Production System

Abstract

To provide, according to the present invention, a production system capable of easily referring to a video relating to a particular action or operation of a device.SOLUTION: A production system 10 includes a log creating unit 51a, a video creating unit 51b, a recording unit 51c and a control unit 51d. The log creating unit 51a creates at least one of log information relating to the action of a device 20 that executes a process or log information relating to the operation by a worker who operates the device 20. The video creating unit 51b creates at least one of video data on the action of the device 20 or video data on the operation by the worker. The recording unit 51c records the log information created by the log creating unit 51a and the video data created by the video creating unit 51b in association with each other. The control unit 51d controls the recording unit 51c. The control unit 51d records the video data in a time slot with reference to such log information in association with the log information in the recording unit 51c.SELECTED DRAWING: Figure 5

Description

[Technical field]

[0001] The present invention relates to a production system that performs at least one of weighing, packaging, inspection, and boxing of food products. [Background technology]

[0002] Conventionally, systems have been used that automatically record images of the state in which equipment is operating and the state in which a worker is operating the equipment, for the purpose of analyzing the cause of an error, etc. For example, Patent Document 1 (JP Patent Publication 2003-150230 A) discloses a system that captures images of the state in which a worker operates equipment during product assembly work, and enables the contents of multiple work processes to be confirmed through a series of images. Summary of the Invention [Problem to be solved by the invention]

[0003] However, in conventional systems, video of the operation of equipment and the operation of equipment by workers is stored linked to the date and time when the video was recorded, and when referencing past video, it is necessary to search for the video based on the date and time. Therefore, even when referring to video of the time when a specific operation such as an error occurred in the equipment or when a worker performed a specific operation such as restoring the status, it is necessary to specify the date and time when referring to the video.

[0004] An object of the present invention is to provide a production system that can easily refer to an image related to a specific operation or manipulation of a device. [Means for solving the problem]

[0005] A production system according to a first aspect of the present invention is a system that performs at least one of weighing, packaging, inspection, and boxing of food. The production system includes a log generation unit, a video generation unit, a recording unit, and a control unit. The log generation unit generates at least one of log information related to the operation of the equipment performing the processing and log information related to the operation of the worker operating the equipment. The video generation unit generates at least one of video data of the equipment operation and video data of the worker operation. The recording unit records the log information generated by the log generation unit and the video data generated by the video generation unit in association with each other. The control unit controls the recording unit. The control unit causes the recording unit to record the video data for a time period based on the log information in association with the log information.

[0006] This production system uses log information related to the operation of equipment or the operations of workers to easily refer to images related to specific operations or operations of equipment.

[0007] A production system according to a second aspect of the present invention is the production system according to the first aspect, wherein the base point is the point at which the operation of the equipment starts or ends when the log generation unit generates log information regarding the operation of the equipment.

[0008] A production system according to a third aspect of the present invention is the production system according to the first or second aspect, wherein the base point is the time when the worker's operation starts or the time when the worker's operation ends when the log generating unit generates log information regarding the worker's operation.

[0009] A production system according to a fourth aspect of the present invention is a production system according to any one of the first to third aspects, in which the control unit causes the recording unit to record video data for a time period from a time point a predetermined period before the base point to a time point a predetermined period after the base point in association with log information.

[0010] A production system according to a fifth aspect of the present invention is the production system according to any one of the first to fourth aspects, and includes a cloud computer connected to the devices via the Internet. The cloud computer has at least one of a log generation unit, a video generation unit, a recording unit, and a control unit.

[0011] A production system according to a sixth aspect of the present invention is the production system according to the fifth aspect, further comprising a local computer. The local computer has an access right to the cloud computer and is connected to the device via a local line.

[0012] A production system according to a seventh aspect of the present invention is the production system according to any one of the first to sixth aspects, further comprising a detection unit and an identification unit. The detection unit detects a test piece inserted into the equipment by an operator. The identification unit identifies the test piece and the operator who inserted the test piece based on the video data. The control unit further causes the detection unit to record the action of detecting the test piece in the recording unit in association with the test piece and the operator identified by the identification unit.

[0013] A production system according to an eighth aspect of the present invention is a production system according to any one of the first to seventh aspects, wherein the video generation unit acquires video data of a length of time corresponding to the type of log information from a number of camera devices corresponding to the type of log information.

