Material management system, material management method, and material management program

Abstract

To provide a material management system, a material management method and a material management program, capable of filling a material at proper timing, according to a residual amount of a material such as cement stored in a vessel.SOLUTION: A management server 20 comprises: a control unit 21 coupled to a load cell 12 of a residual amount of a material in a vessel 11; and a measurement information storage unit 23 for, in association with a measurement period, measuring the residual amount of the material. The control unit 21 acquires from the load cell 12, a residual amount of the material in the vessel, then, in association with the measurement period, records the residual amount of the material in the measurement information storage unit 23. The control unit 21 calculates a reduction trend using the measurement period and the residual amount recorded in the measurement information storage unit 23, and using the reduction trend, predicts a future residual amount, and if the future residual amount becomes less than a threshold, places an order to a material supply source system 30.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to a material management system, a material management method, and a material management program for managing materials such as cement stored in a container.

Background Art

[0002] Conventionally, powders such as cement used in construction are transported, stored, and used in silos installed at construction sites. As a method for checking the amount of powder in the silo container, in the case of visual inspection, it requires labor for the opening and closing operations of the silo container, and it is difficult to accurately grasp the remaining amount by visual inspection. Therefore, a method using a load cell for measuring the weight of the powder in the container has been studied (see, for example, Patent Document 1). In the technique described in Patent Document 1, in a double structure in which an inner container is installed inside an outer container, a load cell for measuring the load of the inner container is attached. Also, a method using a photographed image inside the container has been studied (see, for example, Patent Document 2). In the technique described in Patent Document 2, a photographed image of the storage state of the powder introduced into the container is acquired, and the amount of powder in the container is estimated using a powder amount estimation model.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Patent Document 2

Summary of the Invention

Problems to be Solved by the Invention

[0004] However, it may be difficult to grasp the remaining amount of the material. For example, powders flow depending on the situation, and the accumulation state of the powders is different. For this reason, depending on the accumulation state, there may be an error in the weight measured by the load cell or the remaining amount predicted using the photographed image. In this case, there is a possibility that the main body cannot be filled at an appropriate timing.

Means for Solving the Problem

[0005] The material management system for solving the above problems includes a control unit connected to a measurement unit for measuring the remaining amount of materials in a container, and a measurement information storage unit for recording the remaining amount of the materials in association with the measurement time. Then, the control unit acquires the remaining amount of the materials in the container from the measurement unit, records it in the measurement information storage unit in association with the measurement time, calculates a decreasing trend using the measurement time and the remaining amount recorded in the measurement information storage unit, predicts a future remaining amount using the decreasing trend, and places an order with the supplier of the materials when the future remaining amount becomes less than a threshold value.

Effect of the Invention

[0006] According to the present invention, materials such as cement stored in a container can be filled at an appropriate timing.

Brief Description of the Drawings

[0007]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Mode for Carrying Out the Invention

[0008] Hereinafter, an embodiment in which a material management system, a material management method, and a material management program are embodied will be described with reference to FIGS. 1 to 7. In this embodiment, management of cement (powder as a material) used at a construction site is performed.

[0009] As shown in FIG. 1, using a management server 20 as a material management system, the cement stored in the silo 10 (inside the container) is managed. This silo 10 is provided with a load cell 12 (measurement unit) that measures the weight of the container 11 for accumulating powder. Further, the management server 20 is connected to a supply source system 30 via a network.

[0010] (Hardware configuration example) FIG. 2 is a hardware configuration example of an information processing apparatus H10 that functions as the management server 20 and the supply source system 30.

[0011] The information processing apparatus H10 includes a communication device H11, an input device H12, a display device H13, a storage device H14, and a processor H15. Note that this hardware configuration is an example, and it may have other hardware.

[0012] The communication device H11 is an interface that establishes a communication path with other devices and executes data transmission and reception, and is, for example, a network interface card or a wireless interface.

[0013] The input device H12 is a device that receives input from an administrator or the like, and is, for example, a mouse or a keyboard. The display device H13 is a display or a touch panel that displays various information.

