Production management system, management device, program, and production management method

Abstract

To provide a production management technique configured to flexibly respond to a change of workers while reducing a workload.SOLUTION: When a worker brings a worker management tag 5 close to a tag reader 3, the tag reader 3 reads a worker code from the worker management tag 5 to be transmitted to a work-site terminal 2. The work-site terminal 2 transmits the worker code together with a process code to a management device 1. The management device 1 uses the worker code and the process code received from the work-site terminal 2, and a worker management table 1020, to manage a work condition in a process that the worker is in charge of. When the worker brings a lot management tag 6 close to the tag reader 3, the tag reader 3 reads a lot number from the lot management tag 6 to be transmitted to the work-site terminal 2. The work-site terminal 2 transmits the lot number together with the process code to the management device 1. The management device 1 manages the progress of a work regarding a lot, using the lot number and the process code received from the work-site terminal 2 and a lot management table 1030.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to a production management technology using RFID (Radio Frequency Identification) tags. [Background technology]

[0002] Patent Document 1 discloses a production management system using RFID tags. This production management system is configured with on-site terminals and tag reader devices installed at each process of a product production line, a database connected to the on-site terminals installed at each process via a network, and RFID tags attached to each product flowing through the production line. Here, the RFID tag stores tag information including the tag ID of the RFID tag and the production number, item number, and lot number of the product to which the RFID tag is attached. In addition, the on-site terminal stores the process code of the process in which the on-site terminal is installed and the worker code of the worker in charge of this process.

[0003] In the production management system with the above configuration, when a worker brings a product that has arrived at the work site of the process for which he is responsible close to a tag reader device, the tag reader device reads the tag information from the RFID tag attached to the product and transmits it to an on-site terminal. The on-site terminal transmits the tag information received from the tag reader device, together with the process code and worker code registered in the on-site terminal, to a database. The database registers the tag information, process code, and worker code received from the on-site terminal, together with the work time, which is the time of reception. In this way, the workers at each process are managed along with the work time for each product flowing through the production line. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] JP 2008-4102 A Summary of the Invention [Problem to be solved by the invention]

[0005] However, in the production management system described in Patent Document 1, an RFID tag must be attached to each product that flows through the production line. Also, the worker must have a tag reader read the RFID tags attached to all products that flow through the work site of the process that the worker is responsible for. This results in a heavy workload. Furthermore, since the worker's worker code is pre-registered in the on-site terminal installed in the work site of the process that the worker is responsible for, every time the worker in charge of a process is changed, the worker code registered in the on-site terminal installed in the work site of that process must be changed, which is cumbersome.

[0006] The present invention has been made in consideration of the above circumstances, and an object of the present invention is to provide a production management technique that can reduce the workload and flexibly accommodate changes in workers. [Means for solving the problem]

[0007] In order to solve the above problem, in the production management system of the present invention, a field terminal and a tag reader device are installed at each process of a product production line, and the field terminal is used to register the process code of the process where the field terminal is installed. A management device is connected to the field terminal installed at each process, and a worker management table that stores a worker management record having fields for registering a worker code, a process code, a work start time, and a work end time, and a lot management table that stores a lot management record having fields for registering a lot number, a process code, a work start time, and a process end time are provided in the management device. For each lot, which is a group of products manufactured under the same conditions, a lot management tag is prepared as an RFID tag in which a lot number assigned to the lot is registered, and the lot management tag is attached to a lot box or the like that contains products belonging to the lot corresponding to the lot management tag. For each worker, a worker management tag is prepared as an RFID tag in which a worker code assigned to the worker is registered, and the worker management tag is attached to an employee ID card or the like of the worker corresponding to the worker management tag.

[0008] When a worker brings a worker management tag close to a tag reader device at the start and end of work at the work site of the process he or she is in charge of, the tag reader device reads the worker code from the worker management tag and transmits it to the site terminal. In response to this, the site terminal transmits the worker code to the management device together with the process code registered to the worker. When the management device receives the worker code and process code from the site terminal, it searches the worker management table for a worker management record in which the received worker code and process code and the work start time are registered, but the work end time is not registered. If the corresponding worker management record does not exist in the worker management table, it determines that the worker code and process code received from the site terminal are a message that the worker has started work, and creates a new worker management record in which the received worker code and process code are registered together with the work start time. On the other hand, if the corresponding worker management record exists in the worker management table, it determines that the worker code and process code received from the site terminal are a message that the worker has finished work, and registers the work end time in this worker management record.

[0009] Here, the work start time or work end time registered in the worker management record may be, for example, the time when the worker code and process code are received by the management device or the time when they are transmitted from the field terminal.

[0010] Also, when a worker brings a lot management tag close to a tag reader device at the start and end of a process for a lot that has flowed through the work site for which the worker is responsible, the tag reader device reads the lot number from the lot management tag and transmits it to the site terminal. In response to this, the site terminal transmits the lot number together with the process code registered in the site terminal to the management device. When the management device receives the lot number and process code from the site terminal, it searches the lot management table for a lot management record in which the received lot number, process code, and process start time are registered, but the process end time is not registered. If the corresponding lot management record does not exist in the lot management table, it determines that the lot number and process code received from the site terminal are a message for the start of a process for a product belonging to the lot, and creates a new lot management record in which the received lot number and process code are registered together with the process start time. On the other hand, if the corresponding lot management record exists in the lot management table, it determines that the lot number and process code received from the site terminal are a message for the end of a process for a product belonging to the lot, and registers the process end time in this lot management record.

[0011] Here, the process start time or process end time registered in the lot management record may be, for example, the time when the lot number and process code are received by the management device or the time when they are transmitted from the field terminal.

