Production Management System

Abstract

To provide a manufacturing control system that can easily and accurately grasp a manufacturing state and reduce the load of a control staff, etc.SOLUTION: A control device registers the analysis and / or tally, which are performed based on sequential manufacturing information and a manufacturing schedule transmitted from the PLC, into a database. The control device includes: generating real-time display data using the manufacturing schedule and the sequential manufacturing information; transmitting the data to a terminal device on a regular basis; and displaying the updated real-time display onto the terminal device on a regular basis. The real-time display has multiple device icons 120, each of which corresponds to each manufacturing device. The device icon 120 includes a manufacturing device name, a manufacturing quantity, a scheduled manufacturing quantity, etc. When a device icon 120 is chosen, generated information displays, such as an analysis information display, a tally display, a detailed anomaly display, etc. including the information registered into the database, are pop-up displayed on a display screen.SELECTED DRAWING: Figure 14

Description

[Technical Field]

[0001] The present invention relates to a production management system for managing the production of products in a manufacturing factory. [Background technology]

[0002] In manufacturing factories that process raw materials to manufacture products, PLCs (Programmable Logic Controllers) are known that control the operation of manufacturing equipment such as processing devices and inspection devices (see, for example, Patent Document 1). These PLCs store information related to the operation control. The stored information includes manufacturing time information and error information. The manufacturing time information includes status information such as whether the manufacturing equipment is powered on, whether it is powered on but in a standby state where no processing is being performed, or whether it is in an operating state where processing is being performed.

[0003] Also, a system is known that stores information related to drive control in a database (see, for example, Patent Document 2). [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Application Laid-Open No. 2010-721758 [Patent Document 2] Japanese Patent Application Laid-Open No. 2011-3126 Summary of the Invention [Problem to be solved by the invention]

[0005] Those who manufacture products and those who manage production in the manufacturing plant (hereinafter referred to as "management personnel, etc.") understand the current operating status of the manufacturing plant by checking the manufacturing time information and error information displayed on each PLC. In addition, management personnel, etc. understand the manufacturing capacity of the manufacturing plant based on past manufacturing time information and error information stored in a database, for example, and plan future production.

[0006] It is time-consuming for managers and other personnel to patrol the manufacturing plant to check the displays of each PLC and receive reports from those who have checked the displays, which places a burden on managers and other personnel. In addition, in order to understand the manufacturing capacity of a manufacturing plant from past manufacturing time information and error information stored in a database, skills backed by experience are required, which places a heavy burden on managers and other personnel.

[0007] The present invention has been made in consideration of the above-mentioned circumstances, and its purpose is to provide a production management system that enables easy and accurate understanding of the production status and reduces the burden on managers and others. [Means for solving the problem]

[0008] (1) A production management system according to the present invention includes a plurality of controllers that periodically acquire raw information including manufacturing time-series information associated with an equipment ID, a memory that stores an information database that associates generated information obtained by analyzing or aggregating the raw information with the equipment ID, a display, a program that causes the display to display a screen, and a computer that executes the program. The program executes a first display process that periodically acquires the raw information and periodically updates and displays on the display a real-time display screen having a plurality of equipment icons each including a manufacturing equipment name corresponding to the equipment ID and the manufacturing time-series information, and a second display process that, based on selection of an equipment icon, acquires from the information database the generated information associated with the equipment ID indicated by the equipment icon and displays on the display a generated information display screen including the generated information.

[0009] The real-time display screen allows managers and other personnel to check the operating status of the manufacturing equipment indicated by the original information in real time. Furthermore, by selecting an equipment icon on the real-time display screen, managers and other personnel can check the generated information obtained by analyzing and collecting the original information for each manufacturing equipment. As a result, the production management system according to the present invention allows managers and other personnel to easily and accurately grasp the production status and reduces the burden on managers and other personnel.

[0010] (2) The real-time display screen may have a plurality of display areas, each of which is assigned a name object indicating an area of ​​a manufacturing plant and which are separated from one another. The program has one of the display areas associated with the device ID and location information indicating the location of the device icon in that display area.

[0011] A manufacturing factory is divided into multiple areas by floors, walls, etc., and each area is used for processing, finishing, inspection, etc. The real-time display screen is divided into multiple display areas corresponding to the above areas. The equipment icons are arranged in display areas corresponding to the actual locations in the manufacturing factory of the manufacturing equipment indicated by the equipment ID. Therefore, managers and the like can intuitively recognize which equipment icons are associated with which manufacturing equipment. As a result, the burden on managers and the like is further reduced.

[0012] (3) The manufacturing time information included in the device icon may include the product name, operating time, and manufacturing quantity indicated by the product ID.

[0013] The manufacturing time information included in the equipment icon includes the product name, operating time, and production quantity indicated by the product ID. That is, the equipment icon displays the manufacturing equipment name, product name, operating time, and production quantity. Therefore, managers and other personnel can easily grasp the product name, operating time, and production quantity for each manufacturing equipment. As a result, the burden on managers and other personnel is further reduced.

[0014] (4) The raw information may further include error information. The generated information display screen includes a first graph associating normal operation periods and abnormal stop periods specified based on the error information with time.

[0015] With the above configuration, the manager or the like can easily grasp, for each manufacturing device, when an error occurred, the period during which the error occurred, the period during which the device was operating normally, etc. As a result, the burden on the manager or the like is further reduced.

[0016] (5) The original information may further include error information. The generated information display screen includes a table in which dates, operation times, production quantities, cumulative normal operation times, and cumulative abnormal stop times are associated with each other.

[0017] With the above configuration, the manager or the like can easily grasp the cumulative time of normal operation, the cumulative time of abnormal stoppage, and the production quantity for each date, which further reduces the burden on the manager or the like.

[0018] (6) The raw information may further include error information, and the generated information display screen may include a second graph in which the error types and the number of errors indicated by the error information are associated with each other.

[0019] According to the above configuration, the administrator or the like can easily recognize the type of error and the number of errors by looking at the graph, which further reduces the burden on the administrator or the like.

[0020] (7) The memory may further store a production schedule database that associates product IDs, equipment IDs, and production schedules. The equipment icon may further include a planned production quantity included in the production schedule and an achievement rate calculated by the program based on the planned quantity and the production quantity.

[0021] The program calculates the achievement rate based on the planned production quantity and production volume registered in the production schedule database, and includes the achievement rate and planned production quantity in the equipment icon. This allows managers and other personnel to easily grasp the achievement rate for each manufacturing device, further reducing the burden on managers and other personnel.

[0022] (8) The real-time display screen may further include a display switching icon for switching between the manufacturing time information displayed on the device icon and cumulative information that is a cumulative total of the manufacturing time information. Based on selection of the display switching icon, the program further executes a display switching process for displaying the cumulative information on the device icon instead of the manufacturing time information without changing the position of the device icon on the real-time display screen.

[0023] Since the display of the manufacturing time information and the generation information can be switched without changing the position of the device icon, the manager or the like can check both the current manufacturing time information and the cumulative information, which is the cumulative manufacturing time information, for the manufacturing device of interest without changing his or her line of sight, thereby further reducing the burden on the manager or the like.

[0024] (9) The production management system according to the present invention may further include a plurality of temperature and humidity sensors installed in the plurality of areas, each outputting a sensor ID and temperature and humidity information. The real-time display screen may further include a plurality of temperature and humidity display objects arranged in the plurality of display areas, each displaying the temperature and humidity information. The arrangement information may further include a correspondence between the sensor ID and the arrangement position of the temperature and humidity display object. The program may further display a manufacturing caution object on the real-time display screen when the temperature and humidity information in at least one of the display areas is equal to or greater than a threshold.

[0025] According to the above configuration, when the temperature or humidity is such that it may affect the quality of the product, a manufacturing caution object is displayed on the real-time display screen to alert the manager, etc. As a result, the burden on the manager, etc. is further reduced.

[0026] (10) The memory may further store a production schedule database that associates product IDs, equipment IDs, and production schedules. The real-time display screen has a total number object in each of the display areas that displays a total planned quantity for each display area according to the production schedule and a total production quantity for each display area according to the production chronological information.

[0027] The total planned quantity and total production quantity are displayed in each display area of ​​the real-time display screen. This allows managers and other personnel to more easily grasp the production status in each area of ​​the manufacturing plant. As a result, the burden on managers and other personnel is further reduced. [Effects of the Invention]

[0028] The production management system according to the present invention makes it possible to easily and accurately grasp the production status, thereby reducing the burden on management personnel and the like. [Brief explanation of the drawings]

[0029] [Figure 1] FIG. 1 is a diagram showing the configuration and functions of a production management system 10. [Figure 2] FIG. 2 is a layout diagram showing the layout of manufacturing equipment 30 in manufacturing factory 20. [Figure 3] FIG. 3(A) is a diagram showing a production schedule database, and FIG. 3(B) is a diagram showing a raw information database. [Figure 4] FIG. 4 is a diagram showing the analysis information database. [Figure 5] FIG. 5(A) is a diagram showing an average cycle time database, and FIG. 5(B) is a diagram showing a setup change time database. [Figure 6]FIG. 6(A) is a diagram showing the summary database, and FIG. 6(B) is a diagram showing the measurement value database. [Figure 7] 10 is a flowchart showing a process of registering a production schedule, original information, and analysis information in a database. [Figure 8] FIG. 8 is a flowchart showing the process of displaying the real-time display screen. [Figure 9] FIG. 9 is a flowchart showing the process of displaying the tally display screen. [Figure 10] FIG. 10 is a flowchart showing the process of displaying the analysis information display screen. [Figure 11] FIG. 11 is a flowchart showing the process of displaying the current period cumulative total display screen. [Figure 12] FIG. 12 is a flowchart showing the process of displaying the abnormality details display screen, NG details monthly display screen, NG details daily display screen, measurement value display screen, average cycle time display screen, and setup change time display screen. [Figure 13] FIG. 13 is a flowchart showing a process for displaying the temperature and humidity history display screen and the camera image display screen. [Figure 14] FIG. 14 is a diagram showing a real-time display screen. [Figure 15] FIG. 15 is a diagram showing a real-time display screen. [Figure 16] FIG. 16 is a diagram showing the total display screen. [Figure 17] FIG. 17 is a diagram showing the analysis information display screen. [Figure 18] FIG. 18 is a diagram showing the current term cumulative total display screen. [Figure 19] FIG. 19 is a diagram showing the abnormality details display screen. [Figure 20] FIG. 20 shows the NG detail monthly display screen. [Figure 21] FIG. 21 is a diagram showing the NG detail daily display screen. [Figure 22] FIG. 22 is a diagram showing the measurement value display screen. [Figure 23]FIG. 23 is a diagram showing an average cycle time display screen. [Figure 24] FIG. 24 is a diagram showing the setup change time display screen. [Figure 25] FIG. 25 is a diagram showing the temperature and humidity history display screen.

[0030] A preferred embodiment of the present invention will be described below with reference to the accompanying drawings. It should be noted that this embodiment is merely one aspect of the production management system according to the present invention, and it goes without saying that the implementation may be changed without departing from the spirit of the present invention. For example, the execution order of each process described below may be changed without departing from the spirit of the present invention. Alternatively, some of the processes described below may be omitted without departing from the spirit of the present invention.

[0031] Fig. 1 is a configuration diagram showing the configuration of a production management system 10 according to one embodiment of the present invention. Fig. 1 is also a functional block diagram showing the functions of a management device 60, a first server 70, a second server 80, and a terminal device 90 that make up the production management system 10.

[0032] The production management system 10 is a system used for production management in the manufacturing factory 20. Production management means that those who manufacture products or manage production in the manufacturing factory 20 (hereinafter referred to as "management personnel, etc.") understand the operating status of the manufacturing equipment 30, the types of products currently being manufactured, the types of products to be manufactured, the number of units to be manufactured, the yield, etc. The management personnel, etc. use the production management system 10 to understand the current manufacturing status, identify problems from past manufacturing history and make improvements to the current situation, and plan future manufacturing schedules based on the current manufacturing status and past manufacturing history.

[0033] In this embodiment, a production management system 10 is described which is used for production management at two manufacturing factories 20, a head office factory 21 and a regional factory 22. However, the production management system 10 may be used for production management at one or three or more manufacturing factories 20.

[0034] 2 is a layout diagram showing the arrangement of each manufacturing device 30 installed on the first floor of the manufacturing factory 20. The manufacturing devices 30 include a processing device 31, a coolant device 32, a finishing device 33, and a cleaning device 34. Although not shown in FIG. 2, the manufacturing devices 30 also include an inspection device 35 (see FIG. 1).

[0035] The manufacturing factory 20 is divided into multiple areas 40 by floors, walls, etc. Manufacturing equipment 30 for the same purpose is installed in each area 40. Examples of the same purpose include "processing," "coolant," "finishing," and "inspection." In the example shown in FIG. 2, the first floor of the manufacturing factory 20 is divided into six areas 40: a "cylinder" area 41, a "coolant" area 42, a "width / outer diameter" area 43, an "inner diameter" area 44, a "finishing" area 45, and a "cleaning" area 46.

[0036] The "Cylinder" area 41 is an area intended for processing raw materials into cylindrical parts, for example. The "Coolant" area 42 is an area intended for cooling cylindrical parts. The "Width / Outer Diameter" area 43 is an area intended for processing the outer part of the cylindrical part, for example, drilling, bending, cutting, etc. The "Inner Diameter" area 44 is an area intended for processing the inner part of the cylindrical part, for example, drilling, bending, cutting, etc. The "Finishing" area 45 is an area intended for finishing the processed part (product), such as polishing. The "Cleaning" area 46 is an area intended for cleaning the finished product.

[0037] In the example shown in FIG. 2, four processing devices 31 that process raw materials into cylindrical members are arranged in a "Cylinder" area 41. One coolant device 32 that performs cooling is arranged in a "Coolant" area 42. Two processing devices 31 that process the outer portions of the cylindrical members are arranged in a "Width / Outer Diameter" area 43. Nine processing devices 31 that process the inner portions of the cylindrical members are arranged in an "Inner Diameter" area 44. Two finishing devices 33 that perform finishing are arranged in a "Finishing" area 45. One cleaning device 34 that cleans the products is arranged in a "Cleaning" area 46. Although not shown in FIG. 2, an inspection device 35 (see FIG. 1) that inspects the products is arranged in another area (not shown) in the manufacturing plant 20.

[0038] The raw materials are transported in order by forklift or conveyor to the "Cylinder" area 41, "Coolant" area 42, "Outer diameter / width" area 43, and "Inner diameter" area 44, and after processing etc. in each of areas 41, 42, 43, and 44, they are transported to the "Finishing" area 45. After the product is polished or other finishing in the "Finishing" area 45, it is transported to the "Cleaning" area 46 and washed. After cleaning, the product is transported to the "Inspection" area (not shown) and inspected, such as for dimensional measurement.