[0014] The storage device H14 is a storage device that stores data and various programs for executing various functions of the management server 20 and the supply source system 30. Examples of the storage device H14 include a ROM, a RAM, and a hard disk.

[0015] Processor H15 controls each process (for example, the process in control unit 21 described later) in management server 20 and supply source system 30 by using programs and data stored in storage device H14. As an example of processor H15, there are, for example, a CPU, an MPU, etc. This processor H15 expands a program stored in a ROM or the like to a RAM and executes various processes corresponding to various processes. For example, when the application programs of management server 20 and supply source system 30 are started, processor H15 operates a process that executes each process.

[0016] Processor H15 is not limited to performing software processing for all processes it executes. For example, processor H15 may include a dedicated hardware circuit (for example, an application specific integrated circuit: ASIC) that performs hardware processing for at least a part of the processes it executes. That is, processor H15 can be configured as a circuitry including (1) one or more processors that operate according to a computer program (software), (2) one or more dedicated hardware circuits that execute at least a part of various processes, or (3) a combination thereof. The processor includes a CPU and memories such as a RAM and a ROM, and the memories store program codes or instructions configured to cause the CPU to execute processes. The memory, that is, the computer-readable medium, includes any available medium that can be accessed by a general-purpose or dedicated computer.

[0017] (Functions of the material management system) Management server 20 includes a control unit 21, a calendar storage unit 22, and a measurement information storage unit 23. By executing a material management program, control unit 21 functions as a management unit 210, a prediction unit 211, and an instruction unit 212.

[0018] Management unit 210 executes a process of acquiring measurement (weight) information from load cell 12. This management unit 210 holds information regarding a predetermined measurement period (for example, 10 seconds). The prediction unit 211 executes a process of predicting the remaining amount of cement in the future based on the measurement information. This prediction unit 211 holds information regarding the evaluation period (from 1 hour ago to 8 hours ago), the number of samples, and the lead time from the order receipt to the delivery used for generating the approximation formula. Further, the prediction unit 211 stores the determination remaining amount b0 used for selecting the approximation formula at the time of prediction.

[0019] The instruction unit 212 executes a process of placing an order for cement with the supplier system 30. This instruction unit 212 holds information regarding the transmission destination of the cement order (such as the address of the supplier system 30), information for identifying this construction site, and information regarding the threshold value of the remaining amount for placing an order.

[0020] The calendar storage unit 22 records the first calendar information regarding the business days of the construction site and the second calendar information regarding the business days of the cement supplier (order destination). The first and second calendar information are recorded when the business days and holidays of the construction site (material usage site) and the supplier are registered respectively. In the first and second calendar information, information for identifying the business state (business days and holidays) is recorded for the calendar date.

[0021] The measurement information storage unit 23 records a measurement management record (measurement information) that measures the weight (remaining amount) of cement in the container 11 of the silo 10. This measurement management record is recorded when measurement information is acquired from the load cell 12 periodically. In this measurement management record, the measurement date and time and data regarding the remaining amount are recorded.

[0022] In the measurement date and time data area, data regarding the year, month, day, and time when the remaining amount was acquired are recorded. In the remaining amount data area, data regarding the current weight measured by the load cell 12 are recorded.

[0023] The supplier system 30 is the computer system of the supplier company that supplies cement. In response to the order received by the supplier system 30, the supplier company delivers the cement. In this case, a lead time (e.g., two days) from the receipt of the order to the delivery is required.

[0024] (Recording Process) Next, the recording process will be described with reference to FIG. 3. First, the control unit 21 of the management server 20 executes a determination process on whether it is the measurement time (step S101). Specifically, the management unit 210 of the control unit 21 calculates the elapsed time from the previous measurement time from the system timer. And when the elapsed time has passed the predetermined waiting time (e.g., two minutes), it is determined as the measurement time.

[0025] If it is still determined that the waiting time for the measurement time has not passed and it is not the measurement time (in step S101, when "NO"), the control unit 21 of the management server 20 waits until the next measurement time.