[0012] For example, the present invention provides A production management system that manages the progress of work on products flowing through a production line, Installed at each process of the production line , connected to each other A tag reader device and a field terminal, A management device connected to all of the field terminals; A worker management tag is provided for each worker and is an RFID (Radio Frequency Identification) tag in which the worker code of the corresponding worker is registered; a lot management tag which is an RFID tag provided for each lot, which is a group of the products manufactured under the same conditions, and in which the lot number of the corresponding lot is registered; The tag reader device A tag reader device reads the worker code and the lot number from the worker management tag and the lot management tag, respectively. Connect to and transmitting the information to the on-site terminal that is The field terminal includes: The process code of the process in which the on-site terminal is installed is registered. Local site terminal Connect to a tag reader device that is connected to the site terminal and transmits the worker code and the lot number received from the tag reader device to the management device together with a process code that is registered in the site terminal; The management device includes: a worker management table storage means for storing a worker management record having fields for registering a worker code, a process code, a work start time, and a work end time; a lot management table storage means for storing a lot management record having fields for registering a lot number, a process code, a process start time, and a process end time; a worker management table updating means for, when receiving a worker code and a process code from the on-site terminal, searching the worker management table storage means for a worker management record in which the received worker code and process code are registered with a work start time and in which a work end time is not registered, and if the worker management record is not stored in the worker management table storage means, newly storing in the worker management table storage means the worker management record in which the received worker code and process code are registered with a work start time and in which a work end time is not registered, and if the worker management record in which the received worker code and process code are registered with a work start time and in which a work end time is not registered is stored in the worker management table storage means, registering a work end time in the worker management record; and a lot management table updating means for, when receiving a lot number and a process code from the on-site terminal, searching for the lot management record in which the received lot number and process code are registered with a process start time and in which a process end time is not registered from the lot management table storage means, and if the lot management record is not stored in the lot management table storage means, newly storing in the lot management table storage means the lot management record in which the received lot number and process code are registered with the process start time and in which a process end time is not registered, and registering the process end time in the lot management record if the lot management record in which the received lot number and process code are registered with the process start time and in which a process end time is not registered is stored in the lot management table storage means. Effect of the Invention

[0013] In the present invention, a lot management tag is prepared for each lot, which is a group of products manufactured under the same conditions, and the progress of work on the products is managed on a lot-by-lot basis. Therefore, there is no need to attach an RFID tag to each and every product that flows through the production line. Also, workers do not need to have a tag reader read the RFID tags attached to all products that flow through the work site of the process they are in charge of. This reduces the workload.

[0014] Furthermore, in the present invention, when work begins and ends in a process that a worker is responsible for, a tag reader device installed at the work site of that process reads the worker code from the worker management tag attached to the worker, thereby managing the work start and end times for each worker's process, thereby making it possible to flexibly respond even if the worker in charge of a process is changed.

[0015] Furthermore, in the present invention, when a lot that has flowed into a process for which an operator is responsible starts and ends, a tag reader device installed at the work site of the process reads the lot number from the lot management tag attached to the lot, thereby managing the start and end times of the process for the lot. As described above, the work start and end times of the process for which each operator is responsible are also managed, so that the operator in charge of each process for the lot can be identified from the management contents of both.

[0016] In this way, according to the present invention, it is possible to provide a production management technique that can reduce the workload and flexibly accommodate changes in workers. [Brief description of the drawings]

[0017] [Figure 1] FIG. 1 is a schematic diagram of a production management system according to an embodiment of the present invention. [Diagram 2] FIG. 2 is a sequence diagram showing an example of the operation of the production management system according to the embodiment of the present invention. [Diagram 3] FIG. 3 is a schematic functional configuration diagram of the management device 1. As shown in FIG. [Figure 4] FIG. 4 is a diagram showing an example of registered contents of the worker management table 1020. As shown in FIG. [Diagram 5] FIG. 5 is a diagram showing an example of registered contents of the lot management table 1030. As shown in FIG. [Figure 6] FIG. 6 is a diagram showing an example of registered contents of the production management table 1040. As shown in FIG. [Figure 7] FIG. 7 is a flow diagram for explaining the worker management table update process of the management device 1. As shown in FIG. [Figure 8] FIG. 8 is a flow diagram for explaining the lot management table update process of the management device 1. As shown in FIG. [Figure 9] FIG. 9 is a flow diagram for explaining the production management table update process of the management device 1. As shown in FIG. [Figure 10]FIG. 10 is a flow diagram for explaining the worker management tag read request process of the management device 1. As shown in FIG. [Figure 11] FIG. 11 is a flow chart for explaining the lot management tag reading request process of the management device 1. As shown in FIG. [Figure 12] FIG. 12 is a schematic functional configuration diagram of the field terminal 2. As shown in FIG. [Figure 13] FIG. 13 is a diagram for explaining the operation flow of the on-site terminal 2. As shown in FIG. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0018] An embodiment of the present invention will be described below.

[0019] FIG. 1 is a schematic configuration diagram of a production management system according to the present embodiment.

[0020] As shown in the figure, the production management system of this embodiment manages the progress of work on products (not shown) flowing through a production line 8, and is configured to include tag reader devices 3 and on-site terminals 2 installed at each process A to C of the production line 8, a management device 1 connected to all of the on-site terminals 2 via a network 4 such as a WAN (Wide Area Network) or LAN (Local Area Network), worker management tags 5 which are RFID (Radio Frequency Identification) tags prepared for each worker, and lot management tags 6 which are RFID tags prepared for each lot, which is a group of products manufactured under the same conditions.

[0021] A worker code, which is identification information of the worker corresponding to this worker management tag 5, is registered in the worker management tag 5. The worker management tag 5 is used by being attached to, for example, an employee ID card of the worker corresponding to this worker management tag 5.