[0039] As shown in FIG. 1, the production management system 10 includes a PLC (Programmable Logic Controller) 50, a management device 60, a first server 70, a second server 80, a terminal device 90, a camera 110, and a temperature and humidity sensor 111.

[0040] The cameras 110 are installed in the manufacturing factory 20. For example, the cameras 110 are installed in each of the areas 40. Video data generated by the cameras 110 through image capture is transmitted to the management device 60 via the communication network 11 together with a camera ID that can individually identify the camera 110. The video data may be video data or still image data.

[0041] The temperature and humidity sensor 111 is installed in the manufacturing factory 20. For example, the temperature and humidity sensor 111 is installed in each area 40, and measures the temperature and humidity in each area 40. Temperature and humidity information indicating the temperature and humidity measured by the temperature and humidity sensor 111 is transmitted to the management device 60 via the communication network 11 together with a sensor ID that can individually identify the temperature and humidity sensor 111. Note that the temperature and humidity sensor 111 may be included in the PLC 50. In this case, the temperature and humidity information is included in the raw information that the PLC 50 transmits to the management device 60.

[0042] The PLC 50, management device 60, first server 70, second server 80, terminal device 90, camera 110, and temperature and humidity sensor 111 are connected to a communication network 11 by wire or wirelessly. The communication network 11 may be a local area network (LAN), a wide area network (WAN), or the Internet. In the example shown in Fig. 1, a LAN is installed at each of the head office factory 21 and the regional factories 22, and the LANs are interconnected via the Internet. Note that Fig. 1 does not show gateway devices such as routers that connect the LANs to the Internet, switching hubs that control communication, and the like.

[0043] The management device 60 communicates with the first server 70, the second server 80, and the terminal device 90 using, for example, a TCP / IP communication protocol. The management device 60, the first server 70, the second server 80, and the terminal device 91 are installed in the head office factory 21, and the management device 60 communicates with the first server 70, the second server 80, and the terminal device 90 via a LAN or a WAN. On the other hand, the terminal device 92 is installed in the regional factory 22, and the terminal device 93 is a portable mobile terminal. The terminal devices 92 and 93 communicate with the management device 60 by sending HTTP requests and receiving HTTP responses that are responses to the HTTP requests.

[0044] The PLC 50 is a device that controls the operation of the manufacturing equipment 30 and periodically acquires and stores, at a predetermined sampling period, an equipment ID that identifies the manufacturing equipment 30 that it controls, manufacturing time information, error information, and the like. The manufacturing time information includes, for example, whether or not power is supplied to the manufacturing equipment 30, the number of products processed (manufactured quantity) after power is supplied, and measurement information. If the manufacturing equipment 30 is an inspection device, the measurement information includes measurement values ​​obtained by measuring the dimensions of each part of the product and information indicating whether the product is good or bad. The error information includes, for example, an error code corresponding to a malfunction that has occurred in the manufacturing equipment 30. For example, the PLC 50 acquires or generates a corresponding predetermined error code when a cylinder, motor, or the like of the manufacturing equipment 30 stops unintentionally.

[0045] The PLC 50 may be built into the manufacturing apparatus 30 in advance, or may be attached to the manufacturing apparatus 30 later. The PLC 50 may control the drive of one manufacturing apparatus 30, or may control the drive of multiple manufacturing apparatuses 30. In the example shown in FIG. 1, one PLC 50 is attached to one manufacturing apparatus 30. The PLC 50 corresponds to the "controller" recited in the claims.

[0046] The PLC 50 has a display (not shown) that displays periodically acquired manufacturing time information and error information, and an additional memory (not shown) that stores the information and the device ID. The additional memory has a storage capacity that can store, for example, three days' worth of manufacturing time information and error information. In other words, the PLC 50 can store several days' worth of manufacturing time information and error information, but cannot store long-term manufacturing time information or error information, such as one month's worth. The PLC 50 updates the manufacturing time information by, for example, overwriting the oldest manufacturing time information or error information with newly acquired manufacturing time information or error information.

[0047] The PLC 50 associates the acquired device ID, manufacturing time information, and error information with the acquisition date and time and periodically transmits them to the management device 60 as raw information. For example, the PLC 50 acquires manufacturing time information and error information at a sampling period of several hundred milliseconds to several seconds, and transmits multiple pieces of acquired manufacturing time information and error information at intervals of several seconds to several tens of seconds. Note that the raw information transmitted by the PLC 50 does not need to include the acquisition date and time. In that case, for example, the date and time when the raw information was received by the management device 60 may be added to the raw information.

[0048] The management device 60 is a server, a personal computer, or the like. The management device 60 includes a CPU 61, which is a central processing unit, a memory 62, and a communication interface 63. The communication interface 63 is connected to the communication network 11 by a wired connection such as a LAN (registered trademark) cable, or is connected to the communication network 11 by a wireless LAN such as Wi-Fi (registered trademark).

[0049] The memory 62 is RAM, ROM, hard disk memory, EEPROM, USB (registered trademark) memory, etc. The memory 62 stores a first program 64, a second program 65, a third program 66, a fourth program 67, an operating system OS 68, and a production schedule database. Note that in FIG. 1, "database" is abbreviated to "DB." Any or all of the programs 64, 65, 66, 67, and a terminal program 104 (described below) correspond to "programs" in the claims. The memory 62 corresponds to "memory" in the claims.

[0050] The first program 64 is a program for transmitting the raw information transmitted by the PLC 50 to the first server 70 and registering it in the raw information database.

[0051] The second program 65 is a program for displaying the raw information transmitted by the PLC 50 on the display 107 or touch panel 109 of the terminal device 90 in real time, and for registering the aggregated data in the aggregated database.

[0052] The third program 66 is a program for generating analysis information, cycle time, and setup change time based on the raw information transmitted by the PLC 50, registering the analysis information in the analysis information database, registering the cycle time in the cycle time database, and registering the setup change time in the setup change time database.

[0053] The fourth program 67 is a program for displaying the above-mentioned analysis information, the above-mentioned cycle time, and the above-mentioned setup change time on the display 107 or touch panel 109 of the terminal device 90.

[0054] The programming language of the first program 64, the second program 65, and the third program 66 is, for example, Python. The fourth program 67 is a program that creates web page data or the created web page data itself. The web page data is written in, for example, HTML. The HTML may include CSS and JavaScript.

[0055] The OS 68 is Windows (registered trademark), macOS (registered trademark), Linux (registered trademark), Unix (registered trademark), ChromeOS (registered trademark), iOS (registered trademark), etc. The OS 68 has various DLLs (Dynamic Link Libraries) such as a DLL for communication and a DLL for display.

[0056] 3A shows an example of a production schedule database stored in the memory 62. The production schedule database is created using, for example, EXCEL (registered trademark) or ACCESS (registered trademark).

[0057] The production schedule database is a database in which process codes, factory identification information, product codes, planned production quantities, equipment to be used, planned start dates and times, and planned end dates and times are registered in association with each other. Specifically, the production schedule database has multiple records (rows) and multiple columns. One record is registered in the production schedule database for one production schedule. Each column is assigned one of the above-mentioned "process code," "factory identification information," "product code," "planned production quantity," "equipment to be used," "planned start dates and times," and "planned end dates and times."

[0058] In each field of the column corresponding to the item "Process Code," a process code is registered as identification information for identifying the production plan (record). The process code is, for example, a lot number. In the illustrated example, "202111-A001," "202111-A002," and "202111-B001" are registered as process codes.

[0059] Each field in the column corresponding to the item "Factory Identification Information" is registered with factory identification information that individually identifies the manufacturing factory 20. In the illustrated example, "001" indicating the head office factory and "002" indicating a regional factory are registered.

[0060] In each field of the column corresponding to the item "product code," a product code is registered as identification information for identifying the type of product. In the illustrated example, "A000002," "B000005," and "C000002" are registered as product codes. The product code may also be the product name. The product code corresponds to the "product ID" described in the claims.

[0061] In each field of the column corresponding to the item "Planned Production Quantity," the planned number of items to be produced for each production plan is registered. In the illustrated example, "2500," "1500," and "2000" are registered as the planned production quantities.

[0062] In each field of the column corresponding to the item "Device to be Used," the device ID of the manufacturing device 30 to be used in each manufacturing plan is registered. In the illustrated example, device IDs such as "A01," "B02," and "C05" are registered as devices to be used. Note that, in one manufacturing plan, multiple manufacturing devices 30 can be registered, such as a manufacturing device 30 that processes "cylinder," a manufacturing device 30 that processes "outer diameter / width," a manufacturing device 30 that processes "inner diameter," and a manufacturing device 30 that performs "finishing."

[0063] Each field in the column corresponding to the item "Scheduled Start Date and Time" registers the scheduled start date and time of production for each manufacturing device 30. In the illustrated example, "2021.11.01 10:15," "2021.11.01 15:00," and "2021.11.01 13:30" are registered as the scheduled start dates and times.

[0064] In each field of the column corresponding to the item "Scheduled End Date and Time," the scheduled end date and time of production for each manufacturing device 30 is registered. In the illustrated example, "2021.11.03 18:00," "2021.11.02 9:15," and "2021.11.03 11:00" are registered as the scheduled end dates and times.

[0065] The registration of a new record in the production schedule database, i.e., the registration of a new production schedule, is performed by a manager or the like. The manager or the like plans (drafts) a production schedule based on the product name, order quantity, delivery date, etc., written on the order form for receiving the order, and registers it in the production schedule database. Note that the first program 64, the second program 65, or a program not shown may automatically generate a new production schedule based on the order form or other production schedule, and register it in the production schedule database.

[0066] The production schedule database shown in Fig. 3(A) is an example, and the production schedule database may have columns with items other than those shown in Fig. 3(A), or may not have some of the columns with the items shown in Fig. 3(A). In addition, the production schedule database may be stored in memory 72, memory 74, memory 82, or memory 84, which will be described later.

[0067] As shown in FIG. 1, the first server 70 includes a CPU 71 which is a central processing unit, a memory 72, and a communication interface 73.

[0068] The memory 72 is a RAM, a ROM, a hard disk memory, an EEPROM, a USB (registered trademark) memory, etc. The memory 72 stores an operating system (OS, not shown) and a first server program 75. This OS, like the OS 68, is Windows (registered trademark), etc. The memory 72 corresponds to the "memory" recited in the claims.

[0069] The first server 70 is, for example, an in-house server installed in a server room at the head office, or may be a web server that makes a URL public.

[0070] The first server 70 is a so-called Redis (registered trademark) server. A Redis server is a server that operates a key-value store type database that runs on memory. A Redis server enables high-speed access to the database by expanding all information registered in the database into memory (RAM) and processing (reading / writing). In addition, a Redis server operates a key-value store type database in which one piece of information is registered by setting one key for each piece of information. In other words, a Redis server can register information in various data formats in the database.

[0071] A memory 74 is connected to the first server 70. The memory 74 may be a hard disk or a storage server. The memory 74 may also be a part of the memory 72. The memory 74 corresponds to the "memory" recited in the claims.

[0072] The memory 74 stores a raw information database, an analysis information database, an average cycle time database, and a setup change time database. The analysis information database, the average cycle time database, and the setup change time database correspond to the "information database" set forth in the claims.

[0073] The raw information database is deployed on the memory 72 (RAM) and accessed by the first server program 75 of the first server 70. That is, the raw information database allows high-speed reading and writing of information. The analysis information database may also be deployed on the memory 72 (RAM) and accessed by the first server program 75 of the first server 70.

[0074] The raw information database is a database that registers the raw information transmitted by the PLC 50. The first program 64 and the first server program 75 register the raw information in the raw information database.

[0075] 3B shows an example of the raw information database, which is created using, for example, EXCEL (registered trademark) or ACCESS (registered trademark).

[0076] The raw information database is a database in which equipment IDs, process codes, product codes, and manufacturing time information are registered in association with each other. Each record in the raw information database is individually identified by the equipment ID and the process code. That is, manufacturing time information is registered for each manufacturing equipment 30 individually identified by the equipment ID and for each manufacturing lot individually identified by the process code.

[0077] The raw information database has multiple records (rows) and multiple columns. Each column is assigned one of the following items: "Device ID," "Process Code," "Product Code," or "Manufacturing Timeline Information."

[0078] Each field in the column corresponding to the item "equipment ID" registers an equipment ID, which is identification information assigned to the manufacturing equipment 30. In the illustrated example, "A01" is registered.

[0079] In each field of the column corresponding to the item "Process Code," a process code, which is identification information for identifying a manufacturing lot, is registered. Each sub-record registered in the raw information database is individually identified by this process code. In the illustrated example, "202111A-001" is registered.

[0080] In each field of the column corresponding to the item "product code," a product code, which is identification information for identifying a product, is registered. In the illustrated example, "A000001" is registered.

[0081] The item "Manufacturing Time Information" has multiple sub-columns, each of which is assigned one of the following items: "Date and Time," "Error Flag," "Error Code," "Power Flag," "Operation Flag," and "Manufacturing Quantity."

[0082] In each field of the sub-column corresponding to the item "date and time", the date and time when the PLC 50 transmitted the raw information or the date and time when the management device 60 received the raw information is registered.

[0083] Each field in the sub-column corresponding to the "Error Flag" item registers an error flag included in the raw information sent by the PLC 50. The error flag is information indicating whether an error (abnormality) has occurred. For example, an "ON" error flag indicates that an error has occurred, and an "OFF" error flag indicates that no error has occurred.

[0084] In each field of the sub-column corresponding to the item "Error Code", an error code included in the original information sent by the PLC 50 is registered.

[0085] The error code is information indicating the type of error (abnormality) that has occurred. Examples of error types include "air pressure abnormality," "emergency stop," "consecutive leak test failures," and "consecutive laser test failures." A correspondence table associating error codes with error types is stored in advance in the memory 62 or the like.

[0086] In each field of the sub-column corresponding to the item "power flag," a power flag included in the original information transmitted by the PLC 50 is registered. The power flag is information indicating whether or not power is being supplied to the manufacturing equipment 30. For example, a power flag of "ON" indicates that power is being supplied to the manufacturing equipment 30, and a power flag of "OFF" indicates that power is not being supplied to the manufacturing equipment 30.

[0087] In each field of the sub-column corresponding to the item "operation flag," an operation flag included in the original information sent by the PLC 50 is registered. The operation flag is information indicating whether the manufacturing equipment 30 is operating and manufacturing or inspecting a product (goods). For example, an operation flag of "ON" indicates that the manufacturing equipment 30 is manufacturing or inspecting a product, and an operation flag of "OFF" indicates that the manufacturing equipment 30 is not manufacturing or inspecting a product.