[0026] On the other hand, when it is determined that it is the measurement time (in step S101, when "YES"), the control unit 21 of the management server 20 executes the remaining quantity acquisition process (step S102). Specifically, the management unit 210 of the control unit 21 acquires the weight for a predetermined measurement period (e.g., 10 seconds) from the load cell 12. And the management unit 210 specifies the average value of the weight during the measurement period as the remaining quantity.

[0027] Next, the control unit 21 of the management server 20 executes a determination process on whether it has changed (step S103). Specifically, the management unit 210 of the control unit 21 compares the most recent remaining quantity recorded in the measurement information storage unit 23 with the newly acquired remaining quantity. And when the two are different, it is determined that it has changed.

[0028] If it is determined that there is no change (in step S103, when "NO"), the control unit 21 of the management server 20 returns to step S101 and waits until the next measurement time. On the other hand, when it is determined that there is a change (when "YES" in step S103), the control unit 21 of the management server 20 executes the recording process of the measurement information (step S104). Specifically, the management unit 210 of the control unit 21 generates a measurement management record in which the current date and time (measurement date and time) and the newly acquired remaining amount are recorded, and records it in the measurement information storage unit 23.

[0029] (Error correction process) Next, the error correction process will be described with reference to FIGS. 4 and 5. This error correction process is performed when the container 11 of the silo 10 is filled with cement.

[0030] First, the control unit 21 of the management server 20 executes the acquisition process of the filling information (step S201). Specifically, when the management unit 210 of the control unit 21 detects a sudden increase in weight in the measurement information acquired from the load cell 12, it determines that filling has been performed.

[0031] Next, the control unit 21 of the management server 20 executes the sliding process of the measurement information (step S202). Specifically, the management unit 210 of the control unit 21 calculates the filling amount from the difference between the weight immediately before filling and the weight immediately after filling. Next, the management unit 210 acquires the measurement management record for a predetermined period from the measurement information storage unit 23. As the predetermined period, for example, the period from the previous filling to immediately before the current filling is used. Then, the management unit 210 adds the filling amount to the remaining amount recorded in the measurement management record and updates it. In this case, as shown in FIG. 5, the remaining amount history before filling slides according to the filling amount.

[0032] (Prediction process) Next, the prediction process will be described with reference to FIGS. 6 and 7. In this embodiment, two calculation methods are used to calculate the decreasing trend.

[0033] First, the control unit 21 of the management server 20 executes a determination process on whether it is the prediction time (step S301). Specifically, the prediction unit 211 of the control unit 21 calculates the elapsed time from the previous prediction time from the system timer. And when the elapsed time has passed the predetermined waiting time (for example, 1 hour), it is determined as the prediction time.

[0034] If it is still determined that the waiting time for the prediction time has not passed and it is not the prediction time (in step S301, when the answer is "NO"), the control unit 21 of the management server 20 waits until the next prediction time.

[0035] On the other hand, when it is determined that it is the prediction time (in step S301, when the answer is "YES"), the control unit 21 of the management server 20 executes a process of obtaining the slope of the weight change (step S302). Specifically, the prediction unit 211 of the control unit 21 obtains the remaining amount of the number of samples n in the evaluation period from the measurement information storage unit 23. The evaluation period is assumed to be from 1 hour ago to 8 hours ago. And the prediction unit 211 calculates the slope a1 with a higher weight as it gets closer to the current date and time using the following formula.

[0036]

Equation

[0037] Here, i is from 1 (the closest in the evaluation period) to n, k(i) is the i-th weighting value, and W(i) is the remaining amount at the measurement date and time t(i). And for the weighting value k(i), a larger value is used as the measurement date and time t(i) gets closer to the current date and time. For example, [n + 1 - i] can be used as the weighting value k(i).

[0038] Next, the control unit 21 of the management server 20 executes a process of calculating the first approximation formula using the weighted average (step S303). Specifically, the prediction unit 211 of the control unit 21 generates the first approximation formula (W(t) = a1·t + b1) with the slope a1 set using the remaining amount closest to the evaluation period as the intercept b1. Thereby, the first approximation formula using the weighted average value is generated, and the decreasing trend can be specified to predict the future remaining amount.

