Management System

Abstract

To provide a management system with which it is possible to detect abnormality having occurred in a product manufacturing process that includes a plurality of steps and prevent abnormal products from flowing out.SOLUTION: A management system comprises: an apparatus 10 that includes an abnormality information generation unit for generating management data that includes at least identification information on an abnormal product and a communication unit capable of transmitting the management data generated by the abnormality information generation unit to a control device; an apparatus 15 for dismantling that includes a read unit for reading the identification information on the abnormal product and a communication unit capable of transmitting the read information having been read by the read unit to the control device; and the control device 20 that includes a communication unit capable of receiving the management data and read information transmitted from the apparatus 15 for dismantling, a storage unit for storing the management data transmitted from the apparatus 10, and a determination unit for determining regarding the state of the abnormal product on the basis of the management data and the information transmitted from the apparatus 15 for dismantling. The determination unit determines that abnormality has occurred in the handling of the abnormal product when the read information is not transmitted from a remote facility even when a prescribed condition is met.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a management system. [Background technology]

[0002] BACKGROUND ART Traceability using IDs is known as a method for managing data on products manufactured through a manufacturing process including multiple steps (for example, Patent Document 1). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Publication No. 2018-205948 Summary of the Invention [Problem to be solved by the invention]

[0004] It is extremely difficult to completely eliminate the occurrence of abnormalities in the manufacturing process of a product. Therefore, a system for detecting abnormalities and preventing the release of defective products was required in relation to the operation of traceability.

[0005] An object of the present invention is to provide a management system that can detect abnormalities that occur in a product manufacturing process that includes multiple steps and prevent the outflow of defective products. [Means for solving the problem]

[0006] The management system of the present invention for achieving the above object is a management system in which a plurality of devices that are used in sequence in accordance with the order of a plurality of processes included in an overall process for manufacturing a product, an isolation facility for isolating an unfinished product that has developed an abnormality in any of the plurality of processes, and a control device are communicably connected, and the control device manages the operation of the plurality of devices and the products manufactured using the plurality of devices, and the devices have an abnormality information generation unit that generates management data including at least identification information of the abnormal product when an abnormality occurs in a process using the device, and the management data generated by the abnormality information generation unit is transmitted to the control device. The isolation facility has a reading unit that reads the identification information of the abnormal product and a communication unit that can transmit the reading information read by the reading unit to the control device, and the control device has a communication unit that can receive the management data transmitted from the equipment and the reading information transmitted from the isolation facility, a memory unit that stores the management data transmitted from the equipment, and a judgment unit that performs processing based on the management data and the information transmitted from the isolation facility, and if the reading information is not transmitted from the isolation facility even when specified conditions are met, the judgment unit judges that an abnormality has occurred in the handling of the abnormal product.

[0007] This makes it possible to determine whether an abnormality has occurred in the handling of the abnormal product based on whether or not the read information has been transmitted from the isolation facility. In other words, it is possible to determine whether an abnormal product that should have been moved to the isolation facility has been moved to the isolation facility. Therefore, it is possible to detect an abnormality that has occurred in a product manufacturing process that includes multiple steps.

[0008] In the management system of the present invention, the anomaly information generation unit includes a generation unit that generates, as the management data, data indicating identification information corresponding to the operation of the equipment, the storage unit stores data indicating pre-registered identification information, the generation unit includes a first reading unit that reads first identification information given to each of parts used in manufacturing, and includes the first identification information read by the first reading unit and second identification information given in advance to the process in information indicating at least one of the start and completion of a process using the equipment, the storage unit stores temporary data in the storage unit that can individually identify intermediate products that have completed some of the multiple processes, and the temporary data is the first identification information given to parts used in the manufacture of the intermediate products. The information, the second identification information indicating the last process involved in the production of the intermediate product, and a retention count value are associated with each of the intermediate products, the retention count value being a numerical value indicating the number of times that other intermediate products produced in the same process as the last process have started or completed the next process before the intermediate product, or a numerical value indicating the number of times that other intermediate products produced in the same process as the last process have started or completed production after the intermediate product has been produced, the first identification information functions as identification information for the abnormal product, and the determination unit determines whether the predetermined condition is met based on the identification information included in the data transmitted from the device, the identification information stored in the storage unit, the retention count value, and a predetermined threshold value. Note that "completion" includes not only "normal completion" which refers to the intended completion of each process in the production of the device (or a workpiece which is an intermediate product produced in the process of manufacturing the device), but also "abnormal completion" which is not normal and results in an unintended process or product.

[0009] An increase in the retention count indicates that for some reason a certain intermediate product is unable to start the next process. This makes it possible to determine whether an abnormality has occurred in one of multiple processes based on the retention count value. Therefore, it becomes possible to detect abnormalities that have occurred in the manufacturing process of a product that includes multiple processes.

[0010] In the management system of the present invention, the predetermined threshold value includes a first threshold value for stopping at least one of the plurality of devices that is used in the final process, and the judgment unit judges whether an abnormality has occurred in the handling of the abnormal product based on the value of the retention count and the first threshold value, and if it is determined that an abnormality has occurred in the handling of the abnormal product, stops at least one of the plurality of devices that is used in the final process.

[0011] Therefore, if an abnormality is detected in any of the processes based on the value of the retention count, the equipment can be stopped.

[0012] In the management system of the present invention, at least one of the plurality of devices and the control device is equipped with an alarm unit that issues an alarm to an operator of the device, the predetermined threshold value includes a second threshold value for determining whether or not the alarm unit should operate, and the judgment unit determines whether an abnormality has occurred in the handling of the abnormal product based on the value of the retention count and the second threshold value, and operates the alarm unit if it is determined that an abnormality has occurred in the handling of the abnormal product.

[0013] Therefore, if an abnormality is detected in any of the processes based on the value of the retention count, a notification to that effect can be given.

[0014] In the management system of the present invention, the judgment unit activates the alarm unit when a predetermined time has passed or a predetermined time has arrived after the temporary data including the first identification information that functions as identification information for the abnormal product is stored in the memory unit.

[0015] Therefore, if an abnormality is detected in any of the multiple processes, a notification to that effect can be given.

[0016] In the management system of the present invention, the device includes an adding unit that adds additional information about the abnormality that has occurred in the abnormal product to the management data.

[0017] Therefore, information about abnormalities occurring in abnormal products can be managed.

[0018] In the management system of the present invention, the isolation facility is equipped with work equipment that performs work to re-introduce the abnormal product into one of the multiple processes, the memory unit stores display data for displaying and outputting work content according to the additional information, the communication unit of the control device transmits the display data to the work equipment, the communication unit of the isolation facility receives the display data, and the work equipment is equipped with a display unit that can display the display data.

[0019] Therefore, the operator can carry out the work to reintroduce the defective product into one of the multiple processes, and the details of the work can be displayed to guide the operator.

[0020] In the management system of the present invention, the memory unit stores correspondence data indicating the correspondence between re-insertable parts resulting from work content corresponding to the additional information and the process to which the parts are to be re-inserted, the communication unit of the control device transmits the correspondence data to the work equipment, the communication unit of the isolation facility receives the correspondence data, and the display unit further performs display based on the correspondence data.

[0021] Therefore, it is possible to guide the user as to where to re-insert parts that have been generated after the work.

[0022] In the management system of the present invention, if the re-insertable part is a part that cannot be individually assigned the identification information, an output unit is provided that generates and outputs the dedicated identification information, and the memory unit stores the dedicated identification information.

[0023] Therefore, identification information can be given to the re-introduced parts. [Effects of the Invention]

[0024] According to the management system of the present invention, it is possible to detect abnormalities that occur in a manufacturing process for a product that includes multiple steps, and to prevent the outflow of defective products. [Brief explanation of the drawings]

[0025] [Figure 1] FIG. 1 is a schematic diagram showing an example of the main configuration of a management system. [Figure 2] FIG. 2 is a block diagram showing the main configuration of the device. [Figure 3] FIG. 3 is a block diagram showing the main configuration of a PLC. [Figure 4] FIG. 4 is a diagram showing an example of a process list. [Figure 5] FIG. 5 is a diagram showing an example of the process sequence master. [Figure 6] FIG. 6 is a diagram showing an example of the relationship between a plurality of processes included in the overall process for each production item number indicated by the process sequence master. [Figure 7] FIG. 7 is a diagram showing an example of the process master. [Figure 8A] FIG. 8A is a schematic diagram showing a process corresponding to the process master. [Figure 8B] FIG. 8B is a diagram showing an example of the process list of FIG. 8A. [Figure 9] FIG. 9 is a diagram showing an example of the input quantity master. [Figure 10] FIG. 10 is a diagram illustrating an example of the certified worker list. [Figure 11] FIG. 11 is a diagram showing schematic data as an example of a BOM master. [Figure 12] FIG. 12 is a diagram showing the BOM tree structure represented by the BOM master in FIG. [Figure 13] FIG. 13 is a diagram showing data that functions as a BOM master BOMM in the embodiment. [Figure 14] FIG. 14 is a diagram illustrating a tree structure that is a BOM tree structure derived from the data of FIG. [Figure 15] FIG. 15 is a diagram showing an example of a managed individual serial master. [Figure 16] FIG. 16 is a diagram showing an example of a state of the individual management work state table. [Figure 17] FIG. 17 is a schematic diagram showing the state of the first step and the second step corresponding to FIG. [Figure 18] FIG. 18 is a diagram showing an individual management workpiece state table in a state different from the state shown in FIG. [Figure 19] FIG. 19 is a schematic diagram showing the state of the first step and the second step corresponding to FIG. [Figure 20] FIG. 20 is a diagram showing an individual management workpiece state table in a state different from the state shown in FIG. 16 and the state shown in FIG. [Figure 21] FIG. 21 is a diagram showing an individual management workpiece state table in a state different from the states of FIG. 16, FIG. 18 and FIG. [Figure 22] FIG. 22 is a diagram showing an individual management workpiece state table in a state different from the state of FIG. 16, the state of FIG. 18, the state of FIG. 20, and the state of FIG. [Figure 23] FIG. 23 is a diagram showing an individual management workpiece state table in a state different from the states of FIG. 16, FIG. 18, FIG. 20, FIG. 21, and FIG. [Figure 24] FIG. 24 is a diagram showing an individual management workpiece state table in a state different from the state of FIG. 16, the state of FIG. 18, the state of FIG. 20, the state of FIG. 21, the state of FIG. 22 and the state of FIG. [Figure 25] FIG. 25 is a diagram illustrating an example of the product master. [Figure 26] FIG. 26 is a diagram showing an example of the state of the result registration data. [Figure 27] FIG. 27 is a diagram showing the result registration data in a state different from that shown in FIG. [Figure 28] FIG. 28 is a diagram showing the result registration data in a state different from the state in FIG. 26 and the state in FIG. [Figure 29] FIG. 29 is a diagram showing the result registration data in a state different from the states of FIGS. 26, 27 and 28. In FIG. [Figure 30] FIG. 30 is a diagram showing an example of a state of the lot part counter. [Figure 31] FIG. 31 is a diagram showing the lot part counter in a state different from the state shown in FIG. [Figure 32] FIG. 32 is a diagram showing a lot part counter in a state different from the state shown in FIG. 30 and the state shown in FIG. [Figure 33] FIG. 33 is a diagram showing an example of the relationship between a plurality of processes included in an overall process. [Figure 34] FIG. 34 is a diagram showing an example of NG mode data. [Figure 35] FIG. 35 is a diagram showing an example of a processing-awaiting defective product management table for managing workpieces whose "status" field in the status table is set to "abnormal completion." [Figure 36] FIG. 36 is a diagram showing an example of disassembly mode data. [Figure 37] FIG. 37 is a diagram illustrating an example of the reintroduction master. [Figure 38] FIG. 38 is a diagram showing a tree structure B13, which is a BOM tree structure BOMT derived from the re-entry master of FIG. [Figure 39] FIG. 39 is a diagram illustrating an example of the disassembly master. [Figure 40] FIG. 40 is a diagram showing an example of dismantling equipment. [Figure 41] FIG. 41 is a schematic diagram showing an example of the display content of the touch panel. [Figure 42] FIG. 42 is a diagram showing an example of the procedure data D15. [Figure 43] FIG. 43 is a diagram showing an example of the re-introduction instruction display screen. [Figure 44] FIG. 44 is a diagram showing a state in which the opening / closing cover of the reuse pallet of the dismantling equipment shown in FIG. 40 is open. [Figure 45] FIG. 45 is a diagram showing a state in which the opening / closing cover of the NG shooter of the dismantling device shown in FIG. 40 is open. [Figure 46] FIG. 46 is a diagram illustrating an example of the re-entry counter. [Figure 47] FIG. 47 is a diagram showing an example of the re-entry counter after the components that were managed separately in FIG. 46 are assembled together. [Figure 48]FIG. 48 is a schematic diagram showing an example of workpieces etc. placed as reusable parts on a reusable pallet. [Figure 49] FIG. 49 is a schematic diagram showing a reusable pallet on which multiple types of workpieces generated during dismantling work can be individually placed. [Figure 50] FIG. 50 is a flowchart showing an example of the flow of processing performed by the calculation unit as the production line operation start processing. [Figure 51] FIG. 51 is a flowchart showing an example of the flow of the process for checking certified workers. [Figure 52] FIG. 52 is a flowchart showing an example of the flow of the check process for the program selected by the program selection unit. [Figure 53] FIG. 53 is a flowchart showing an example of the flow of the reading and checking process of the identification tag. [Figure 54] FIG. 54 is a flowchart showing an example of the flow of one-cycle startup check processing of a process. [Figure 55] FIG. 55 is a flowchart showing an example of the flow of the lot part counter check process. [Figure 56] FIG. 56 is a flowchart showing an example of the flow of a process for checking completion of one cycle of a process. [Figure 57] FIG. 57 is a flowchart showing an example of the flow of the retention counter check process. DETAILED DESCRIPTION OF THE INVENTION

[0026] Hereinafter, embodiments of the present invention will be described with reference to the drawings, but the present invention is not limited thereto. The requirements of each embodiment described below can be combined as appropriate. In addition, some components may not be used.

[0027] FIG. 1 is a schematic diagram showing an example of the main configuration of a management system. The management system includes a plurality of devices 10 and a control device 20. The control device 20 is, for example, a PLC (Programmable Logic Controller), but is not limited to this and may be any device that performs the functions of the control device 20 described below, and can be modified as appropriate. FIG. 1 shows four devices 10, namely, a first device 11, a second device 12, a third device 13, and a fourth device 14, as an example of the plurality of devices 10, but this is merely an example and is not limiting. The number of devices 10 may be two or more, or may be three or less, or five or more.

[0028] The multiple devices 10 are provided corresponding to the multiple processes included in the manufacturing process (overall process) for manufacturing products manufactured by the management system. FIG. 1 illustrates four processes: a first process F1 using a first device 11, a second process F2 using a second device 12, a third process F3 using a third device 13, and a fourth process F4 using a fourth device 14. The overall process includes multiple processes performed in the order of the first process F1, the second process F2, the third process F3, and the fourth process F4. Hereinafter, unless otherwise specified, the term "multiple processes" refers to multiple processes included in the manufacturing process (overall process) for manufacturing products manufactured by the management system. When there are three or fewer devices 10 or five or more devices 10, the number of the multiple processes corresponds to the number of devices 10.

[0029] In addition, in the embodiment, a normal product storage area and an NG product storage area are provided as destinations for products in the process of being manufactured (work) or completed products (finished products) manufactured using the equipment 10 in each of the multiple processes. The normal product storage area is where normal work or finished products that have been manufactured correctly are placed. The NG product storage area is where abnormal work or finished products that have experienced some kind of abnormality during the manufacturing process are placed. Note that NG is a Japanese-English acronym that means "No Good."

[0030] In the example shown in FIG. 1, normal product areas include a first normal product area 52, a second normal product area 54, a third normal product area 56, and a fourth normal product area 58. Furthermore, NG product areas include a first NG product area 53, a second NG product area 55, a third NG product area 57, and a fourth NG product area 59. The first normal product area 52 is used to place work that has completed (normally completed) the first process F1 using the first device 11. The second normal product area 54 is used to place work that has completed (normally completed) the second process F2 using the second device 12. The third normal product area 56 is used to place work that has completed (normally completed) the third process F3 using the third device 13. The fourth normal product area 58 is used to place normal completed products from the fourth process F4 using the fourth device 14. The first NG product area 53 is used to place work that has abnormally completed the first process F1 using the first device 11. The second NG storage area 55 is where work that has ended abnormally in the second process F2 using the second device 12 is placed. The third NG storage area 57 is where work that has ended abnormally in the third process F3 using the third device 13 is placed. The fourth NG storage area 59 is where abnormal finished products from the fourth process F4 using the fourth device 14 are placed.

[0031] In the example shown in FIG. 1 , an initial parts storage area 51 is provided as a storage area for parts used to manufacture the workpieces manufactured in the first process F1. The first process F1 is a process in which a workpiece manufactured using the first equipment 11 and parts placed in the initial parts storage area 51 is placed in the first normal product storage area 52 or the first non-returnable product storage area 53. The second process F2 is a process in which a workpiece manufactured using the second equipment 12 and parts placed in the first normal product storage area 52 is placed in the second normal product storage area 54 or the second non-returnable product storage area 55. The third process F3 is a process in which a workpiece manufactured using the third equipment 13 and parts placed in the second normal product storage area 54 is placed in the third normal product storage area 56 or the third non-returnable product storage area 57. The fourth process F4 is a process in which a finished product manufactured using the fourth equipment 14 and parts placed in the third normal product storage area 56 is placed in the fourth normal product storage area 58 or the fourth non-returnable product storage area 59. The workpieces placed in the NG product storage areas (first NG product storage area 53, second NG product storage area 55, and third NG product storage area 57) will not be used as materials in the next process.

[0032] A worker performs a process using each of the multiple devices 10. FIG. 1 illustrates a worker H1 performing a first process F1 using a first device 11, a worker H2 performing a second process F2 using a second device 12, a worker H3 performing a third process F3 using a third device 13, and a worker H4 performing a fourth process F4 using a fourth device 14. However, the number of workers is not limited to one per process, and multiple workers may be present. Furthermore, the worker for each process is a predetermined certified worker. The certified workers are determined by a certified worker list D5, which will be described later.

[0033] The management system is further provided with dismantling equipment 15. The dismantling equipment 15 includes one or more devices for performing abnormality response measures such as dismantling, disassembling, reworking, and discarding of abnormally terminated workpieces or abnormal finished products, and a touch panel 152 that functions as an operation screen. The dismantling equipment 15 is provided as a destination for workpieces that have developed an abnormality as a result of being manufactured by the equipment 10.

[0034] 2 is a block diagram showing the main configuration of the device 10. The device 10 includes a communication unit 31, a memory unit 32, an individual management serial number reading unit 33, an assembly lot part ID reading unit 34, a worker ID reading unit 35, a driving unit 36, a notification unit 37, a program selection unit 38, a sensing unit 39, a determination unit 40, an operation control unit 41, an input unit 42, and the like.