[0088] For example, when power is being supplied to the manufacturing equipment 30 but the equipment is in a preparation period for changing the product to be manufactured (when no errors have occurred), "ON" is registered in the "power flag" item, "OFF" is registered in the "operation flag" item, and "OFF" is registered in the "error flag" item. Also, when power is being supplied to the manufacturing equipment 30 but an error has occurred and the equipment is in an emergency stop, "ON" is registered in the "power flag" item, "OFF" is registered in the "operation flag" item, and "ON" is registered in the "error flag" item. That is, the state of the manufacturing equipment 30 can be analyzed based on the information registered in the "power flag," "operation flag," and "error flag" items. The third program 66 implemented in the management device 60 identifies the state of the manufacturing equipment 30 based on the information registered in the raw information database, and also identifies the type of error, the date and time of occurrence, the date and time of resolution, the duration of the error state, and the like, and registers the identified information as analysis information in the analysis information database ( FIG. 4 ). That is, the raw information is analyzed and registered in the analysis database.

[0089] Although not shown in FIG. 3(B), the item "Manufacturing Time Information" further has a predetermined number of sub-columns when the manufacturing equipment 30 is the inspection equipment 35. Each of the predetermined number of sub-columns is assigned one of the items, for example, "Inspection Date and Time," "Inspection Name 1," "Inspection Name 2," and "Inspection Name 3." Inspection Name 1, Inspection Name 2, and Inspection Name 3 are the names of the inspections performed by the inspection equipment 35, such as "Abnormality Detected," "Consecutive NG in External Dimensions," and "Consecutive NG in Pin Inspection."

[0090] In the field of the subcolumn labeled with the item "Inspection Date and Time," the date and time when the inspection was performed by the inspection device 35 is registered. In the fields of the subcolumns labeled with the items "Inspection Name 1," "Inspection Name 2," etc., the measurement values ​​and pass / fail results of the inspection of the corresponding name by the inspection device 35 are registered. That is, in the raw information database, the device ID of the inspection device 35, the process code, the product code, the inspection date and time, and the measurement values ​​(or pass / fail results) are registered in association with each other. Note that the raw information database shown in FIG. 3(B) is only an example, and the raw information database may have columns labeled with items other than those shown in the figure, or may not have some of the columns labeled with the items shown in the figure.

[0091] Fig. 4 shows an example of an analysis information database. Fig. 4(A) shows the analysis database when the manufacturing equipment 30 is a processing equipment 31. Fig. 4(B) shows the analysis database when the manufacturing equipment 30 is an inspection equipment 35. The analysis information database is created using, for example, EXCEL (registered trademark) or ACCESS (registered trademark).

[0092] The analysis information is registered in the analysis information database by the third program 66 and the first server program 75.

[0093] The analysis information database is a database in which equipment IDs, process codes, product codes, and analysis information are registered in association with each other. Each record in the analysis information database is individually identified by an equipment ID. That is, analysis information is registered for each manufacturing equipment 30 individually identified by an equipment ID. Each record in the analysis information database is also individually identified by a product code. That is, analysis information is registered for each production lot.

[0094] The analysis information database shown in Figure 4(A) has multiple records (rows) and multiple columns. Each column is assigned one of the following items: "equipment ID," "process code," "product code," and "analysis information." The items "equipment ID," "process code," and "product code" are the same as the items "equipment ID," "process code," and "product code" in the original information database.

[0095] The "Analysis Information" item has multiple sub-columns, each of which is assigned one of the following items: "Date," "Status," "Error Type," "Start Time," "End Time," and "Duration."

[0096] In each field of the subcolumn corresponding to the item "Date," a date is registered. In the illustrated example, "2021.11.01" is registered.

[0097] Each field in the subcolumn corresponding to the "Status" item registers "Stopped," "Ready," "Operating," "Abnormally Stopped," and other statuses of the manufacturing equipment 30. "Stopped" indicates that no power is being supplied to the manufacturing equipment 30. "Ready" indicates that preparations are underway to switch from manufacturing one product to manufacturing another (so-called "changeover"). "Operating" indicates that the manufacturing equipment 30 is manufacturing, inspecting, or otherwise processing a product. "Abnormally Stopped" indicates that product manufacturing, inspection, or other operations have been stopped due to the occurrence of an error such as "Air Pressure Abnormal," "Emergency Stop," "Continuously Failed Leak Test," or "Continuously Failed Laser Test."

[0098] The type of error that occurred is registered in each field of the subcolumn corresponding to the "Error Type" item. Error types include "Abnormal Air Pressure," "Emergency Stop," "Continuously Failed Leak Test," and "Continuously Failed Laser Test." Note that "Error Type" is registered only in fields corresponding to subrecords whose "Status" item is "Abnormal Stop," while "-" or "None" are registered in fields of subrecords corresponding to the "Stopped," "Preparation Period," and "Operation" items.

[0099] In each field of the sub-column corresponding to the item "Start Time," a "time" is registered. The registered "time" indicates the time when the manufacturing equipment 30 entered a stopped state, a ready state, an operating state, an abnormally stopped state, etc.

[0100] In each field of the sub-column corresponding to the item "End Time," a "time" is registered. The registered "time" indicates the time when the manufacturing equipment 30 transitioned from a stopped state, a ready state, an operating state, an abnormally stopped state, etc. to another state.

[0101] In each field of the subcolumn corresponding to the item "period," a "period" is registered. The registered "period" indicates the period during which the manufacturing equipment 30 was in a stopped state, a ready state, an operating state, an abnormally stopped state, or the like. In the illustrated example, "30 minutes" or "2 hours and 42 minutes" is registered. Note that in the illustrated example, the "period" is registered in minutes, but the period may also be registered in seconds.

[0102] The analysis information database shown in Figure 4(B) has multiple records (rows) and multiple columns. Each column is assigned one of the following items: "equipment ID," "process code," "product code," and "analysis information." The items "equipment ID," "process code," and "product code" are the same as those in the analysis database shown in Figure 4(A).

[0103] A column labeled with the item "analysis information" has multiple subcolumns labeled with one of the items "date," "status," "error type," "start time," "end time," and "period," similar to the analysis information database shown in FIG. 4(A). The column labeled with the item "analysis information" also has multiple subcolumns labeled with the names of inspection items. In the example shown in FIG. 4(B), the column labeled with the item "analysis information" has subcolumns labeled with "abnormality detected," "outer diameter dimension consistently failed," and "pin inspection consistently failed." The column labeled with the item "analysis information" may also have subcolumns labeled with the names of other search items.

[0104] In the field of the sub-column with the name of the test item, the number of times the test indicated by the name was "fail" is registered.

[0105] 5A shows an average cycle time database, which is created using, for example, EXCEL (registered trademark) or ACCESS (registered trademark).

[0106] The registration of information in the average cycle time database is performed by the third program 66 and the first server program 75.

[0107] The average cycle time database is a database in which equipment IDs, product codes, process names, cycle times, and quantities are registered in association with each other. Each record in the average cycle time database is individually identified by an equipment ID or product code. In other words, the cycle time is registered for each manufacturing equipment 30 and each product (item).

[0108] The average cycle time database has multiple records (rows) and multiple columns. Each column is assigned one of the following items: "equipment ID," "product code," "process name," "cycle time," or "quantity." The items "equipment ID" and "product code" are the same as the items "equipment ID" and "product code" in the original information database.

[0109] The item "Process Name" indicates the name of a process such as processing or inspection performed by the manufacturing equipment 30 indicated by the equipment ID. The item "Cycle Time" indicates the average time required to process or inspect one product. The item "Quantity" indicates the number of products processed or inspected by the manufacturing equipment 30 indicated by the equipment ID. The time required for manufacturing and the number of manufactured products are identified based on the manufacturing time chronological information registered in the raw information database, and the cycle time is calculated by dividing the time required for manufacturing by the number of manufactured products. In other words, the average cycle time database is a database in which analysis information (cycle time) obtained by analyzing the raw information is registered. The cycle time database may be an integrated database with the analysis information database.

[0110] The information registered in the analysis information database, the average cycle time database, the setup time database, the tally database and the measurement value database described below corresponds to the "generated information" described in the claims. The analysis information database, the average cycle time database, the setup time database, the tally database and the measurement value database correspond to the "information database" described in the claims.

[0111] 5B shows the setup change time database, which is created using, for example, EXCEL (registered trademark) or ACCESS (registered trademark).

[0112] The third program 66 and the first server program 75 register information in the setup change time database.

[0113] The setup change time database is a database in which equipment IDs, start dates and times, end dates and times, product codes, and setup change times are registered in association with each other. Each record in the setup change time database is individually identified by an equipment ID. That is, for each manufacturing equipment 30 individually identified by an equipment ID, the setup change time when processing (inspection) is switched from one product to another is registered.

[0114] The setup change time database has multiple records (rows) and multiple columns. Each column is assigned one of the following items: "equipment ID," "start date and time," "end date and time," "product code," and "setup change time." The items "equipment ID" and "product code" are the same as the items "equipment ID" and "product code" in the original information database.

[0115] The item "Start Date and Time" indicates the date and time before switching from processing (inspection) of one product to processing (inspection) of another product. The item "End Date and Time" indicates the date and time after switching from processing (inspection) of one product to processing (inspection) of another product.

[0116] The item "Product Code" has two sub-columns named "Before Setup" and "After Setup." The item "Before Setup" indicates the product code of the product that was being processed or inspected before the changeover. The item "After Setup" indicates the product code of the product that will be processed or inspected after the changeover. In the illustrated example, the date and time before the inspection device 35 indicated by device ID "A01" switched the inspection target from product code "A000001" to product code "A000003" was 15:15:08 on February 2, 2018, and the date and time after the inspection target was switched was 15:38:38 on February 2, 2018, and the time required for the changeover (setup) (setup time) was 16 minutes and 46 seconds.

[0117] For example, the start date and time (disclosure date and time) and end date and time (end date and time) of the changeover are identified based on the planned production quantity registered in the production schedule database and the production quantity, flags, and date and time registered in the original information database, and the changeover time is calculated from the identified start date and time and end date and time and registered in the changeover time database. In other words, the changeover time database is a database in which generated information (changeover time) obtained by analyzing the original information using the production schedule is registered. Note that the changeover time database may be integrated with the analysis information database.

[0118] 1 is, for example, an in-house server installed in a server room at the head office. The second server 80 may also be a web server that makes a URL public.

[0119] The second server 80 has a CPU 81, which is a central processing unit, a memory 82, and a communication interface 83. The memory 82 is a RAM, a ROM, a hard disk memory, an EEPROM, a USB (registered trademark) memory, or the like. The memory 82 stores an operating system (not shown) and a second server program 85. This OS, like the OS 68, is Windows (registered trademark), or the like.

[0120] A memory 84 is connected to the second server 80. The memory 84 may be a hard disk or a storage server. The memory 84 may also be a part of the memory 82. The memories 82 and 84 correspond to the "memory" recited in the claims.

[0121] The memory 84 stores a summary database and a measurement value database. The summary database and the measurement value database correspond to the "information database" set forth in the claims.

[0122] The tally database is a database that registers the number of products (manufactured quantity) manufactured each day by the manufacturing apparatus 30. The registration of tally information in the tally database is performed by the second program 65 and the second server program 85.

[0123] 6A shows an example of the tally database, which is created using, for example, EXCEL (registered trademark) or ACCESS (registered trademark).

[0124] The aggregation database is a database in which dates, factory identification information, equipment IDs, product codes, operating hours, production quantities, target achievement rates (%), operating ratios (%), power-on times, and power-off times are registered in association with each other. That is, the operating hours, production quantities, target achievement rates (%), operating ratios (%), power-on times, and power-off times are registered in the aggregation database for each date, each manufacturing factory, each manufacturing equipment 30, and each product.

[0125] The aggregation database has multiple records (rows) and multiple columns. Each column is assigned one of the following items: "Date," "Factory Identification Information," "Equipment ID," "Product Code," "Operating Time," "Production Quantity," "Target Achievement Rate (%)," "Operating Ratio (%)," "Power-On Time," and "Power-Off Time." The items "Date," "Factory Identification Information," "Equipment ID," and "Product Code" are the same as the items "Date," "Factory Identification Information," "Equipment ID," and "Product Code" described in the analysis information database and the production schedule database.

[0126] Each column with the items "Operating Time" and "Production Quantity" has three sub-columns. The multiple sub-columns of the items "Operating Time" and "Production Quantity" are each assigned one of the following items: "Daytime," "Nighttime," and "Total." Daytime operating hours are registered in each field of the sub-column corresponding to the sub-item "Daytime" of the item "Operating Time." Daytime refers to the period from 8:00 to 20:00 (12 hours), for example. Nighttime operating hours are registered in each field of the sub-column corresponding to the sub-item "Nighttime" of the item "Operating Time." Nighttime operating hours are registered in each field of the sub-column corresponding to the sub-item "Nighttime" of the item "Operating Time." Nighttime refers to the period from 20:00 to 8:00 the following day (12 hours), for example. The total value of daytime and nighttime operating hours is registered in each field of the sub-column corresponding to the sub-item "Total" of the item "Operating Time." In each field of the sub-column (sub-row) corresponding to the sub-item "Daytime" of the item "Production quantity", the daytime production quantity is registered. In each field of the sub-column (sub-row) corresponding to the sub-item "Nighttime" of the item "Production quantity", the nighttime production quantity is registered. In each field of the sub-column (sub-row) corresponding to the sub-item "Total" of the item "Production quantity", the total value of the production quantity during the day and night is registered.

[0127] Each field in the subcolumn corresponding to the item "Target Achievement Rate (%)" registers the target achievement rate, which is expressed as a percentage (%) of the current production quantity compared to the planned production quantity. The target achievement rate (%) is calculated by dividing the production quantity included in the original information sent by the PLC 50 by the planned production quantity registered in the production schedule database and multiplying the result by 100.

[0128] The column with the item "Operation Rate (%)" has two sub-columns. Each of the two sub-columns is assigned one of the sub-items "Daytime" and "Nighttime." In each field of the sub-column corresponding to the sub-item "Daytime" of the item "Operation Rate (%)," an operation rate indicated by the percentage (%) of the manufacturing equipment 30 operating during the daytime is registered. The operation rate is calculated by dividing the daytime operation time calculated based on the original information by 12 hours (half a day) and multiplying the result by 100. In each field of the sub-column corresponding to the sub-item "Nighttime" of the item "Operation Rate (%)," an operation rate indicated by the percentage (%) of the manufacturing equipment 30 operating during the nighttime is registered. The operation rate is calculated by dividing the nighttime operation time calculated based on the original information by 12 hours (half a day) and multiplying the result by 100.

[0129] In each field of the column labeled "Power ON Time," the total time that the manufacturing equipment 30 was powered on is registered. The time that the power was on is, for example, the total of the operating time and standby time. In each field of the column labeled "Power OFF Time," the total time that the manufacturing equipment 30 was not powered on is registered.