[0039] Next, the control unit 21 of the management server 20 executes a calculation process of a second approximation formula using the least squares method (step S304). Specifically, the prediction unit 211 of the control unit 21 applies the remaining amount of the number of samples n to the least squares method to calculate a second approximation formula.

[0040]

Number

[0041]

Number

[0042] The bar means the average value. As a result, a second approximation formula using the least squares method is generated, and the decreasing trend can be specified to predict the future remaining amount.

[0043] Next, the control unit 21 of the management server 20 executes a prediction process of the current remaining amount using the first approximation formula from the previous weight value (step S305). Specifically, the prediction unit 211 of the control unit 21 substitutes the remaining amount b0 for determination used at the previous prediction and the elapsed time from the previous prediction into the first approximation formula to calculate the current remaining amount (first predicted value). Next, the control unit 21 of the management server 20 executes a prediction process of the current remaining amount using the second approximation formula from the previous weight value (step S306). Specifically, the prediction unit 211 of the control unit 21 substitutes the remaining amount b0 for determination used at the previous prediction and the elapsed time from the previous prediction into the second approximation formula to calculate a second predicted value for the current remaining amount.

[0044] Next, the control unit 21 of the management server 20 executes a selection process of an approximation formula in which the remaining amount predicted value is close to the current actually measured value (step S307). Specifically, the prediction unit 211 of the control unit 21 compares the first predicted value, the second predicted value, and the current remaining amount (current actually measured value). Then, an approximation formula (selected approximation formula) that calculates a predicted value close to the current remaining amount is specified. Then, the prediction unit 211 updates and stores the current actually measured value as the remaining amount b0 for determination.

[0045] Next, the control unit 21 of the management server 20 executes prediction processing for the future remaining quantity after the lead time (step S308). Specifically, the prediction unit 211 of the control unit 21 predicts the remaining quantity (future remaining quantity) immediately after the lead time has elapsed using a selected approximation formula. As shown in FIG. 7, the remaining quantity after the lead time is predicted using the first and second approximation formulas eq1 and eq2 that calculate prediction values close to the current remaining quantity (actual remaining quantity). Here, since the first approximation formula eq1 is close to the current remaining quantity, the remaining quantity at the time when the lead time has elapsed is calculated using the first approximation formula eq1.

[0046] Next, the control unit 21 of the management server 20 executes determination processing as to whether the future remaining quantity is less than the threshold value (step S309). Specifically, the instruction unit 212 of the control unit 21 compares the future remaining quantity with the threshold value.

[0047] If it is determined that the future remaining quantity is greater than or equal to the threshold value (in the case of "NO" in step S309), the process returns to step S301 and waits until the next prediction time. On the other hand, if it is determined that the future remaining quantity is less than the threshold value (in the case of "YES" in step S309), the control unit 21 of the management server 20 executes determination processing as to whether it is a site holiday after the lead time (step S310). Specifically, the instruction unit 212 of the control unit 21 acquires first calendar information from the calendar storage unit 22 and checks the business status of the date of the lead time.

[0048] If it is determined that it is not a site holiday after the lead time (in the case of "NO" in step S310), the control unit 21 of the management server 20 executes determination processing as to whether it is a supplier holiday after the lead time (step S311). Specifically, the instruction unit 212 of the control unit 21 acquires second calendar information from the calendar storage unit 22 and checks the business status of the date of the lead time.

[0049] When it is determined that it is a site holiday after the lead time, or when it is determined that it is a supplier holiday after the lead time (when "YES" in steps S310 and S311), the control unit 21 of the management server 20 executes an order date adjustment process (step S312). Specifically, the instruction unit 212 of the control unit 21 adjusts the supply date according to the lead time. Here, when it is determined that it is a site holiday after the lead time, one day is added to the supply date according to the lead time. When it is determined that it is a supplier holiday after the lead time, one day is subtracted from the supply date according to the lead time.