[0035] The communication unit 31 communicates with the control device 20. Specifically, the communication unit 31 includes a circuit and other components that function as a NIC (Network Interface Controller), and performs various processes related to communication with the control device 20. The protocol used for communication between the device 10 and the control device 20 via the communication unit 31 may be the same as a protocol used in a public communication network such as the Internet, or may be a dedicated protocol. Furthermore, the communication line used for communication between the device 10 and the control device 20 may be wired, wireless, or a combination of wired and wireless.

[0036] The storage unit 32 stores various software programs and data used in the operation of the device 10. The data includes information indicating the process ID of the process in which the device 10 is used. Hereinafter, the term "programs, etc." refers to software programs and data. Specifically, the storage unit 32 includes at least one storage device such as a flash memory, an SSD (Solid State Drive), or an HDD (Hard Disk Drive). The storage unit 32 stores the programs, etc. in the storage device.

[0037] The individual management serial reading unit 33 reads an ID (serial) given to a part or workpiece that is used as material in a process using the equipment 10. The assembly lot part ID reading unit 34 reads an ID (assembly lot part ID) given to a lot part (lot part) that is used as material in a process using the equipment 10. The worker ID reading unit 35 reads an ID (worker ID) given to a worker who carries out a process using the equipment 10. The serial, assembly lot part ID, and worker ID will be described later. Note that ID stands for identification and refers to information that functions as identification information.

[0038] Note that some or all of the individual management serial number reading unit 33, assembly lot part ID reading unit 34, and worker ID reading unit 35 may share a physically common configuration. For example, if some or all of the serial number, assembly lot part ID, and worker ID are characters, character strings, symbols, or patterns added based on a common format, or a combination of some or all of these, some or all of the individual management serial number reading unit 33, assembly lot part ID reading unit 34, and worker ID reading unit 35 are provided as reading devices compatible with that format. More specifically, if some or all of the serial number, assembly lot part ID, and worker ID are barcodes, some or all of the individual management serial number reading unit 33, assembly lot part ID reading unit 34, and worker ID reading unit 35 are physically common barcode readers. Furthermore, if the serial number, assembly lot part ID, and worker ID are all or partly comprised of characters, character strings, or symbols, or a combination of all or part of these, then all or part of the individual management serial reading unit 33, assembly lot part ID reading unit 34, and worker ID reading unit 35 may be configured as a camera or the like including an image sensor capable of capturing these. Of course, the individual management serial reading unit 33, assembly lot part ID reading unit 34, and worker ID reading unit 35 may each have a physically different configuration.

[0039] The drive unit 36 ​​causes the equipment 10 to perform various physical operations to manufacture a workpiece or a finished product. Specifically, the drive unit 36 ​​includes an electric motor, a power supply device that supplies power to the electric motor, and a coupling mechanism such as gears that couple the electric motor to a movable part of the drive unit 36. The specific configurations of the drive unit 36 ​​and the machines operated by the drive unit 36 ​​correspond to the specific operations of the equipment 10 required in each process. Therefore, the drive unit 36 ​​common to multiple equipment 10 is a functional and conceptual drive unit 36, and the specific drive unit 36 ​​provided in the first equipment 11, the specific drive unit 36 ​​provided in the second equipment 12, the specific drive unit 36 ​​provided in the third equipment 13, and the specific drive unit 36 ​​provided in the fourth equipment 14 are all different.

[0040] The notification unit 37 notifies the worker or other people of various information related to the operation of the device 10. Specifically, the notification unit 37 includes at least one of a speaker for outputting a warning or providing information by sound, a display device for outputting an image, etc. The notification unit 37 may further include a light for issuing a warning by blinking light, etc.

[0041] The program selection unit 38 accepts a selection operation by an operator or other person to select one of a plurality of programs, etc., which are provided in advance and correspond to specific operational details of the device 10. While FIG. 2 illustrates a first program 38a, a second program 38b, etc., as selectable programs, the number of selectable programs may be two or more. Similar to the specific configuration of the drive unit 36, the specific control details of the plurality of programs, etc., selectable by the program selection unit 38 included in each of the plurality of devices 10 correspond to specific operational details of the device 10 required in each process. Each of the plurality of programs, etc., selectable by the program selection unit 38 corresponds to a different operation. Each of the plurality of programs, etc., selectable by the program selection unit 38 may be stored in the storage unit 32 or in another storage device (not shown) included in the device 10.

[0042] The sensing unit 39 performs various sensing operations related to the operation of the device 10. Specifically, the sensing unit 39 includes, for example, various sensors, cameras, etc. for acquiring information about the state of the workpiece, parts, etc. during production or before and after production by the operation of the driving unit 36. The determination unit 40 determines whether the workpiece or finished product is normal or NG based on the sensing by the sensing unit 39. The specific configurations of the sensing unit 39 and the determination unit 40 correspond to the specific configurations of the device 10 required for each process.

[0043] The operation control unit 41 is a controller that controls various operations of the device 10, and includes an arithmetic circuit that reads and executes programs stored in the storage unit 32, as well as various circuits and the like for functioning as a controller. The operation control by the operation control unit 41 is performed in accordance with commands from the control device 20. Details of the operation control of the device 10 by the operation control unit 41 will be described later together with the explanation of the processing content of the arithmetic unit 23.

[0044] The input unit 42 accepts various inputs to the device 10 other than the program selection by the program selection unit 38. Specifically, the input unit 42 includes, for example, switches corresponding to various operation contents. The program selection unit 38 and the input unit 42 may share a common physical configuration, or may have different physical configurations. Alternatively, a so-called touch panel-like configuration may be employed in which a display device functioning as the notification unit 37 and a touch operation detection unit functioning as the program selection unit 38 and the input unit 42 are integrally provided.

[0045] Although not shown, the dismantling equipment 15 is provided with equipment including at least the above-mentioned communication unit 31 and individual management serial reading unit 33. Information indicating the serial number read by the individual management serial reading unit 33 of the equipment provided in the dismantling equipment 15 is transmitted to the control device 20 via the communication unit 31. If the information transmitted to the control device 20 via the communication unit 31 also includes information read by a configuration similar to that of the worker ID reading unit 35, it is also possible to record the worker who performed work such as dismantling, disassembling, reworking, or discarding a workpiece that has ended abnormally or an abnormal finished product.

[0046] 3 is a block diagram showing the main configuration of the control device 20. The control device 20 includes a communication unit 21, a storage unit 22, a calculation unit 23, a notification unit 24, an input unit 25, and the like.

[0047] The communication unit 21 communicates with the multiple devices 10. Specifically, like the communication unit 31, the communication unit 21 includes a circuit and other components that function as a NIC, and performs various processes related to communication with the multiple devices 10.

[0048] The storage unit 22 stores various programs and the like used in the operation of the control device 20. Specifically, like the storage unit 32, the storage unit 22 includes at least one of storage devices such as a flash memory, an SSD (Solid State Drive), and an HDD (Hard Disk Drive). The storage unit 22 stores programs and the like in such storage devices.

[0049] The calculation unit 23 performs various processes related to the operation of the control device 20. Specifically, the calculation unit 23 includes a calculation circuit and the like that functions as a CPU (Central Processing Unit), and the calculation circuit executes programs and the like corresponding to the processing contents from the storage unit 22, thereby performing various processes related to the operation of the control device 20.

[0050] The notification unit 24 notifies workers and other people of various information related to the operation of the management system. Specifically, like the notification unit 37, the notification unit 24 includes at least one of a speaker for outputting a warning or providing information by voice, a display device for displaying an image, etc. The notification unit 37 may further include a light for issuing a warning by blinking light, etc.

[0051] The input unit 25 receives various inputs to the control device 20. Specifically, the input unit 25 includes, for example, a part or all of the same configuration as the configuration exemplified in the description of the input unit 42 above.

[0052] Next, various data used in the management system and the flow of processes using such various data will be described with reference to FIGS.

[0053] FIG. 4 is a diagram showing an example of a process list D1. The process list D1 is data having a column for "Line ID," a column for "Process No.", and a column for "Process ID" corresponding to each of the multiple processes included in the overall process performed on each production line. The term "column" refers to the vertical arrangement of data in the table format shown in FIG. 4 and other figures. The term "record" refers to the horizontal arrangement of data excluding the column names shown in the top row of the data shown in FIG. 4 and other figures. The term "field" refers to one of multiple rectangles formed by a grid-like division made up of vertical lines separating columns, vertically arranged column names, and the top row of records and horizontal lines separating multiple records. Multiple fields included in one record constitute one data set. This data set represents information about the management system, the processes performed by the management system, and the products, workpieces, parts, and other items handled by the management system.

[0054] Each production line has the same "Line ID." In the example shown in Figure 4, "LINE1" and "LINE2" are used as "Line ID." The "Process No." field contains a number corresponding to the order of processes performed on each production line. The "Process ID" field contains a character string that serves as an identification code for distinguishing between processes. In Figure 4, four records are registered, each with "LINE1" registered in the "Line ID" field. The records include a record with "1" registered in the "Process No." field and "PRCS01A" registered in the "Process ID" field, a record with "2" registered in the "Process No." field and "PRCS02A" registered in the "Process ID" field, a record with "3" registered in the "Process No." field and "PRCS03A" registered in the "Process ID" field, and a record with "4" registered in the "Process No." field and "PRCS04A" registered in the "Process ID" field.

[0055] Although details are omitted, the control device 20 also interprets the contents of the process list D1 in a similar manner for records in which "LINE2" is registered in the "LineID" field. In the embodiment, the process assigned the process ID "PRCS01A" is performed by the first device 11. The process assigned the process ID "PRCS02A" is performed by the second device 12. The process assigned the process ID "PRCS03A" is performed by the third device 13. The process assigned the process ID "PRCS04A" is performed by the fourth device 14.

[0056] FIG. 5 is a diagram showing an example of a process sequence master D2. The process sequence master D2 is data having a "production part number" column, a "process ID" column, a "part identification" column, a "previous process identification" column, a "previous process ID" column, and a "part number" column. The "production part number" column contains a field in which an ID assigned to a product to be manufactured is registered. The product is manufactured through a process assigned a process ID registered in the "process ID" field of the record containing the field. Therefore, the combination of the process list D1 in FIG. 4 and the process sequence master D2 in FIG. 5 indicates that the products assigned production part numbers "PRDCT001," "PRDCT002," and "PRDCT003" shown in FIG. 5 are manufactured through processes assigned process IDs "PRCS01A," "PRCS02A," "PRCS03A," and "PRCS04A" that belong to the production line "LINE1" represented in the process list D1 in FIG. 4.

[0057] Each record in the process sequence master D2 indicates more detailed information about the process to which each process ID is assigned. The value registered in the "Part identification" field is 0 unless there is a special note. These special notes will be explained later. The value registered in the "Previous process identification" field is 1 unless there is a special note. These special notes will be explained later. The "Previous process ID" field registers the process ID of the process that takes place before the process indicated by the process ID of each record. However, for records in the field indicating the first process to be performed in the manufacture of a product of each "production number," no process ID is registered in the "Previous process ID" field (in Figure 5, this is indicated as "-").

[0058] FIG. 6 is a diagram showing an example of the relationship between multiple processes included in the overall process for each production part number indicated by the process sequence master D2. First, the records included in the process sequence master D2 in FIG. 5 will be described sequentially from top to bottom for the processes related to the manufacture of a product assigned the production part number of "PRDCT001" (hereinafter referred to as the first product). A record with "PRCS01A" assigned to the "Process ID" has a "Previous Process ID" of "-". That is, this record indicates that the first process performed in the manufacture of the first product is the process assigned the process ID of "PRCS01A". Furthermore, a record with "PRCS02A" assigned to the "Process ID" has a "Previous Process ID" of "PRCS01A". That is, this record indicates that in the manufacture of the first product, the process assigned the process ID of "PRCS02A" is performed after the process assigned the process ID of "PRCS01A". Furthermore, a record with "PRCS03A" assigned to the "Process ID" has a "Previous Process ID" of "PRCS02A". That is, this record indicates that in the production of the first product, the process assigned the process ID of "PRCS03A" will be performed after the process assigned the process ID of "PRCS02A." Also, the record with "PRCS04A" assigned to the "Process ID" has "PRCS03A" as the "Previous Process ID." That is, this record indicates that in the production of the first product, the process assigned the process ID of "PRCS04A" will be performed after the process assigned the process ID of "PRCS03A." And the records assigned the production part number of "PRDCT001" are the four records described above. That is, the process sequence master D2 indicates that the production of the first product will be completed with the process assigned the process ID of "PRCS04A." The "PRDCT001" column in Figure 6 corresponds to these four records.

[0059] Next, the records included in the process sequence master D2 in Figure 5 will be explained sequentially from top to bottom for the processes related to the manufacture of a product (hereinafter referred to as the second product) assigned the production part number "PRDCT002." A record with "PRCS01A" assigned to the "Process ID" has a "Previous Process ID" of "-." That is, this record indicates that the first process performed in the manufacture of the second product is the process assigned the process ID "PRCS01A." Furthermore, a record with "PRCS02A" or "PRCS03A" assigned to the "Process ID" has a "Previous Process ID" of "PRCS01A." That is, this record indicates that in the manufacture of the second product, the process assigned the process ID "PRCS02A" or "PRCS03A" is performed after the process assigned the process ID "PRCS01A." Furthermore, there are two records with "PRCS04A" assigned to the "Process ID." One of the two has a "Previous Process ID" of "PRCS02A." The other of the two has a "Previous Process ID" of "PRCS03A." This indicates that, in the production of the second product, a process with a process ID of "PRCS04A" is performed after a process with a process ID of "PRCS02A" or "PRCS03A." Furthermore, the other of the two has a "2" registered in the "Previous Process ID" field. This is registered in one of the multiple records indicating that either a process with a process ID of "PRCS02A" or "PRCS03A" can be the previous process, as in the case of the "PRCS04A" process in the production of the second product. This is noteworthy because the value registered in the "Previous Process ID" field is no longer 1. The records with the production part number of "PRDCT002" are the four records described above. This indicates, in other words, that the production of the second product is completed by the process with a process ID of "PRCS04A," as indicated by the process sequence master D2. The "PRDCT002" column in FIG. 6 corresponds to the four records.6, a process configuration in which the second process F2 and the third process F3 are parallel between the first process F1 and the fourth process F4 is adopted when, for example, one type of process required between the first process F1 and the fourth process F4 is a process that takes longer from start to finish than the first process F1 and the fourth process F4. By performing such a long process in parallel as the second process F2 and the third process F3, it is possible to prevent the process from becoming a bottleneck in the overall progress.

[0060] Next, we will explain the records included in the process sequence master D2 in Figure 5, starting from the top, for the processes related to the manufacture of a product assigned the production part number "PRDCT003" (hereinafter referred to as the third product). Records with "PRCS01A" or "PRCS02A" assigned to the "Process ID" have a "Previous Process ID" of "-". In other words, this record indicates that the first process performed in the manufacture of the third product is the process assigned the process ID "PRCS01A" or "PRCS02A". In other words, this indicates that in the processes related to the manufacture of the third product, the process assigned the process ID "PRCS01A" and the process assigned the process ID "PRCS02A" are performed separately without going through a previous process. There are also two records with "PRCS03A" assigned to the "Process ID". In one of these two, the "Previous Process ID" is "PRCS01A". In the other of these two, the "Previous Process ID" is "PRCS02A". Furthermore, the other of the two records has "Part Identification" set to "1." This indicates that the process assigned the Process ID of "PRCS03A" uses both the workpiece manufactured in the process assigned the Process ID of the record with "Part Identification" set to "0" and the workpiece manufactured in the process assigned the Process ID of the record with "Part Identification" set to "1." In other words, these two records indicate that in the manufacture of the third product, the process assigned the Process ID of "PRCS03A" is carried out using both the workpiece manufactured in the process assigned the Process ID of "PRCS01A" and the workpiece manufactured in the process assigned the Process ID of "PRCS02A." This is noteworthy because the value registered in the "Part Identification" field is no longer 0. Note that the record with "Process ID" set to "PRCS04A" has "Previous Process ID" set to "PRCS03A." In other words, this record indicates that in the manufacture of the third product, the process assigned the Process ID of "PRCS04A" is carried out after the process assigned the Process ID of "PRCS03A." The records assigned with the production part number "PRDCT003" are the four records described above. That is, the process sequence master D2 indicates that the production of the third product will be completed in the process assigned with the process ID "PRCS04A."The "PRDCT003" column in FIG. 6 corresponds to the four records.

[0061] While Figures 5 and 6 show an example where there are two parallel processes, a manufacturing process for a product with three or more parallel processes can also be registered using a similar system. In this case, the number of records assigned with the process ID of a process with multiple previous processes will be three or more. As shown in the example of "PRDCT002," a work or product manufactured in a process with multiple previous processes can use any one of the workpieces from the previous process. The "Part No." in the process sequence master D2 shown in Figure 5 will be discussed later.

[0062] FIG. 7 is a diagram showing an example of the process master D3. The process master D3 is data having a column for "process ID," a column for "production part number," and a column in which a value indicating the number of the program selected by the program selection unit 38 in the manufacture of a product corresponding to the production part number is registered. The "process ID" column corresponds to the column of the same name in the process list D1. Furthermore, the ID registered in the field included in the "process ID" column corresponds to the ID registered in the field included in the column in the process sequence master D2 in which the process ID indicating the chronological order of multiple processes included in the overall process performed on each production line is registered. The ID is either the process ID included in the process list D1 or the process sequence master D2. The "production part number" column corresponds to the column of the same name in the process sequence master D2.

[0063] 7 illustrates a column called "Appropriate Prg. Selection No." as an example of a column in which a value indicating the number of the program selected by the program selection unit 38 in manufacturing a product corresponding to the production part number is registered. "Prg." is an abbreviation for program. Also, in FIG. 7, "1" is registered as the value in the field of the record "PRDCT001," and "2" is registered as the value in the field of the record "PRDCT002."

[0064] FIG. 8A is a schematic diagram showing processes corresponding to the process master D3. FIG. 8B is a diagram showing an example of the process list of FIG. 8A. As shown in FIG. 8A, for the process "PRDCT001," "1" registered in the field of the record "PRDCT001" shown in FIG. 7 is selected as the "Prg. Selection No.". Also, as shown in FIG. 8A, for the process "PRDCT002," "2" registered in the field of the record "PRDCT002" shown in FIG. 7 is selected as the "Prg. Selection No.". Note that the program with "Prg. Selection No." of "1" is, for example, the first program 38a. Also, the program with "Prg. Selection No." of "2" is, for example, the second program 38b. The program selection operation corresponding to such a "Prg. Selection No." is performed, for example, by an operator's selection operation on the program selection unit 38 of the device 10. That is, the field registered in the "Appropriate Prg. Selection No." column in the record shown in FIG. 7 indicates a code (e.g., a number) that identifies the program to be selected in the process of "Process ID" that is performed when manufacturing the "Production Part Number" of that record. Note that the code is not limited to numbers, but may be alphabets or the like, and can be changed as appropriate. Also, the number of columns in which values ​​indicating the numbers of programs selected by program selection unit 38 in manufacturing a product corresponding to the production part number are registered may be two or more, but it is preferable that there is one.