[0130] The tally database also manages temperature and humidity history information. Although not shown in FIG. 6A, the tally database further includes a column labeled "Temperature and Humidity History." The column labeled "Temperature and Humidity History" includes multiple subcolumns named after the areas 40, such as the "Cylinder" area 41 and the "Outer Diameter / Width" area 42. Each record (row) of the tally database includes multiple subrecords corresponding to "time." Specifically, multiple subrecords are provided for each "date," for example, in one-minute increments. The temperature and humidity information transmitted by the temperature and humidity sensor 111 to the management device 60 is registered in each field corresponding to the subrecord and the subcolumn. That is, the tally database stores temperature and humidity history information, which is information associating the date and time with the temperature and humidity information. A temperature and humidity history database for managing temperature and humidity history information, separate from the tally database, may be stored in the memory 82 or 84 of the second server 80. Alternatively, the temperature and humidity history database may be stored in the memory 72 or 74 of the first server 70 as part of the analysis information database or separately from the analysis information database. Alternatively, the temperature and humidity history database may be stored in the memory 62 of the management device 60.

[0131] 6B shows an example of the measurement value database, which is created using, for example, EXCEL (registered trademark) or ACCESS (registered trademark).

[0132] The measurement value database is a database in which factory identification information, equipment ID, product code, inspection date and time, and measurement and judgment information are registered in association with each other. That is, the inspection date and time and measurement and judgment information are registered in association with each other for each manufacturing factory, each manufacturing equipment 30, and each product in the measurement value database.

[0133] The column labeled with the item "Measurement and judgment value information" has multiple sub-columns labeled with items such as "OK / NG," "D / μm," "D1 / μm," and "D1 taper." The field of the sub-column labeled with the item "OK / NG" registers the pass / fail (OK / NG) judged by the inspection device 35. The sub-columns labeled with the items "D / μm," "D1 / μm," and "D1 taper" register the dimensions (measured values) of the product measured by the inspection device 35.

[0134] As shown in FIG. 1 , terminal devices 91, 92, and 93, which are terminal devices 90, are connected to a communication network 11. The terminal device 91 is a personal computer installed in the head office factory 21. The terminal device 91 is communicably connected to the management device 60, for example, via a wired or wireless LAN. The terminal device 92 is a personal computer installed in the regional factory 22. The terminal device 92 is connected to the management device 60, for example, via a wired or wireless LAN and the Internet. The terminal device 93 is a mobile terminal such as a smartphone or tablet used in the head office factory 21 or the regional factory 22. The terminal device 93 is connected to the management device 60, for example, via a mobile communication network and the Internet.

[0135] The terminal device 91 and the terminal device 92 have the same configuration. The terminal devices 91 and 92 each include a CPU 101, which is a central processing unit, a memory 102, and a communication interface 103. Note that the CPU 101, memory 102, and communication interface 103 of the terminal device 92 are not shown in Fig. 1.

[0136] The CPU 101 of the terminal device 90, the CPU 61 of the management device 60, the CPU 71 of the first server 70, and the CPU 81 of the second server 80 correspond to the "computer" set forth in the claims.

[0137] The memory 102 is a RAM, a ROM, a hard disk memory, an EEPROM, a USB (registered trademark) memory, etc. The memory 102 stores a terminal program 104, a browser 105, and an OS 106. The OS 106 is an operating system, and like the OS 68, is Windows (registered trademark) or the like.

[0138] The browser 105 is Google Chrome (registered trademark), Firefox (registered trademark), Microsoft Edge (registered trademark), Internet Explorer (registered trademark), etc. The browser 105 displays, for example, a web page indicated by the web page data generated by the fourth program 67 on the display 107 via the OS 106.

[0139] The terminal program 104 is a program that displays a real-time display screen on the display 107 or the touch panel 109. The terminal program 104 may be an application program separate from the browser 105, a plug-in program for the browser 105, or the browser 105 itself. When the terminal program 104 is a plug-in program for the browser 105, for example, the terminal program 104 is installed in the terminal device 90 by an administrator or the like starting the browser 105 of the terminal device 90 and accessing a URL made public by the server 70, 80 or the management device 60 or the like.

[0140] The terminal program 104 may also have a function of registering a production schedule in a production schedule database. For example, the terminal program 104 accepts a production schedule input into the terminal device 90 by a manager or the like, and transmits the accepted production schedule together with an instruction to the management device 60. The instruction is, for example, a command. The OS 68 or the second program 65 of the management device 60 registers the production schedule in the production schedule database in accordance with the received instruction. Note that a management program that registers the production schedule in the production schedule database may be installed in the management device 60 separately from the second program 65.

[0141] A display 107 and an input device 108 are connected to the terminal devices 91 and 92. The input device 108 is a keyboard and mouse, a microphone for voice input, or the like.

[0142] The terminal device 93 is a tablet or the like, and includes a CPU 101 and a memory 102 similar to those of the terminal devices 91 and 92, and a touch panel 109 including a display and a touch sensor (input device).

[0143] 7 to 13 are flowcharts showing the processing executed by each program, such as the programs 64, 65, 66, and 67 installed in the management device 60, the server programs 75 and 85 installed in the servers 70 and 80, and the terminal program 104 installed in the terminal device 90. That is, FIGS. 7 to 13 show the processing executed in the production management system 10. Specifically, FIG. 7 is a flowchart showing the processing for registering a production schedule, raw information, analysis information, aggregated information, measured values, and the like in a database. FIG. 8 is a flowchart showing the processing for displaying a real-time display screen (see FIGS. 14 and 15). FIG. 9 is a flowchart showing the processing for displaying an aggregated display screen (see FIG. 16). FIG. 10 is a flowchart showing the processing for displaying an analysis information display screen (see FIG. 17). FIG. 11 is a flowchart showing the processing for displaying a current-period cumulative display screen (see FIG. 18). Fig. 12 is a flowchart showing the process of displaying an abnormality detail display screen (see Fig. 19), a NG detail monthly display screen (see Fig. 20), a NG detail daily display screen (see Fig. 21), a measurement value display screen (see Fig. 22), an average cycle time display screen (see Fig. 23), and a setup change time display screen (see Fig. 24). Fig. 13 is a flowchart showing the process of displaying a temperature and humidity history display screen (see Fig. 25) and a camera image display screen (not shown).

[0144] 14 and 15 are diagrams showing a portion of the real-time display screen displayed on the display 107 or touch panel 109 of the terminal device 90. Note that Fig. 15 is the portion that is displayed by operating the scroll bar of the real-time display screen in Fig. 14.

[0145] FIG. 16 is a diagram showing a summary display screen displayed on the display 107 or touch panel 109 of the terminal device 90. FIG. 17 is a diagram showing an analysis information display screen displayed on the display 107 or touch panel 109 of the terminal device 90. FIG. 18 is a diagram showing a current period cumulative display screen displayed on the display 107 or touch panel 109 of the terminal device 90. FIG. 19 is a diagram showing an abnormality detail display screen displayed on the display 107 or touch panel 109 of the terminal device 90. FIG. 20 is a diagram showing a NG detail monthly display screen displayed on the display 107 or touch panel 109 of the terminal device 90. FIG. 21 is a diagram showing a NG detail daily display screen displayed on the display 107 or touch panel 109 of the terminal device 90. FIG. 22 is a diagram showing a measurement value display screen displayed on the display 107 or touch panel 109 of the terminal device 90. FIG. 23 is a diagram showing an average cycle time display screen displayed on the display 107 or touch panel 109 of the terminal device 90. Fig. 24 is a diagram showing a setup change time display screen displayed on the display 107 or touch panel 109 of the terminal device 90. Fig. 25 is a diagram showing a temperature and humidity history display screen displayed on the display 107 or touch panel 109 of the terminal device 90.

[0146] The processing executed in the production management system 10 will be described below with reference to FIGS.

[0147] A manager or the like inputs a production schedule into the terminal device 90 using the input device 108 or touch panel 109. The terminal device 90 transmits the input production schedule to the management device 60. As shown in Fig. 7, the second program 65 of the management device 60 or the management program registers the production schedule in the production schedule database (S12) based on the management device 60 receiving the production schedule (S11: Yes). If the management device 60 does not receive the production schedule (S11: No), the second program 65 or the management program skips the processing of step S12.

[0148] Furthermore, the management device 60 receives the sensor IDs and temperature and humidity information transmitted from each of the temperature and humidity sensors 111, and the camera IDs and video data transmitted from each of the cameras 110 (S13).

[0149] Meanwhile, the PLC 50 acquires the manufacturing time information and stores the manufacturing time information in the attached memory (S31), and also adds a device ID and acquisition date and time to the manufacturing time information and transmits it to the management device 60 as original information (S32). The PLC 50 repeatedly executes the processes of steps S31 and S32 at predetermined time intervals (sampling intervals) until it determines that the process is finished (S33: No). The PLC 50 determines that the process is finished based on, for example, the power being turned off or an end instruction being input (S33: Yes), and ends the process (end).

[0150] The management device 60 receives the raw information transmitted by the PLC 50 (S32). The first program 64 of the management device 60 transmits the received raw information together with a registration request to the first server 70 (S14). The registration request is, for example, a command.

[0151] The first server 70 receives the raw information and the registration request sent by the management device 60 (S14). The first server program 75 of the first server 70 registers the raw information in the raw information database in accordance with the received registration request (S15).

[0152] Meanwhile, the third program 66 of the management device 60 reads the production schedule from the production schedule database to analyze the original information and generate analysis information (S21). The third program 66 identifies the equipment ID and process code indicating the manufacturing equipment 30 to be analyzed from the read production schedule, and transmits a request for analysis information including the identified equipment ID and process code to the first server 70 (S22). The request is, for example, a command.

[0153] The first server 70 receives the request sent by the management device 60 (S22). The first server program 75 of the first server 70 identifies a record in the raw information database (see FIG. 3(B)) that has a device ID and a process code that match the device ID and the process code included in the received request, and reads out the manufacturing time information included in the identified record (S23). The first server program 75 returns analysis information including the read manufacturing time information (raw information) and the device ID and the process code used to identify the record to the management device 60 as a response to the request received in step S22 (S24).

[0154] The manufacturing time series information included in the analysis information returned by the first server 70 may be all of the manufacturing time series information acquired at each sampling period, or it may be thinned-out manufacturing time series information obtained by thinning out some of the manufacturing time series information from all of the manufacturing time series information.

[0155] The management device 60 receives the analysis information returned by the first server 70 (S24). The third program 66 of the management device 60 generates or calculates the analysis information (see FIG. 4), cycle time, changeover time, etc. based on the received analysis information (S25). Specifically, the third program 66 identifies the status of the manufacturing equipment 30 based on each flag included in the manufacturing time information, identifies the error type based on the error code included in the manufacturing time information, and identifies the start time, end time, period, and date based on the date and time included in the manufacturing time information. The third program 66 also counts the number of NGs included in the manufacturing time information for each inspection item of the inspection device 35. The third program 66 also calculates the cycle time based on the manufacturing quantity, each flag, and date and time included in the manufacturing time information. The third program 66 also calculates the changeover time based on the flags and date and time included in the manufacturing time information.

[0156] The third program 66 of the management device 60 transmits a registration request including the generated or calculated analysis information, cycle time, setup time, equipment ID, etc. to the first server 70 (S26). The registration request is, for example, a command to register the included analysis information in the analysis information database, the included cycle time in the average cycle time database, and the included setup time in the setup time database.

[0157] The transmission of the request for analysis information (S21) and the transmission of the request for registration of analysis information, etc. (S26) may be performed by the first program 64 instead of the third program 66. That is, communication with the first server 70 may be performed by the first program 64. In this case, for example, the third program 66 instructs the first program 64 via the OS 68 to transmit the request for analysis information (S21) and the request for registration of analysis information, etc. (S26).

[0158] The first server 70 receives the registration request including the analysis information (S26). The first server program 75 of the first server 70 generates new records in the analysis information database, the average cycle time database, and the setup time database in accordance with the received registration request, and registers the analysis information, cycle time, setup time, etc. (S27).

[0159] Meanwhile, the second program 65 of the management device 60 calculates the operating time, production volume, target achievement rate, operating ratio, etc. based on the raw information received by the management device 60 in step S32, and registers them in the aggregation database (S28). The second program 65 also registers the measurement values ​​included in the raw information in the measurement database (S28).

[0160] Next, a process for displaying a real-time display screen on the display 107 or touch panel 109 of the terminal device 90 will be described with reference to FIG.

[0161] The administrator or the like starts the terminal program 104 on the terminal device 90. The administrator or the like selects an icon to instruct the display of a real-time display screen on a home screen (not shown) that the terminal program 104 has displayed on the display 107 or touch panel 109, for example.

[0162] In response to receiving the selection of an icon instructing the display of a real-time display screen (S41), the terminal program 104 transmits a request for real-time display screen data to the management device 60 (S42). The request is a command including, for example, factory identification information indicating the type of manufacturing factory (headquarters factory 21 or regional factory 22) and screen identification information indicating the type of screen (real-time display screen).

[0163] The management device 60 receives a request for real-time display screen data (S42). In response to the fact that the received request includes screen identification information indicating the real-time display screen, the second program 65 of the management device 60 determines whether the humidity indicated by the temperature and humidity information acquired in step S13 (see FIG. 7) is equal to or greater than a threshold humidity pre-stored in the memory 62 (S421). The threshold humidity is, for example, 50%. If the second program 65 determines that the humidity is equal to or greater than the threshold humidity (S421: Yes), it turns on a manufacturing warning flag (S422). The manufacturing warning flag is a flag used by the second program 65 to determine whether to display a manufacturing warning object 129 indicating "Humidity exceeds 50% in some places. Beware of rust!" on the real-time display screen (see FIG. 14). If the second program 65 determines that the humidity is less than the threshold humidity (S421: No), it turns off the manufacturing warning flag (S423). The threshold humidity corresponds to the "threshold humidity" recited in the claims. The second program 65 may determine whether the temperature indicated by the temperature and humidity information is equal to or higher than a threshold temperature, instead of the humidity. In this case, the threshold temperature corresponds to the "threshold" in the claims. The second program 65 may also determine whether the temperature indicated by the temperature and humidity information is equal to or higher than a threshold temperature, in addition to the humidity. In this case, the second program 65 may turn on a manufacturing caution flag when it determines that the humidity is equal to or higher than the threshold humidity and that the temperature is equal to or higher than the threshold temperature. In this case, the threshold humidity and the threshold temperature correspond to the "threshold" in the claims.

[0164] Next, the second program 65 of the management device 60 identifies a record in the production schedule database (see FIG. 3(A)) that has factory identification information that matches the factory identification information included in the request received in step S42, and reads out information (production schedule) from the identified record (S43). The second program 65 generates real-time display screen data based on the read production schedule and the original information received in step S32 (see FIG. 7) (S44). The real-time display screen data is screen data for displaying the real-time display screens shown in FIGS. 14 and 15 on the display 107 or touch panel 109.