[0014] A production system according to a ninth aspect of the present invention is the production system according to any one of the first to eighth aspects, in which the control unit causes the recording unit to record video data for a plurality of time periods in association with log information. Effect of the Invention

[0015] The production system according to the present invention can easily refer to images related to specific operations or manipulations of equipment. [Brief description of the drawings]

[0016] [Figure 1]1 is a schematic configuration diagram of a production system 10 according to a first embodiment. [Diagram 2] FIG. 2 is a block diagram of a control terminal 50. [Diagram 3] 1 is an example of log information generated by a log generating unit 51a. [Figure 4] 2 is a flowchart of the operation of the production system 10. [Diagram 5] 13 is an example of a video confirmation screen displayed on the operation terminal 60. [Figure 6] FIG. 11 is a block diagram of a control terminal 50 according to a second embodiment. [Figure 7] 13 is an example of a document on which the metal detector check results are recorded. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0017] -First embodiment- A first embodiment of the present invention will be described with reference to the drawings. The embodiment described below is one of the specific examples of the present invention and does not limit the technical scope of the present invention.

[0018] (1) Overall configuration of production system 10 The production system 10 according to this embodiment performs at least one of the processes of weighing, packaging, inspecting, and boxing food. The production system 10 is installed in a facility that produces food such as confectionery. The facility in which the production system 10 is installed mainly comprises a factory 101, a control room 102, and an office 103. In the factory 101, a food production line is installed, and workers and the like perform work such as weighing, packaging, inspecting, and boxing food. In the control room 102, a manager or the like with prescribed authority controls and maintains the production line. In the office 103, the workers and the manager or the like acquire operation information of the production line.

[0019] 1 is a schematic configuration diagram of a production system 10. The production system 10 mainly comprises equipment 20, a camera 30, a recording terminal 40, a control terminal 50, and an operation terminal 60. The equipment 20, the camera 30, and the recording terminal 40 are installed in a factory 101. The control terminal 50 is installed in a control room 102. The operation terminal 60 is installed in an office 103.

[0020] The equipment 20 is installed on the production line and is used to perform various processes on food. The equipment 20 is, for example, a food measuring device, a food packaging device, an inspection device for packaged food, and a boxing device for packaged food. One or more pieces of equipment 20 are installed in the factory 101. In the factory 101, workers operate the equipment 20.

[0021] The camera 30 (imaging device) captures video of the operation of the equipment 20 or the operation of a worker in the factory 101. Video is an image or a video. Video is a video with sound or a video without sound. One or more cameras 30 are installed in the factory 101. The camera 30 captures the situation in which the equipment 20 is operating and the situation in which a worker is operating the equipment 20, and converts the captured video into specified data. One equipment 20 may be captured by multiple cameras 30, and multiple equipment 20 may be captured by one camera 30.

[0022] The recording terminal 40 is a computer connected to the camera 30. The recording terminal 40 controls the camera 30 and records and stores the video captured by the camera 30. The recording terminal 40 is equipped with a large-capacity HDD and SSD for storing the video as video data.

[0023] The control terminal 50 is a computer that functions as a server. The control terminal 50 is connected to the device 20, the recording terminal 40, and the operation terminal 60 by wire or wirelessly. The control terminal 50 transmits and receives various data between the device 20, the recording terminal 40, and the operation terminal 60. The control terminal 50 is operated by an administrator or the like who has a predetermined authority.

[0024] The operation terminal 60 is, for example, a personal computer. The operation terminal 60 is operated by an operator 70 who has a predetermined authority. The operator 70 is, for example, a manager, a worker who works in the factory 101, or an employee who works in the facility where the production system 10 is installed.

[0025] The recording terminal 40 and the operation terminal 60 function as clients of the control terminal 50 which functions as a server.

[0026] (2) Detailed Description of Control Terminal 50 2 is a block diagram of the control terminal 50. The control terminal 50 is mainly composed of a CPU 51, a ROM 52, a RAM 53, a HDD (hard disk drive) 54, a media drive 55, and the like. The elements 51 to 55 of the control terminal 50 are connected to each other via bus lines such as an address bus and a data bus. An SSD (solid state drive) may be used instead of the HDD 54. The media drive 55 is a device into which a storage medium such as a CD-ROM or a USB memory is inserted, and which reads and writes data from the storage medium. The storage media inserted into the ROM 52, the RAM 53, the HDD 54, and the media drive 55 are non-transitory recording media.