[0065] As shown in Figure 8A, lot parts may be used to manufacture a product corresponding to a production part number. Lot parts are parts that do not have an ID assigned to each part itself, but rather are assigned an ID collectively to multiple parts. Specific examples of lot parts include parts used to fasten workpieces together, such as bolts and nuts, and other fine parts. In Figure 8B, product P001, whose production part number is "PRDCT001," is assembled with lot part L1, which has been assigned an ID of "LPART001," lot part L2, which has been assigned an ID of "LPART002," and lot part L3, which has been assigned an ID of "LPART003," in a process, which has been assigned a process ID of "PRCS01A." Furthermore, a product P002 with a production part number of "PRDCT002" is assembled with a lot part L1 with an ID of "LPART001", a lot part L2 with an ID of "LPART002", and a lot part L4 with an ID of "LPART004" in a process with a process ID of "PRCS01A".

[0066] Although FIG. 8A illustrates an example in which the types and number of lot parts are three, the number of lot parts used in the manufacture of a product may be two or less, or may be four or more.

[0067] 9 is a diagram showing an example of the incoming quantity master D4. The incoming quantity master D4 is data having a column in which an ID indicating a lot part used in manufacturing a product corresponding to a production part number is registered, and a column in which a value indicating the number of lot parts (incoming quantity) corresponding to one lot identification tag data is registered.

[0068] Lot parts are managed in units of containers (for example, boxes) containing multiple items of the same type. Each container is attached with an identification tag. The identification tag is read by the assembly lot part ID reading unit 34 described above, and is used to manage the number of parts used (number of parts sent out) relative to the number of parts in the lot (number of parts received). The handling of such identification tags will be described later.

[0069] The number of lot parts (quantity) corresponding to one lot identification sheet data refers to the number of lot parts of that type contained in a container that contains one type of lot part. In Figure 9, the column field in which the IDs indicating the lot parts used in the manufacture of the product corresponding to the production part number are registered shows four records in which the IDs "LPART001," "LPART002," "LPART003," and "LPART004" described above with reference to Figures 7 and 8A are registered. Furthermore, the value registered in the "quantity" column field is exemplified as "10" for the records "LPART001," "LPART002," and "LPART003," and as "20" for the record "LPART004." In this way, the quantity of parts for each lot is managed by each record in the quantity master D4.

[0070] In FIG. 9, lot parts with IDs "LPART001," "LPART002," "LPART003," and "LPART004" are shown as examples of lot parts whose quantities are registered in the quantity master D4, but this is not limited to these. The lot parts whose quantities are registered in the quantity master D4 are all lot parts used in the manufacture of a product. The total number of such lot parts is not limited to four, but may be three or less, or five or more.

[0071] FIG. 10 is a diagram showing an example of a certified worker list D5. The certified worker list D5 is data having a "process ID" column, a "production part number" column, and a column in which IDs indicating certified workers are registered. FIG. 10 shows a "worker identification" column and a "worker ID" column as examples of columns in which IDs indicating certified workers are registered. A certified worker refers to a worker who is authorized to be in charge of the process corresponding to the ID in the "process ID" column, which is included in the overall process related to the manufacture of the product corresponding to the ID registered in the "production part number" column. The "process ID" column is the same as the "process ID" column in the process list D1 and the process sequence master D2. The "production part number" column is the same as the "production part number" column in the process sequence master D2.

[0072] In FIG. 10, one record in the certified worker list D5 indicates information about one certified worker for a combination of "process ID" and "production part number." Specifically, there are four records indicating certified workers for the combination of "PRCS01A" and "PRDCT001," i.e., the process assigned the process ID "PRCS01A" in the manufacture of a product assigned the production part number "PRDCT001." The certified worker list D5 shown in FIG. 10 also has four records indicating certified workers for the combination of "PRCS01A" and "PRDCT002," i.e., the process assigned the process ID "PRCS01A" in the manufacture of a product assigned the production part number "PRDCT002." Records with the same combination of "process ID" and "production part number" are assigned different "worker identification" numbers. In FIG. 10, the "worker identification" numbers are 1 to 4, and four certified workers are registered for each combination, but this is not limited to four. The number may be three or less, or five or more. In other words, the maximum value of the worker identification number increases or decreases depending on the number of certified workers for the combination of "process ID" and "production part number." Also, in FIG. 10, examples of worker IDs are "OPE001," "OPE002," ..., "OPE008," but this is only an example and is not limiting. For example, the worker ID for the combination of "PRCS01A" and "PRDCT001" may be the same as the worker ID for the combination of "PRCS01A" and "PRDCT002." In this case, the certified worker assigned that worker ID is the certified worker in the "PRCS01A" process for both the "PRDCT001" and "PRDCT002" products.

[0073] In the example shown in Fig. 8A, worker H1, whose certified worker ID is "OPE001," is performing the process of certified worker "PRDCT001," which matches the record shown in Fig. 10. Also, worker H5, whose certified worker ID is "OPE005," is performing the process of certified worker "PRDCT002," which matches the record shown in Fig. 10.

[0074] Next, a BOM (Bill of Materials) used in the embodiment will be described with reference to FIGS.

[0075] Fig. 11 is a diagram showing schematic data as an example of a BOM master BOMM. Fig. 12 is a diagram showing a BOM tree structure BOMT represented by the BOM master BOMM of Fig. 11. The BOM master BOMM is data having a column of "No.", a column of "Part Name.", a column of "Part CD.", a column of "Class.", a column of "Layer.", and a column of "Number Used."

[0076] The "No" field is assigned a unique numerical value that is gradually increased from the starting number of the record located at the top of the BOM tree structure BOMT shown in Fig. 12. In Fig. 11, the nine records in the BOM master BOMM are assigned "No" values ​​that gradually increase from 1 in the order of the records, such as 1, 2, ..., 9. The number in the "No" field indicates the order in which each record is read and interpreted by the control device 20, and also functions as an identification number that indicates the configuration of each record.

[0077] The "Part Name" field is registered with the name of the product, work, or part indicated by each record in the BOM Master BOMM. Here, the "Part Name" of a record to which a starting number is assigned in the "No" field corresponds to the product name of the product indicated by the BOM Master BOMM. Also, the "Part Name" of a record to which a number other than the starting number is assigned in the "No" field corresponds to the name of the work or part that constitutes the product indicated by the BOM Master BOMM. That is, in the example shown in Figure 11, "EPS Assy," whose "No" is 1, is the name of the product, and the configuration of the product named "EPS Assy" is indicated in relation to other records. The "Part CD" field is registered with a code name corresponding to the part name.

[0078] The "Classification" field stores data indicating whether the product, work, or part indicated by each record is treated as an "individual part" or a "lot part." In Figure 11, records with "piece" written in the "Classification" field are treated as "individual parts." Also, records with "Lot" written in the "Classification" field are treated as "lot parts."

[0079] "Individual parts" are divided into "parent" and "child" as defined by "part identification" in Figure 5. A parent part refers to a product, work, or part to which primary identification information is assigned in a master-slave relationship of identification information (ID) assigned to ensure the traceability of a work. A child part refers to a work or part to which secondary identification information is assigned in a master-slave relationship of identification information assigned to ensure the traceability of a work. Lot parts are as described above.

[0080] In the "Layer" field, a value indicating the layer in the BOM tree structure BOMT is registered. Note that in the example of FIG. 12, the number of the highest layer in the hierarchical structure of the BOM tree structure BOMT is set to 0, and the numbers increase gradually for each subsequent layer. The numerical value registered in the "Layer" field in FIG. 11 corresponds to the number in the hierarchical structure of this BOM tree structure BOMT. Below, by explaining the correspondence between FIG. 11 and FIG. 12, it will be explained how the BOM master BOMM is interpreted by the control device 20 as the BOM tree structure BOMT.

[0081] The control device 20 reads records from the BOM master BOMM in the order of the values ​​registered in "No." Therefore, the control device 20 first reads records in the BOM master BOMM in FIG. 11 where "No" is 1. The record where "No" is 1 has "EPS Assy" as the "Part Name" and "Level" as "0." Therefore, as shown in FIG. 12, "EPS Assy" is placed at the top of the BOM tree structure BOMT, at the highest level (0). Note that "piece" is always registered in the "Classification" of records where "0" is registered in the "Level" field.

[0082] Next, the control device 20 reads out the record in the BOM master BOMM in Fig. 11 where "No." is 2. The record where "No." is 2 has a "Part Name" of "GB Shaft Assy" and a "Level" of "1." Therefore, as shown in Fig. 12, "GB Shaft Assy" is placed at the top level in the BOM tree structure BOMT, at the level (1) one level below "EPS Assy," which is at the top level (0).

[0083] The control device 20 then reads out the record in the BOM master BOMM in Fig. 11 where "No." is 3. The record where "No." is 3 has a "Part Name" of "GB Assy" and a "Level" of "2." Therefore, as shown in Fig. 12, "GB Assy" is placed in the level (2) one level below "GB Shaft Assy" which is in the second level (1) in the BOM tree structure BOMT.

[0084] The control device 20 then reads out the record in the BOM master BOMM in Fig. 11 where "No." is 4. The record where "No." is 4 has "Part Name" as "GB" and "Level" as "3." Therefore, as shown in Fig. 12, "GB" is placed in the level (3) one level below "GB Assy" which is in the third level (2) in the BOM tree structure BOMT.

[0085] Next, the control device 20 reads the record whose "No." is 5 in the BOM master BOMM of FIG. 11. The record whose "No." is 5 has a "Part Name" of "Bolt" and a "Level" of "3." Furthermore, the "Classification" of this record is "Lot." Therefore, as shown in FIG. 12, "Bolt" is placed in the same level (3) as "GB," which is in the fourth level (3) in the BOM tree structure BOMT. Here, "GB" and "Bolt" are configured to be in the fourth level (3). Furthermore, "piece" is registered in the "Classification" field of the record indicating "GB." In contrast, "Lot" is registered in the "Classification" field of the record indicating "Bolt." This indicates that "GB" is used as a parent part, and a Lot part called "Bolt" is assembled to this parent part to generate a "GB Assy."

[0086] Next, the control device 20 reads the record with "No." 6 in the BOM master BOMM of FIG. 11. The record with "No." 6 has a "Part Name" of "Shaft Assy" and a "Level" of "2." Furthermore, the "Classification" of this record is "unit." Therefore, as shown in FIG. 12, "Shaft Assy" is placed in the same level (2) as "GB Assy," which is in the third level (2) in the BOM tree structure BOMT. Here, "GB Assy" and "Shaft Assy" are configured to be in the third level (2). Furthermore, "unit" is registered in the "Classification" field of the record indicating "GB Assy." In contrast, "unit" is registered in the "Classification" field of the record indicating "Shaft Assy." This indicates that "GB Assy" is a parent part, and a child part called "Shaft Assy" is assembled to this parent part. As shown in FIG. 5, "0" in "Part Identification" indicates "parent," and "1" in "Part Identification" indicates "child." There can also be two or more child parts. For example, when a gearbox, shaft, and sensor are combined in one process, the gearbox becomes the "parent" (0), the shaft becomes the "child" (1: child part 1), and the sensor becomes the "child" (2: child part 2).

[0087] Furthermore, the record with "No" set to 5 is in the hierarchical layer "3," while the record with "No" set to 6 is in the hierarchical layer "2." In this way, when the value registered in the hierarchical layer field is decreased, it indicates that the components included in the layer with the previous number (for example, 3) among the records read before the decrease are assembled to form one workpiece in the layer one level above. However, records that have already been interpreted as forming one workpiece are excluded. In the example shown in Figures 11 and 12, before the record with "No" set to 6 and hierarchical layer "2" is read, records with "No" set to 4 and 5 and hierarchical layer "3" are read. Therefore, it is interpreted that the "Bolt" represented by the record with "No" set to 5 is assembled to the "GB" represented by the record with "No" set to 4, forming a workpiece of "GB Assy" in the layer one level above (2).

[0088] The control device 20 then reads out the record in the BOM master BOMM in Fig. 11 where "No." is 7. The record where "No." is 7 has a "Part Name" of "Shaft" and a "Level" of "3." Therefore, as shown in Fig. 12, "Shaft" is placed in the level (3) one level below "Shaft Assy" which is in the third level (2) in the BOM tree structure BOMT.

[0089] The control device 20 next reads out the record in the BOM master BOMM in FIG. 11 where "No." is 8. The record where "No." is 8 has a "Part Name" of "C-Ring" and a "Layer" of "3." Furthermore, the "Classification" of this record is "Lot." Therefore, as shown in FIG. 12, "C-Ring" is placed in the same layer (3) as "Shaft," which is in the fourth layer (3) in the BOM tree structure BOMT. Here, "Shaft" and "C-Ring" are configured to be in the fourth layer (3). Furthermore, "piece" is registered in the "Classification" field of the record indicating "Shaft." In contrast, "Lot" is registered in the "Classification" field of the record indicating "C-Ring."

[0090] Next, the control device 20 reads out the record whose "No." is 9 in the BOM master BOMM of FIG. 11. The record whose "No." is 9 has a "Part Name" of "ECU" and a "Level" of "1." Furthermore, the "Classification" of this record is "unit." Therefore, as shown in FIG. 12, the "ECU" is placed in the same level (1) as the "GB Shaft Assy" which is in the second level (1) in the BOM tree structure BOMT. Here, the "GB Shaft Assy" and the "ECU" are configured to be in the second level (1). Furthermore, "unit" is registered in the "Classification" field of the record indicating the "GB Shaft Assy." In contrast, the "Classification" field of the record indicating the "ECU" has "unit" registered. This indicates that the "GB Shaft Assy" is a parent part and the child part called the "ECU" is assembled to this parent part.

[0091] Furthermore, the record with "No" 8 is in the hierarchical level "3," while the record with "No" 9 is in the hierarchical level "1." As mentioned above, when the value registered in the hierarchical level field decreases, it indicates that the components included in the hierarchical level (for example, 3) of the records read before the decrease are assembled to form one workpiece in the hierarchical level one level above. However, records that have already been interpreted as forming one workpiece are excluded. In this example, before the record with "No" 9 and hierarchical level "1" is read, a combination of records with "No" 7 and 8 and a combination of records with "No" 3 and 6 and hierarchical level "2" are read. Therefore, it is interpreted that the "C-Ring" represented by the record with "No" 8 is assembled to the "Shaft" represented by the record with "No" 7, and the workpiece of "Shaft Assy" in the hierarchical level one level above (2) is formed. Here, the records with "No" 4 and 5 are also in the "3" hierarchical level, but they have already been interpreted when the reading of the record with "No" 6 was completed, so they are not referenced here. Also, the "Shaft Assy" represented by the record with "No" 6 is assembled to the "GB Assy" represented by the record with "No" 3, and it is interpreted that the "GB Shaft Assy" workpiece at the next higher hierarchical level (1) is configured.

[0092] In the BOM master BOMM shown in FIG. 11, the record with "No." set to 9 is the last record. In this case, the control device 20 interprets the BOM tree structure BOMT of the product represented by the BOM master BOMM as being completed with the last record. In this interpretation, configurations that are not yet assembled despite being on the same hierarchical level are assembled to form a single workpiece or product on the next higher hierarchical level. In this case, a combination of records with "No." set to 2 and 9, which are on the same hierarchical level, corresponds to a configuration that is not yet assembled despite being on the same hierarchical level. Therefore, it is interpreted that the "ECU" represented by the record with "No." set to 9 is assembled to the "GB Shaft Assy" represented by the record with "No." set to 2, forming a product of "EPS Assy" on the next higher hierarchical level (0). In this way, the BOM tree structure BOMT is derived from the BOM master BOMM. In other words, the data structure of the BOM master BOMM is predetermined so that it can be interpreted as the BOM tree structure BOMT.

[0093] The "Number of pieces used" column indicates the number of configurations indicated by each record. In the example shown in FIG. 11, the "Number of pieces used" for the record with "No" set to "5" is 3. This indicates that three "Bolts" indicated by the record with "No" set to "5" will be assembled. Furthermore, the "Number of pieces used" for the record with "No" set to "8" is 2. This indicates that two "C-Rings" indicated by the record with "No" set to "8" will be assembled. The "Number of pieces used" for all other records is 1. Therefore, except for the configurations with the above-mentioned "Number of pieces used" set to 2 or more, it is indicated that the other parts, workpieces, or products are one configuration.

[0094] The above illustrates the ability to derive a BOM tree structure BOMT from a BOM master BOMM, but the following explanation will be based on the product configuration represented by tree structure B2 shown in FIG. 14, which is derived from data B1 shown in FIG. 13. FIG. 13 is a diagram showing data B1 that functions as a BOM master BOMM in an embodiment. FIG. 14 is a diagram showing tree structure B2, which is a BOM tree structure BOMT derived from data B1 of FIG. 13. The mechanism by which tree structure B2 shown in FIG. 14 is derived from data B1 shown in FIG. 13 is similar to the mechanism by which the BOM tree structure BOMT shown in FIG. 12 is derived from the BOM master BOMM shown in FIG. 11.

[0095] In the tree structure B2 shown in FIG. 14, the "Product" at the top level (0) is configured by a combination of "Intermediate Product 1" and "Individual Part 5" at the level (1) immediately below it. Furthermore, "Intermediate Product 1" at level (1) is configured by a combination of "Intermediate Product 2" and "Child Part 3" at the level (2) immediately below it. Furthermore, "Intermediate Product 2" at level (2) is configured by a combination of "Intermediate Product 3" and "Individual Part 3" at the level (3) immediately below it. Furthermore, "Intermediate Product 3" at level (3) is configured by a combination of "Individual Part 1", "Individual Part 2", "Lot Part 1", "Lot Part 2", and "Lot Part 3" at the level (4) immediately below it. Note that the part CDs of "Lot Part 1", "Lot Part 2", and "Lot Part 3" correspond to the "Assembly Lot Part ID" in the quantity master D4 described with reference to FIG. 9. That is, the quantity master D4 is used to manage "Lot parts 1", "Lot parts 2", and "Lot parts 3" used in the products manufactured on the production line of the embodiment.

[0096] FIG. 15 is a diagram showing an example of the managed individual item serial master D6. The managed individual item serial master D6 is data having a "production part number" column, a "No." column, and an "individual item management serial" column. The "production part number" column is the same as the "production part number" column in the process sequence master D2. The "No." column corresponds to the "No." column in the BOM master data used in the embodiment, i.e., data B1 shown in FIG. 13. The "individual item management serial" field registers an ID (serial) for managing parts (individual items) each assigned an ID. Hereinafter, unless otherwise specified, the term "individual item" refers to a part used in the manufacture of a product, which, unlike lot parts, is assigned an ID (serial). Hereinafter, unless otherwise specified, the term "serial" refers to a character string or the like assigned to an individual item as an ID. Such a character string may include a numerical value. Furthermore, the serial number is not limited to a string of characters, but may be represented by a single letter or number, a combination thereof, a symbol, a code, or a mixture of these, or may be represented by an identifiable image such as a one-dimensional or multi-dimensional barcode.