[0165] 14 and 15, the real-time display screen includes a plurality of equipment icons 120. One equipment icon 120 corresponds to one manufacturing equipment 30 and has a manufacturing equipment name, which is the name of the manufacturing equipment 30. In the example shown in FIGS. 14 and 15, the manufacturing equipment names are "A01," "centralized coolant," "B02," "C04," "D02," "cleaning machine," etc. Note that "A01," "B02," "C04," and "D02" may also be the above-mentioned equipment IDs.

[0166] The real-time display screen is divided into multiple display areas 130 by lines or the like. One display area 130 corresponds to one area 40 (see FIG. 2). Specifically, display area 131 (130) corresponds to the "cylinder" area 41. Display area 132 (130) corresponds to the "coolant" area 42. Display area 133 (130) corresponds to the "width / outer diameter" area 43. Display area 134 (130) corresponds to the "inner diameter" area 44. Display area 135 (130) corresponds to the "finishing" area 45. Display area 136 (130) corresponds to the "washing machine" area 46. Each display area 130 is arranged in the real-time display screen in the same position as the respective areas 40 in the manufacturing factory 20.

[0167] A name object 123 indicating "Cylinder" is placed in display area 131. A name object 124 indicating "Coolant" is placed in display area 132. A name object 125 indicating "Width / Outer Diameter" is placed in display area 133. A name object 126 indicating "Inner Diameter" is placed in display area 134. A name object 127 indicating "Finishing" is placed in display area 135. A name object 128 indicating "Washing Machine" is placed in display area 136. Name objects 123, 124, 125, 126, 127, and 128 allow an administrator or the like to recognize which display area each display area 130 corresponds to.

[0168] The equipment icons 120 are arranged in respective display areas 130. The equipment icons 120 are arranged in display areas 130 and positions corresponding to the areas 40 and positions in the manufacturing factory 20 where the manufacturing equipment 30 indicated by the attached manufacturing equipment name is located. In the example shown in FIG. 14, the equipment icon 120 with the manufacturing equipment name "A01" is arranged in the upper left of the display area 131. The manufacturing equipment 30 (see FIG. 2) having the equipment ID "A01" is arranged in the upper left of the "cylinder" area 41 corresponding to the display area 131.

[0169] A manager or the like viewing the real-time display screen can intuitively recognize the manufacturing equipment 30 corresponding to the equipment icon 120 based on the position where the equipment icon 120 is displayed. In addition, the manager or the like can easily find the equipment icon 120 corresponding to the manufacturing equipment 30 that the manager or the like wants to check from among the many equipment icons 120. In other words, the manager or the like can quickly and accurately check the manufacturing status.

[0170] In addition to the name of the manufacturing equipment, the equipment icon 120 has original information and some information about the production schedule. In the example shown in Fig. 14, the information that is part of the original information is the name (product code and product name) of the product currently being manufactured (processed, inspected, etc.), operating hours, the name of the product to be manufactured next, and the quantity manufactured to date, and the information that is part of the production schedule is the planned production quantity. In Fig. 14, for the equipment icon 120 having the manufacturing equipment name "A01", the name of the product currently being manufactured is "A000003", the name of the product to be manufactured next is "C000020", the operating hours is "4:51:15", the quantity manufactured to date is "911", and the planned production quantity is "3187".

[0171] Furthermore, the equipment icon 120 has information based on the original information and the production schedule. In the example shown in FIG. 14, the information based on the original information and the production schedule is the target achievement rate (%). The target achievement rate (%) is the value (expressed as a percentage) obtained by dividing the production quantity to date by the planned production quantity and multiplying the result by 100. In FIG. 14, the equipment icon 120 having the manufacturing equipment name "A01" has the target achievement rate (%) of "28.6%." Note that the equipment icon 120 may have other original information, production schedule, or other information in addition to the information shown in FIG. 14.

[0172] The operating time and the quantity manufactured to date that the equipment icon 120 possesses are the above-mentioned manufacturing time information. That is, the equipment icon 120 is an object that displays the current status of the manufacturing equipment 30 in real time. A real-time display screen having multiple equipment icons 120 collectively displays the current status of all the manufacturing equipment 30 in the manufacturing factory 20.

[0173] The device icon 120 is also an object that allows an administrator or the like to instruct the display of a tally display screen (see FIG. 16). When the device icon 120 is selected, the tally display screen is displayed as a pop-up. "Pop-up display" means that the screen is displayed in a window separate from the real-time display screen.

[0174] The real-time display screen also has a manufacturing caution object 129. The manufacturing caution object 129 is an object that makes a manager or the like aware of cautions regarding the manufacturing of a product. In the illustrated example, the manufacturing caution object 129 displays "There are some areas where the humidity is over 50%. Watch out for rust!"

[0175] The real-time display screen also has a temperature display object 137 that indicates the temperature, and a humidity display object 138 that indicates the humidity. The temperature display object 137 and the humidity display object 138 correspond to the "temperature and humidity display object" described in the claims.

[0176] The real-time display screen also has a plurality of total number objects 139. The total number objects 139 are objects that display the total number of planned production quantities for each display area 130 and the total number of production quantities for each display area 130 up to the present time.

[0177] The real-time display screen further includes a temperature and humidity history icon 160. The temperature and humidity history icon 160 is an icon that accepts an instruction to display the temperature and humidity history display screen (see FIG. 25).

[0178] 15, the real-time display screen further includes a plurality of camera icons 161. The camera icons 161 are icons that accept an instruction to display the video captured by the camera 110.

[0179] The real-time display screen further includes a display switching icon 140. The display switching icon 140 is an object that allows an administrator or the like to input an instruction to switch the display between the real-time display screen and the current period cumulative display screen (see FIG. 18).

[0180] The real-time display screen further includes a business end icon 141. The business end icon 141 is an object for inputting, into the terminal device 90, an instruction to end the display of the real-time display screen.

[0181] The generation of real-time display screen data by the second program 65 (S44) will be described in detail. The second program 65 has in advance format data for generating real-time display screen data. The format data may be part of the second program 65, or may be stored in the memory 62 separately from the second program 65. Furthermore, the format data is associated with the above-mentioned screen identification information indicating the real-time display screen.

[0182] The format data has multiple input fields into which one of the product name, operating time, production quantity to date, planned production quantity, and target achievement rate (%) is input. The second program 65 inputs the production schedule read in step S43, the raw information received in step S32, and the target achievement rate (%) calculated from the production schedule and raw information into the input fields to generate real-time display screen data. The format data also has an input field into which temperature and humidity information is input. This input field is associated with the sensor ID. That is, the temperature and humidity detected by a specific temperature and humidity sensor are input into a specific input field. The format data also has an input field into which a production warning is input. If the production warning flag is on, the second program 65 inputs the production warning into the input field. The format data, which specifies the placement positions of icons and objects such as the device icon 120, the temperature display object 137, the humidity display object 138, and the total number object 139, corresponds to "placement position information" as defined in the claims.

[0183] The format data may be a function that takes the product name or the like as an argument and returns real-time display screen data, or may be a class that generates real-time display screen data as an instance. In other words, the format data may be data that is the source for generating real-time display screen data.

[0184] As shown in FIG. 8, the second program 65 of the management device 60 returns the generated real-time display screen data to the terminal device 90 as a response to the request received in step S42 (S45).

[0185] The terminal device 90 receives the real-time display screen data returned by the management device 60 (S45). The terminal program 104 of the terminal device 90 displays the real-time display screen indicated by the received real-time display screen data on the display 107 or the touch panel 109 (S46). For example, the terminal program 104 inputs a command including a file path indicating the real-time display screen data into the OS 106, thereby displaying the real-time display screen on the display 107 or the touch panel 109. The processing of step S46 corresponds to the "first display processing" set forth in the claims.

[0186] The terminal program 104 periodically transmits, for example, a request for real-time display screen data (S42) to the management device 60, and periodically updates the real-time display screen. Alternatively, the second program 65 of the management device 60 may periodically transmit the real-time display screen data to the terminal device 90 based on receiving the request for real-time display screen data, until a stop request is made from the terminal device 90.

[0187] The format data may be stored in the memory 102 of the terminal device 90. In this case, the second program 65 transmits the production schedule read in step S43, the raw information received in step S32 (see FIG. 7), and the target achievement rate (%) calculated from the production schedule and raw information to the terminal device 90. The terminal program 104 of the terminal device 90 inputs the received raw information, production schedule, and target achievement rate (%) into the format data, generates real-time display screen data, and displays it on the display 107 or touch panel 109.

[0188] The programs 64, 65, 66, and 67 of the management device 60 repeatedly execute the processing from S11 (see FIG. 7) onwards until an end instruction is input (S49: No). An end instruction is issued, for example, before a holiday or before maintenance. When the programs 64, 65, 66, and 67 determine that an end instruction has been input (S49: Yes), they end the processing (end).

[0189] Similarly, the first server program 75 of the first server 70 repeatedly executes the processing from S15 (see FIG. 7) onwards until an end instruction is input or until the first server 70 is powered off (S50: No). An end instruction is issued, for example, before a holiday or before maintenance. When the first server program 75 determines that an end instruction has been input (S50: Yes), it ends the processing (end).

[0190] Next, a description will be given of the processing when the administrator or the like selects the device icon 120 on the real-time display screen (see FIG. 14) and the tally display screen (see FIG. 16) pops up.

[0191] The terminal program 104 of the terminal device 90 determines whether the device icon 120, the display switching icon 140, the temperature and humidity history icon 160, or the camera icon 161 has been selected on the real-time display screen (see FIG. 14) (S47). If the terminal program 104 determines that the icons 120, 140, 160, and 161 have not been selected (S47: No), it determines whether an end instruction has been input (S51). An end instruction is input to the terminal device 90 when the work end icon 141 is selected or when the "x" in the upper right corner of the real-time display screen is selected. If the terminal program 104 determines that an end instruction has not been input (S51: No), it repeatedly executes the processing from step S42 onward. That is, the terminal program 104 repeatedly updates and displays the real-time display screen. If the terminal program 104 determines that an end instruction has been input (S51: Yes), it ends the processing (END).

[0192] When the terminal program 104 of the terminal device 90 determines in step S47 that the icons 120, 140, 160, and 161 have been selected (S47: Yes), it determines whether the selected icon is the device icon 120, the display switching icon 140, the temperature and humidity history icon 160, or the camera icon 161 (S48). When the terminal program 104 determines that the selected icon is the device icon 120 (S48: Device Icon), it executes processing (see FIG. 9) to pop up a summary display screen (see FIG. 16) on the display 107 or the touch panel 109.

[0193] The tally display screen shown in FIG. 16 is a table similar to the tally database (see FIG. 6(A)). However, the tally display screen does not include items related to temperature and humidity history information that the tally database has. The table displayed on the tally display screen corresponds to the "table" described in the claims.

[0194] The tally display screen has multiple rows and multiple columns. The multiple columns are labeled with the same items as in the tally database, such as "date" and "operating hours." The rows on the tally display screen are distinguished from one another by dates such as "2021 / 10 / 25." That is, each row indicates the daytime operating hours, nighttime operating hours, total operating hours, daytime production quantities, nighttime production quantities, total production quantities, target achievement rates, etc., for a manufacturing device 30 having a manufacturing device name such as "A01" displayed in the device icon 120 designated by an administrator or the like, on each date such as "2021 / 10 / 25."

[0195] Below, we will explain items that are not shown in the summary database (see Figure 6(A)), such as the item "Operation ratio daytime / nighttime."

[0196] The column with the heading "Daytime / Nighttime Operation Rate" has two subcolumns. Each field in one subcolumn displays the percentage of operation time relative to all daytime hours. Each field in the other subcolumn displays the percentage of operation time relative to all nighttime hours.

[0197] Each field in the column labeled "Abnormal Stoppage Accumulative Time" displays the time during which normal operation of the manufacturing equipment 30 was stopped due to an error, i.e., the total time during which the equipment was stopped due to an abnormality. Each field in the column labeled "Normal Stoppage Accumulative Time" displays the total time during which production was stopped, for example, due to preparations to switch from the production of one product to the production of another product. Each field in the column labeled "Number of Abnormal Occurrences" displays the number of times an error (abnormality) occurred that day. Each field in the column labeled "First Production Time" displays, for example, the time required from the start of production until the first product is produced, including warm-up time. Each field in the column labeled "Cycle Time (Seconds)" displays the time required to produce one product (cycle time).

[0198] The tally display screen further includes a graph icon 142 and a close icon 143. The graph icon 142 is an object that accepts an instruction to display the analysis information display screen (see FIG. 15). The close icon 143 is an object that accepts an instruction to close the tally display screen. Note that the instruction to close the tally display screen may also be accepted by clicking "X" in the upper right corner of the tally display screen.

[0199] With reference to FIG. 9, a process in which the terminal program 104 of the terminal device 90 displays the above-mentioned tally display screen on the display 107 or touch panel 109 of the terminal device 90 will be described.

[0200] First, the terminal program 104 sends a request for tally display screen data to the management device 60 (S52). The request is, for example, a command instructing the management device 60 to return tally display screen data. The command includes the device ID corresponding to the device icon 120 selected by the manager or the like, screen identification information indicating the type of screen (tally display screen), and factory identification information.

[0201] The management device 60 receives the request sent by the terminal device 90 (S52). The second program 65 of the management device 60 sends a reply request for registration information, etc., including the device ID and factory identification information included in the received request, to the second server 80 (S54). The request is, for example, a command including the device ID and factory identification information.

[0202] The second server program 85 of the second server 80 identifies a record in the aggregation database (see FIG. 6(A)) that has a device ID and factory identification information that match the device ID and factory identification information included in the received reply request, and reads out the information (registration information) that the identified record has (S55). The second server program 85 also identifies a record in the cycle time database (see FIG. 6(A)) that has a device ID that matches the device ID and factory identification information included in the received reply request, and reads out the cycle time that the identified record has (S55). The second server program 85 returns the read registration information and cycle time to the management device 60 (S56).

[0203] The management device 60 receives the registration information returned by the second server 80 (S56). The second program 65 of the management device 60 inputs the received registration information and cycle time into the input fields of the format data indicated by the screen identification information, and generates tally display screen data (S57). The second program 65 returns the generated tally display screen data to the terminal device 90 as a response to the request received in step S52 (S58).

[0204] The format data may be stored in the memory 102 of the terminal device 90. In this case, the second program 65 returns the registration information and cycle time read in step S43 to the terminal device 90 as a response to the request received in step S53. The terminal program 104 of the terminal device 90 inputs the received registration information into the format data to generate summary display screen data.