[0050] Then, when the order date adjustment process (step S312) or when it is determined that it is not a supplier holiday after the lead time (when "NO" in step S311), the control unit 21 of the management server 20 executes an order process (step S313). Specifically, the instruction unit 212 of the control unit 21 transmits order information to the supplier system 30. This order information includes site information and information regarding the supply date.

[0051] According to this embodiment, the following effects can be obtained. (1) In this embodiment, when it is determined that there is a change (when "YES" in step S103), the control unit 21 of the management server 20 executes a measurement information recording process by associating the newly acquired remaining quantity with the measurement date and time (step S104). Thereby, the memory capacity can be compressed by recording only the information amount in the case of a change.

[0052] (2) In this embodiment, the control unit 21 of the management server 20 executes a slide process of the measurement information (step S202). Thereby, by biasing the measurement information before filling according to the filling amount, even immediately after filling, prediction can be performed using the measurement information before and after filling.

[0053] (3) In this embodiment, the control unit 21 of the management server 20 executes the calculation process of the first approximation formula using the weighted average (step S303). Thereby, considering the usage tendency of cement in the most recent period, the remaining amount in the future can be predicted. For example, when the past usage tendency and the usage tendency in the most recent period are different, the future can be predicted by utilizing the decreasing tendency in the most recent period.

[0054] (4) In this embodiment, the control unit 21 of the management server 20 executes the calculation process of the second approximation formula using the least squares method (step S304). Thereby, considering the usage tendency of cement throughout, the remaining amount in the future can be predicted. For example, when there is a large variation in the measurement information, the decreasing tendency can be predicted throughout.

[0055] (5) In this embodiment, the control unit 21 of the management server 20 executes the selection process of the approximation formula in which the predicted remaining amount value is close to the current measured value (step S307). Thereby, using the approximation formula that reflects the current remaining amount, the remaining amount in the future can be predicted.

[0056] (6) In this embodiment, the control unit 21 of the management server 20 executes the prediction process of the future remaining amount after the lead time (step S308). Thereby, considering the period required for filling the cement, the remaining amount can be predicted.

[0057] (7) In this embodiment, when it is determined that it is a site holiday after the lead time or when it is determined that it is a supplier holiday after the lead time (when "YES" in steps S310 and S311), the control unit 21 of the management server 20 executes the adjustment process of the order date (step S312). Thereby, considering the holiday, filling can be performed. Since cement is not used on the site holiday, filling can be postponed. Also, considering the supplier holiday, filling can be advanced.

[0058] This embodiment can be implemented with the following modifications. This embodiment and the following modification examples can be implemented in combination with each other within a technically non - conflicting range. ·In the above-described embodiment, the management server 20 is used to manage the cement stored in the silo 10 as a material management program. The present invention can be applied to materials whose remaining quantity changes according to the usage situation. ·In the above-described embodiment, the control unit 21 of the management server 20 executes error correction processing. Instead of this, the prediction processing may be suspended until the evaluation period elapses after filling.

[0059] ·In the above-described embodiment, the load cell 12 is used to acquire measurement information about the current remaining quantity of cement. The method for specifying the remaining quantity of cement is not limited to the measurement using the load cell 12. For example, as in the prior art, the remaining quantity may be calculated by image processing using a photographed image inside the container 11.

[0060] ·In the above-described embodiment, the control unit 21 of the management server 20 executes the calculation process (step S303) of the first approximation formula using the weighted average and the calculation process (step S304) of the second approximation formula using the least squares method. The plurality of approximation formulas used for prediction only need to have different evaluation methods and are not limited to the weighted average and the least squares method.

[0061] ·In the above-described embodiment, the control unit 21 of the management server 20 executes the prediction process of the future remaining quantity after the lead time (step S308). Here, it is only necessary to be able to predict the timing when cement filling is required. For example, an approximation formula may be used to predict the filling required timing when the future remaining quantity becomes less than the threshold value. Then, when the filling required timing falls within the period from the order placement to the supply, the control unit 21 places an order. Also in this case, the control unit 21 of the management server 20 adjusts the order placement timing in consideration of the holidays of the construction site and the supplier in the same manner as in step S312.