[0022] A lot number, which is identification information of a lot corresponding to the lot management tag 6, is registered in the lot management tag 6. The lot management tag 6 is used by being attached to a lot box 7 that contains products belonging to the lot corresponding to the lot management tag 6.

[0023] The tag reader device 3 reads the worker code and lot number from the worker management tag 5 and lot management tag 6 that have come within communication distance, and transmits them to the on-site terminal 2 that is installed in the same process as the tag reader device 3.

[0024] The on-site terminal 2 has registered therein the process code of the process in which the on-site terminal 2 is installed, and transmits to the management device 1 each of the worker code and lot number received from the tag reader device 3 installed in the same process as the on-site terminal 2, together with the process code registered in the on-site terminal 2.

[0025] The management device 1 manages the progress of work on products flowing through each process A to C of the production line 8 on a lot-by-lot basis, based on the worker code and lot number received together with the process code from the on-site terminals 2 installed in each process A to C of the production line 8.

[0026] FIG. 2 is a sequence diagram showing an example of the operation of the production management system according to the present embodiment.

[0027] First, when starting work in a process for which the worker is responsible, the worker approaches the tag reader device 3 installed at the work site for the process and has the tag reader device 3 read the worker management tag 5 attached to the worker's employee ID card or the like. The tag reader device 3 reads the worker code from the worker management tag 5 that has come within communication distance (S100) and transmits the worker code to the field terminal 2 installed at the same work site as the tag reader device 3 (S101). When the field terminal 2 receives the worker code from the tag reader device 3, it transmits the worker code together with the process code registered in the field terminal 2 to the management device 1 via the network 4 (S102).

[0028] Next, when the management device 1 receives the worker code and process code from the on-site terminal 2, it searches for a worker management record 1021 in which the worker code and process code are registered together with the work start time and in which the work end time is not registered from the worker management table 1020 described below (see FIG. 4). Here, it is assumed that the corresponding worker management record 1021 does not exist in the worker management table 1020. In this case, the management device 1 determines that the worker code and process code received from the on-site terminal 2 are a message indicating the start of work in the process in which the worker is responsible, and creates a new worker management record 1021 in which the received worker code and process code are registered together with the work start time, and stores this worker management record in the worker management table 1020 (S103). The work start time is, for example, the time when the worker code and process code are received or the time when they are sent from the on-site terminal 2.

[0029] Next, at the work site of the process that the worker is in charge of, the worker brings a lot box 7 that has arrived at this work site close to a tag reader device 3 installed at this work site, and has the tag reader device 3 read the lot management tag 6 attached to this lot box 7. The tag reader device 3 reads the lot number from the lot management tag 6 that has been brought close enough to a communication distance (S104), and transmits it to the field terminal 2 installed at the same work site as this tag reader device 3 (S105). When the field terminal 2 receives the lot number from the tag reader device 3, it transmits this lot number together with the process code registered in its own field terminal 2 to the management device 1 via the network 4 (S106).

[0030] Next, when the management device 1 receives the lot number and process code from the field terminal 2, it searches for a lot management record 1031 in which the lot number and process code are registered together with the process start time and in which the process end time is not registered from a lot management table 1030 described later (see FIG. 5). Here, it is assumed that the corresponding lot management record 1031 does not exist in the lot management table 1030. In this case, it determines that the lot number and process code received from the field terminal 2 are a message for starting a process for the product contained in the lot box 7, and creates a new lot management record 1031 in which the received lot number and process code are registered together with the process start time, and stores this lot management record 1031 in the lot management table 1030 (S107). The process start time is, for example, the time when the lot number and process code are received or the time when they are transmitted from the field terminal 2.

[0031] Then, the management device 1 searches the worker management table 1020 for a worker management record 1021 in which the process code registered in the newly created lot management record 1031 is registered together with the work start time, and in which the work end time is not registered. Also, the management device 1 searches the production management table 1040, described below, for a production management record 1041 in which the lot number and process code registered in this newly created lot management record 1031 are registered (see FIG. 6). Then, the management device 1 registers the worker code registered in the worker management record 1021 searched for from the worker management table 1020 in the production management record 1041 searched for from the production management table 1040 (S108).

[0032] Thereafter, when the worker finishes work on the product contained in the lot box 7 in his / her assigned process, he / she brings the lot box 7 close to the tag reader device 3 installed at the work site and causes the tag reader device 3 to read the lot management tag 6 attached to the lot box 7. The tag reader device 3 reads the lot number from the lot management tag 6 that has been brought close enough to a communication distance (S109) and transmits the lot number to the on-site terminal 2 installed at the same work site as the tag reader device 3 (S110). When the on-site terminal 2 receives the lot number from the tag reader device 3, it transmits the lot number together with the process code registered in its own on-site terminal 2 to the management device 1 via the network 4 (S111).

[0033] Next, when the management device 1 receives the lot number and process code from the field terminal 2, it searches the lot management table 1030 for a lot management record 1031 in which the lot number and process code are registered together with the process start time, but in which the process end time is not registered. In this case, the corresponding lot management record 1031 exists in the lot management table 1030 because it was newly created in S107. In this case, the management device 1 determines that the lot number and process code received from the field terminal 2 are a message indicating the end of the process for the product contained in the lot box 7, and registers the process end time in this lot management record 1031 (S112). The process end time is, for example, the time when the lot number and process code are received or the time when they are transmitted from the field terminal 2.

[0034] In this way, the workers of processes A to C constituting the production line 8 have the tag reader device 3 installed at their own work site read the lot management tag 6 attached to each lot box 7 that comes through their own work site at the start and end of work on the product contained in the lot box 7. This allows the management device 1 to manage the status of the products flowing through the production line 8 (the progress of work on the product: which process it has progressed to, which process it is stuck at, etc.) on a lot-by-lot basis together with the workers of each process.