[0205] The terminal device 90 receives the tally display screen data returned by the management device 60 (S58). The terminal program 104 of the terminal device 90 inputs the received tally display screen data into the display 107 or touch panel 109, and displays a pop-up tally display screen (S59). The tally display screen corresponds to the generated information display screen described in the claims. The processing of step S59 corresponds to the "second display processing" described in the claims.

[0206] Next, a description will be given of the processing that is performed when the administrator or the like selects the graph icon 142 or the close icon 143 on the tally display screen (see FIG. 16).

[0207] The terminal program 104 of the terminal device 90 determines whether the graph icon 142 or the close icon 143 has been selected on the tally display screen (S60). The terminal program 104 continues to display the tally display screen until the icon 142 or 143 is selected (S60: No). Note that selection of the close icon 143 also includes selection of the "x" in the upper right corner of the tally display screen. When the terminal program 104 determines that the icon 142 or 143 has been selected (S60: Yes), it determines whether the selected icon was the close icon 143 (or "x") or the graph icon 142 (S61). When the terminal program 104 determines that the close icon 143 (or "x") has been selected, it closes the tally display screen (see FIG. 16) (S62) and executes the processing from step S42 onward (see FIG. 8) to display the real-time display screen. The terminal program 104 closes the tally display screen by inputting a command to the OS 106 to instruct the OS 106 to close the tally display screen.

[0208] When the terminal program 104 of the terminal device 90 determines in step S61 that the graph icon 142 has been selected (S61: Graph), it executes a process (see FIG. 10) to display the analysis information display screen (FIG. 17).

[0209] The analysis information display screen shown in Fig. 17 is a screen that displays, in a graph, analysis information about the manufacturing equipment 30 designated by the manager, etc. Fig. 17 shows the analysis information display screen when the manufacturing equipment 30 is the inspection equipment 35.

[0210] The analysis information display screen has a device name object 144 indicating the name of the manufacturing device, a year / month object 145, and a graph 146. The graph 146 corresponds to the "first graph" recited in the claims.

[0211] The manufacturing equipment name displayed by the equipment name object 144 is the same as the manufacturing equipment name of the equipment icon 120 selected by the administrator or the like on the real-time display screen (see FIG. 14). In the illustrated example, "K02" is displayed as the manufacturing equipment name (inspection equipment name). The year and month object 145 displays the current year and month. In the illustrated example, the year and month object 145 is "2021 / 09", which indicates September 2021. The year and month object 145 is also a context menu (pop-up menu), and when the year and month object 145 is selected, a calendar containing 12 icons that accept selections from January to December is displayed.

[0212] The graph 146 has a vertical axis 147, a horizontal axis 148, and a plurality of bars 149. The vertical axis 147 indicates each date in the month indicated by the year / month object 145. In the illustrated example, September 28th is indicated as "9-28," and September 27th is indicated as "9-27." The horizontal axis 148 has 13 numbers, such as "0" and "1," that indicate time. Note that in the illustrated example, the numbers from "0" to "3" are hidden by the calendar. Furthermore, the number "23" indicates 11:00 PM, and the "0" to the right of "23" indicates midnight the following day.

[0213] One bar 149 is displayed for each date, such as "9-22." That is, one bar 149 indicates the analysis information for one date. The bar 149 also has multiple sections, such as a section indicating a stopped state, a section indicating a ready state, a section indicating an operating state, and a section indicating an abnormally stopped state. The sections are distinguishable from one another by color, hatching, or the like. The stopped state, ready state, operating state, and abnormally stopped state are information that matches the state registered in the "status" field of the analysis information in the analysis information database (see FIG. 4(A)). In the example shown in FIG. 4(A), in a record in which an abnormal stop is registered in the "status" field, "13:12" is registered in the field corresponding to the "start time," "13:43" is registered in the field corresponding to the "end time," and "31 minutes" is registered in the field corresponding to the "duration." In this case, on the analysis information display screen shown in Fig. 17, one end (left end) of the portion of bar 149 indicating the abnormal stop state is located at 13:12 on the horizontal axis, and the other end (right end) is located at 13:43 on the horizontal axis. The length of the portion indicating the abnormal stop state corresponds to the period "31 minutes." Note that when manufacturing equipment 30 is inspection equipment 35, the "abnormal stop state" also includes, for example, a case where a measurement value outside the allowable range is measured multiple times in succession.

[0214] The analysis information display screen further includes an abnormality detail icon 151 , a monthly detail icon 152 , a daily detail icon 153 , a measurement data icon 154 , an average cycle time icon 155 , and a setup change time icon 156 .

[0215] The abnormality details icon 151 is an icon that accepts a display instruction for an abnormality details display screen (see FIG. 19). The monthly details icon 152 is an icon that accepts a display instruction for an NG details monthly display screen (see FIG. 20). The daily details icon 153 is an icon that accepts a display instruction for an NG details daily display screen (see FIG. 21). The measurement data icon 154 is an icon that accepts a display instruction for a measurement value display screen (see FIG. 22). The average cycle time icon 155 is an icon that accepts a display instruction for an average cycle time display screen (see FIG. 23). The setup change time icon 156 is an icon that accepts a display instruction for a setup change time display screen (see FIG. 24).

[0216] Hereinafter, the process of displaying the analysis information display screen (see FIG. 17) on the display 107 or touch panel 109 of the terminal device 90 will be described with reference to FIG.

[0217] The terminal program 104 of the terminal device 90 transmits a request for analysis information display screen data to the management device 60 (S71). The request is, for example, a command instructing the management device 60 to return analysis information display screen data. The command includes the device ID corresponding to the device icon 120 selected by the administrator or the like, and screen identification information indicating the analysis information display screen.

[0218] The management device 60 receives the request sent by the terminal device 90 (S71). Based on the received request, the second program 65 of the management device 60 starts the fourth program 67 and instructs it to generate analysis information display screen data (S72). For example, the second program 65 inputs a command to the OS 68, including a fourth program ID indicating the fourth program 67, a second program ID indicating itself, a device ID, and screen identification information. The OS 68 starts the fourth program 67 indicated by the fourth program ID, and passes the device ID, the screen identification information, and the second program ID to the fourth program 67.

[0219] The activated fourth program 67 generates analysis information display screen data indicated by the screen identification information for the manufacturing apparatus 30 indicated by the passed apparatus ID.

[0220] More specifically, the fourth program 67 transmits a return request for the analysis information to the first server 70 (S73). The return request is, for example, a command including the device ID.

[0221] The first server 70 receives the reply request sent by the management device 60 (S73). The first server program 75 of the first server 70 identifies a record in the analysis information database (see FIG. 4) that has a device ID that matches the device ID included in the received reply request. The first server program 75 then reads out the analysis information contained in the identified record (S74). The first server program 75 returns the read analysis information to the management device 60 as a response to the reply request received in step S73 (S75).

[0222] The management device 60 receives the analysis information returned by the first server 70 (S75). The fourth program 67 of the management device 60 has in advance format data for generating analysis information display screen data, the format data being associated with screen identification information indicating the analysis information display screen. The format data is data in HTML format including CSS and JavaScript, and has input fields into which the manufacturing equipment name and analysis information (see FIG. 4(A)) are input. In other words, the analysis information display screen (see FIG. 13) is a so-called Web page. The fourth program 67 inputs the analysis information received in step S75 into the input field of the format data, and generates analysis information display screen data (S76). This format data may be the above-mentioned function or class.

[0223] The fourth program 67 of the management device 60 returns the file path indicating the generated analysis information display screen data and the second program ID to the OS 68. The OS 68 passes the file path to the second program 65 indicated by the second program ID. The second program 65 returns the analysis information display screen data indicated by the passed file path as a response to the request received in step S71 (S77). In other words, communication with the terminal device 90 is performed collectively by the second program 65.

[0224] Although the example in which the fourth program 67 transmits a request for analysis information to the first server 70 and acquires the analysis information has been described, the first program 64 or the third program 66 may transmit the request for analysis information to the first server 70. That is, the first program 64 or the third program 66 may communicate with the first server 70. In this case, the second program 65, having received a request for analysis information display screen data (S71), passes screen identification information indicating the analysis information display screen to the first program 64 or the third program 66. The first program 64 or the third program 66 then transmits a request for analysis information including the passed screen identification information to the first server 70 (S74), and receives the analysis information returned by the first server 70 (S75). The first program 64 or the third program 66 passes a file path indicating the received analysis information to the second program 65. The second program 65 starts the fourth program 67 via the OS 68, and passes the received file path, screen identification information, and second program ID to the fourth program 67. Then, the second program 65 receives from the fourth program 67 via the OS 68 a file path indicating the analysis information display screen data generated by the fourth program 67.

[0225] Furthermore, although an example has been described in which the second program 65 returns the analysis information display screen data to the terminal device 90, the fourth program 67 may return the analysis information display screen data directly to the terminal device 90. For example, the fourth program 67 may receive a request for analysis information display screen data (Web page data) sent by the terminal program 104, generate the analysis information display screen data (Web page data), and return it to the terminal device 90.

[0226] The terminal device 90 receives the analysis information display screen data returned by the management device 60 (S77). The terminal program 104 of the terminal device 90 instructs the browser 105 via the OS 106 to pop-up display the received analysis information display screen data on the display 107 or the touch panel 109. The browser 105 pops up the analysis information display screen data on the display 107 or the touch panel 109 (S78). If the terminal program 104 is a plug-in program for the browser 105, the terminal program 104 directly inputs an instruction (command) to the OS 106 to pop-up display the analysis information display screen data on the display 107 or the touch panel 109. The analysis information display screen corresponds to the generated information display screen recited in the claims. The processing of step S78 corresponds to the "second display processing" recited in the claims.

[0227] The terminal program 104 of the terminal device 90 determines whether or not the icons 151, 152, 153, 154, 155, and 156 are selected on the analysis information display screen (S100). The processing performed when the icons 151, 152, 153, 154, 155, and 156 are selected on the analysis information display screen (S100: Yes) will be described later.

[0228] When the terminal program 104 of the terminal device 90 determines that none of the icons 151, 152, 153, 154, 155, and 156 have been selected on the analysis information display screen (S100: No), it determines whether an end instruction has been input (S79). An end instruction is input, for example, by clicking "x" in the upper right corner of the screen. The terminal program 104 displays the analysis information display screen on the display 107 or touch panel 109 (S78) until an end instruction is input (S79: No). Based on the input of an end instruction (S79: Yes), the terminal program 104 closes the analysis information display screen (S80) and executes the processing from step S59 onward (see FIG. 9) in which the summary display screen is displayed.

[0229] Next, the current period cumulative display screen (see Figure 18) that is displayed when an administrator or the like selects the display switching icon 140 on the real-time display screen (see Figure 14), and the process for displaying the current period cumulative display screen will be explained.

[0230] As shown in Fig. 18, the current period cumulative total display screen is a screen having the same layout as the real-time display screen (see Fig. 14). The current period cumulative total display screen has equipment icon 121 instead of equipment icon 120 on the real-time display screen. The position and shape of equipment icon 121 are the same as those of equipment icon 120. Unlike equipment icon 120, equipment icon 121 displays the current period cumulative total instead of the current production status.

[0231] More specifically, the equipment icon 121 has the name of the product currently being manufactured (processed, inspected, etc.), the current period's cumulative operating time, the current period's cumulative production quantity, the current period's planned production quantity, and the current period's target achievement rate (%). The current period's cumulative operating time is the cumulative operating time for a specified period (current period) such as a quarter or half year. The current period's cumulative production quantity is the cumulative production quantity for that specified period. The current period's planned production quantity is the cumulative production quantity for that specified period. The current period's target achievement rate (%) is the value (expressed as a %) obtained by dividing the current period's production quantity by the current period's planned production quantity and multiplying the result by 100. In FIG. 18, for the equipment icon 121 having the manufacturing equipment name "A01," the name of the product currently being manufactured is "A000003," the cumulative operating time for this period is "1153:16:57," the cumulative production quantity for this period is "175521," the planned production quantity for this period is "369692," and the target achievement rate for this period (%) is "47.5%." Note that the equipment icon 121 may also have information other than the cumulative operating time for this period, the cumulative production quantity for this period, the planned production quantity for this period, and the target achievement rate for this period (%). The cumulative operating time for this period, the cumulative production quantity for this period, and the planned production quantity for this period correspond to the "cumulative information" set forth in the claims.

[0232] The current operating time and current production quantity of the equipment icon 121 are the above-mentioned manufacturing time information. That is, the equipment icon 121 is a display object that displays the current operating status of the manufacturing equipment 30. When the equipment icon 121 is selected, a summary display screen (see FIG. 16) is displayed on the display 107 or touch panel 109 of the terminal device 90, similar to when the equipment icon 120 is selected.

[0233] Next, the process of displaying the current period cumulative total display screen will be described. As shown in Fig. 8, when the terminal program 104 of the terminal device 90 determines that the icon selected by the manager or the like on the real-time display screen (see Fig. 14) is the display switching icon 140 (S48: switching icon), it executes the process shown in Fig. 11. First, the terminal program 104 sends a request for current period cumulative total display screen data to the management device 60 (S81). The request is, for example, a command including screen identification information indicating the current period cumulative total display screen and the above-mentioned factory identification information.

[0234] The management device 60 receives the request sent by the terminal device 90 (S81). The second program 65 of the management device 60 sends a request for returning the aggregated information to the second server 80 based on the fact that the received request includes screen identification information indicating the current period cumulative total display screen (S82). The return request is, for example, a command including the type of requested information and factory identification information.

[0235] The second server 80 receives the return request for the aggregated information (S82). The second server program 85 of the second server 80 identifies a record in the aggregation database (FIG. 6(A)) that has factory identification information that matches the factory identification information included in the received return request, and reads out information contained in the identified record. Based on the read out information, the second server program 85 calculates and acquires the current term's cumulative operating time and current term's cumulative production quantity for each manufacturing device 30 (S83). Note that if the current term's cumulative operating time and current term's cumulative production quantity have been registered in advance in the aggregation database, the second server program 85 reads out and acquires the current term's cumulative operating time and current term's cumulative production quantity from the aggregation database (S83).

[0236] The second server program 85 of the second server 80 returns the acquired aggregated information to the management device 60 as a response to the reply request received in step S82 (S84). The management device 60 receives the aggregated information returned by the second server 80 (S84). The aggregated information may be calculation information for calculating the current term's cumulative operating time and the current term's cumulative production quantity. In this case, the current term's cumulative operating time and the current term's cumulative production quantity are calculated by the second program 65 of the management device 60 based on the aggregated information.

[0237] The second program 65 of the management device 60 identifies a record in the production schedule database that has factory identification information that matches the factory identification information included in the request received in step S81. Then, the second program 65 reads information from the identified record and, based on the read information, calculates and obtains the planned production quantity for the current fiscal year for each manufacturing device 30 (S85). Note that if the planned production quantity for the current fiscal year has been registered in advance in the production schedule database, the second program 65 reads and obtains the planned production quantity for the current fiscal year from the production schedule database (S85).