[0027] The CPU 51 executes various programs stored in the ROM 52, HDD 54, and storage media. The CPU 51 reads and executes these programs to operate as a log generating unit 51a, a video generating unit 51b, a recording unit 51c, and a control unit 51d. These elements 51a to 51d are composed of command sets executable by the CPU 51, and are predetermined functions realized by the control terminal 50.

[0028] (2-1) Log generation unit 51a The log generating unit 51a generates at least one of log information (equipment log information) related to the operation of the equipment 20 that processes food in the factory 101 and log information (operation log information) related to the operation of the equipment 20 by a worker. The log information generated by the log generating unit 51a is temporarily stored in the HDD 54 or the like.

[0029] The log information includes, for example, a time, an identifier (ID), and data. The time is, for example, the time when the log information is generated or the time when the log information is saved in the HDD 54 or the like. The identifier is a numerical value or a character string for uniquely identifying the log information. In the case of device log information, the data is information on the specific operation of the device 20, and in the case of operation log information, the data is information on the specific operation of the worker. In the case of device log information, the data is, for example, error information output by the device 20. In the case of operation log information, the data is, for example, an identifier of the button of the device 20 pressed by the worker and the coordinates of the touch panel of the device 20 touched by the worker.

[0030] Fig. 3 is an example of log information generated by the log generating unit 51a. In Fig. 3, both the device log information and the operation log information are arranged in the order of the time when the log information was generated or saved. The log generating unit 51a may output the device log information and the operation log information together without distinguishing them as shown in Fig. 3, or may output the device log information and the operation log information separately. In Fig. 3, each piece of log information includes a time and data.

[0031] In Fig. 3, if there is video data associated with log information, a camera icon is shown in the row related to that log information. The camera icon is shown to the left of the log information data. By checking the presence or absence of the camera icon, the operator 70 can easily know whether or not there is video data associated with the log information.

[0032] (2-2) Image generation unit 51b The video generating unit 51b generates at least one of video data of the operation of the device 20 and video data of the operation of the worker. The video generating unit 51b acquires the video stored in the recording terminal 40 and generates the video data.

[0033] The video generating unit 51b acquires video data of a length of time corresponding to the type of log information from the number of cameras 30 corresponding to the type of log information. For example, when there are multiple cameras 30 capturing the operation of a certain device 20 or the work of a certain worker, the video generating unit 51b acquires video data of a predetermined length of time based on the images captured by each of the multiple cameras 30.

[0034] (2-3) Recording unit 51c The recording unit 51c records the log information generated by the log generating unit 51a and the video data generated by the video generating unit 51b in association with each other. The association between the log information and the video data is performed by the control unit 51d. The recording unit 51c records the log information and the video data in association with each other based on the processing result of the control unit 51d.

[0035] (2-4) Control unit 51d The control unit 51d performs a process of associating the log information with the video data. The control unit 51d causes the recording unit 51c to record the video data generated by the video generating unit 51b in a time period based on the log information generated by the log generating unit 51a in association with the log information. The video data associated with the log information is at least a part of the video data generated by the video generating unit 51b. When the log generating unit 51a generates the device log information, the base point is the time when the operation of the device 20 starts or the time when the operation of the device 20 ends. When the log generating unit 51a generates the operation log information, the base point is the time when the operation of the worker starts or the time when the operation of the worker ends. The video data in the time period based on the log information is, for example, video data in a time period from a time period before the base point by a predetermined period to a time period after the base point by a predetermined period.

[0036] (3) Operation of production system 10 Fig. 4 is a flowchart of the operation of the production system 10. Fig. 4 shows a process in which the control terminal 50 records log information and video data in association with each other, and the operation terminal 60 displays the video data related to a specific operation or behavior of the device 20.

[0037] The equipment 20 in the factory 101 is connected to a control terminal 50 in a control room 102. While the production line in the factory 101 is operating, the equipment 20 collects data on the operation of the equipment 20 and operations by workers, and transmits the data to the control terminal 50 as history data (step S1). The history data is data on which each piece of log information shown in Fig. 3 is based. The history data includes data on the time when it was created.