[0035] Thereafter, when the worker finishes work in the process he or she is in charge of, he or she approaches the tag reader device 3 installed at the work site of the process he or she is in charge of and has the tag reader device 3 read the worker management tag 5 attached to the worker's employee ID card or the like. In response to this, the tag reader device 3 reads the worker code from the worker management tag 5 that has been brought close enough to communicate (S113) and transmits it to the field terminal 2 installed at the same work site as the tag reader device 3 (S114). When the field terminal 2 receives the worker code from the tag reader device 3, it transmits this worker code together with the process code registered in its own field terminal 2 to the management device 1 via the network 4 (S115).

[0036] Next, when the management device 1 receives the worker code and process code from the on-site terminal 2, it searches the worker management table 1020 for a worker management record 1021 in which the worker code and process code are registered together with the work start time, but in which the work end time is not registered. In this case, the corresponding worker management record 1021 exists in the worker management table 1020 because it was newly created in S103. In this case, it determines that the worker code and process code received from the on-site terminal 2 are a message indicating the end of work in the process in which the worker is responsible, and registers the received worker code and process code together with the work end time in this worker management record 1021 (S116). The work end time is, for example, the time when the worker code and process code are received, or the time when they are sent from the on-site terminal 2.

[0037] Next, the management device 1 and the on-site terminal 2 constituting the production management system according to this embodiment will be described in detail. Since existing RFID tags can be used for the worker management tag 5 and the lot management tag 6, detailed description thereof will be omitted. Furthermore, since an existing RFID tag reader device can be used for the tag reader device 3, detailed description thereof will be omitted.

[0038] First, the management device 1 will be described.

[0039] FIG. 3 is a schematic functional configuration diagram of the management device 1. As shown in FIG.

[0040] As shown in the figure, the management device 1 includes a network interface unit 100, a man-machine interface unit 101, a worker management table memory unit 102, a lot management table memory unit 103, a production management table memory unit 104, a worker management table update unit 105, a lot management table update unit 106, a production management table update unit 107, a worker management tag read request unit 108, and a lot management tag read request unit 109.

[0041] The network interface unit 100 is an interface for connecting to the network 4 .

[0042] The man-machine interface unit 101 is an interface for accepting various operations from the user and displaying information to the user. For example, in accordance with the operation accepted from the user, the man-machine interface unit 101 displays the registered contents of the worker management table storage unit 102, the lot management table storage unit 103, and the production management table storage unit 104.

[0043] Note that instead of the man-machine interface unit 101, or in addition to the man-machine interface unit 101, a management terminal communication unit may be provided that transmits and receives information to and from a management terminal (not shown) connected to the network 4 via the network interface unit 100. The management terminal communication unit receives, for example, various instructions from the management terminal via the network interface unit 100, and transmits information according to the received instructions (for example, the registered contents of the worker management table storage unit 102, the lot management table storage unit 103, and the production management table storage unit 104) to this management terminal.

[0044] The worker management table storage unit 102 stores a worker management table 1020 for managing the work status of each worker.

[0045] FIG. 4 is a diagram showing an example of registered contents of the worker management table 1020. As shown in FIG.

[0046] As shown in the figure, worker management table 1020 stores worker management records 1021. Worker management record 1021 has a field 1022 for registering a worker code which is identification information of a worker, a field 1023 for registering a process code which is identification information of a process, a field 1024 for registering a work start time, and a field 1025 for registering a work end time.

[0047] In Figure 4, a worker management record 1021 in which the work end time in field 1025 is not registered indicates that a worker identified by a worker code in field 1022 is working at the work site of a process identified by a process code in field 1023.

[0048] The lot management table storage unit 103 stores a lot management table 1030 for managing the progress of work on a lot.

[0049] FIG. 5 is a diagram showing an example of registered contents of the lot management table 1030. As shown in FIG.

[0050] As shown in the figure, a lot management table 1030 stores a lot management record 1031. The lot management record 1031 has a field 1032 for registering a lot number which is identification information of a lot, a field 1033 for registering a process code which is identification information of a process, a field 1034 for registering a process start time, and a field 1035 for registering a process end time.

[0051] In FIG. 5, a lot management record 1031 in which the process end time in field 1035 is not registered indicates that a product belonging to a lot identified by a lot number in field 1032 is in the process of being worked on or is waiting in a process identified by a process code in field 1033.

[0052] The production management table storage unit 104 stores a production management table 1040 for managing the workers in charge of lots for each process constituting the production line 8.

[0053] FIG. 6 is a diagram showing an example of registered contents of the production management table 1040. As shown in FIG.

[0054] As shown in the figure, a production management table 1040 stores a production management record 1041. The production management record 1041 has a field 1042 in which a lot number is registered, a field 1043 in which a process code is registered, a field 1044 in which a scheduled process start time is registered, and a field 1045 for registering a worker code.

[0055] In FIG. 6, a production management record 1041 in which a worker code has been registered in field 1045 indicates that, for a product belonging to a lot identified by a lot number in field 1042, work at a process identified by a process code in field 1043 has been performed or is being performed by a worker identified by the worker code in field 1045.

[0056] The worker management table update unit 105 updates the worker management table 1020 stored in the worker management table storage unit 102 based on the worker code and process code received from the field terminal 2 via the network interface unit 100 .

[0057] The lot management table update unit 106 updates the lot management table 1030 stored in the lot management table storage unit 103 based on the lot number and process code received from the field terminal 2 via the network interface unit 100 .

[0058] The production management table update unit 107 updates the production management table 1040 stored in the production management table memory unit 104 based on the worker management table 1020 stored in the worker management table memory unit 102 and the lot management table 1030 stored in the lot management table memory unit 103.