[0238] The second program 65 of the management device 60 calculates the current term target achievement rate (%) for each manufacturing device 30 based on the acquired current term cumulative production quantity and current term planned production quantity (S86). The second program 65 generates current term cumulative display screen data based on the acquired current term cumulative operating time, current term cumulative production quantity, current term planned production quantity, and current term target achievement rate (%) (S87).

[0239] More specifically, the second program 65 of the management device 60 has in advance format data for generating current term cumulative display screen data. The format data has input fields for inputting the current term cumulative operating time, the current term cumulative production quantity, the current term planned production quantity, and the current term target achievement rate (%). The second program 65 generates the current term cumulative display screen data by inputting the current term cumulative operating time, the current term cumulative production quantity, the current term planned production quantity, and the current term target achievement rate (%) into the respective input fields of the format data. Note that the format data may be the above-mentioned functions or classes.

[0240] The format data may be stored in the memory 102 of the terminal device 90. In this case, the second program 65 returns the current term's cumulative operating time, the current term's cumulative production quantity, the current term's planned production quantity, and the current term's target achievement rate (%) to the terminal device 90 as a response to the request received in step S81. The terminal program 104 of the terminal device 90 inputs the received information into the format data to generate current term's cumulative display screen data.

[0241] The second program 65 of the management device 60 returns the generated current term cumulative display screen data to the terminal device 90 as a response to the reply request received in step S81 (S88).

[0242] The terminal device 90 receives the current term cumulative total display screen data returned by the management device 60 (S88). The terminal program 104 of the terminal device 90 inputs the received current term cumulative total display screen data into the display 107 or touch panel 109, and displays the current term cumulative total display screen on the display 107 or touch panel 109 (S89). The processing of step S89 corresponds to the "display switching processing" set forth in the claims.

[0243] The terminal program 104 of the terminal device 90 determines whether an end instruction has been input (S90). The end instruction is input to the terminal device 90 when the business end icon 141 is selected or when the "X" in the upper right corner of the current term cumulative display screen is selected. If the terminal program 104 determines that an end instruction has been input (S90: Yes), it terminates the processing (END). If the terminal program 104 determines that an end instruction has not been input (S90: No), it determines whether the display switching icon 140 has been selected (S91). If the terminal program 104 determines that the display switching icon 140 has not been selected (S91: No), it executes the processing from step S81 onwards again. That is, the current term cumulative display screen is updated and displayed at predetermined time intervals. If the terminal program 104 determines that the display switching icon 140 has been selected (S91: Yes), it executes the processing from step S42 onwards for updating and displaying the real-time display screen again.

[0244] Next, the processing when the icons 151, 152, 153, 154, 155, and 156 are selected on the analysis information display screen (see FIG. 17) will be described.

[0245] When the terminal program 104 of the terminal device 90 determines that the icons 151, 152, 153, 154, 155, and 156 have been selected on the analysis information display screen (S100: Yes in FIG. 10), it identifies screen identification information from the type of the selected icon (S101), as shown in FIG. 12. Note that the abnormality detail icon 151 is pre-associated with screen identification information indicating the abnormality detail display screen, the monthly detail icon 152 is pre-associated with screen identification information indicating the NG detail monthly display screen, the daily detail icon 153 is pre-associated with screen identification information indicating the NG detail daily display screen, the measurement data icon 154 is pre-associated with screen identification information indicating the measurement data display screen, the average cycle time icon 155 is pre-associated with screen identification information indicating the average cycle time display screen, and the setup change time icon 156 is pre-associated with screen identification information indicating the setup change time display screen.

[0246] The terminal program 104 of the terminal device 90 transmits a request for returning the display screen data indicated by the identified screen identification information to the management device 60 (S102). The request is, for example, a command including the identified screen identification information. The command is a command instructing the return of the display screen data indicated by the included screen identification information.

[0247] The management device 60 receives the reply request sent by the terminal device 90 (S102). Based on the receipt of the reply request, the second program 65 of the management device 60 starts the fourth program 67 and instructs it to generate display screen data (S103). For example, the second program 65 inputs a command to the OS 68, including a fourth program ID indicating the fourth program 67, a second program ID indicating itself, a device ID, and screen identification information. The OS 68 starts the fourth program 67 indicated by the fourth program ID, and passes the device ID, the screen identification information, and the second program ID to the fourth program 67.

[0248] The activated fourth program 67 generates the display screen data indicated by the screen identification information for the manufacturing apparatus 30 indicated by the transferred apparatus ID.

[0249] More specifically, the fourth program 67 transmits a reply request for information for generating display screen data (hereinafter referred to as "screen data information") to the first server 70 or the second server 80 (S104). For example, if the display screen indicated by the screen identification information is a NG detail monthly display screen, a NG detail daily display screen, an average cycle time display screen, or a setup change time display screen, the reply request is transmitted to the first server 70, which stores an analysis information database, an average cycle time database, and a setup change time database in which information (data) required for generating these display screens is registered. On the other hand, if the display screen indicated by the screen identification information is a measurement data display screen, the reply request is transmitted to the second server 80, which stores a measurement value database. The reply request is a command including, for example, the device ID and information identification information indicating the type of screen data information. The information identification information is pre-stored in the memory 62 in association with the type of display screen. For example, when the type of display screen is an abnormality detail display screen (see FIG. 19), the information identification information is information indicating the name of an inspection item such as "abnormality detected" or "continuous NG in outer diameter dimension" registered in the analysis information database (see FIG. 4(B)), the number of NGs, etc.

[0250] The first server 70 or the second server 80 receives the reply request sent by the management device 60 (S104). The first server program 75 of the first server 70 or the second server program 85 of the second server 80 identifies, in each database, a record having a device ID that matches the device ID included in the received reply request. Then, the first server program 75 or the second server program 85 reads out information contained in the identified record (S105). The first server program 75 or the second server program 85 returns the read out information as screen data information to the management device 60 as a response to the request received in step S104 (S106).

[0251] The transmission of the request for screen data information (S105) may be performed by the first program 64 or the third program 66 instead of the fourth program 67. That is, the first program 64 may communicate with the first server 70, and the third program 66 may communicate with the second server 80. In that case, for example, the fourth program 67 instructs the first program 64 or the third program 66 to transmit the request for screen data information via the OS 68.

[0252] The management device 60 receives the screen data information returned by the first server 70 (S106). The fourth program 67 of the management device 60 has in advance format data for generating an abnormality detail display screen, a NG detail monthly display screen, a NG detail daily display screen, a measurement value display screen, an average cycle time display screen, and a setup change time display screen. The format data is data in HTML format including CSS and JavaScript, and has input fields into which the screen data information is input. In other words, the NG detail monthly display screen, the NG detail daily display screen, the measurement value display screen, the average cycle time display screen, and the setup change time display screen are so-called Web pages. The fourth program 67 inputs the table screen data information received in step S106 into the input fields of the format data to generate display screen data (S107). This format data may be the above-mentioned functions or classes. In addition, when an image of a database is acceptable, such as a measurement value display screen (see FIG. 22), an average cycle time display screen (see FIG. 23), or a setup change time display screen (see FIG. 24), image data showing the image of the database may be used as the screen data information. In this case, the format data has an input field into which the image data is input.

[0253] The fourth program 67 of the management device 60 returns the file path and second program ID indicating the generated display screen data to the OS 68. The OS 68 passes the file path to the second program 65 indicated by the second program ID. The second program 65 returns the display screen data indicated by the passed file path to the terminal device 90 as a response to the reply request received in step S102 (S108). That is, communication with the terminal device 90 is performed collectively by the second program 65. However, the fourth program 67 may also return the display screen data directly to the terminal device 90. For example, the fourth program 67 receives a request for display screen data (Web page data) sent by the terminal program 104, generates the display screen data (Web page data), and returns it to the terminal device 90.

[0254] The terminal device 90 receives the analysis information display screen data returned by the management device 60 (S108). The terminal program 104 of the terminal device 90 instructs the browser 105 via the OS 106 to pop-up the received display screen data on the display 107 or the touch panel 109. The browser 105 pops up the display screen data on the display 107 or the touch panel 109 (S109). If the terminal program 104 is a plug-in program for the browser 105, the terminal program 104 directly inputs an instruction (command) to the OS 106 to pop-up the display screen data on the display 107 or the touch panel 109. The abnormality details display screen, NG details monthly display screen, NG details daily display screen, measurement value display screen, average cycle time display screen, and setup change time display screen shown in the display screen data correspond to the generated information display screen described in the claims. The processing of step S109 corresponds to the "second display processing" described in the claims.

[0255] The following describes in detail the abnormality details display screen, NG details monthly display screen, NG details daily display screen, measurement value display screen, average cycle time display screen, and setup change time display screen.

[0256] 19, the anomaly details display screen has a plurality of year and month icons 171 indicating the year and month, an equipment name object 144 indicating the name of a manufacturing equipment, and a graph 172. Of the plurality of year and month icons 171, the year and month icon 171 indicating the year and month currently displayed by the graph 172 is displayed in a form different from the other year and month icons 171. In the illustrated example, the year and month icon 171 indicating the year and month currently displayed by the graph 172 is displayed in dark gray, and the other year and month icons 171 are displayed in light gray.

[0257] Graph 172 has a first vertical axis 173 indicating the number of abnormalities (errors), a second vertical axis 174 indicating the cumulative ratio, a horizontal axis 175 indicating the type of abnormality, a count display bar 176 indicating the number of abnormalities, and a line graph 177 indicating the cumulative ratio. The cumulative ratio indicates the ratio (percentage) of each abnormality to the total number of abnormalities. The count display bar 176 has a daytime display section 178 indicating the number of abnormalities during the daytime and a nighttime display section 179 indicating the number of abnormalities during the nighttime. The daytime display section 178 and the nighttime display section 179 are distinguished by color, hatching, etc. Graph 172 corresponds to the "second graph" recited in the claims.

[0258] The type of abnormality (error) indicated by the horizontal axis 175 indicates that abnormalities have occurred consecutively in the inspection, such as "pin inspection," "marking inspection," or "hexagon inspection."

[0259] The anomaly details display screen allows a manager or the like to easily recognize, for each manufacturing apparatus 30 with an apparatus name indicated by an apparatus name object and for each anomaly type, the number of anomalies that occurred during the daytime, the number of anomalies that occurred at night, the number of anomalies that occurred during the daytime and at night, and the cumulative ratio of the anomalies that occurred in the year and month indicated by the year / month icon 171. By checking the anomaly details display screen, the manager or the like can, for example, identify the type of anomaly that occurs most frequently and take measures such as maintenance of the manufacturing apparatus 30 that processes the portion corresponding to the identified anomaly type. Alternatively, by checking the anomaly details display screen, the manager or the like can, for example, take measures such as increasing attention at night if the number of anomalies that occur most frequently at night. The manager or the like can then check the anomaly details display screen to see whether the measures were effective by checking the progress since the measures were taken.

[0260] 20, the NG detail monthly display screen has a plurality of year and month icons 171, an equipment name object 144 indicating the name of the manufacturing equipment, and a graph 180. The graph 180 has a first vertical axis 181 indicating the number of abnormalities (errors), a second vertical axis 182 indicating the cumulative ratio, a horizontal axis 183 indicating the type of abnormality, a number of times display bar 184 indicating the number of abnormalities, and a line graph 185 indicating the cumulative ratio. The number of times display bar 184 has a daytime display section 186 indicating the number of abnormalities during the day and a nighttime display section 187 indicating the number of abnormalities during the night.

[0261] The type of abnormality indicated by the horizontal axis 183 indicates, for example, "pin inspection," "marking inspection," "hexagon inspection," etc., and in this respect, the graph 180 differs from the graph 172 on the abnormality details display screen (see FIG. 19).

[0262] The NG detail monthly display screen allows a manager or the like to easily recognize, for each manufacturing apparatus 30 with an apparatus name indicated by an apparatus name object and for each type of abnormality, the number of abnormalities that occurred during the day, the number of abnormalities that occurred at night, the number of abnormalities that occurred during the day and at night, and the cumulative ratio of abnormalities that occurred in the year and month indicated by the year / month icon 171. The manager or the like can check the NG detail monthly display screen and take measures against the occurrence of abnormalities.

[0263] 21 has a plurality of date icons 188, a device name object 144, and a graph 180. Of the plurality of date icons 188, the date icon 188 indicating the date currently displayed by the graph 180 is displayed in a form different from the other date icons 188. In the illustrated example, the date icon 188 indicating the date currently displayed by the graph 180 is displayed in dark gray, and the other date icons 188 are displayed in light gray.

[0264] The NG detail daily display screen allows a manager or the like to easily recognize the number of abnormalities that occurred during the day, the number of abnormalities that occurred at night, the number of abnormalities that occurred during the day and at night, and the cumulative ratio of the abnormalities that occurred, for each manufacturing apparatus 30 with an apparatus name indicated by an apparatus name object, for each type of abnormality (error), and for each date.The manager or the like checks the NG detail daily display screen and takes measures against the occurrence of abnormalities.

[0265] The measurement value display screen shown in FIG. 22 has a plurality of year / month icons 171, the device name object 144, and a table 190. Table 190 has a plurality of columns and rows. The plurality of rows are labeled with items such as "product," "time," "OK," and "D / μm." Each field in the column labeled with the item "product" displays a product code (or product name) such as "A000001." Each field in the column labeled with the item "time" displays the time at which the measurement was performed. Each field in the column labeled with the item "OK" displays "OK" indicating that the inspection was passed, or "NG" indicating that the inspection was not passed. Each field in the column labeled with the item "D / μm" displays a measurement value.

[0266] The measurement value display screen allows a manager or the like to easily recognize each measurement value obtained by measurement, the pass / fail result of the inspected product, and the time of the inspection for each manufacturing device 30 whose device name is indicated by the device name object, in the year and month indicated by the year / month icon 171. The manager or the like checks the measurement value display screen and takes measures against any abnormalities that may occur.

[0267] The average cycle time display screen shown in FIG. 23 has a table 191. Table 191 has multiple columns and rows. Each of the multiple columns is labeled with one of the following items: "machine," "product code," "product name," "process," "cycle time," and "quantity." Each field in the column labeled with the item "machine" displays an equipment ID as the name of the manufacturing equipment 30. Each field in the column labeled with the item "product code" displays a product code as identification information for identifying the product (product). Each field in the column labeled with the item "product" displays the name of the product indicated by the product code. Note that the product code and the product name may be the same. Each field in the column labeled with the item "process" displays the name of the process in which the manufacturing equipment 30 (inspection equipment 35) performed the inspection. Each field in the column labeled with the item "cycle time" displays the average time required to inspect one product (product). Each field in the column labeled with the item "quantity" displays the number of products (products) inspected by the inspection equipment 35.