[0038] Next, the control terminal 50 controls the recording terminal 40 in the factory 101 to start shooting with the camera 30 based on the history data received from the equipment 20 (step S2). That is, the control terminal 50 starts shooting video related to the operation of the equipment 20 and the operation of the worker, using the history data as a trigger. At this time, the control terminal 50 transmits the history data that became the trigger to the recording terminal 40. An identifier is assigned to each piece of history data by the control terminal 50.

[0039] Next, the recording terminal 40 accumulates and stores the video captured by the camera 30 (step S3). The recording terminal 40 stores the video in association with an identifier that is uniquely assigned to the video. The identifier of the video may be assigned by the recording terminal 40, or may be assigned by the control terminal 50 in step S2 and transmitted to the recording terminal 40.

[0040] Next, the recording terminal 40 transmits the video captured and stored by the camera 30 to the control terminal 50 (step S4).

[0041] Next, the recording terminal 40 transmits to the control terminal 50 a combination of the time or identifier contained in the history data received from the control terminal 50 and the identifier of the video captured and stored using the history data as a trigger (step S5). Note that the transmission of the video identifier in step S5 may be performed separately from or simultaneously with the transmission of the video in step S4.

[0042] Next, the control terminal 50 generates log information and video data from the history data and video received from the recording terminal 40, and records the log information and video data in association with each other (step S6). This enables the control terminal 50 to store the history data and its identifier, and the video corresponding to the history data and its identifier in association with each other.

[0043] The operation terminal 60 in the office 103 is connected to the control terminal 50 in the control room 102. An operator 70 of the operation terminal 60 can operate the operation terminal 60 to view the data stored in the control terminal 50 (step S7).

[0044] The operator 70 selects the log information of which he / she wishes to confirm the video from the list of log information (see FIG. 3) displayed on the screen of the operation terminal 60. As a result, a video confirmation screen is displayed on the display of the operation terminal 60. On the video confirmation screen, data related to the selected log information and video data associated with that log information are displayed.

[0045] Fig. 5 is an example of a video confirmation screen displayed on the operation terminal 60. Fig. 5 displays log information and video associated with the log information. The operator 70 can operate the video confirmation screen shown in Fig. 5 to confirm the video of the operation of the device 20 and the operation of the worker. If the video is a video, the operator 70 can operate the video confirmation screen to perform various operations such as playing the video.

[0046] In the video confirmation screen of FIG. 5, the top column shows data related to the log information selected from the list of log information shown in FIG. 3. Detailed data of the log information is shown in "Date and Time", "Operation ID", "Title", "Value" and "Code" below. The "Operation ID" column shows an identifier of the log information. The "Value" column shows, for example, a method of solving an error when the log information is related to an error occurrence. The "Code" column shows, for example, an error code when the log information is related to an error occurrence. The "Camera" column at the bottom is an area for video data associated with the log information. In FIG. 5, four video data (videos 1 to 4) associated with the log information are shown. The operator 70 can individually play and check each video data.

[0047] (4) Features In the production system 10, the operator 70 of the operation terminal 60 can identify the video that caused the recording of the log information based on the log information. Therefore, in the production system 10, the operator 70 can easily refer to the driving video related to a specific operation or behavior of the device 20. Therefore, the production system 10 can reduce the burden and mistakes of the operator 70 when referring to the driving video.

[0048] -Second embodiment- A production system 10 according to a second embodiment of the present invention will be described. Since the basic configuration, operation, and features of this embodiment are the same as those of the production system 10 according to the first embodiment, differences from the first embodiment will be mainly described.

[0049] (1) Detailed Description of Control Terminal 50 Fig. 6 is a block diagram of the control terminal 50 of this embodiment. The block diagram of Fig. 6 differs from the block diagram of the control terminal 50 of the first embodiment of Fig. 2 only in the elements included in the CPU 51. In this embodiment, compared to the first embodiment, the CPU 51 further operates as a detection unit 51e and an identification unit 51f. The detection unit 51e and the identification unit 51f are composed of an instruction set executable by the CPU 51, and are predetermined functions realized by the control terminal 50.