[0059] When the process code received from the on-site terminal 2 together with the lot number is registered together with the work start time and there is no worker management record 1021 in the worker management table 1020 for which the work end time is not registered, the worker management tag read request unit 108 sends a worker management tag read request message to the on-site terminal 2 that sent the lot number and process code, prompting the tag reader device 3 to read the worker management tag 5.

[0060] When a lot management record 1031 in which the process code received from the on-site terminal 2 together with the worker code is registered together with the process start time and the process end time is not registered in the lot management table 1030 within a specified time (e.g., 15 minutes), the lot management tag reading request unit 109 sends a lot management tag reading request message to the on-site terminal 2 that sent the worker code and process code, prompting the tag reader device 3 to read the lot management tag 5.

[0061] The functional configuration of the management device 1 having the above configuration may be realized in hardware by an integrated logic IC such as an ASIC (Application Specific Integrated Circuit) or an FPGA (Field Programmable Gate Array), or may be realized in software by a computer such as a DSP (Digital Signal Processor).Alternatively, it may be realized by a CPU loading a predetermined program from an auxiliary storage device into memory and executing it in a general-purpose computer such as a PC (Personal Computer) equipped with a CPU, a memory, an auxiliary storage device such as a HDD or a DVD-ROM, a communication interface such as a modem or a NIC (Network Interface Card), and input / output devices such as a display and a keyboard.

[0062] FIG. 7 is a flow diagram for explaining the worker management table update process of the management device 1. As shown in FIG.

[0063] When the network interface unit 100 receives a worker code and a process code from the on-site terminal 2 via the network 4 (YES in S200), the worker management table update unit 105 searches the worker management table 1020 for a worker management record 1021 in which this worker code and process code are registered together with the work start time and in which the work end time is not registered (S201).

[0064] If the corresponding worker management record 1021 does not exist in the worker management table 1020 (NO in S202), the worker management table update unit 105 determines that the worker code and process code received from the on-site terminal 2 in S200 are a message indicating the start of work in the worker's responsible process, and creates a new worker management record 1021 in which this worker code and process code are registered and registers it in the worker management table 1020 (S203), and also registers the work start time (the time the worker code and process code were received, the time of transmission from the on-site terminal 2, etc.) in this worker management record 1021 (S204).

[0065] On the other hand, if the corresponding worker management record 1021 exists in the worker management table 1020 (YES in S202), the worker management table update unit 105 determines that the worker code and process code received from the on-site terminal 2 in S200 are a message indicating the end of work for the worker's responsible process, and registers the work end time (the time the worker code and process code were received, the time of transmission from the on-site terminal 2, etc.) in this worker management record 1021 (S205).

[0066] FIG. 8 is a flow diagram for explaining the lot management table update process of the management device 1. As shown in FIG.

[0067] When the network interface unit 100 receives a lot number and process code from the field terminal 2 via the network 4 (YES in S210), the lot management table update unit 106 searches the lot management table 1030 for a lot management record 1031 in which this lot number and process code are registered together with the process start time and in which the process end time is not registered (S211).

[0068] If the corresponding lot management record 1031 does not exist in the lot management table 1030 (NO in S212), the lot management table update unit 106 determines that the lot number and process code received from the on-site terminal 2 in S210 are a message for the start of a process for the product contained in the lot box 7, and creates a new lot management record 1031 in which this lot number and process code are registered and registers it in the lot management table 1030 (S213), and also registers the process start time (the time the lot number and process code are received, the time of transmission from the on-site terminal 2, etc.) in this lot management record 1031 (S214).

[0069] On the other hand, if the corresponding lot management record 1031 exists in the lot management table 1030 (YES in S212), the lot management table update unit 106 determines that the lot number and process code received from the on-site terminal 2 in S210 are a message indicating the end of the process for the product contained in the lot box 7, and registers the process end time (the time the lot number and process code were received, the time of transmission from the on-site terminal 2, etc.) in this lot management record 1031 (S215).

[0070] FIG. 9 is a flow diagram for explaining the production management table update process of the management device 1. As shown in FIG.

[0071] The production management table update unit 107 monitors the lot management table 1030, and when a lot management record 1031 is newly created and registered in the lot management table 1030 (YES in S220), the production management table update unit 107 searches the worker management table 1020 for a worker management record 1021 in which the process code registered in this newly created lot management record 1031 is registered together with the work start time and in which the work end time is not registered (S221).

[0072] If a corresponding worker management record 1021 exists in the worker management table 1020 (YES in S222), a production management record 1041 in which the lot number and process code registered in the newly created lot management record 1031 are registered is searched for in the production management table 1040 (S223), and the worker code registered in the worker management record 1021 found in S221 is registered in the found production management record 1041 (S224).

[0073] On the other hand, if the corresponding worker management record 1021 does not exist in the worker management table 1020 (NO in S222), the process waits until a predetermined time (e.g., 10 minutes) has elapsed for such worker management record 1021 to be registered in the worker management table 1020 (S225). If the predetermined time times out without such worker management record 1021 being registered in the worker management table 1020 (YES in S225), a predetermined error process is performed, such as outputting a message to the man-machine interface unit 101 to the effect that the worker management record 1021 is not registered in the worker management table 1020 for the worker in charge of the process specified by the process code registered in the newly created lot management record 1031 (S226).

[0074] FIG. 10 is a flow diagram for explaining the worker management tag read request process of the management device 1. As shown in FIG.

[0075] When the network interface unit 100 receives the lot number and process code from the on-site terminal 2 via the network 4 (YES in S230), the worker management tag reading request unit 108 searches the worker management table 1020 for a worker management record 1021 in which the received process code is registered together with the work start time and in which the work end time is not registered (S231).