[0268] The average cycle time display screen allows the manager or the like to easily recognize the average time required to process or measure one item (product) for each manufacturing device 30 whose name is displayed in the "Machine" item. The manager or the like checks the average cycle time display screen and makes future manufacturing plans, etc.

[0269] The setup change time display screen shown in FIG. 24 has a table 192. Table 192 has multiple columns and rows. Each of the multiple columns is labeled with one of the items "equipment name," "start time," "end time," "before setup change," "after setup change," and "setup change time." The field in the column labeled with the item "equipment name" displays the equipment ID (or the name of the manufacturing equipment). The fields in the column labeled with the item "start time" display the time when the setup change started. The fields in the column labeled with the item "end time" display the time when the setup change ended. The fields in the column labeled with the item "before setup change" display the product code and product name of the product before the setup change. The fields in the column labeled with the item "before setup change" display the product code and product name of the product after the setup change. The fields in the column labeled with the item "setup change time" display the time required for the setup change.

[0270] The setup change time display screen allows a manager or the like to easily recognize the time (setup change time) required to transition from processing or inspecting one product to processing or inspecting another product for each manufacturing device 30. The manager or the like creates a manufacturing plan taking into account the setup change time displayed on the setup change time display screen.

[0271] Next, a description will be given of the processing when the temperature and humidity history icon 160 or the camera icon 161 is selected by an administrator or the like on the real-time display screen (see FIGS. 14 and 15).

[0272] When the terminal program 104 of the terminal device 90 determines that the icon selected by the manager or the like on the real-time display screen is the temperature and humidity history icon 160 (S48 in Fig. 8: temperature and humidity history icon), it sends a request for temperature and humidity history display screen data to the management device 60 (S111), as shown in Fig. 13. The request is, for example, a command including screen identification information indicating the temperature and humidity history display screen.

[0273] The management device 60 receives the request sent by the terminal device 90 (S111). The second program 65 of the management device 60 accepts the received request (S112). The second program 65 sends a return request for temperature and humidity information to the second server 80 based on the fact that the received request includes screen identification information indicating the temperature and humidity history display screen (S113). The return request is, for example, a command including the type of requested information and factory identification information.

[0274] The second server 80 receives the reply request for the temperature and humidity information (S113). The second server program 85 of the second server 80 identifies a record in the aggregation database (FIG. 6(A)) that has factory identification information that matches the factory identification information included in the received reply request, and reads out the temperature and humidity information contained in the identified record (S114). The second server program 85 returns the read temperature and humidity information to the management device 60 as a response to the reply request received in step S113 (S115).

[0275] The management device 60 receives the temperature and humidity information returned by the second server 80 (S115). The second program 65 of the management device 60 generates temperature and humidity history display screen data based on the received temperature and humidity information (S116). More specifically, the second program 65 has in advance format data for generating temperature and humidity history display screen data. The format data has input fields for inputting the factory name and temperature and humidity information. The second program 65 inputs the factory name and temperature and humidity information into the input fields of the format data to generate the temperature and humidity history display screen data. The format data may be the above-mentioned function or class. The temperature and humidity information may also be image data.

[0276] The second program 65 of the management device 60 returns the generated temperature and humidity history display screen data to the terminal device 90 as a response to the request received in step S111 (S117).

[0277] The terminal device 90 receives the temperature and humidity history display screen data returned by the management device 60 (S117). The terminal program 104 of the terminal device 90 inputs the received temperature and humidity history display screen data into the display 107 or touch panel 109, and causes a temperature and humidity history display screen to pop up and be displayed on the display 107 or touch panel 109 (S118).

[0278] 25 has a factory name object 193 indicating the name of the manufacturing factory, and a temperature and humidity graph 194. The temperature and humidity graph 194 has a vertical axis indicating temperature and humidity, a horizontal axis indicating time, a temperature line 195 that displays temperature, and a humidity line 196 that displays humidity. The temperature and humidity graph 194 shows the changes in temperature and humidity at the manufacturing factory 20 on the current date.

[0279] The temperature and humidity history information screen may have a calendar icon 197. The terminal program 104 of the terminal device 90 acquires the desired date selected by the administrator or the like using the calendar icon 197. Based on the acquisition of the desired date, the terminal program 104 sends a request for temperature and humidity history screen data further including the desired date to the management device 60 (S111). The terminal program 104 receives temperature and humidity history display screen data indicating the temperature and humidity history information for the desired date returned by the management device 60 in response to the request (S117). The terminal program 104 causes the display 107 or touch panel 109 to display the temperature and humidity history display screen for the desired date (S118).

[0280] 13, the terminal program 104 of the terminal device 90 determines whether an end instruction has been input (S119). An end instruction is input to the terminal device 90, for example, by selecting the "X" in the upper right corner of the temperature and humidity history display screen. If the terminal program 104 determines that an end instruction has been input (S119: Yes), it closes the temperature and humidity history display screen (S120). If the terminal program 104 determines that an end instruction has not been input (S119: No), it continues to display the temperature and humidity history display screen.

[0281] When the terminal program 104 of the terminal device 90 determines that the icon selected by the administrator or the like on the real-time display screen is the camera icon 161 (S48: camera icon in Fig. 8), it transmits a request for video data to the management device 60 (S121), as shown in Fig. 13. The request is a command including, for example, the camera ID indicating the camera 110 corresponding to the camera icon 161 selected by the administrator or the like and screen identification information indicating the video data.

[0282] The management device 60 receives the request transmitted by the terminal device 90 (S121). Based on the reception of the request, the second program 65 of the management device 60 identifies the video data transmitted by the camera 110 indicated by the camera ID from among the video data received by the management device 60 in step S13 (see FIG. 7) (S122). The second program 65 returns the identified video data to the terminal device 90 as a response to the request received in step S121 (S123).

[0283] The terminal device 90 receives the video data returned by the management device 60 (S123). The terminal program 104 of the terminal device 90 inputs the received video data into the display 107 or the touch panel 109, and displays a camera video display screen as a pop-up on the display 107 or the touch panel 109 (S124).

[0284] The terminal program 104 of the terminal device 90 determines whether an end instruction has been input (S125). An end instruction is input to the terminal device 90, for example, by selecting the "X" in the upper right corner of the camera image display screen. If the terminal program 104 determines that an end instruction has been input (S125: Yes), it closes the camera image display screen (S126). If the terminal program 104 determines that an end instruction has not been input (S125: No), it continues to display the camera image display screen.

[0285] [Effects of the embodiment]

[0286] In this embodiment, a manager or the like can check the operating status of each manufacturing apparatus 30 in real time on the real-time display screen. In addition, by selecting an apparatus icon 120 on the real-time display screen, the manager or the like can check analysis information, aggregate information, etc. obtained by analyzing and collecting raw information for each manufacturing apparatus 30. As a result, the production management system 10 can easily and accurately grasp the production status and reduce the burden on the manager or the like.

[0287] In this embodiment, the equipment icons 120 are arranged in the display area 130 according to the actual locations of the manufacturing equipment 30 in the manufacturing factory 20. Therefore, the manager or the like can intuitively recognize which equipment icon 120 is associated with which manufacturing equipment 30. As a result, the burden on the manager or the like is further reduced.

[0288] In this embodiment, the equipment icon 120 displays the name of the manufacturing equipment 30, the product name, operating time, and production quantity of the product currently being processed, inspected, etc. Therefore, a manager or the like can easily grasp the product name, operating time, and production quantity for each manufacturing equipment 30. As a result, the burden on the manager or the like is further reduced.

[0289] In this embodiment, the analysis information display screen is displayed on the terminal device 90 in response to a request from a manager or the like. Therefore, the manager or the like can easily grasp when an abnormality occurred, the period during which the abnormality occurred, the period during which the manufacturing apparatus 30 was operating normally, and the like for each manufacturing apparatus 30. As a result, the burden on the manager or the like is further reduced.

[0290] In this embodiment, the tally display screen is displayed on the terminal device 90 in response to a request from the manager. Therefore, the manager can easily grasp the cumulative time of normal operation, the cumulative time of abnormal stoppage, and the number of manufactured units for each date. As a result, the burden on the manager is further reduced.

[0291] In this embodiment, the abnormality details display screen is displayed on the terminal device 90 in response to a request from the administrator. Therefore, the administrator can easily grasp the type of abnormality and the number of times the abnormality has occurred by looking at the graph. As a result, the burden on the administrator is further reduced.

[0292] In this embodiment, the achievement rate, which indicates the ratio of the current production quantity to the planned production quantity, and the planned production quantity are displayed on the equipment icon 120. Therefore, a manager or the like can easily grasp the achievement rate for each manufacturing equipment 30. As a result, the burden on the manager or the like is further reduced.

[0293] In this embodiment, the current period cumulative total display screen is displayed on the terminal device 90 in response to a request from the manager. The current period cumulative total display screen is displayed in the same layout as the real-time display screen. Therefore, the manager or the like can check both the current production time information and the cumulative production time information for the manufacturing apparatus 30 of interest without changing his or her line of sight. As a result, the burden on the manager or the like is further reduced.

[0294] In this embodiment, a temperature display object 137 and a humidity display object 138 that display the temperature and humidity are displayed in area 130 on the real-time display screen, and when the humidity is equal to or higher than the threshold humidity, a manufacturing warning object 129 is displayed on the real-time display screen. By displaying the manufacturing warning object 129 on the real-time display screen, a warning is issued to a manager or the like. As a result, the burden on the manager or the like is further reduced.

[0295] In this embodiment, a total number object 139 indicating the total number of products to be manufactured (total planned quantity) and the total number of products manufactured up to the present time (total production quantity) is displayed on the real-time display screen for each display area 130. This allows managers and the like to more easily recognize the manufacturing status in each area 130 of the manufacturing factory 20. As a result, the burden on managers and the like is further reduced.

[0296] [Variations]

[0297] In the above embodiment, an example has been described in which the management device 60 that performs management is a single device. However, the management device 60 may be configured with multiple devices. The programs 64, 65, 66, and 67 may be distributed and implemented in multiple devices.

[0298] In the above embodiment, an example has been described in which the production management system 10 includes two servers, the first server 70 and the second server 80. However, the production management system 10 may include one server or three or more servers. [Explanation of symbols]

[0299] 10. Production control system 11. Communication Network 20...Manufacturing factory 30...Manufacturing equipment 40... Area 50 PLCs 60...Management device 61, 71, 81, 101... Computer 62, 72, 74, 82, 84, 102... Memory 64, 65, 66, 67, 75, 85, 104... Program 70...First Server 80...Second Server 90 Terminal equipment 107···Display 109···Touch panel 110···Temperature and humidity sensor 120, 121...Device icon 123~128...Name object 129 Manufacturing Caution Object 130···Display area 140 Display switch icon 146···Graph (1st graph) 137 Temperature display object (temperature and humidity display object) 138 Humidity display object (Temperature and humidity display object) 139... Total Objects 172···Graph (2nd graph)

Claims

1. a plurality of controllers each periodically acquiring raw information including manufacturing time information associated with a device ID; a memory for storing an information database in which generated information obtained by analyzing or aggregating the raw information is associated with the device ID; The display and a program for displaying a screen on the display; A production management system comprising: a computer that executes the program; The above program is a first display process for periodically acquiring the raw information and periodically updating and displaying on the display a real-time display screen having a plurality of device icons each including a manufacturing device name corresponding to the device ID and the manufacturing time information; a second display process of acquiring the generation information associated with the device ID indicated by the device icon from the information database based on the selection of the device icon, and displaying a generation information display screen including the generation information on the display; A production management system in which the manufacturing time information included in the device icon includes a product name, operating time, and manufacturing quantity indicated by a product ID.

2. The real-time display screen shown above is The manufacturing plant has a plurality of display areas each having a name object indicating each area and separated from each other, The above program is 2. The production management system according to claim 1, further comprising: one of said display areas associated with said device ID; and layout information indicating the layout position of said device icon in said display area.

3. The original information further includes error information, 2. The production management system according to claim 1, wherein the generated information display screen includes a first graph that associates normal operation periods and abnormal stop periods specified based on the error information with time.

4. The original information further includes error information, 2. The production management system according to claim 1, wherein the production information display screen includes a table in which dates, operation times, production quantities, accumulated normal operation times, and accumulated abnormal stop times are associated with each other.

5. The original information further includes error information, 2. The production management system according to claim 1, wherein the generated information display screen includes a second graph in which the error types and the number of errors indicated by the error information are associated with each other.

6. the memory further stores a production schedule database in which product IDs, device IDs, and production schedules are associated with each other; The above device icon is The planned production quantity included in the above production schedule, 2. The production management system according to claim 1, further comprising an achievement rate calculated by the program based on the planned production quantity and the production quantity.

7. the real-time display screen further includes a display switching icon for switching between the manufacturing time information displayed on the device icon and cumulative information, which is a cumulative total of the manufacturing time information; The above program is 7. A production management system as described in any one of claims 1 to 6, further comprising: a display switching process that, based on the selection of the display switching icon, displays the cumulative information on the equipment icon instead of the manufacturing time information without changing the position of the equipment icon on the real-time display screen.

8. the memory further stores a production schedule database in which product IDs, device IDs, and production schedules are associated with each other; 3. The production management system according to claim 2, wherein the real-time display screen has a total number object in each of the plurality of display areas that displays a total planned quantity for each of the display areas according to the production schedule and a total production quantity for each of the display areas according to the production chronological information.

9. A plurality of controllers each periodically acquiring raw information including manufacturing time information associated with a device ID; a memory for storing an information database in which generated information obtained by analyzing or aggregating the raw information is associated with the device ID; The display and a program for displaying a screen on the display; a computer that executes the program; A production management system including a plurality of temperature and humidity sensors that are installed in each area of ​​a manufacturing factory and each output a sensor ID and temperature and humidity information, The above program is a first display process for periodically acquiring the raw information and periodically updating and displaying on the display a real-time display screen having a plurality of device icons each including a manufacturing device name corresponding to the device ID and the manufacturing time information; a second display process of acquiring the generation information associated with the device ID indicated by the device icon from the information database based on the selection of the device icon, and displaying a generation information display screen including the generation information on the display; The real-time display screen shown above is the display device has a plurality of mutually separated display areas, each of which is assigned a name object indicating the area, and a plurality of temperature and humidity display objects disposed in the plurality of display areas, respectively, for displaying the temperature and humidity information; The above program is the display area corresponding to the device ID, the display area indicating the position of the device icon in the display area, and the position of the temperature and humidity display object indicating the correspondence between the sensor ID and the position of the temperature and humidity display object; The production management system further displays a manufacturing caution object on the real-time display screen based on the temperature and humidity information being equal to or greater than a threshold value in at least one of the display areas.

Images