[0050] (1-1) Detection unit 51e Detection unit 51e detects the test piece inserted into device 20 by an operator. Device 20 is a metal detector for detecting metal contained in goods produced on a production line. For example, when film-packaged food is produced on a production line, the metal detector detects whether or not there is a metallic foreign object to be removed inside the bag in which the food is packaged. In this case, the metal detector is attached to a food packager.

[0051] A control standard is set for the metal detector (device 20) to prove that it operates with sufficient sensitivity and can reject metallic foreign bodies. For example, the control standard is "capable of detecting and rejecting stainless steel: 3.5 mm or more, iron: 2.5 mm or more." The test piece is used to check whether the metal detector meets the specified control standard. The test piece is, for example, a metal piece made of iron or stainless steel. Information such as the material, model number, weight, and dimensions is written on the test piece. The metal detector is checked using the test piece before, during, and after production on the production line. An operator inserts the test piece through the metal detector's insertion port to check whether the metal detector meets the specified control standard.

[0052] When the metal detector (device 20) detects a metallic foreign object, it transmits a predetermined detection signal to the control terminal 50. The detection unit 51e of the control terminal 50 detects the test piece or metallic foreign object inserted into the device 20 based on the detection signal received from the metal detector.

[0053] (1-2) Specific part 51f The identification unit 51f identifies the test piece and the worker (inputter) who inserted the test piece based on the video data. Specifically, the identification unit 51f analyzes the video data to identify the test piece and the inputter included in the video captured by the camera 30.

[0054] In this embodiment, video of the metal detector (device 20) in operation is captured by several cameras 30. One of the cameras 30 is installed near the metal detector's insertion port at a location where the test piece can be reliably captured. The video captured by this camera 30 is used to determine the type of test piece and whether or not the test piece has been inserted. The other of the cameras 30 is installed at the discharge section of the packaging device to which the metal detector is attached, and is used to determine, for example, whether or not multiple bags containing packaged products have been discharged.

[0055] The identification unit 51f identifies the test piece and the person who puts it in by using a still image analysis technique and a video analysis technique. The identification unit 51f may identify the test piece and the person who puts it in by analyzing the video by using a machine learning technique such as pattern recognition.

[0056] For example, in order to identify the person who puts in the metal (the worker who checks the operation of the metal detector), the person who puts in the metal is asked to wear an employee ID card with an employee number and name written on it in advance. The identification unit 51f recognizes the characters contained in the employee ID card from the image captured by the camera 30 installed in a position where it can photograph the employee ID card, and identifies the person who puts in the metal. Facial recognition, iris authentication, or fingerprint authentication may also be used as a method for identifying the person who puts in the metal. In addition, in the case of a test piece, the identification unit 51f may identify the test piece by recognizing the characters written on the test piece.

[0057] (2) Operation of production system 10 The worker checking the operation of the metal detector (device 20) first brings the test piece close to the insertion port of the packaging machine to which the metal detector is attached. At this time, the identification unit 51f identifies the test piece and the worker based on the image captured by the camera 30.

[0058] Next, the worker inserts a test piece into the inlet of the packaging machine to check the operation of the metal detector. The time from when the test piece is inserted into the packaging machine to when it is discharged from the packaging machine is determined by the settings of the packaging machine. Therefore, even if there is a short time interval between the insertion of the test piece and the insertion of an actual metal foreign object, the detection unit 51e can distinguish between the two. In other words, the detection unit 51e can detect the test piece inserted into the packaging machine. The worker may check the operation of the metal detector by inserting multiple test pieces of different types into the packaging machine.

[0059] In this embodiment, the control unit 51d further causes the recording unit 51c to record the operation of the detection unit 51e to detect the test piece, in association with the test piece and the worker (inserter) identified by the identification unit 51f. Specifically, the control unit 51d automatically creates a slip on which the metal detector check result is recorded.

[0060] FIG. 7 is an example of a form on which the check results of the metal detector are recorded. The form shown in FIG. 7 includes the date on which the check was performed (work date), the person who performed the check (the employee number and name of the worker), and a check result table. The check result table includes data on "operation check," "multiple-packaging," and "recording time" for each type of test piece used in the check. The data on "operation check" relates to the check results using the test piece. The data on "multiple-packaging" relates to the check results of the items discharged from the packaging device. Here, the data on "multiple-packaging" relates to the check results of whether the discharged items are in a state where a predetermined number of bags are connected together. In the "operation check" and "multiple-packaging" columns, if the check results are normal, "○" is recorded, and if they are not normal, an error number or the like is recorded. In the "recording time" column, the time when the above check results were obtained is recorded.