[0097] Each record in the controlled individual serial master D6 indicates which "production part number" each individual is used to manufacture by the contents registered in the "production part number" field. In FIG. 15, "PRDCT001" is registered in the "production part number" field of all the records shown as examples. This indicates that each record included in the controlled individual serial master D6 is information about an individual used to manufacture a product with "PRDCT001" attached.

[0098] Furthermore, each record in the managed individual serial master D6 indicates which "No." configuration each individual corresponds to by the registered content of the "No." field. For example, the managed individual serial master D6 shown in FIG. 15 includes a record in which "5" is registered in the "No." field. This record is a record indicating information about an individual in which "5" is registered in the "No." field in data B1 shown in FIG. 13, i.e., an individual whose "part name" is "individual part." The managed individual serial master D6 shown in FIG. 15 also includes a record in which "6" is registered in the "No." field. This record is a record indicating information about an individual in which "6" is registered in the "No." field in data B1 shown in FIG. 13, i.e., an individual whose "part name" is "individual part 2." The managed individual serial master D6 shown in FIG. 15 also includes a record in which "10" is registered in the "No." field. This record is a record indicating information about an individual in which "30" is registered in the "No." field in data B1 shown in FIG. 13, i.e., an individual whose "part name" is "individual part 3." The managed individual serial master D6 shown in FIG. 15 also includes a record in which "11" is registered in the "No" field. This record is a record indicating information about an individual in which "11" is registered in the "No" field in data B1 shown in FIG. 13, i.e., an individual whose "part name" is "individual part 4." The managed individual serial master D6 shown in FIG. 15 also includes a record in which "12" is registered in the "No" field. This record is a record indicating information about an individual in which "12" is registered in the "No" field in data B1 shown in FIG. 13, i.e., an individual whose "part name" is "individual part 5."

[0099] Furthermore, each record in the managed individual serial master D6 indicates the serial number assigned to each individual by the registered contents of the "Individual Serial Number" field. For example, a record in which "5" is registered in the "No." field has "ABC001," "ABC002," "ABC003," "ABC004," or "ABC005" registered in the "Individual Serial Number" field, and the registered contents of the "Individual Serial Number" for each record are different. Also, a record in which "6" is registered in the "No." field has "DEF007" or "DEF005" registered in the "Individual Serial Number" field, and the registered contents of the "Individual Serial Number" for each record are different. Also, a record in which "10" is registered in the "No." field has "GHI009" registered in the "Individual Serial Number" field. Also, a record in which "11" is registered in the "No." field has "JKL010" registered in the "Individual Serial Number" field. Furthermore, in the record in which "12" is registered in the "No." field, "MNO011" is registered in the "Individual Product Management Serial" field. Although not shown, regardless of whether the number registered in the "No." field is the same or different, the registered contents of the "Individual Product Management Serial" field of each record are unique.

[0100] In this embodiment, the fact that each individual has a unique serial number is not ensured by the correspondence by the managed individual serial master D6, but is ensured by actually affixing the serial number to each individual by engraving, printing, or other methods. In other words, the serial number of each individual actually exists as something unique to each individual.

[0101] Furthermore, in the relationship between records having the same "No." in the correspondence between Figures 13 and 15, the first three characters (e.g., ABC) of "Part CD" in Figure 13 are the same as the first three characters of "Individual Management Serial" in Figure 15, but this is merely an example that takes into consideration the ease of understanding of the correspondence in the explanation of the embodiment, and does not limit the relationship between the actual part CD and the individual management serial.

[0102] The example shown in FIG. 15 is for illustrative purposes only and does not indicate the specific serial numbers or number of serials assigned to actual individual units. If a management individual serial master D6 is prepared in advance, information about all individual units prepared corresponding to the number of finished products to be manufactured is registered in the management individual serial master D6. Preparing a management individual serial master D6 in advance is not essential. Specifically, in each device 10 used on a production line involved in the manufacture of a product (e.g., product "PRDCT001"), the individual management serial reader 33 may acquire the serial number of each individual unit by reading the serial number of the individual unit when the individual unit is first used in each process flow after the start of product manufacture. In this case, however, a reading order for each type of individual unit (parent part, child part) used in the manufacture of each process must be predetermined, and the worker must correctly read the serial numbers according to the reading order. If this procedure is not followed and the reading order is reversed, the serial number of an individual parent part may be mistakenly read as the serial number of a child part, or the serial number of an individual child part may be mistakenly read as the serial number of a parent part. One way to prevent such errors from occurring is to provide each individual part with identification information indicating the type of individual part corresponding to "No" separately from the serial number, and then read and acquire this identification information using a reading device such as the individual part management serial number reader 33. The type of individual part and the serial number may be distinguished by the communication area (packet range, etc.) or by the communication timing (reading order).

[0103] In the following, in order to make it easier to understand the relationship between the individual and the serial number, an explanation will be given based on the contents of the managed individual serial master D6.

[0104] The data indicating which individual item is input into which process with which "process ID" is the above-mentioned process sequence master D2 (see Figure 5). The process sequence master D2 has a column for "part number." In the "part number" field, a number indicating which "number" part is input into which process with each "process ID" related to the production of each "production part number" indicated by each record is registered. The "part number" in the process sequence master D2 corresponds to the "number" in data B1 shown in Figure 13.

[0105] For example, in the process sequence master D2, there is a record in which "PRDCT001" is registered in the "production part number" field, "PRCS01A" is registered in the "process ID" field, and 25, 26 are registered in the "part number" field. This record indicates that in the process of "PRCS01A" in the manufacture of "PRDCT001," a parent part whose "number" in data B1 is "25" and a child part 1 whose "number" is "26" are assembled, although this is not explicitly shown in FIG. 13. In the process sequence master D2A shown in FIG. 8B, "PRDCT001" is registered in the "production part number" field, "PRCS01A" is registered in the "process ID" field, "1," "2," and "3" are registered in the "lot part identification" field, and "LPART001," "LPART002," and "LPART003" are registered in the "lot part ID" field. As shown in FIG. 8A, a lot part L1 with an ID of "LPART001", a lot part L2 with an ID of "LPART002", and a lot part L3 with an ID of "LPART003" are assembled in a process with a process ID of "PRCS01A".

[0106] Furthermore, in the process sequence master D2, there is a record in which "PRDCT001" is registered in the "production part number" field, "PRCS02A" is registered in the "process ID" field, and 24, 30 are registered in the "part number" field. This record indicates that in the "PRCS02A" process in the manufacture of "PRDCT001", an intermediate product 1 whose "number" is "24" in data B1 and a child part 2 whose "number" is "30" are assembled, although this is not explicitly shown in FIG. 13. In the process sequence master D2A shown in FIG. 8B, "PRDCT002" is registered in the "production part number" field, "PRCS01A" is registered in the "process ID" field, "1", "2", and "3" are registered in the "Lot part identification" field, and "LPART001", "LPART002", and "LPART004" are registered in the "Lot part ID" field. As shown in Fig. 8A, in a process assigned a process ID of "PRCS01A," lot part L1 assigned an ID of "LPART001," lot part L2 assigned an ID of "LPART002," and lot part L4 assigned an ID of "LPART004" are assembled. Similarly, for other records in the process sequence master D2, the "part numbers" correspond to the configurations assigned "Nos." in data B1.

[0107] The process list D1, process sequence master D2, process master D3, input quantity master D4, certified worker list D5, and data B1 are stored in the memory unit 22. Furthermore, if a managed individual serial master D6 is prepared in advance, the managed individual serial master D6 is stored in the memory unit 22. The calculation unit 23 performs various processes based on these data stored in the memory unit 22 and data transmitted from the device 10. Each component of the management system operates in response to commands generated based on the relevant processes.

[0108] 16 is a diagram showing an example of the individual management work status table T. The individual management work status table T is data managed by the control device 20 for the determination made by the calculation unit 23. The individual management work status table T may be stored and held in the memory unit 22, or may be stored in a primary storage device (not shown) from which the calculation unit 23 reads and expands programs, etc. The individual management work status table T is generated and updated in accordance with the processing performed by the calculation unit 23.

[0109] The individual management work status table T is data having a column for "individual management serial", a column for "process ID", a column for "individual type", a column for "status", and a column for "retention counter". The "individual management serial" and "individual type" columns correspond to the columns of the same name in the managed individual serial master D6. A field included in the "process ID" column registers a process ID indicating the status of the process (e.g., first process F1, second process F2, third process F3, or fourth process F4) to which the part or work indicated by the serial registered in the "individual management serial" field belongs. A field included in the "status" column registers a parameter (e.g., a character string, etc.) that can identify the status of the part or work indicated by the serial registered in the "individual management serial" field in the process registered in the "process ID" field. The fields included in the "Stall Counter" column store a numerical value to manage the number of times that a part or workpiece indicated by the serial number registered in the "Individual Management Serial" field is left behind and not put into the next process, contrary to the "first in, first out" rule, between the time the work in the process registered in the "Process ID" field is completed and the time it is put into the next process.

[0110] For example, a record in which "ABC001" or "ABC003" is registered in the "Individual Management Serial" field has "PRCS01A" registered in the "Process ID" field, "Parent" registered in the "Individual Type" field, and "Completed Normally" registered in the "Status" field. This indicates that a workpiece manufactured in the first process F1 using an individual with the serial number "ABC001" or "ABC003" as the parent part has successfully completed the first process F1 and been placed in the first normal storage area 52.

[0111] Fig. 17 is a schematic diagram showing the state of the first process F1 and the second process F2 corresponding to Fig. 16. In Fig. 17, a work P1 having the serial number "ABC001" and a work P3 having the serial number "ABC003" are placed in the first normal storage area 52.

[0112] 16, the record in which "ABC002" is registered in the "Individual Management Serial" field has "PRCS01A" registered in the "Process ID" field, "Parent" registered in the "Individual Type" field, and "Abnormal Completion" registered in the "Status" field. This indicates that a workpiece manufactured in the first process F1 using an individual with the serial number "ABC002" as the parent part and having completed the process has been placed in the first NG stockpile 53 due to an abnormality. In FIG. 17, workpiece P2 with the serial number "ABC002" is placed in the first NG stockpile 53.

[0113] 16, the record in which "ABC005" is registered in the "Individual Management Serial" field has "PRCS01A" registered in the "Process ID" field, "Parent" registered in the "Individual Type" field, and "Incomplete" registered in the "Status" field. This indicates that a workpiece with the individual with the serial number "ABC005" as the parent part has been input into the first device 11 in the first process F1, and production has not been completed. In FIG. 17, individual P5 with the serial number "ABC005" is in the first device 11.

[0114] 16, the record in which "DEF007" is registered in the "Individual Management Serial" field has "PRCS01A" registered in the "Process ID" field, "Child" registered in the "Individual Type" field, and "Incomplete" registered in the "Status" field. This indicates that a workpiece in which the individual with the serial number "DEF007" is a child part has been input into the first device 11 in the first process F1, and production has not been completed. In FIG. 17, an individual C7 with the serial number "DEF007" is in the first device 11.

[0115] Furthermore, if there is a record in which "child" is registered in the "individual type" field and "incomplete" is registered in the "status" field, there will always be another record in the individual management work status table T at the same time that has the same registered contents in the "process ID" and "status" fields as that record and that has "parent" registered in the "individual type" field.

[0116] Furthermore, the works P1, P2, and P3 that have completed the first process F1, and the work P4 described later, also include the same type of child parts as "DEF007." Specifically, the child parts Cx, Cy, Cz, and C8 shown in FIG. 17 are the related child parts.

[0117] 16, the record in which "ABC004" is registered in the "Individual Management Serial" field has "PRCS02A" registered in the "Process ID" field, "Parent" registered in the "Individual Type" field, and "Incomplete" registered in the "Status" field. This indicates that a workpiece whose parent part is a workpiece with the serial number "ABC004" has been input into the second device 12 in the second process F2, and production has not been completed. In FIG. 17, a workpiece P4 with the serial number "ABC004" is inside the second device 12.

[0118] 16, the record in which "GHI009" is registered in the "Individual Management Serial" field has "PRCS02A" registered in the "Process ID" field, "Child" registered in the "Individual Type" field, and "Incomplete" registered in the "Status" field. This indicates that a workpiece in which the individual with the serial number "GHI009" is a child part has been input into the second equipment 12 in the second process F2, and production has not been completed. In FIG. 17, an individual C9 with the serial number "GHI009" is in the second equipment 12.

[0119] FIG. 18 is a diagram showing the individual management workpiece status table T in a state T2 that is different from the state T1 in FIG. 16. The individual management workpiece status table T is rewritten by the calculation unit 23 according to the progress of the processes in the management system. Here, the different states of the individual management workpiece status table T that are the subject of rewriting are individually assigned symbols such as states T1 and T2, thereby distinguishing between the identity of the object and the different states of the relevant object. In state T2, the "status" field of the record for "ABC005," which had a "status" field of "incomplete" in state T1, has been changed to "normal completion." This indicates that the workpiece manufactured in the first process F1 using the individual with the serial number "ABC005" as the parent part, has successfully completed the first process F1 and has been placed in the first normal storage area 52.

[0120] Fig. 19 is a schematic diagram showing the states of the first process F1 and the second process F2 corresponding to Fig. 18. The individual P5 that was in the first device 11 in Fig. 17 has been moved to the first normal storage area 52 in Fig. 19.

[0121] Furthermore, in state T2, the record for "DEF007" that existed in state T1 has been deleted. This is because individual C7, a child part in the first process F1, has been assembled to another individual (individual P5), which is the parent part of that process. In this way, in the individual management work status table T, when a process using a child part is completed, subsequent work is managed using a record including the serial number of the parent part of that process, and the record of the child part is deleted. Figure 19 shows individual C7 assembled to individual P5.

[0122] In this way, the serial number of the workpiece that has completed the process is managed in a unified manner using that of the parent part. Note that information indicating the child parts and lot parts included in the workpiece or finished product managed by the serial number of the parent part is associated with the serial number of the parent part using the performance registration data M described later. This ensures the traceability of the parent part, child parts, and lot parts. In other words, a master-slave relationship of identification information is established with the parent part as the master.

[0123] Furthermore, in state T2, the value registered in the "Stall Counter" field of the record in which "PRCS01A" is registered in the "Process ID" field is updated from the value in state T1. Hereinafter, when we refer to the value of the stall counter, unless otherwise specified, it refers to the value registered in the "Stall Counter" field.

[0124] In the embodiment, when the manufacturing of a workpiece in a process corresponding to a certain process ID is completed, the calculation unit 23 increments (by 1) the value of the retention counter of the record in which the same process ID as the process is registered. In the example shown in Fig. 16 and Fig. 18, the "status" of the record "ABC005" in which "PRCS01A" is registered in the "process ID" field changes from "uncompleted" in state T1 to "normally completed" in state T2, and therefore the value of the retention counter of the record in which "PRCS01A" is registered in the "process ID" field is incremented.

[0125] Specifically, a record in which "PRCS01A" is registered in the "Process ID" field is a record in which "ABC001," "ABC002," "ABC003," or "ABC005" is registered in the "Individual Management Serial" field. The value of the backlog counter for a record in which "ABC001" is registered in the "Individual Management Serial" field was "4" in state T1 and has been updated to "5" in state T2. The value of the backlog counter for a record in which "ABC002" is registered in the "Individual Management Serial" field was "3" in state T1 and has been updated to "4" in state T2. The value of the backlog counter for a record in which "ABC003" is registered in the "Individual Management Serial" field was "2" in state T1 and has been updated to "3" in state T2.

[0126] The calculation unit 23 resets the value of the retention counter to the initial value (0) for newly generated records. As will be described later, when a workpiece with a "normal completion" corresponding to each record is input to the next process, a new record for that workpiece corresponding to the next process is registered, and the previous record for that workpiece is deleted. For workpieces with an "abnormal completion" status, the value of the retention counter is updated to the initial value (0) when the individual management serial reading unit 33 in the dismantling equipment 15 acquires the serial number. Therefore, for workpieces corresponding to records with a retention counter value of 1 or greater, the retention state is resolved by moving them to the appropriate destination.

[0127] The retention counter value is used to manage whether the work flow, in which workpieces that have completed a process are input to the next process, follows the "first-in, first-out" principle between processes. Ideally, between two consecutive processes, the workpieces that were produced earlier in the earlier process should be input to the equipment 10 earlier in the later process. This desirable state is referred to as a "first-in, first-out" state between processes. However, because the movement of workpieces between the previous and following processes is performed manually by humans (operators) via a normal product storage area, it is possible that a workpiece that was produced relatively later among multiple workpieces that have completed the earlier process may be input to the equipment 10 earlier in the later process. Furthermore, "abnormally completed" workpieces placed in the NG product storage area may be left unattended because they are not input to the next process. If such "abnormally completed" workpieces are discovered after being left unattended for a long period of time, there is a non-zero chance that they may be confused with "normally completed" workpieces for some reason.

[0128] Therefore, the calculation unit 23 registers and updates the value of the retention counter in each record of the individual management workpiece status table T. This makes it possible to monitor the degree to which a workpiece that has already been treated as having been "completed normally" or "completed abnormally" is retained without being moved to the appropriate destination, based on the value of the retention counter in each record corresponding to each workpiece.

[0129] As explained above with regard to the difference in the retention counter value between state T1 and state T2, when a record with "normal completion" or "abnormal completion" has already been registered in the individual management work status table T, and a new record with the same process ID as the registered record and with "normal completion" or "abnormal completion" registered in the "status" field is generated, the retention counter value is incremented (+1). Therefore, for example, a work corresponding to a record with a retention counter value of "5" indicates that five new workpieces have been manufactured in the process that manufactures that workpiece since that workpiece was manufactured, and that those workpieces have not yet been input into the equipment 10 for the next process. In this way, the retention counter value indicates the degree to which the workpiece corresponding to each record continues to be retained in the normal product storage area or the NG product storage area.

[0130] In addition, a threshold value is set for performing processing based on the value of the retention counter. Specifically, a stop threshold value is set with the aim of stopping the progress of some or all of the processes in the management system when, for example, a specific workpiece continues to be retained without being moved to its proper destination. The stop threshold value is preferably a value sufficiently larger than 1 (for example, 10 or 20) with the aim of overlooking a certain degree of temporary retention of workpieces.

[0131] When a record occurs in which the value of the retention counter is equal to the stop threshold, the calculation unit 23 treats it as a work retention abnormality occurring, and performs processing corresponding to the work retention abnormality.