[0076] If the corresponding worker management record 1021 does not exist in the worker management table 1020 (NO in S232), the worker management tag read request unit 108 sends a worker management tag read request message to the on-site terminal 2, which is the sender of the lot number and process code, via the network interface unit 100, prompting the tag reader device 3 to read the worker management tag 5 (S233).

[0077] FIG. 11 is a flow chart for explaining the lot management tag reading request process of the management device 1. As shown in FIG.

[0078] When the network interface unit 100 receives the operator code and the process code from the on-site terminal 2 via the network 4 (YES in S240), the lot management tag read request unit 109 searches the lot management table 1030 for a lot management record 1031 in which the received process code is registered together with the process start time and in which the process end time is not registered for a predetermined time (e.g., 15 minutes) (S241 to S243). If the corresponding lot management record 1031 is not registered in the lot management table 1030 within the predetermined time (NO in S242, YES in S243), a lot management tag read request message is transmitted via the network interface unit 100 to the on-site terminal 2 that is the sender of the operator code and the process code, prompting the tag reader device 3 to read the lot management tag 5 (S244).

[0079] Next, the on-site terminal 2 will be described.

[0080] FIG. 12 is a schematic functional configuration diagram of the field terminal 2. As shown in FIG.

[0081] As shown in the figure, the field terminal 2 includes a network interface unit 200 , a tag reader device interface unit 201 , a man-machine interface unit 202 , a tag information processing unit 203 , and a message processing unit 204 .

[0082] Network interface unit 200 is an interface for connecting to network 4, and tag reader device interface unit 201 is an interface for connecting to tag reader device 3. In addition, man-machine interface unit 202 is an interface for accepting various operations from a user and displaying information to the user.

[0083] The tag information processing unit 203 receives, via the tag reader interface unit 201, the worker code and Lot NumberEach of these is transmitted to the management device 1 via the network interface unit 200 together with the process code of this process.

[0084] Then, the message processing unit 204 transmits the lot management tag reading request message and the worker management tag reading request message received from the management device 1 via the network interface unit 200 to the man-machine interface unit 202 .

[0085] The functional configuration of the on-site terminal 2 configured as above may be realized in hardware by an integrated logic IC such as an ASIC or an FPGA, or may be realized in software by a computer such as a DSP, like the management device 1. Alternatively, it may be realized by a general-purpose computer such as a PC equipped with a CPU, a memory, an auxiliary storage device such as a HDD or a DVD-ROM, a communication interface such as a modem or a NIC, and input / output devices such as a display and a keyboard, in which the CPU loads a predetermined program from the auxiliary storage device onto the memory and executes it.

[0086] FIG. 13 is a diagram for explaining the operation flow of the on-site terminal 2. As shown in FIG.

[0087] When the tag information processing unit 203 receives an operator code or lot number from a tag reader device 3 installed in the same process as the local on-site terminal 2 via the tag reader device interface unit 201 (YES in S300), it transmits the received operator code or lot number, together with the process code registered in the local on-site terminal 2, to the management device 1 via the network interface unit 200 (S301).

[0088] In addition, when the message processing unit 204 receives a lot management tag read request message or worker management tag read request message from the management device 1 via the network interface unit 200 (YES in S302), it outputs the received lot management tag read request message and worker management tag read request message from the man-machine interface unit 202 (S303).

[0089] One embodiment of the present invention has been described above.

[0090] In this embodiment, a lot management tag 6 is prepared for each lot, which is a group of products manufactured under the same conditions, and the progress of work on the products is managed on a lot-by-lot basis. Therefore, there is no need to attach an RFID tag to each and every product that flows through the production line 8. Also, workers do not need to have the tag reader device 3 read the RFID tags attached to all products that flow through the work site of the process they are in charge of. This reduces the workload.

[0091] Furthermore, in this embodiment, when work begins and ends in the process that a worker is responsible for, the tag reader device 3 installed at the work site of this process reads the worker code from the worker management tag 5 attached to the worker, thereby managing the work start time and work end time for each worker's process, thereby allowing for flexible response even when the worker in charge of a process is changed.

[0092] Furthermore, in this embodiment, at the start and end of a process for a lot that has flowed into a process for which the worker is responsible, the tag reader device 3 installed at the work site of this process reads the lot number from the lot management tag 6 attached to the lot, thereby managing the process start and end times for the lot at each process. As described above, the work start and end times for the process for which each worker is responsible are also managed, so that the worker in charge of the lot at each process can be identified from the management contents of both.

[0093] As described above, according to the present embodiment, it is possible to provide a production management technique that can reduce the workload and flexibly accommodate changes in workers.

[0094] Furthermore, in this embodiment, when the management device 1 receives a lot number and a process code from the on-site terminal 2, if this received process code is registered together with the work start time and there is no worker management record 1021 in which the work end time is not registered in the worker management table 1020, the management device 1 transmits a worker management tag read request message to the on-site terminal 2 that has transmitted the lot number and process code via the network interface unit 100, prompting the tag reader device 3 to read the worker management tag 5. In response to this, the on-site terminal 2 outputs the worker management tag read request message received from the management device 1. This makes it possible to prevent the worker from forgetting to read the worker management tag 5 into the tag reader device 3.

[0095] Furthermore, in this embodiment, when the management device 1 receives an operator code and a process code from the on-site terminal 2, if the received process code is registered together with the process start time and a lot management record 1031 in which the process end time is not registered within a predetermined time in the lot management table 1030, the management device 1 transmits a lot management tag read request message to the on-site terminal 2, which is the sender of the operator code and process code, via the network interface unit 100, to prompt the tag reader device 3 to read the lot management tag 5. In response to this, the on-site terminal 2 outputs the lot management tag read request message received from the management device 1. This makes it possible to prevent an operator from forgetting to read the lot management tag 6 into the tag reader device 3.