[0061] (3) Features In a factory 101 where a metal detector (device 20) is a critical control point (CCP), a specific management standard is required for the CCP. For this reason, it is necessary to periodically check the metal detector using a test piece. The results of the metal detector check are recorded in a form to be kept as a record document. However, manually creating a large number of forms takes time and costs money, and there is a risk of recording errors.

[0062] In this embodiment, the control unit 51d can automatically create a ledger in which the results of the metal detector check using the test piece are recorded, and therefore the production system 10 can reduce the time required to create the CCP ledger.

[0063] --Variations-- Although the embodiment of the present invention has been described above, the present invention is not limited to the above embodiment, and various modifications are possible without departing from the gist of the invention. For example, at least one of the following modified examples can be applied to the present invention.

[0064] (1) Variation A In the embodiment, the control terminal 50 is installed in a control room 102 in the facility where the production system 10 is installed, and the operation terminal 60 is installed in an office 103 in the facility. However, the control terminal 50 does not have to be installed in the facility where the production system 10 is installed. For example, a cloud computer may be used instead of the control terminal 50. In this case, the cloud computer is connected to the device 20, the recording terminal 40, and the operation terminal 60 via the Internet. The cloud computer has at least one function of the log generation unit 51a, the video generation unit 51b, the recording unit 51c, and the control unit 51d. Therefore, in this modification, the cloud computer generates log information and video data, and performs processes such as association between the log information and the video data outside the facility where the production system 10 is installed. A cloud service may be used instead of the cloud computer.

[0065] In this modified example, the operation terminal 60 is a local computer installed in the facility where the production system 10 is installed. The operation terminal 60 has a predetermined access right to the cloud computer, and is connected to the device 20 via a local line.

[0066] (2) Variation B In the embodiment, the control unit 51d causes the recording unit 51c to record the video data generated by the video generating unit 51b, which is video data for a time period based on the log information generated by the log generating unit 51a, in association with the log information. However, the video data used by the control unit 51d to associate with the log information may be composed of video data for a plurality of time periods. For example, the video data may be a combination of video images from a plurality of time periods that are separate from each other. [Industrial Applicability]

[0067] The production system according to the present invention is useful because it allows easy reference to images related to specific operations or manipulations of equipment. [Explanation of symbols]

[0068] 10 Production System 20 equipment 30 Camera (photography device) 51a Log generation unit 51b Image generation unit 51c Recording Division 51d Control section 51e Detection unit 51f Specific part [Prior art documents] [Patent documents]

[0069] [Patent Document 1] JP 2003-150230 A

Claims

1. An apparatus for performing at least one of weighing, packaging, inspection, and boxing of food products; a control unit that records at least one of log information related to the operation of the device and log information related to an operation of a worker who operates the device, and at least one of video data of the operation of the device and video data of the operation of the worker in association with each other; Equipped with When the device executes a specific operation or when the operator performs a specific operation during operation, the device transmits history data on which the log information is based to the control unit; the control unit starts taking video relating to the operation of the device and the operation of the worker based on the history data received from the device, and stores the video in a recording terminal, and then generates log information and video data from the history data and video received from the recording terminal, respectively, and records the log information and the video data in association with each other; a detection unit that detects a test piece inserted into the device by the operator; an identification unit that identifies the test piece and the worker who inserted the test piece based on the video data; Further equipped with The device is a metal detector for detecting metals contained in products produced on a production line, the test piece is a piece of metal, and is used to check whether the metal detector meets a predetermined management standard, The control unit further records the operation of the detection unit detecting the test piece in association with the test piece and the worker identified by the identification unit. Production system.

2. A cloud computer connected to the device via the Internet, The cloud computer includes the control unit. The production system according to claim 1 .

3. a local computer having access rights to the cloud computer and connected to the device via a local line; The production system according to claim 2 .

4. the control unit acquires the video data of a length of time corresponding to the type of the log information from a number of image capture devices corresponding to the type of the log information. The production system according to any one of claims 1 to 3.

5. The control unit records the video data for a plurality of time periods in association with the log information. The production system according to any one of claims 1 to 3.

Images