[0132] The specific content of the processing corresponding to the workpiece accumulation abnormality is arbitrary, but examples include processing in which the calculation unit 23 generates and transmits data (stop command) that functions as an instruction to stop the equipment 10 in the process that manufactured the workpiece corresponding to the record where the value of the accumulation counter has become equal to the stop threshold, or all of the equipment 10, or processing in which the calculation unit 23 generates and transmits data (alarm command) that functions as an instruction to operate at least one of the alarm unit 37 of the equipment 10 that manufactured the workpiece and the equipment 10 in the process next to the process in which the equipment 10 is used, and the alarm unit 24 of the control device 20, to notify that a workpiece accumulation abnormality has been detected. Each equipment 10 and the alarm unit 24 operates in accordance with such instructions.

[0133] The threshold for making a judgment based on the value of the accumulation counter may be set in multiple stages. For example, the stop threshold may be set as the first threshold, and a warning threshold may be set as a threshold (second threshold) smaller than the first threshold. In this case, when a record occurs in which the value of the accumulation counter is equal to the warning threshold, it is treated as a work accumulation symptom, and the calculation unit 23 performs processing corresponding to the work accumulation symptom. The warning threshold is desirably a value sufficiently larger than 1 and smaller than the stop threshold (for example, 5 to 9), with the aim of overlooking a certain degree of temporary work accumulation.

[0134] The specific content of the process corresponding to the workpiece retention symptom is arbitrary, but an example thereof may be a process in which the calculation unit 23 generates and transmits data (notification command) that functions as a command to operate at least one of the notification unit 37 of the equipment 10 in the process next to the process in which the equipment 10 in the process that manufactured the workpiece corresponding to the record whose retention counter value became equal to the warning threshold and the notification unit 24 of the control device 20 to notify that a workpiece retention abnormality has been detected. Each equipment 10 and the notification unit 24 operate in accordance with the command.

[0135] Data indicating thresholds such as the stop threshold and the warning threshold may be stored and held in the storage unit 22, or may be stored in another storage device (not shown) that can be accessed by the calculation unit 23.

[0136] 40, the update of the value of the retention counter and the detection and notification that accompany the update are not limited to the timing when a certain process is completed, but may be the timing when a certain process is started.

[0137] 16 to 19, as described with reference to FIGS. 7 and 8B, assembly of lot parts is also performed in the first process F1. Although not shown, the individual management work status table T also includes a "production part number" column. That is, the individual management work status table T is configured to manage which process ID for which production part number is in what state. By combining the various information (production part number, assembly lot part ID, parent part serial number, child part serial number, etc.) contained in the process master D3 and process master 2A described with reference to FIGS. 7 and 8B with the information contained in the individual management work status table T, it is possible to manage which production part number and which process each of the various parts (parent part, child part) managed in the individual management work status table T corresponds to.

[0138] FIG. 20 is a diagram showing the individual management workpiece status table T in state T3, which is different from state T1 in FIG. 16 and state T2 in FIG. 18. In state T3, the "status" field of the record for "ABC004," which had been set to "incomplete" in states T1 and T2, has been changed to "normally completed." This indicates that the workpiece manufactured in the second process F2 using the workpiece with the serial number "ABC004" as the parent part has successfully completed the second process F2 and been placed in the second normal storage area 54. Furthermore, in state T3, the record for "GHI009," which existed in states T1 and T2, has been deleted. This is because individual C9, a child part in the second process F2, has been assembled to another individual (workpiece P4), the parent part of that process.

[0139] The following describes the change in the state of the individual management workpiece state table T from the input of an individual or workpiece to a certain process until the completion of the process, with reference to FIGS. 21 to 24.

[0140] 21 is a diagram showing the individual management workpiece status table T in a state T4 that is different from the state T1 in FIG. 16, the state T2 in FIG. 18, and the state T3 in FIG. 20. In the state T4, the "status" of the record for "ABC004" in which "PRCS03A" is registered in the "process ID" field is newly registered as "put in." This indicates that the workpiece assigned the serial number of "ABC004" that successfully completed the second process F2 in the state T3 and was placed in the second normal storage area 54, as indicated by the record for "ABC004" in which "PRCS02A" is registered in the "process ID" field, has been put into the third device 13 as a parent part.

[0141] In state T4, the "Status" of the record "JKL010" in which "PRCS03A" is registered in the "Process ID" field is newly registered as "Inputted." This indicates that the part given the serial number "JKL0101" has been input to the third device 13 as a child part.

[0142] 22 is a diagram showing the individual management workpiece status table T in a state T5 that is different from state T1 in FIG. 16, state T2 in FIG. 18, state T3 in FIG. 20, and state T4 in FIG. 21. The "Status" of the record for "ABC004" in which "PRCS03A" is registered in the "Process ID" field and the "Status" of the record for "JKL010" in which "PRCS03A" is registered in the "Process ID" field have been updated from "Input" in state T4 to "Incomplete" in state T5. This indicates that the third process F3 has started with the workpiece given the serial number "ABC004" and the part given the serial number "JKL010" that have been input into the third device 13.

[0143] Also, "ABC004," which had "PRCS02A" registered in the "Process ID" field in state T4, has been deleted. This is because the third process F3 was started by the workpiece given the serial number "ABC004" and the part given the serial number "JKL010" that were input to the third device 13, and "ABC004," which completed the second process F2 corresponding to "PRCS02A," is no longer in a state of waiting for the next process.

[0144] Figure 23 is a diagram showing the individual management workpiece status table T in a state T6 that is different from state T1 in Figure 16, state T2 in Figure 18, state T3 in Figure 20, state T4 in Figure 21, and state T5 in Figure 22. In state T6, the "status" of the record for "ABC004," in which "PRCS03A" is registered in the "process ID" field, is newly registered as "normal completion." This indicates that the workpiece manufactured in the third process F3 using the individual with the serial number "ABC004" as the parent part has successfully completed the third process F3 and has been placed in the third normal storage area 56.

[0145] 24 is a diagram showing the individual management work status table T in state T7, which is different from state T1 in FIG. 16, state T2 in FIG. 18, state T3 in FIG. 20, state T4 in FIG. 21, state T5 in FIG. 22, and state T6 in FIG. 23. In state T7, "PRCS03A" is registered in the "Process ID" field in state T6, and two records (the "ABC004" record and the "JKL010" record) that had "Incomplete" registered in the "Status" field have been deleted. This is because, for these two records, the third process F3 had been treated as not having been completed up until state T5, but the newly registered record in state T6 confirmed that the third process F3 had been completed, and so these two records are no longer necessary for management purposes.

[0146] As explained above with reference to Figures 21 to 24, in the individual management work status table T, records before and after a change in at least one of the process (record of "Process ID") and the state within the process (field of "Status") are registered, and the records before and after are compared, and if the comparison is successful, the previous record is deleted, thereby managing the process and state using the serial number of the parent part as a key.

[0147] These new records are registered based on information transmitted from the device 10. Specifically, when a process using the device 10 (for example, any of the first process F1 to fourth process F4) is started, the individual management serial reading unit 33 of the device 10 for that process (for example, any of the first device 11 to fourth device 14) reads the serial number of the individual or workpiece containing the individual to be input into that process. In response to the serial number reading, information indicating the serial number is transmitted from the device 10 via the communication unit 31 under the control of the operation control unit 41. The memory unit 22 of the control device 20 receives the information via the communication unit 21. The memory unit 22 registers a record in the individual management work status table T based on the received information. As a result, a new record is registered whose "status" field is "inputted," as described with reference to FIG. 21. The storage unit 22 extracts from the individual management workpiece status table T a record whose "individual item management serial number" is the same as that of the newly registered record, whose "process ID" is the one immediately preceding that of the newly registered record, whose individual item type is "parent," and whose status is "normally completed." If extracted, the storage unit 22 treats the newly registered record as having been normally registered. In this case, as described with reference to FIG. 22, the storage unit 22 sets the "status" of the new record to "incomplete" and deletes the extracted record, i.e., the record with the old "status." On the other hand, if the record is not extracted, the storage unit 22 determines that the newly registered record is abnormal and treats it as having detected a process progress abnormality. The calculation unit 23 performs processing corresponding to the process progress abnormality.

[0148] The specific content of the processing corresponding to the process progress abnormality is arbitrary, but examples include processing in which the calculation unit 23 generates and transmits data (stop command) that functions as a command to stop the device 10 provided in the process indicated by the "process ID" of the newly registered record, and processing in which the calculation unit 23 generates and transmits data (alert command) that functions as a command to operate at least one of the alarm unit 37 of the device 10 and the alarm unit 24 of the control device 20 to notify that a process progress abnormality has been detected. Each device 10 and the alarm unit 24 operates in accordance with the command.

[0149] If the content registered in the "Process ID" field of the newly registered record indicates that the newly registered record is the first process in the process sequence master D21 that does not have a "previous process" (e.g., previous process 1 and previous process 2), this extraction and normal / abnormal determination are omitted. However, in this case, the storage unit 22 determines whether the managed individual serial master D6 contains a record whose content registered in the "Individual Product Management Serial," "Process ID," and "Individual Product Type" fields is identical to that of the newly registered record. If so, the storage unit 22 considers the newly registered record to have been registered normally. Also, at this time, the storage unit 22 sets the "Status" of the new record to "Incomplete," as described with reference to FIG. 22. On the other hand, if no such content is contained, the storage unit 22 may consider the newly registered record to have had a process progress abnormality detected, as described above. In this manner, the start of the process is managed. If the management individual serial master D6 showing the relationship between all individuals and serial numbers is not prepared in advance in the memory unit 22, a determination is made at the time of reading by the individual management serial reading unit 33 as to whether the serial number is a new one, and if it is a new serial number, the new serial number is associated with the type of individual (the above-mentioned "No." and "Part No."), and management based on this association continues thereafter.

[0150] When a process that has been started under the above-described management is completed, information indicating the completion status of the process (normal completion or abnormal completion) is transmitted from the equipment 10 of the process. The storage unit 22 of the control device 20 registers a record in the individual management work status table T based on the received information. As a result, a new record is registered in which the "status" field is set to "normal completion," as described with reference to FIG. 23. Note that if the process is completed abnormally, the field will be set to "abnormal completion." The distinction between "normal completion" and "abnormal completion" may be based on the results of sensing the work or finished product by the sensing unit 39, or on input by the worker to the input unit 42.

[0151] In response to the new registration of such a record, the storage unit 22 extracts from the individual management workpiece status table T a record whose "process ID" is the same as that of the newly registered record and whose "status" is "incomplete." If extracted, the storage unit 22 determines whether the extracted records include a record with the same "individual management serial number." If it is determined that the extracted records include a record with the same "individual management serial number," the storage unit 22 treats the newly registered record as having been registered normally. In this case, the storage unit 22 also deletes the extracted record, i.e., the record with the old "status," as described with reference to FIG. 24. Specifically, if the newly registered record is not extracted, or if the extracted records do not include a record with the same "individual management serial number," the storage unit 22 determines that the newly registered record is abnormal and treats it as if a registered data abnormality has been detected. The calculation unit 23 performs processing corresponding to the registered data abnormality.

[0152] The specific content of the processing corresponding to the registered data abnormality is arbitrary, but examples include processing in which the calculation unit 23 generates and transmits data (stop command) that functions as a command to stop the device 10 provided in the process indicated by the "process ID" of the newly registered record, and processing in which the calculation unit 23 generates and transmits data (alert command) that functions as a command to operate at least one of the alarm unit 37 of the device 10 and the alarm unit 24 of the control device 20 to notify that a registered data abnormality has been detected. Each device 10 and the alarm unit 24 operates in accordance with the relevant command.

[0153] Next, the result registration data M that is generated and updated in accordance with the normal management of each process and the product master D7 that serves as the basis for the result registration data M will be described with reference to FIGS. 25 to 29. FIG.

[0154] FIG. 25 is a diagram showing an example of the product master D7. The product master D7 is data having a column for "production part number," a column for "individual part management serial 1 (parent part)," a column for "individual part management serial 2 (child part)," a column for "individual part management serial 3 (child part)," a column for "individual part management serial 4 (child part)," a column for "individual part management serial 5 (child part)," a column for "assembly lot part ID 1," a column for "assembly lot part ID 2," and a column for "assembly lot part ID 3." The "production part number" column corresponds to the column of the same name in the process sequence master D2. The product master D7 is data indicating the parent part, child part, and lot part to be included in the product indicated by the ID registered in the "production part number" field. Note that while FIG. 25 shows an example of one record, in reality, records corresponding to each production part number are registered.

[0155] Specifically, "ABC***" is registered in the field included in the "Individual Management Serial 1 (Parent Part)" column of each record in the product master D7. This indicates that the serial number of the individual part treated as the parent part in the manufacture of the product corresponding to the "Production Part Number" of that record is "ABC***." Note that "***" is a substitute character indicating a wildcard.

[0156] Additionally, "DEF***" is registered in the field contained in the column "Individual management serial 2 (child part)." Additionally, "GHI***" is registered in the field contained in the column "Individual management serial 3 (child part)." Additionally, "JKL***" is registered in the field contained in the column "Individual management serial 4 (child part)." Additionally, "MNO***" is registered in the field contained in the column "Individual management serial 5 (child part)." These indicate that the serial numbers of the individuals treated as child parts in the manufacture of the product corresponding to the "Production part number" of that record are "DEF***," "GHI***," "JKL***," and "MNO***."

[0157] Furthermore, "LPART001" is registered in the field contained in the column "Assembly Lot Part ID1." "LPART002" is registered in the field contained in the column "Assembly Lot Part ID2." "LPART003" is registered in the field contained in the column "Assembly Lot Part ID3." These indicate that the serial numbers of the lot parts assembled in the manufacture of the product corresponding to the "Production Part Number" of that record are "LPART001," "LPART002," and "LPART003."

[0158] The number of child parts is not limited to four, and the number of lot parts is not limited to 3. A product manufactured by the management system may be a product that includes one or more parent parts and multiple other parts (at least one of child parts and lot parts) that are assembled to the parent parts through multiple processes, and data corresponding to the serial numbers and IDs of the parent parts and multiple other parts may be registered in the product master D7.

[0159] Note that the contents of the product master D7 illustrated in FIG. 25 do not necessarily represent the actual data stored in the storage unit 22. For example, the above "ABC***" may be replaced with "25," which is the "No." of the record having the part CD of "ABC***" in data B1. Other fields in the product master D7, such as "DEF***," may also be replaced with the "No." of the record having the same part CD in data B1. The use of "ABC***" and the like in the product master D7 illustrated in FIG. 25 is for the sake of convenience in easily explaining that the product master D7 is a concept that serves as the format of the subsequent performance registration data M, and does not limit the actual data of the product master D7.

[0160] Furthermore, the product master D7 does not have to be stored in advance in the storage unit 22. The product master D7 reflects the content corresponding to the combination of data that can be derived based on the process sequence master D2 and data B1, and even if the product master D7 is not prepared in advance, as long as the process sequence master D2 and data B1 are available, the control device 20 can derive the relationships between various parts related to one finished product by reading out the process sequence master D2 and data B1. Of course, the product master D7 may be stored in the storage unit 22 in advance.

[0161] 26 is a diagram showing an example of the state of the performance registration data M. The performance registration data M is data managed by the control device 20 to ensure product traceability. The performance registration data M may be stored and held in the storage unit 22, or may be stored in another storage device (not shown) that is accessible from the calculation unit 23. The performance registration data M is generated and updated in accordance with the processing performed by the calculation unit 23.

[0162] The performance registration data M has columns with the same names as multiple columns included in the product master D7, and a "status" column. Of the columns included in the performance registration data M, fields included in the columns with the same names as multiple columns included in the product master D7 record the serial number of the parent part of each product, the serial number of the child part to be assembled to the parent part, and the lot part ID, all associated with each other on a record-by-record basis. Furthermore, the field included in the "status" column of each record records the latest status of the product.

[0163] State M1 shown in FIG. 26 is the actual result registration data M for the state corresponding to state T1 shown in FIG. 16. Therefore, records in which the serial numbers of "ABC001," "ABC002," "ABC003," and "ABC004," which are treated as parent parts, are registered in the "Individual Part Management Serial 1 (Parent Part)" field are registered in state M1. Furthermore, "Normal Completion" or "Abnormal Completion" is registered in the "Status" field of each record. Furthermore, the serial numbers and lot IDs of the child parts assembled to the parent parts indicated by these serial numbers upon completion of the first process F1 are registered in each record. For example, in the record for "ABC001," the individual assigned the serial number "ABC001" is the parent part, the individual assigned the serial number "DEF00x" is the child part corresponding to "Individual Part Management Serial 2 (Child Part)," and further, it is recorded that the workpieces assembled with the lot IDs "LPART001," "LPART002," and "LPART003" after the first process F1 were manufactured in a normal state. The recording mechanism is similar for other records (records "ABC002," "ABC003," and "ABC004"). Note that in the explanations with reference to FIGS. 26 to 29, the information in fields indicated as "LPART001," "LPART002," and "LPART003" is a convenient example indicating which lot parts with which lot part IDs were assigned were assembled, and the information (character strings) actually registered in the fields of the performance registration data M are not the character strings "LPART001," "LPART002," and "LPART003." Such information (character strings) may include, for example, a combination of numbers indicating the manufacturing date of each lot part, such as "yyyymmdd," or may include a character string indicating the material of the lot part, such as "A05C." When such numbers or character strings are employed, the lot part that the numbers or character strings indicate can be determined by defining in advance in the product master D7 which field (column) indicates which item, and managing the number or character string by the position of the field (column) in which the number or character string is registered, or by further including information (character string) indicating which lot part the number or character string is.

[0164] It should be noted that "ABC005", which has not yet completed the first process F1, is not registered at the time of status M1.

[0165] Fig. 27 is a diagram showing the result registration data M of a state M2 different from the state M1 of Fig. 26. The result registration data M is rewritten by the calculation unit 23 in accordance with the progress of the process in the management system. Here, by assigning individual symbols such as states M1 and M2 to the different states of the result registration data M to be rewritten, the identity of the object and the different states of the object can be distinguished from each other.

[0166] State M2 shown in Fig. 27 is the result registration data M for a state corresponding to state T2 shown in Fig. 18. Therefore, in state M2, in addition to the content shown in state M1, a record is newly registered in state M2 in which the serial number of "ABC005" that has newly completed the first process F1 is registered in the field of "Individual part management serial 1 (parent part)". The newly registered record also records that the individual with the serial number "ABC005" is the parent part, the individual with the serial number "DEF007" is the child part corresponding to "Individual part management serial 2 (child part)", and the lot parts with IDs "LPART001", "LPART002", and "LPART003" have been successfully assembled in the first process F1.

[0167] Fig. 28 is a diagram showing the result registration data M for a state M3 that is different from the state M1 in Fig. 26 and the state M2 in Fig. 27. The state M3 shown in Fig. 28 is the result registration data M for a state that corresponds to the state T3 shown in Fig. 20. Therefore, in the state M3, it is recorded that the individual that has been given the serial number "GHI009" for the workpiece indicated by the record "ABC004" registered in the state M2 has been successfully assembled in the second process F2 as a child part that corresponds to "individual management serial number 3 (child part)."