[0096] The present invention is not limited to the above-described embodiment, and various modifications are possible within the scope of the present invention.

[0097] For example, in the above embodiment, the management device 1 may further be provided with a process start request unit that monitors the production management table 1040 stored in the production management table storage unit 104 and prompts a lot on which work has not yet been started in a process to start work even after a predetermined time (e.g., 15 minutes) has passed since the scheduled process start time of the process, and a field terminal information storage unit that stores address information of the field terminals 2 installed in each of the processes A to C that constitute the production line 8 in association with the process code of the corresponding process.

[0098] Here, when the process start request unit detects from the production management table 1040 a production control record 1041 in which the worker code is not registered and the scheduled process start time has passed a predetermined time, it transmits a process start request message via the network interface unit 100 to the field terminal 2 identified by the address linked to the process code registered in this production management record 1041 and stored in the field terminal information storage unit, urging the start of process work for the lot identified by the lot number registered in this production management record 1041. In this way, it is possible to draw attention to a lot for which the process has not started as scheduled.

[0099] In the above embodiment, the lot management tag 5 is attached to the lot box 7, but the present invention is not limited to this. The lot management tag 5 may be attached to a lot management plate or the like that is transported together with the products that belong to the lot. [Explanation of symbols]

[0100] 1: Management device 2: On-site terminal 3: Tag reader device 4: Network 5: Worker management tag 6: Lot management tag 7: Lot box 100: Network interface section 101: Man-machine interface section 102: Worker management table storage unit 103: Lot management table storage unit 104: Production management table storage unit 105: Worker management table update unit 106: Lot management table update section 107: Production management table update section 108: Tag reading request unit for worker management 109: Tag reading request unit for lot management 200: Network interface section 201: Tag reader device interface unit 202: Man-machine interface unit 203: Tag information processing unit 204: Message processing unit

Claims

1. A production management system that manages the progress of work on products flowing through a production line, a tag reader device and a field terminal which are installed at each process of the production line and connected to each other; A management device connected to all of the field terminals; a worker management tag, which is an RFID (Radio Frequency Identification) tag provided for each worker and in which the worker code of the corresponding worker is registered; a lot management tag which is an RFID tag provided for each lot, which is a group of the products manufactured under the same conditions, and in which a lot number of the corresponding lot is registered; The tag reader device reading the worker code and the lot number from the worker management tag and the lot management tag, respectively, and transmitting them to the on-site terminal connected to the own tag reader device; The field terminal includes: The process code of the process in which the on-site terminal is installed is registered. Transmitting the operator code and the lot number received from the tag reader device connected to the local on-site terminal together with a process code registered in the local on-site terminal to the management device; The management device includes: a worker management table storage means for storing a worker management record having fields for registering a worker code, a process code, a work start time, and a work end time; a lot management table storage means for storing a lot management record having fields for registering a lot number, a process code, a process start time, and a process end time; a worker management table updating means for, when receiving a worker code and a process code from the on-site terminal, searching the worker management table storage means for a worker management record in which the received worker code and process code are registered with a work start time and in which a work end time is not registered, and if the worker management record is not stored in the worker management table storage means, newly storing in the worker management table storage means the worker management record in which the received worker code and process code are registered with a work start time and in which a work end time is not registered, and if the worker management record in which the received worker code and process code are registered with a work start time and in which a work end time is not registered is stored in the worker management table storage means, registering a work end time in the worker management record; a lot management table updating means for, when receiving a lot number and a process code from the on-site terminal, searching the lot management table storage means for the lot management record in which the received lot number and process code are registered together with a process start time and in which a process end time is not registered, and if the lot management record is not stored in the lot management table storage means, newly storing in the lot management table storage means the lot management record in which the received lot number and process code are registered together with a process start time and in which a process end time is not registered, and if the lot management record in which the received lot number and process code are registered together with a process start time and in which a process end time is not registered is stored in the lot management table storage means, registering the process end time in the lot management record. A production management system characterized by the above.

2. The production management system according to claim 1, The management device includes: a production management table storage means for storing a production management record in which lot numbers and process codes are registered in advance and which has a field for registering operator codes; and a production management table updating means for, when the lot management record in which a lot number, a process code and a process start time are registered but a process end time is not registered, searching the production management table storage means for the production management record in which the lot number and the process code are registered, and searching the worker management table storage means for the worker management record in which the process code is registered together with the work start time but a work end time is not registered, and registering the worker code of the searched worker management record in the searched production management record. A production management system characterized by the above.

3. The production management system according to claim 2, The production management record has a scheduled start time of the process registered in advance, The management device includes: The production management system further comprises a process start request means for transmitting a process start request message to the on-site terminal installed in a process specified by a process code registered in the production management record, to prompt the start of process work for a lot specified by a lot number registered in the production management record, if the production management record is stored in the production management table storage means and the worker code is not registered and the scheduled process start time has passed a predetermined time. A production management system characterized by the above.

4. The production management system according to any one of claims 1 to 3, The management device includes: and a worker management tag read request means for, when a lot number and a process code are received from the on-site terminal, searching the worker management table storage means for the worker management record in which the process code and work start time are registered and the work end time is not registered, and if the worker management record is not stored in the worker management table storage means, transmitting a worker management tag read request message to the on-site terminal that is the sender of the lot number and the process code, prompting the tag reader device to read the worker management tag. A production management system characterized by the above.

5. The production management system according to any one of claims 1 to 4, The management device includes: and a lot management tag read requesting means for, when receiving an operator code and a process code from the on-site terminal, monitoring the registration of the lot management record in which the process code is registered together with the lot number and the process start time and the process end time is not registered in the lot management table storage means, and if the lot management record is not registered in the lot management table storage means within a predetermined time, transmitting a lot management tag read request message to the on-site terminal which is the sender of the operator code and process code, prompting the tag reader device to read the lot management tag. A production management system characterized by the above.