[0062] ·In the above embodiment, the control unit 21 of the management server 20 executes a process of acquiring filling information (step S201). Here, filling is detected based on measurement information. The method of detecting filling is not limited to the case of using measurement information. For example, the management server 20 may acquire the filling information input to the administrator terminal.

[0063] ·In the above embodiment, the calendar storage unit 22 records the first calendar information regarding the business days of the construction site and the second calendar information regarding the business days of the cement supplier (order destination). The real-time adjustment is not limited to holidays. For example, the busyness or slackness of the site or the supplier may be considered. In this case, when the control unit 21 of the management server 20 acquires the busyness information of the site or the supplier, the lead time is made longer than when the slackness information is acquired to ensure the number of buffer days.

Explanation of Signs

[0064] 10... silo, 11... container, 12... load cell, 20... management server, 21... control unit, 210... management unit, 211... prediction unit, 212... instruction unit, 22... calendar storage unit, 23... measurement information storage unit.

Claims

1. A material management system comprising a control unit connected to a measurement unit for measuring the remaining amount of materials in a container, and a measurement information storage unit for recording the remaining amount of the materials in association with the measurement time, wherein the control unit acquires the remaining amount of the materials in the container from the measurement unit, records it in the measurement information storage unit in association with the measurement time, uses the measurement time and the remaining amount recorded in the measurement information storage unit to calculate a plurality of reduction trends by a plurality of calculation methods, applies the remaining amount in the past evaluation period to the plurality of reduction trends to predict the current remaining amount, and uses the reduction trend in which the predicted remaining amount is close to the actual remaining amount to predict the future remaining amount, when the future remaining amount becomes less than a threshold value, places an order with the supplier of the materials, characterized in that it is a material management system.

2. The material management system according to claim 1, characterized in that at least one of an approximate formula using a weighted average and an approximate formula using the least squares method is used as the calculation method.

3. The control unit identifies the site closing days at the place where the materials are used, and transmits an order instructing filling after the site closing days to the supplier, characterized in that it is the material management system according to claim 1 or 2.

4. The control unit identifies the supplier closing days of the supplier of the materials, and transmits an order instructing filling before the supplier closing days to the supplier, characterized in that it is the material management system according to claim 1 or 2.

5. A method for managing the materials using a material management system comprising a control unit connected to a measurement unit for measuring the remaining amount of materials in a container, and a measurement information storage unit for recording the remaining amount of the materials in association with the measurement time, wherein the control unit acquires the remaining amount of the materials in the container from the measurement unit, records it in the measurement information storage unit in association with the measurement time, uses the measurement time and the remaining amount recorded in the measurement information storage unit to calculate a plurality of reduction trends by a plurality of calculation methods, applies the remaining amount in the past evaluation period to the plurality of reduction trends to predict the current remaining amount, and uses the reduction trend in which the predicted remaining amount is close to the actual remaining amount to predict the future remaining amount, when the future remaining amount becomes less than a threshold value, places an order with the supplier of the materials, characterized in that it is a material management method.

6. A program for managing the materials using a material management system comprising a control unit connected to a measurement unit for measuring the remaining amount of materials in a container, and a measurement information storage unit for recording the remaining amount of the materials in association with the measurement time, The control unit obtains the remaining amount of the material in the container from the measurement unit, records it in the measurement information storage unit in association with the measurement time, uses the measurement time and the remaining amount recorded in the measurement information storage unit to calculate a plurality of reduction trends by a plurality of calculation methods, applies the remaining amount in the past evaluation period to the plurality of reduction trends to predict the current remaining amount, and uses the reduction trend in which the predicted remaining amount is close to the actual remaining amount to predict the future remaining amount in the future, A material management program, characterized in that when the future remaining amount becomes less than a threshold value, it functions as means for placing an order with the supplier of the material.

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