10 Receiving Processing Section 12 Processing section 13 Order DB 14 Management DB 15 Manufacturing planning database 20 Receiving Processing Section 21 Processing section

Claims

1. A processor; A memory for storing a program; Equipped with A material management system for managing a plurality of materials stored in a material storage facility, Each material is taken out from the material storage area to a material processing device, and a plurality of products are manufactured from the material using the material processing device. If the material is not used up, the material is returned to the material storage area. The processor executes the program, Acquire material arrival information indicating the amount and location of the material that has arrived at the material storage facility; acquiring material removal information indicating materials removed from the material storage site to the material processing device; acquiring material return information indicating the consumption amount and storage location of the material returned from the material processing device to the material storage site; outputting the remaining amount and the storage location of each material stored in the material storage area based on the material arrival information, the material take-out information, and the material return information; the material is a coil; By referring to a management database in which materials, steel types, plate thicknesses, and storage locations are associated, a material whose steel type and plate thickness match the manufacturing plan is searched for, and a layout screen of the material storage location is displayed, and a plurality of storage locations in which the plurality of materials found as a result of the search are temporarily stored are highlighted on the layout screen. If the amount of the material selected by the processing worker among the plurality of materials exceeds the required weight calculated based on the production plan, it is determined that the amount of the material selected by the processing worker is sufficient; if the amount of the material selected by the processing worker from among the plurality of materials is less than the required weight, requesting the processing worker to select an additional material; Material management system.

2. The obtaining of the material return information includes: Obtaining usage history information indicating the usage history of the material; calculating a consumption amount of the material based on the usage history information; The material management system of claim 1 .

3. The obtaining of the material return information includes: Acquire manufacturing plan information for manufacturing the plurality of products; calculating a consumption amount of the material based on the manufacturing plan information; The material management system of claim 1 .

4. The storage area is a space for temporarily storing only one of the materials, A material management system according to any one of claims 1 to 3.

5. the material is a metal coil; The material processing device is a blanking press. A material management system according to any one of claims 1 to 4.

6. A material management method for managing a plurality of materials stored in a material storage facility, comprising: Each material is taken out from the material storage area to a material processing device, and a plurality of products are manufactured from the material using the material processing device. If the material is not used up, the material is returned to the material storage area. Acquire material arrival information indicating the amount and location of the material that has arrived at the material storage facility; acquiring material removal information indicating materials removed from the material storage site to the material processing device; acquiring material return information indicating the consumption amount and storage location of the material returned from the material processing device to the material storage site; outputting the remaining amount and the storage location of each material stored in the material storage area based on the material arrival information, the material take-out information, and the material return information; the material is a coil; By referring to a management database in which materials, steel types, plate thicknesses, and storage locations are associated, a material whose steel type and plate thickness match the manufacturing plan is searched for, and a layout screen of the material storage location is displayed, and a plurality of storage locations in which the plurality of materials found as a result of the search are temporarily stored are highlighted on the layout screen. If the amount of the material selected by the processing worker among the plurality of materials exceeds the required weight calculated based on the production plan, it is determined that the amount of the material selected by the processing worker is sufficient; if the amount of the material selected by the processing worker from among the plurality of materials is less than the required weight, requesting the processing worker to select an additional material; Material management methods.

7. A program causing a computer to execute the method according to claim 6.

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