6. A management device that is connected to all on-site terminals installed at each process of a production line and manages the progress of work on products flowing through the production line, a worker management table storage means for storing a worker management record having fields for registering a worker code, a process code, a work start time, and a work end time; a lot management table storage means for storing a lot management record having fields for registering a lot number, a process code, a process start time, and a process end time; When the on-site terminal receives from the tag reader device connected to the on-site terminal a worker code acquired from a worker management tag, which is an RFID (Radio Frequency Identification) tag provided for each worker, and a process code registered in the on-site terminal, from the on-site terminal, a worker management table updating means for searching the worker management table storage means for a worker management record in which the received worker code and process code are registered together with the work start time and in which the work end time is not registered, and if the worker management record is not stored in the worker management table storage means, for newly storing in the worker management table storage means the worker management record in which the received worker code and process code are registered together with the work start time and in which the work end time is not registered, and for registering the work end time in the worker management record if the worker management record in which the received worker code and process code are registered together with the work start time and in which the work end time is not registered is stored in the worker management table storage means; and a lot management table updating means for, when the on-site terminal receives from the tag reader device connected to the on-site terminal a lot number acquired from a lot management tag which is an RFID tag provided for each lot which is a group of products manufactured under the same conditions and a process code registered in the on-site terminal, searching the lot management table storage means for the lot management record in which the received lot number and process code are registered together with a process start time and in which a process end time is not registered, and if the lot management record is not stored in the lot management table storage means, newly storing in the lot management table storage means the lot management record in which the received lot number and process code are registered together with the process start time and in which a process end time is not registered, and if the lot management record in which the received lot number and process code are registered together with the process start time and in which a process end time is not registered is stored in the lot management table storage means, registering a process end time in the lot management record. A management device comprising:

7. A program that causes a computer to function as a management device that manages the progress of work on products flowing through a production line, The computer includes: The production line is connected to all on-site terminals installed at each process step, The program is The computer, a worker management table storage means for storing a worker management record having fields for registering a worker code, a process code, a work start time, and a work end time; a lot management table storage means for storing a lot management record having fields for registering a lot number, a process code, a process start time, and a process end time; a worker management table updating means for, when receiving from the on-site terminal a worker code acquired from a worker management tag, which is an RFID (Radio Frequency Identification) tag provided for each worker, and a process code registered in the on-site terminal, which are received from a tag reader device connected to the on-site terminal, searching for a worker management record in which the received worker code and process code are registered together with a work start time and in which a work end time is not registered from the worker management table storage means, and if the worker management record is not stored in the worker management table storage means, newly storing in the worker management table storage means the worker management record in which the received worker code and process code are registered together with the work start time and in which a work end time is not registered, and if the worker management record in which the received worker code and process code are registered together with the work start time and in which a work end time is not registered is stored in the worker management table storage means, registering a work end time in the worker management record; and when the tag reader device receives from the on-site terminal a lot number acquired from a lot management tag, which is an RFID tag provided for each lot that is a group of products manufactured under the same conditions, and a process code registered in the on-site terminal, the tag reader device functions as a lot management table updating means that searches the lot management table storage means for the lot management record in which the received lot number and process code are registered together with a process start time and in which a process end time is not registered, and if the lot management record is not stored in the lot management table storage means, newly stores in the lot management table storage means the lot management record in which the received lot number and process code are registered together with a process start time and in which a process end time is not registered, and if the lot management record in which the received lot number and process code are registered together with a process start time and in which a process end time is not registered, the lot management table updating means functions as a lot management table updating means that registers a process end time in the lot management record, A program characterized by:

8. A production management method for managing the progress of work on products flowing through a production line, comprising the steps of: a tag reader device and a field terminal connected to each other are installed at each process of the production line, and a management device is connected to all of the field terminals via a network; A worker management tag, which is an RFID (Radio Frequency Identification) tag in which the worker's worker code is registered, is given to each worker, and a lot management tag, which is an RFID tag in which the lot number of the lot is registered, is given to each lot, which is a group of the products manufactured under the same conditions; The tag reader device reading the worker code and the lot number from the worker management tag and the lot management tag, respectively, and transmitting them to the on-site terminal connected to the own tag reader device; The field terminal includes: The process code of the process in which the on-site terminal is installed is registered. Transmitting the operator code and the lot number received from the tag reader device connected to the local on-site terminal together with a process code registered in the local on-site terminal to the management device; The management device includes: a worker management table for storing a worker management record having fields for registering a worker code, a process code, a work start time, and a work end time, and a lot management table for storing a lot management record having fields for registering a lot number, a process code, a process start time, and a process end time, when a worker code and a process code are received from the on-site terminal, the worker management table is searched for a worker management record in which the received worker code and process code are registered with a work start time and in which a work end time is not registered, and if the worker management record is not stored in the worker management table, the worker management record in which the received worker code and process code are registered with a work start time and in which a work end time is not registered is newly stored in the worker management table, and if the worker management record in which the received worker code and process code are registered with a work start time and in which a work end time is not registered is stored in the worker management table, the work end time is registered in the worker management record, When a lot number and a process code are received from the on-site terminal, the lot management table is searched for the lot management record in which the received lot number and process code are registered with the process start time and the process end time is not registered, and if the lot management record is not stored in the lot management table, the lot management record in which the received lot number and process code are registered with the process start time and the process end time is not registered is newly stored in the lot management table, and if the lot management record in which the received lot number and process code are registered with the process start time and the process end time is not registered is stored in the lot management table, the process end time is registered in the lot management record. A production management method comprising:

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