[0168] Fig. 29 is a diagram showing the result registration data M for a state M4 that is different from the state M1 in Fig. 26, the state M2 in Fig. 27, and the state M3 in Fig. 28. The state M4 shown in Fig. 29 is the result registration data M for a state corresponding to the state T7 shown in Fig. 24. Therefore, in state M4, it is recorded that an individual given the serial number "JKL010" was successfully assembled in the third process F3 as a child part corresponding to "individual management serial 4 (child part)" for the workpiece indicated by the record "ABC004" that was registered in state M2 and updated in state M3.

[0169] While the above describes the serial number of an individual item and the ID and status of a lot part in the performance record registration data M, the items that can be recorded in the performance record registration data M are not limited to these. For example, the performance record registration data M may further include a column for registering an ID that is read by the worker ID reader 35 of each device 10 and indicates the worker (certified worker) in charge of each process. In this case, the column position is defined in advance by the product master D7 so that the process in charge can be identified based on the position of the column in which the ID indicating the certified worker is registered. The performance record registration data M may also include a column for registering information that can identify the identification tag data of the assembled lot part. The performance record registration data M may also include a column for registering information (e.g., date and time) indicating the time when each process was completed (passage time). The performance record registration data M may also include a column for registering sensor measurements or the like that indicate the basis for whether a process was completed normally or abnormally. 26 to 29, the "status" column in which "normal completion" or "abnormal completion" is registered may further register information indicating up to which process the process was "normally completed" and at which process the process was "abnormally completed" and for what reason. As a specific example, information such as "normally completed up to process x" or "abnormally completed at process x due to xx" may be registered in the "status" column. In this case, "xx" is registered as a character string indicating the cause of the abnormal completion.

[0170] Next, the management of the number of incoming and outgoing lot parts will be described with reference to FIGS. 30 to 32. FIG.

[0171] 30 is a diagram showing an example of the state of the lot part counter LC. The lot part counter LC is data managed by the control device 20 for the determination made by the calculation unit 23. The individual management workpiece status table T may be stored and held in the storage unit 22, or may be stored in a primary storage device (not shown) from which the calculation unit 23 reads and expands programs, etc. The individual management workpiece status table T is generated and updated in accordance with the processing performed by the calculation unit 23.

[0172] The lot part counter LC shown in FIG. 30 is data having a column for "assembly lot part ID," a column for "incoming quantity," and a column for "outgoing quantity." The column for "assembly lot part ID" corresponds to the "column in which IDs indicating lot parts used in the manufacture of a product corresponding to a production part number are registered" in the explanation with reference to FIG. 9. The column for "incoming quantity" corresponds to the "number of lot parts (incoming quantity) corresponding to one lot identification slip data" in the explanation with reference to FIG. 9. As with the incoming quantity master D4 described above with reference to FIG. 9, in the lot part counter LC, the incoming quantity of each lot part is managed by each record. In other words, when each record is registered, the initial values ​​of the fields for the "assembly lot part ID" and "incoming quantity" of each record correspond to those in the incoming quantity master D4.

[0173] In the fields included in the "output quantity" column, a value indicating the number of lot parts (output quantity) used in the process is registered. The initial value registered in the "output quantity" column is 0. Each record in the lot part counter LC is set in response to reading the identification tag of each lot part corresponding to the ID registered in the "assembly lot part ID" field. This reading is performed by an operator using the assembly lot part ID reading unit 34 of the machine 10. That is, in response to reading the identification tag by the assembly lot part ID reading unit 34 provided in the machine 10 in the process where the lot part is assembled, a record corresponding to each lot part is registered in the lot part counter LC. Details of this record registration will be explained later with reference to the flowchart in FIG. 36.

[0174] The values ​​registered in the fields included in the "Quantity Out" column are updated according to the number of times the process for assembling each lot of parts is performed. Specifically, for example, the value is updated to increase by the number of lot parts used in each process, triggered by the parent part of the corresponding process being registered as "input" in the individual management work status table T or the parent part being registered as "normally completed" or "abnormally completed." In the description of the embodiment, it is assumed that the input quantity of each of the three types of lot parts assigned IDs "LPART001," "LPART002," and "LPART003" assembled in the first process F1 is "10," and that the "Quantity Out" of each of these is incremented (+1) each time the first process F1 is performed.

[0175] Figure 31 is a diagram showing the Lot part counter LC in state LC2, which is different from state LC1 in Figure 30. In state LC2, the "quantity" is registered as the initial value (0) as in state LC1, and then the first process F1 (PROCS01A) using three types of Lot parts given the IDs "LPART001," "LPART002," and "LPART003" is carried out once, and the "quantity" of the records containing these IDs is updated to "1."

[0176] FIG. 32 shows the lot part counter LC in state LC3, which is different from state LC1 in FIG. 30 and state LC2 in FIG. 31. In state LC3, the "Quantity Out" is registered as the initial value (0) as in state LC1. Since then, the first process F1 (PROCS01A) using three types of lot parts with IDs "LPART001," "LPART002," and "LPART003" has been performed 10 times, and the "Quantity Out" of the records containing these IDs has been updated to "10." In other words, state LC3 is a state that includes records ("LPART001," "LPART002," and "LPART003") in which the value registered in the field included in the "Quantity In" column is the same as the value registered in the field included in the "Quantity Out" column. This state indicates that the three types of lot parts with IDs "LPART001," "LPART002," and "LPART003" have used up the incoming quantities managed by the identification tags that have been read at that time. In this way, when a record occurs in which the value registered in the field included in the "quantity in" column is the same as the value registered in the field included in the "quantity out" column, the calculation unit 23 generates data (read request) that functions as a command requesting that the assembly lot part ID reader 34 read a new identification tag for the lot part given the ID registered in the "assembly lot part ID" of the record. The calculation unit 23 transmits the read request to the device 10 in the process including the work in which the lot part is to be assembled. The read request is transmitted to the device 10 via the communication unit 21 and received by the device 10 via the communication unit 31. The operation control unit 41 operates the notification unit 37 to issue a notification (e.g., display output, audio output, etc.) corresponding to the read request, and prompts the worker (certified worker) operating the device 10 to read the identification tag.

[0177] Furthermore, when there is a record in which the value registered in the field included in the “Quantity in” column is the same as the value registered in the field included in the “Quantity out” column, as in state LC3, and an information update occurs in the individual management work status table T in which a new parent part is “input” to the equipment 10 of the process in which the lot part assigned the ID registered in the “Assembly Lot Part ID” of that record is to be assembled, the calculation unit 23 generates data (a stop command) that functions as an instruction to stop the equipment 10 of that process and transmits it to the equipment 10 via the communication unit 21. In other words, it should be impossible to proceed with a process that attempts to use more parts of a lot that have used up the quantity of parts managed by the already read identification tag unless parts of that lot with a new identification tag are introduced. Therefore, the calculation unit 23 does not allow the operation of the equipment 10 to proceed with the process until a new identification tag for the parts of that lot is read by the assembly lot part ID reader 34 provided in the equipment 10 of that process. In response to the stop command, the operation control unit 41 of the device 10 stops the operation of the drive unit 36. Here, the operation control unit 41 may cause the notification unit 37 to notify information indicating that the device 10 has stopped due to waiting for the identification tag of the lot part to be read.

[0178] Next, the handling of work whose "status" field is set to "abnormal completion" will be described in more detail.

[0179] FIG. 33 is a diagram showing an example of the relationship between multiple processes included in the overall process. In FIG. 33, "Pn" is an abbreviation for the process ID of "PRCSn" and can be read as "PRCSn." Here, n is any number ranging from 1 to a number corresponding to the number of processes (e.g., 26) in m-digit decimal notation (e.g., m=2). That is, when m=2, if n is any number ranging from 1 to 9, "0" is assigned to the tens digit. The number of processes included in the overall process shown in FIG. 33 and the order of each process are merely examples and are not intended to be limiting. Furthermore, it is not necessary for individual parts with individual management serial numbers to be used in all processes. For example, "P-17" may be a process in which only lot parts are input.

[0180] The overall process shown in Figure 33 includes processes from "P-01" to "P-26." There are no previous processes for "P-01," "P-03," "P-05," "P-14," and "P-17." The previous process for "P-02" is "P-01." The previous processes for "P-04" are "P-02" and "P-03." The previous process for "P-06" is "P-05." The previous process for "P-07" is "P-04." The previous process for "P-08" is "P-07." The previous processes for "P-09" are "P-06" and "P-08." The previous process for "P-10" is "P-9." The previous process for "P-11" is "P-10." The previous process for "P-12" is "P-11." The previous process for "P-13" is "P-12." The previous process of "P-15" is "P-14". The previous processes of "P-16" are "P-13" and "P-15". The previous processes of "P-18" are "P-16" and "P-17". The previous process of "Pn" where n≧19 is "P-(n-1)".

[0181] Some of the processes included in the overall process shown in Figure 33 are processes for which separate rules have been established for dealing with abnormalities that occur in the process. In Figure 33, processes for which such rules have been established are marked with "Q-*." * is replaced with any number ranging from 1 to the number of processes to which the rule applies (for example, 7). In Figure 33, "P-13" is marked with "Q-1." Furthermore, "P-19" is marked with "Q-2." Furthermore, "P-20" is marked with "Q-3." Furthermore, "P-21" is marked with "Q-4." Furthermore, "P-23" is marked with "Q-5." Furthermore, "P-24" is marked with "Q-6." Furthermore, "P-26" is marked with "Q-7." That is, in the example shown in FIG. 33, rules are applied when an abnormality occurs in processes with process IDs of "PRCS13," "PRCS19," "PRCS20," "PRCS21," "PRCS23," "PRCS24," and "PRCS26." If a process to which such rules are applied completes abnormally, the work resulting from the abnormal completion is dismantled. In addition, the dismantled work, etc., resulting from the dismantling work, are re-input into one of the processes. Note that "dismantled work, etc." is not limited to parts managed by individual serial numbers (for example, it also includes lot parts). For parts not managed by individual serial numbers, traceability is ensured by the reusable ID tag output by the reusable ID tag issuing unit 156, which will be described later.

[0182] In Figure 33, "G-*" is attached to processes in which disassembled workpieces, etc. may be re-input. A different letter (for example, an alphabet) is substituted for each *. In Figure 33, "GA" is attached to "P-04". "GB" is attached to "P-07". "GC" is attached to "P-09". "GD" is attached to "P-10". "GE" is attached to "P-11". "GF" is attached to "P-16". "GG" is attached to "P-17". "GH" is attached to "P-18". "GI" is attached to "P-19". In other words, in the example shown in Figure 33, the processes with process IDs "PRCS04," "PRCS07," "PRCS09," "PRCS10," "PRCS11," "PRCS16," "PRCS17," "PRCS18," and "PRCS19" are processes in which dismantled workpieces and parts may be re-introduced.

[0183] The overall process shown in Fig. 33 is defined and registered in advance in the process sequence masters D2, D2A, etc. Below, various matters related to dismantling work and re-introduction of workpieces and parts that may occur in the manufacturing process of a product manufactured by the overall process described with reference to Fig. 33 will be described with reference to Figs. 34 to 49.

[0184] 34 is a diagram showing an example of NG mode data D11. The NG mode data D11 is data showing the correspondence between some processes for which separate rules for dealing with abnormalities that occur in the processes are defined, and abnormalities that may occur in the processes. The NG mode data D11 is stored in advance in the storage unit 22.

[0185] The NG mode data D11 is data that has at least a column for "Process ID" and a column for "Number" of the NG code. The "Process ID" column corresponds to the column of the same name in the process list D1. However, the process ID character strings registered in the fields included in the "Process ID" column in FIG. 34, with the exception of "PRCS00", are the process IDs of the processes included in the overall process described with reference to FIG. 33. "PRCS00" will be described later.

[0186] The "number" of the NG code is registered so that, in combination with the process ID registered in the field included in the "Process ID" column, the type of abnormality that occurred in the process indicated by the process ID can be identified.

[0187] Specifically, if there is only one type of abnormality that occurs in a certain process, the "number" of the NG code will only be "1." In the example shown in Figure 34, for processes with a process ID of "PRCS13," "PRCS23," "PRCS26," or "PRCS00," there is only one type of abnormality, so there is only one record with the number "1" registered in the NG code field.

[0188] Furthermore, when multiple types of abnormalities occur in a certain process, the "number" of the NG code is not limited to "1" and other values ​​are also registered. For example, in FIG. 34, for the process ID "PRCS19," there are two types of abnormalities, so there are records with the number "1" registered in the NG code field and records with the number "2." Also, for the process ID "PRCS24," there are three types of abnormalities, so there are records with the number "1," "2," and "3" registered in the NG code field. Also, for the processes with process IDs "PRCS20" and "PRCS21," there are four types of abnormalities, so there are records with the number "1," "2," "3," and "4" registered in the NG code field.

[0189] The NG mode data D11 is configured so that it can indicate what kind of abnormality occurred in which process by combining the "process ID" and the "number" of the NG code registered in a field included in the record. For example, in the case of a process with a process ID of "PRCS26," the result of the visual check of the product performed in that process is indicated by the number "1" of the NG code. For other combinations of "process ID" and "number" of the NG code, the correspondence between the "process ID" and the "number" of the NG code is determined in advance so that the type of abnormality that can occur in each process can be identified.

[0190] 34 further includes a column for "Process Name (Details)" that indicates what kind of process the process corresponding to each process ID is, a column for "Number (Q-*)" that indicates the correspondence with "Q-*" in Fig. 33, and a column for "NG Item Details" of the abnormality code that indicates what kind of abnormality the "Number" of the abnormality code indicates. These columns are written so that a person can understand the contents of the NG mode data D11, and are not essential as the actual data of the NG mode data D11 and can be omitted.

[0191] Fig. 35 is a diagram showing an example of a rejected product management table U for managing workpieces whose "status" field in the status table is set to "abnormal completion." The rejected product management table U may be data integrated with other data, such as the individual management workpiece status table T described above, or may be data independent of other data. Fig. 35 shows an example of the rejected product management table U as data independent of other data.

[0192] The NG product management table U is data having at least a column for “individual product management serial number,” a column for “NG process where NG occurred,” a column for “NG code,” and a column for “number of consecutive NGs.” The NG product management table U shown in FIG. 35 also has a column for “dismantled flag.”

[0193] When a record in which "abnormal completion" is registered in the "status" field of the individual management workpiece status table T occurs, the calculation unit 23 sets a new record corresponding to that record in the defective product management table U.

[0194] The serial number of the product or work is registered in the field included in the "Individual Management Serial" column. This serial number is the same as the serial number registered in the "Individual Management Serial" field of the record in which "Abnormal Completion" is registered in the "Status" field of the individual management work status table T.

[0195] A process ID is registered in a field included in the "NG process" column. This process ID is the same serial as the serial registered in the "Process ID" field of a record in which "Abnormal completion" is registered in the "Status" field of the individual management work status table T. When a record in which "Abnormal completion" is registered in the "Status" field of the individual management work status table T occurs, the calculation unit 23 registers the registration contents corresponding to the registration contents of the "Individual management serial" and "Process ID" fields of that record in the "Individual management serial" and "NG process" fields of a new record in the NG product management table U.

[0196] In the field included in the "NG code" column, a value corresponding to the "number" of the NG code in the NG mode data D11 is registered. By combining the registered contents of the "NG process" and "NG code" fields included in one record of the NG product management table U, it is possible to identify in which process and what kind of abnormality occurred in the product corresponding to the "individual management serial number" of that record.

[0197] The value registered in the “NG Code” field corresponds to the input performed in each process. For example, if the “status” is determined to be “abnormally completed” because of a product abnormality automatically detected by the sensing unit 39, a value corresponding to the output automatically generated by the sensing unit 39 in response to the detected abnormality is registered in the “NG Code” field. Also, if the “status” is determined to be “abnormally completed” because of a product abnormality recognized by a process operator, a value corresponding to the output generated by the equipment 10 in response to an input made via the input unit 42 is registered in the “NG Code” field. Alternatively, the dismantling equipment 15 may be allowed to manually select any reason (e.g., test piece or abnormality) for treating the “status” as “abnormally completed” and isolating the individual. Furthermore, the process management of such manually isolated individuals may be managed using a special ID (e.g., “PRCS00”) that functions as a wildcard for the process ID. In this way, an output corresponding to the value registered in the “NG Code” field is generated in response to the occurrence of an abnormality in the process. The output also includes information indicating the process ID of the device 10 in the process that generated the output, and the serial number of the workpiece that was being processed when the output was generated, i.e., the same serial number as the serial number registered in the "individual product management serial number." In other words, the output is generated in response to the occurrence of a record in which "abnormal completion" is registered in the "status" field of the individual product management status table T. The output is transmitted from the device 10 to the control device 20 via communication between the communication unit 31 and the communication unit 21. Therefore, the combination of the "individual product management serial number" and the process ID in the output corresponds to the combination of the "individual product management serial number" and the process ID of the record in which "abnormal completion" is registered in the "status" field of the individual product management status table T, and corresponds to the combination of the "individual product management serial number" and the "NG-occurring process" in the NG product management table U. The calculation unit 23 registers a value corresponding to the output in the "NG code" field.

[0198] The value registered in the "Number of consecutive NGs" field is a value indicating the number of times an abnormality has occurred where the combination of "individual management serial number", "NG occurrence process", and "NG code" is the same. This is related to "re-introducing workpieces after dismantling caused by dismantling work", and will be described later.

[0199] 35 further includes a column for "date and time of abnormality occurrence." When such a column is provided, the control device 20 is provided with a clock unit (such as a timer circuit) that measures the current date and time. When a new record is set in the defective product management table U, the calculation unit 23 obtains the date and time when the record was set from the clock unit, and registers a character string indicating the date and time in the "date and time of abnormality occurrence" field of the record.

[0200] FIG. 36 is a diagram showing an example of dismantling mode data D12. The dismantling mode data D12 is data that defines a rule of action to be applied corresponding to a combination of the "process ID" of the process where an abnormality occurred (NG process) and the "number" of the NG code. More specifically, in this embodiment, the dismantling mode data D12 specifies which of multiple types of dismantling work is to be performed. The dismantling mode data D12 is stored in advance in the storage unit 22.

[0201] The disassembly mode data D12 is data having a column for the "NG occurrence process," a column for the "number" of the NG code, and a column for the "rth NG count" that is predetermined according to the number of consecutive NGs. In the example shown in FIG. 36, r is a natural number ranging from 1 to 3. Therefore, the disassembly mode data D12 in FIG. 36 has columns for the "1st NG count," the "2nd NG count," and the "3rd NG count." However, r may be a natural number equal to or less than 2, or may be a natural number equal to or greater than 4.

[0202] The column for the "NG-occurring process" and the column for the "number" of the NG code are columns that are provided for the same purpose as in the NG product management table U. However, unlike the NG product management table U, the registered contents of each field in the dismantling mode data D12 are unchanged. The calculation unit 23 reads out the dismantling mode data D12 according to the combination of the "process ID" of the NG-occurring process and the "number" of the NG code in the record registered in the NG product management table U, and identifies the record of the dismantling mode data D12 that corresponds to the combination. In this way, the calculation unit 23 can identify the response rule to be applied corresponding to the combination of the "process ID" of the process (NG-occurring process) where the abnormality occurred and the "number" of the NG code, based on the dismantling mode data D12.

[0203] The field included in the "NG count r times" column stores information indicating the "type of dismantling mode to be applied" as a rule of action to be applied in response to the combination of the "process ID" of the process where the abnormality occurred (NG process) and the "number" of the NG code.

[0204] As described above, in the embodiment, when a process, among multiple processes included in the overall process for manufacturing a certain product, for which separate rules for dealing with the occurrence of an abnormality have been established, is abnormally completed, workpieces resulting from the abnormal completion are dismantled. In the embodiment, there are multiple types of dismantling work. FIG. 36 illustrates a case in which there are a total of seven types of dismantling work, including "dismantling mode 1," "dismantling mode 2," "dismantling mode 3," "dismantling mode 4," "dismantling mode 5," "dismantling mode 6," and "dismantling mode 7." However, the number of types of dismantling work may be six or less, or eight or more.

[0205] First, we will explain the case where an abnormality occurs for the first time in a product, i.e., the "first NG occurrence." The dismantling operation to be adopted is determined based on the combination of the "Process ID" of the NG occurrence process and the "NG code number" in the record registered in the NG product management table U. For example, if the Process ID of the NG occurrence process is "PRCS13," "Dismantling mode 6" is applied to the "first NG occurrence." If the Process ID of the NG occurrence process is "PRCS19," "Dismantling mode 2" is applied to the "first NG occurrence" regardless of the NG code number. If the Process ID of the NG occurrence process is "PRCS20," "PRCS21," "PRCS23," "PRCS24," or "PRCS26," "Dismantling mode 1" is applied to the "first NG occurrence" regardless of the NG code number.

[0206] Next, differences that arise depending on the type of dismantling work will be described with reference to FIGS. 37 to 39.

[0207] FIG. 37 is a diagram showing an example of a BOM master D13. FIG. 38 is a diagram showing a tree structure B13, which is a BOM tree structure BOMT derived from the BOM master D13 of FIG. 37. The mechanism by which the tree structure B13 shown in FIG. 38 is derived from the BOM master D13 shown in FIG. 37 is the same as the mechanism by which the BOM tree structure BOMT shown in FIG. 12 is derived from the BOM master BOMM shown in FIG. 11. Note that the BOM master D13 shown in FIG. 37 has a starting number for "No." Furthermore, in addition to the contents of the BOM master BOMM described with reference to FIG. 11, the BOM master D13 shown in FIG. 37 further has a column for "maximum number of reuses." The "maximum number of reuses" will be described later.

[0208] In the tree structure B13 shown in Figure 38, the "Full Assembly" at the top level (0) is composed of the "Pre-Tilt Assembly," "Bracket," and "Lever" at the level immediately below it (1). The "Pre-Tilt Assembly" at level "1" is composed of the "Parts Assembly" and "Motor ECU" at the level immediately below it (2). The "Parts Assembly" at level "2" is composed of the "Pre-Adjustment Assembly" at the level immediately below it (3). The "Parts Assembly" is the "Pre-Adjustment Assembly" that has undergone an adjustment process without adding any additional parts. The "Pre-Adjustment Assembly" at level "3" is composed of the "HGSB," "Worm," "Column," and "Bolt" at the level immediately below it (4). The BOM Master D13 functions as data similar to the data BB described above. Furthermore, the BOM Master D13 functions as data containing information about workpieces and parts resulting from the application of dismantling work to workpieces in a process that was abnormally completed. Specifically, a work or part at a certain level is understood to be a part that can be produced by dismantling the product or work at the level immediately above it.

[0209] Hereinafter, the terms "work before dismantling" and "work after dismantling" will be used to distinguish between work before and after dismantling work is applied. "Work before dismantling" refers to work in a process that has been abnormally completed, to which any type of dismantling work is applied. "Work after dismantling" refers to work after dismantling work has been applied to work before dismantling. The dismantling work may result in only one or more "work after dismantling," or the dismantling work may result in further parts (post-dismantling parts) that have been separated from the "work before dismantling."

[0210] The dismantling master D14 includes information indicating the correspondence between the type of dismantling work and the workpieces, etc., resulting from each dismantling work. Specifically, the record for "Dismantling Mode 1" has "1" registered in the "Part 1 Index" field. This indicates that the workpieces resulting from the dismantling work in "Dismantling Mode 1" are the workpieces, etc., assigned the "No." of "1" in the BOM master D13. The record for "Dismantling Mode 2" has "2" registered in the "Part 1 Index" field, "10" registered in the "Part 2 Index" field, and "11" registered in the "Part 3 Index" field. This indicates that the workpieces, etc., resulting from the dismantling work in "Dismantling Mode 2" are the three workpieces, etc., assigned the "No." of "2," "10," and "11" in the BOM master D13. As explained above, the other records included in the dismantling master D14 also indicate that the workpieces, etc., resulting from the dismantling work of the type indicated by the record title are the workpieces, etc., with the codes registered in the fields of the record. The BOM master D13 shown in FIG. 37 may be included in the contents of the BOM master BOMM described with reference to FIG.

[0211] 39, the maximum number of code fields registered in one record of the disassembly master D14 is seven in total, from "Part 1 Index" to "Part 7 Index," but in reality, these are set to correspond to the maximum number of workpieces, etc. that may be generated after disassembly in the disassembly work. Therefore, the maximum number of code fields registered in one record of the disassembly master D14 may be six or less, or eight or more.

[0212] The dismantling work is carried out by dismantling equipment 15. Matters relating to dismantling equipment 15 will be described below with reference to Figs. 40 to 45.

[0213] 40 is a diagram showing an example of dismantling equipment 15. Dismantling equipment 15 has, for example, a workbench 151, a touch panel 152, a reusable pallet 153, an NG shooter 154, a tool storage area 155, and a reusable ID tag issuing unit 156. In addition, dismantling equipment 15 may have an ID tag storage area, an ID tag writing device, a barcode issuing device, etc.

[0214] The workbench 151 is a table on which workpieces to be dismantled, dismantled workpieces resulting from the dismantling work that have not yet been placed on the reusable pallet 153 or NG chute 154, tools being used for the dismantling work, etc. are temporarily placed. The workers performing the dismantling work use the workbench 151 to perform the dismantling work. Other functions that may be integrated into the dismantling equipment 15 include serial registration of abnormal products to be discarded without being dismantled, and functions such as process skip cancellation and retention cancellation.

[0215] The reusable ID tag issuing unit 156 issues a reusable ID tag that functions as a component for attaching identification information for managing the number of times a part without an individual management serial number (for example, a lot part) is reused. A specific example of the operation of the reusable ID tag issuing unit 156 will be described later.

[0216] 41 is a schematic diagram showing an example of the display content of touch panel 152. Touch panel 152 functions as a display device that displays and outputs various items related to the dismantling work, and also functions as an input device that accepts various items related to the dismantling work.

[0217] 41, the display content displayed on the touch panel 152 has display areas 152a, 152b, 152c, and 152e corresponding to the items of "individual management serial number," "production part number," "reason for dismantling," and "part name." The "individual management serial number" display area 152a displays the serial number of the workpiece to be dismantled, i.e., the serial number of the parent part of the workpiece.

[0218] Although not shown, the dismantling equipment 15 has a configuration similar to the individual management serial number reader 33 of the equipment 10. This configuration of the dismantling equipment 15 allows it to read the serial numbers of the workpieces to be dismantled. The read serial numbers are displayed in the display area 152a. More specifically, the dismantling equipment 15 has a configuration in which the assembly lot part ID reader 34 and the program selector 38 are omitted from the configuration of the equipment 10. However, the notification unit 37 and input unit 42 of the dismantling equipment 15 are provided as a touch panel 152. The drive unit 36 ​​of the dismantling equipment 15 includes an electric motor for operating the opening / closing lids 153a and 154a, which will be described later. The display content of the touch panel 152 and the operation of the dismantling equipment 15 in response to inputs (touch operations) made via the touch panel 152 are controlled by, for example, the operation control unit 41, but may also be controlled by a dedicated operation control circuit.

[0219] The "production part number" display area 152b displays the ID of the production part number corresponding to the workpiece to which the serial number displayed in display area 152a is assigned. The correspondence between the serial number displayed in display area 152a and the ID of the production part number displayed in display area 152b is established, for example, based on the performance registration data M. In addition, the serial number assigned to a workpiece or the like that is generated by dismantling the workpiece to which the serial number displayed in display area 152a is assigned can also be identified by other serial numbers registered in the record in performance registration data M that includes the serial number displayed in display area 152a.

[0220] When the individual management serial number reading unit 33 of the dismantling equipment 15 reads the serial number of the workpiece to be dismantled, the operation control unit 41 of the dismantling equipment 15 transmits information indicating the serial number to the control device 20 via the communication unit 31. The calculation unit 23 of the control device 20 compares the serial number included in the information received from the dismantling equipment 15 with the “individual management serial number 1 (parent part)” of the record included in the performance registration data M, and acquires the registered content of the “production part number” field of the record corresponding to the serial number as the ID of the production part number to be displayed in the display area 152b. The calculation unit 23 transmits the information indicating the acquired ID of the production part number to the dismantling equipment 15 via the communication unit 21. The operation control unit 41 of the dismantling equipment 15 controls the operation of the touch panel 152 to display the ID of the production part number included in the received information in the display area 152b. Note that the NG product management table U may further include a “production part number” column.

[0221] The "Reason for Disassembly" display area 152c displays the content corresponding to the "Details" of the NG code that indicates the type of abnormality that occurred in the workpiece that has been given the serial number displayed in the display area 152a.

[0222] When the individual management serial number reading unit 33 of the dismantling equipment 15 reads the serial number of the workpiece to be dismantled, the operation control unit 41 of the dismantling equipment 15 transmits information indicating the serial number to the control device 20 via the communication unit 31. Up to this point, the operation content related to the display control of the display area 152b is the same, and the calculation unit 23 of the control device 20 can commonly use this information in the process related to determining the content to be displayed in the display areas 152b and 152c. The same applies to the process related to determining the content to be displayed in the display areas 152e, 152f, 152g, 152h, and 152j, which will be described later.

[0223] The calculation unit 23 of the control device 20 compares the serial number included in the information received from the dismantling equipment 15 with the “individual product management serial number” of a record included in the NG product management table U and acquires the registered contents of the “NG-occurring process” and “NG code” fields of the record corresponding to the serial number. If multiple identical serial numbers exist, the “dismantling completion flag” is acquired from the record for which the “false” setting is selected. The calculation unit 23 references the NG mode data D11 to identify a record corresponding to the combination of the “NG-occurring process” and “NG code” in the acquired registered contents. The calculation unit 23 acquires the registered contents of the “details” field of the identified record by referring to the NG mode data D11 as the display contents in the display area 152c. The calculation unit 23 transmits information indicating the acquired display contents to the dismantling equipment 15 via the communication unit 21. The operation control unit 41 of the dismantling equipment 15 controls the operation of the touch panel 152 to display the display contents included in the received information in the display area 152c. Note that the function of the operation control unit 41 may be included in the control device 20.

[0224] The "Part Name" display area 152e displays a list of the names of the workpieces etc. after the dismantling work. More precisely, in this embodiment, the individual parts to be removed in the procedure during the work are displayed. Therefore, in FIG. 41, only a bracket is displayed during step 1 (the number 1 symbol inside a circle). The calculation unit 23 identifies the dismantling mode corresponding to the combination of the "NG occurring process" and "NG code" acquired when determining the display content of the display area 152c, by referring to the dismantling mode data D12. Note that this identification also takes into account the number of consecutive NGs, which will be described later.

[0225] The calculation unit 23 identifies the "numbers" of the workpieces, etc., generated in the dismantling mode corresponding to the combination of the "NG process" and the "NG code" by referring to the dismantling master D14. For example, in the case of dismantling mode 3, "3," "8," "9," "10," and "11" are identified as the "numbers" of the workpieces, etc., generated in the dismantling mode. The calculation unit 23 identifies the corresponding records by referring to the BOM master D13 for each name of the "numbers" of the workpieces, etc., identified by referring to the dismantling master D14, and acquires the registered content of the "name" field of the identified record as the display content in the display area 152e. The calculation unit 23 transmits information indicating the acquired display content to the dismantling equipment 15 via the communication unit 21. The operation control unit 41 of the dismantling equipment 15 controls the operation of the touch panel 152 to display the display content included in the received information in the display area 152e. Note that the function of the operation control unit 41 may be included in the control device 20.

[0226] Each record of the name of the workpiece or the like displayed in a list in the display area 152e is provided with a reuse button BU1 and a disposal button BU2, as shown in Fig. 41. The reuse button BU1 and the disposal button BU2 are used when the worker manually selects whether to reuse or discard the workpiece or the like after dismantling, and respond to touch operations.

[0227] Furthermore, information indicating the number of times the workpiece has been reused is additionally displayed in each record of the name of the workpiece, etc., displayed in a list in the display area 152e. The number of times the workpiece has been reused is determined by referring to a re-entry counter EC, which will be described later.

[0228] The display content displayed on the touch panel 152 also includes a display area 152f corresponding to the "disassembly procedure" item. By referring to the display content in the display area 152f and the display content in the display area 152g, the worker can understand the procedure of the disassembly work. The calculation unit 23 reads and acquires the display content of the "disassembly procedure" corresponding to the disassembly mode identified when determining the display content of the display area 152e from the storage unit 22. Data indicating the "disassembly procedure" for each disassembly mode and the display content of the "disassembly instruction photo" displayed in the display area 152g (for example, procedure data D15, described later) are stored in advance in the storage unit 22. The calculation unit 23 refers to the procedure data D15 to acquire the display content of the "disassembly procedure" corresponding to the disassembly mode identified when determining the display content of the display area 152e. The calculation unit 23 transmits information indicating the display content acquired in this manner to the dismantling equipment 15 via the communication unit 21. The operation control unit 41 of the dismantling device 15 controls the operation of the touch panel 152 so that the display content included in the received information is displayed in the display areas 152f and 152g.

[0229] 42 is a diagram showing an example of procedure data D15. The procedure data D15 has a column for "Procedure No.", a column for "Work Content," a column for "Reusable (Reuse or Disposal)," a column for "Non-Reusable (Disposal Only)," and a column for "Photo."

[0230] In the “Procedure No.” field, a number (numeric value) corresponding to the display order of the “disassembly procedures” displayed in the display area 152f is registered. That is, a number corresponding to the arrangement order of the “disassembly procedures” from top to bottom in the display area 152f is registered in the “Procedure No.” In the correspondence between FIG. 41 and FIG. 42, the numerical value registered in the “Procedure No.” field in FIG. 42 is displayed as a circled number in the display area 152f in FIG. 41, but such display editing is not essential. Note that circled numbers may be registered in the “Procedure No.” field, or simple numbers may be displayed in the display area 152f instead of circled numbers. In the “Work Content” field, a character string directly corresponding to the display content of the “disassembly procedures” displayed in the display area 152f is registered. Therefore, the display order and display content in the display area 152f are determined by the combination of the “Procedure No.” and the “Work Content” in each record of the procedure data D15.

[0231] In the "Reusable (reuse or discard)" field, information indicating the workpieces to be reused among the workpieces resulting from the dismantling work performed in accordance with the "dismantling procedure" displayed in display area 152f is registered. This information is written in correspondence with the "part name" in BOM master D13, but if the part number in the BOM master is registered in memory unit 22, a mechanism may be adopted in which calculation unit 23 acquires the BOM master and procedure data D15 and identifies the "part name."

[0232] In the procedure data D15 shown in FIG. 42, a record having an "operation number" of "1" has "part number 10" registered in the "reusable (reuse or disposal)" field. This indicates that when the disassembly procedure displayed in the display area 152f corresponding to the record having an "operation number" of "1" is performed, a part named "part number 10" is removed in a reusable state from the workpiece to be dismantled. Also, in the procedure data D15 shown in FIG. 42, a record having an "operation number" of "2" has "part number 11" registered in the "reusable (reuse or disposal)" field. This indicates that when the disassembly procedure displayed in the display area 152f corresponding to the record having an "operation number" of "2" is performed, a part named "part number 11" is removed in a reusable state from the workpiece to be dismantled. Also, in the procedure data D15 shown in FIG. 42, a record having an "operation number" of "4" has "part number 9" and "part number 3" registered in the "reusable (reuse or disposal)" field. This indicates that when the disassembly procedure displayed in display area 152f is carried out in accordance with the record whose "Work No." is "4," the work to be disassembled will be separated into "Part No. 9" and "Part No. 3" and will become reusable.

[0233] In the "Non-reusable (disposal only)" field, information indicating workpieces, etc. that will not be reused among the workpieces, etc. that result from the dismantling work performed in accordance with the "dismantling procedure" displayed in the display area 152f is registered. For example, in the procedure data D15 shown in FIG. 42, a record in which the "Work No." is "3" has "Part No. 8" registered in the "Non-reusable (disposal only)" field. This indicates that when the dismantling procedure displayed in the display area 152f corresponding to the record in which the "Work No." is "3" is performed, a part named "Part No. 8" (actually, a type of lot part) will be removed in a non-reusable state from the workpieces that were dismantled.

[0234] In the "Photo" field, information regarding image data corresponding to the display content of the display area 152g is registered. Note that in the example shown in Fig. 42, the registered content of the "Photo" field itself is an image for the purpose of ease of understanding, but a character string or the like that functions as a hyperlink or data path indicating the location of the image data may also be registered. Note that in Figs. 41 and 42, and Figs. 48 and 49 described below, the appearance of each workpiece after disassembly is shown as a combination of rectangles and circles, but this does not represent the actual shape of the workpiece after disassembly, and is for convenience's sake.

[0235] Furthermore, although not shown in Fig. 42, the procedure data D15 includes information indicating to which of the multiple processes included in the overall process the disassembled workpieces etc. will be re-input. This information is displayed, for example, on a re-input instruction display screen 152k that is displayed after the disassembly work is performed according to the display contents of the touch panel 152 shown in Fig. 41.

[0236] Fig. 43 is a diagram showing an example of a re-introduction instruction display screen 152k. The re-introduction instruction display screen 152k is one of the display modes of the touch panel 152. That is, both the display content shown in Fig. 41 and the display content shown in Fig. 43 are displayed on the touch panel 152. Note that the dismantling equipment 15 may be provided with a plurality of touch panels 152, and one of the plurality of touch panels 152 may display the display content shown in Fig. 41, and another may display the re-introduction instruction display screen 152k shown in Fig. 43.

[0237] The display content of the reinput instruction display screen 152k is table data including a column for "reinput parts" and a column for "reinput destination." The "reinput parts" field reflects the content registered in the "reusable (reuse or disposal)" field. The "reinput destination" field reflects the process ID to which workpieces, etc. that have been separated from the dismantling source by dismantling work and are to be reused, are reinput. The example shown in FIG. 43 indicates that "part No. 9" generated by dismantling work is reinput into a process assigned a process ID of "PRCS16," and "part No. 3" is reinput into a process assigned a process ID of "PRCS11." An example of a data configuration that realizes the display content of the reinput instruction display screen 152k is to further add a "reinput destination" column shown in FIG. 43 to the contents of the procedure data D15. As a result, the operation control unit 41 can display the re-input instruction display screen 152k, which shows the correspondence between the "re-input parts" and the "re-input destination", based on the procedure data D15, by using the contents of the "reusable (reusable or discarded)" column in the procedure data D15 as the contents of the "re-input parts" column on the re-input instruction display screen 152k.

[0238] In this way, the combination of the registered contents of the "reusable (reused or discarded)" and "re-input destination" fields in one record included in the procedure data D15 and the combination of the procedure data D15 and the BOM master D13 makes it possible to identify which process each disassembled workpiece will be re-input into. The combination of "reusable (reused or discarded)," i.e., the "re-input part" and "re-input destination" in FIG. 43, makes it possible to identify that "Part No. 9" will be re-input into the process assigned the process ID of "PRCS16" and that "Part No. 3" will be re-input into the process assigned the process ID of "PRCS11." Furthermore, the BOM master D13 makes it possible to identify that the part assigned the "No." of "9" in the BOM master D13 in the procedure data D15 is a "motor ECU," and that the workpiece assigned the "No." of "3" in the BOM master D13 in the procedure data D15 is a "part assembly." Furthermore, the dismantling master D14 indicates that the workpieces, etc., managed by "No." in the BOM master D13 are generated by dismantling work.

[0239] In the "Reintroduced parts" on the reintroduction instruction display screen 152k, "Part No. 10" and "Part No. 11" are not included in the contents registered in the "Reusable (Reuse or Discard)" field shown in Fig. 41. This is because the calculation unit 23 of the control device 20 has determined that "Part No. 10" and "Part No. 11" have reached the upper limit of the number of times they can be reused and are therefore no longer eligible for reuse and should be discarded. A specific explanation of the upper limit of the number of times they can be reused will be given later.

[0240] 41 shows a list of four procedures numbered 1 to 4 in the display area 152f, but the display content is not limited to this and corresponds to the number of records in the procedure data D15. The display content in the display area 152f and the number of records in the procedure data D15 may be three or fewer procedures, or five or more procedures. The content of each procedure is also not limited to the content shown in FIG. 41, but corresponds to the specific content of the dismantling work for each dismantling mode.

[0241] In the example shown in FIG. 41, the first step is highlighted. This indicates that the dismantling work being performed is the first step. The highlighting changes according to the predetermined work performed by the worker. For example, the predetermined work is determined to be completed by moving the dismantled workpieces, etc., generated during the dismantling work to the reuse pallet 153 or the NG chute 154. The display content of the display area 152g is highlighted in the display area 152f and corresponds to the process that is currently being interpreted as being in progress. The correspondence between the display content of the display area 152f and the display content of the display area 152g is confirmed by the registered contents of each record in the procedure data D15. The operation control unit 41 first causes the touch panel 152 to display the display area 152f corresponding to the "Work Content" of the record whose "Procedure No." is "1" in the procedure data D15 and the display area 152g corresponding to the "Photo" of the record. Thereafter, when a disassembled workpiece or the like (e.g., part No. 10) resulting from the disassembly work is moved to the reuse pallet 153 or the NG chute 154, the operation control unit 41 changes the display contents of the display area 152f and the display area 152g to correspond to the record in the procedure data D15 for which the "Procedure No." is "2." Thereafter, the display contents of the display area 152f and the display area 152g are similarly changed as the disassembly work progresses. When all the processes displayed in the display area 152f are completed, the calculation unit 23 of the control device 20 sets the value of the "Disassembly Completed Flag" field of the record in the NG product management table U in which the serial number of the "workpiece before disassembly" for which the disassembly work was performed is registered to "True" according to the display contents of the display area 152f. In other words, the value (initial value) of the "Disassembly Completed Flag" field of the record in the NG product management table U is "False" until the disassembly work using the disassembly equipment 15 is completed.

[0242] FIG. 44 is a diagram showing a state in which the opening / closing lid 153a of the reused pallet 153 of the dismantling equipment 15 shown in FIG. 40 is open. FIG. 45 is a diagram showing a state in which the opening / closing lid 154a of the NG chute 154 of the dismantling equipment 15 shown in FIG. 40 is open. The reused pallet 153 and the NG chute 154 have openings in the dismantling equipment 15 that are provided so that dismantled workpieces, etc. can be placed thereon. The openings are provided so as to be openable and closable by individual movable lids. The reused pallet 153 is provided with an opening / closing lid 153a. The NG chute 154 is provided with an opening / closing lid 154a. The opening / closing lids 153a, 154a open and close in accordance with the operation of the drive unit 36 ​​of the dismantling equipment 15.

[0243] As for which of the reusable pallet 153 and the NG chute 154 is open and which is closed, the reusable pallet 153 is open and the NG chute 154 is closed unless the conditions for disposing of the disassembled workpieces are met. The operator may select to dispose of the disassembled workpieces by pressing the Dispose button BU2 for that workpiece. In that case, the conditions for disposing of the disassembled workpieces are met for that workpiece, and the NG chute 154 is opened and the reusable pallet 153 is closed. In this case, the reusable pallet 153 can be opened again and the NG chute 154 closed by pressing the Reuse button BU1. Furthermore, the conditions for disposing of the disassembled workpieces that have reached the limit of reuse counts (described below) are also met. The operation control unit 41 of the dismantling equipment 15 controls the operation of the drive unit 36 ​​to operate the opening / closing lids 153a and 154a depending on whether the conditions for disposing of the disassembled workpieces are met. The function of the operation control unit 41 may be included in the control device 20.

[0244] The reusable pallet 153 and the NG shooter 154 are each provided with a sensing unit 39 capable of detecting workpieces, and it is possible to determine whether the workpieces are being reused or disposed of appropriately based on the detection results of the sensing unit 39. The sensing unit 39 is, for example, configured to capture images of the workpieces placed on the reusable pallet 153 (or the NG shooter 154) and detect the serial number of the workpieces, but is not limited to this. It may also be configured as a contact sensor or weight sensor that simply detects the placement of a workpiece. In this case, the operation control unit 41 of the dismantling equipment 15 determines that "workpieces, etc. after dismantling corresponding to the procedure" have been placed based on the sensor's detection. In this case, the function of capturing images of the workpieces, etc. may not be necessary. Based on the detection results of the sensing unit 39 of the reusable pallet 153 (or the NG shooter 154), the operation control unit 41 of the dismantling equipment 15 shifts the highlighted step from the currently highlighted step to the step with the highlighted step +1. For example, as shown in FIG. 41, when part No. 10 is placed on the reuse pallet 153 (or NG shooter 154) in accordance with the procedure "Remove part No. 10," the operation control unit 41 transitions the target of highlighting to the second procedure, "Remove part No. 11." Accordingly, the display content in the display area 152e switches from the content relating to "part No. 10" illustrated in FIG. 41 to the content relating to "part No. 11." A similar mechanism is used when the target of highlighting is transitioned to another procedure.

[0245] Furthermore, the display content displayed on the touch panel 152 includes a display area 152g that displays a schematic diagram of the disassembly content corresponding to the currently selected step in the "disassembly procedure," as described above. As described above, the display content of the display area 152g corresponds to the target of highlighting in the display area 152f. As described above, image data corresponding to the display content of the display area 152g is included in the procedure data D15. The calculation unit 23 refers to the procedure data D15 to acquire image data corresponding to the display content of the "disassembly procedure" corresponding to the disassembly mode identified when determining the display content of the display area 152e. The calculation unit 23 transmits the acquired image data to the dismantling device 15 via the communication unit 21. Note that the image data displayed in the display area 152g may be stored in the dismantling device 15, and the access path of the image to be displayed may be switched as the dismantling progresses. The operation control unit 41 of the dismantling device 15 controls the operation of the touch panel 152 to display, in the display area 152g, image data included in the received information that corresponds to the target of highlighting in the display area 152f. The function of the operation control unit 41 may be included in the control device 20.

[0246] Furthermore, the display content displayed on the touch panel 152 includes a display area 152h that indicates how to dispose of workpieces and other items resulting from the currently selected "disassembly procedure." The display area 152h displays content depending on whether the reuse pallet 153, the NG shooter 154, or the reuse ID tag issuing unit 156 (described later) is being used. The display content of the display area 152h corresponds to the disassembled workpieces and other items that will be removed from the pre-disassembly workpieces by executing the highlighted procedure in the display area 152f. For example, if "Remove part No. 10" is highlighted in the display area 152f, the display content of the display area 152h will be "Part No. 10." The display area of ​​the display area 152h also has multiple display positions. Instead of providing multiple display positions, the display content may be switched within a single display position. When the reuse pallet 153 is open, the display content is displayed in the position corresponding to "Place on the reuse pallet." When the NG shooter 154 is open, the display content is displayed in the position corresponding to "Discard into the NG shooter." If the procedure uses the reusable ID tag issuing unit 156 described later, the display content is displayed at the display position corresponding to "Please attach a reusable ID tag to."

[0247] The display content displayed on the touch panel 152 also includes a display area 152j for "number of times dismantled." Display control of the display area 152j will be described later.

[0248] The disassembled workpieces, etc. placed on the reusable pallet 153 can be reintroduced into a process predetermined by the BOM master D13 and the process sequence master D2. The timing at which the serial number of the disassembled workpieces, etc. placed on the reusable pallet 153 can be reintroduced into a process predetermined by the process sequence master D2 is arbitrary. For example, this timing may occur individually for each disassembled workpiece, each time a disassembled workpiece removed from a pre-disassembled workpiece in accordance with the execution of each procedure included in one disassembly mode is placed on the reusable pallet 153. Alternatively, this timing may occur simultaneously for all disassembled workpieces, etc., generated in one disassembly mode, when a disassembled workpiece removed from a pre-disassembly workpiece in accordance with the execution of the final procedure included in one disassembly mode is placed on the reusable pallet 153.

[0249] The serial number of the workpiece after dismantling can be identified based on the serial numbers of each part registered in the records in which the "status" field in the performance record registration data M was set to "abnormal termination" until the dismantling work is completed. In other words, since the workpieces after dismantling are, of course, workpieces, etc. that were assembled to the workpieces before dismantling with serial numbers individually assigned, except for lot parts, each part has a serial number, except for lot parts. It is possible to identify which serial number corresponds to which part based on the managed individual serial master D6. Therefore, the serial number of the "workpieces, etc. after dismantling," which is any of the workpieces, etc. managed by the BOM master D13, can be identified by the calculation unit 23 based on the relationship with the performance record registration data M and the managed individual serial master D6.

[0250] When all dismantling procedures included in one dismantling mode are completed, the operation control unit 41 of the dismantling equipment 15 transmits completion notification information to the control device 20 via the communication unit 31, the completion notification information including information indicating the completion of the dismantling work and information indicating the individual management serial numbers of the workpieces dismantled in the dismantling work before dismantling. Here, the individual management serial numbers of the workpieces dismantled in the dismantling work before dismantling are serial numbers read by the individual management serial reading unit 33 of the dismantling equipment 15 at the start of the dismantling work. When the calculation unit 23 of the control device 20 receives the completion notification information, it changes the "status" of the record in the performance registration data M in which the "status" field is "abnormal termination" and in which the individual management serial number of the workpieces dismantled in the dismantling work before dismantling is registered in the "individual management serial 1 (parent part)" field to "dismantled." Here, the content registered in the "status" may further include information indicating which dismantling mode the workpieces were dismantled in.

[0251] In the embodiment, the record of the performance data M indicating "dismantled" is finalized at that time and remains. Workpieces including parent parts, such as dismantled workpieces that have been reintroduced, are managed in new records upon reintroduction. Child parts removed from parent parts among dismantled workpieces that have been reintroduced do not necessarily need to be reassembled with the same parent part. Which parent part's workpiece is assembled with which reintroduced child part can be identified by checking whether there are duplicate serial numbers between the "dismantled" record in the performance data M and records other than the "dismantled" record in the performance data M. This is because reintroduced child parts are assembled with a parent part in the same way as normal child parts that are not reintroduced. However, unlike normal child parts, reintroduced child parts are registered in the "dismantled" record in the performance data M. In other words, if the same serial number is included in the performance data M, it will be included in one or more "dismantled" records and one other record that is not "dismantled." The calculation unit 23 can manage dismantled workpieces using this mechanism.

[0252] Note that the method for moving disassembled workpieces, etc. from the reusable pallet 153 to the equipment 10 of the process to be reintroduced is arbitrary. For example, the disassembled workpieces, etc. may be moved automatically using a machine such as a belt conveyor or an AGV (Automated Guided Vehicle) that is installed to load and move parts between the reusable pallet 153 and the normal part storage area (or the initial parts storage area 51) of the process to be reintroduced, or may be transported by a person (e.g., an operator). However, the calculation unit 23 determines that an error has occurred when the individual management serial reading unit 33 of the equipment 10 of any process reads all serial numbers registered in records in the performance registration data M whose "status" is "abnormal completion." In other words, if the individual management serial reading unit 33 of any process reads a serial number included in a record whose performance registration data M has "abnormal completion," the process does not proceed to step S43 after step S42, which will be described later, but instead handles the situation as a so-called error, as in step S47. Furthermore, if the serial number included in a record that is marked as "disassembled" in the performance registration data M is read by any device other than the individual management serial reading unit 33 of the equipment 10 installed in the process (the process to be re-input) registered in the "input destination" field of the BOM master D13, the process does not proceed to step S43 after the process of step S42 described below, but rather a so-called error is handled as in the process of step S47.

[0253] Disassembled workpieces, etc., placed in the NG chute 154 cannot be re-introduced. Specifically, data indicating the serial numbers of disassembled workpieces, etc., placed in the NG chute 154 when the conditions for disposal are met is transmitted by the operation control unit 41 of the dismantling equipment 15 to the control device 20 via the communication unit 31. The calculation unit 23 records the serial numbers included in the data in disposal serial data (not shown). Workpieces, etc., given the serial numbers recorded in the disposal serial data will result in an error in processing by the calculation unit 23 (a re-introduction determination process (not shown) performed between the processing of step S42 and the processing of step S43, described later), regardless of which process the individual management serial reading unit 33 of the equipment 10 reads them. That is, a so-called error is handled as in the processing of step S47. The disposal serial data is stored, for example, in the memory unit 22, but may also be stored in another storage device accessible by the calculation unit 23.

[0254] Tools (for example, screwdrivers) that can be used in dismantling work are prepared in the tool storage area 155. The tools are provided so that they can be used by workers who perform the dismantling work with the dismantling equipment 15. In addition, ID tags and barcode issuing devices that are attached to lot parts that are re-introduced after dismantling may also be placed there.

[0255] Next, we will explain how to handle a case where abnormal completions occur consecutively in the same process before and after re-feeding a workpiece.

[0256] When a record of a workpiece having a certain "parent part serial," i.e., an "individual part management serial," is registered in the Rejected Product Management Table U, if the "individual part management serial" has not been registered in the Rejected Product Management Table U before, a new record is created with the "individual part management serial" registered in the field. Even if the "individual part management serial" has already been registered in the Rejected Product Management Table U, if the combination of the process ID of the "NG-occurring process" and the "NG code" number is different, the record is managed individually for each combination of the process ID of the "NG-occurring process" and the "NG code" number. In other words, if a record corresponding to the combination of the process ID of the latest "abnormal completion" process and the "individual part management serial" that caused the latest "abnormal completion" has not yet been registered in the Rejected Product Management Table U, a new record is created for the combination of the "individual part management serial," the "NG-occurring process," and the "NG code." Here, the "number of consecutive NGs" in the newly created record in the Rejected Product Management Table U is set to an initial value (e.g., 0).

[0257] When the "number of consecutive NGs" is the initial value, the dismantling mode determined by referring to the dismantling mode data D12 is the dismantling mode registered in the field included in the column of "first NG count." Note that the conditions based on the combination of "NG process" and "NG code" are as described above.

[0258] A workpiece with an "individual part management serial number" registered in the NG product management table U is treated as a workpiece before dismantling. Then, as described above, dismantling work is performed using the dismantling equipment 15, resulting in dismantled workpieces, etc. Now, let's assume that a workpiece with the "parent part serial number," i.e., an "individual part management serial number," among the dismantled workpieces, again experiences an "abnormal completion" in the same process with the same NG content (NG code). In this case, the calculation unit 23 increments (+1) the value of the "NG-occurring process" in the record corresponding to the combination of the "individual part management serial number," "NG-occurring process," and "NG code" that caused the "abnormal completion." Therefore, for example, if workpieces containing the same parent part experience an "abnormal completion" in the same process with the same NG content (NG code) three times in a row, the value of the "NG-occurring process" becomes the initial value +2 (2).

[0259] When the "number of consecutive NG attempts" is the initial value + 1, the dismantling mode determined by referring to the dismantling mode data D12 is the dismantling mode registered in the field included in the column of "second number of NG attempts." Also, when the "number of consecutive NG attempts" is the initial value + 2, the dismantling mode determined by referring to the dismantling mode data D12 is the dismantling mode registered in the field included in the column of "third number of NG attempts." The conditions based on the combination of "NG occurring process" and "NG code" are as described above.

[0260] The calculation unit 23 transmits data corresponding to various information displayed on the touch panel 152 to the demolition equipment 15 via the communication unit 21, and also transmits information indicating the value of "q" for the qth dismantling count displayed in the display area 152j to the demolition equipment 15 via the communication unit 21. Here, q is the value of the "number of consecutive NG attempts" + 1. The operation control unit 41 of the demolition equipment 15 controls the operation of the touch panel 152 so as to display the value of "q" included in the received information in the display area 152j. Note that the function of this operation control unit 41 may be included in the control device 20.

[0261] Any action can be taken when the maximum value of the "NG count" (r) registered in the disassembly mode data D12 is exceeded. For example, if the "consecutive NG count" is equal to or greater than the initial value + 2, the "third NG count" may continue to be applied, or if the "consecutive NG count" is equal to or greater than the initial value + r, a rule may be determined by the calculation unit 23 such that a workpiece having that "individual management serial" satisfies the conditions for disposing of the workpiece after disassembly, and is placed in the NG shooter 154 as a target for disposal. Data indicating such rules is stored in advance in a storage device that can be referenced by the calculation unit 23, such as the memory unit 22.

[0262] Next, management of the number of times that sub-components among the disassembled workpieces are reused will be described.

[0263] 46 is a diagram showing an example of a re-input counter EC. The re-input counter EC is a counter for managing to which parent part a re-input workpiece or the like treated as a child part after disassembly is assembled.

[0264] The re-entry counter EC is data having a column for "individual management serial number" and a column in which the counter value is registered. The "number of times parts are reused" field shown in Fig. 46 as the column in which the counter value is registered includes a column corresponding to each "No." in the BOM master D13.

[0265] The counter value of the reintroduction counter EC is registered according to the number of serial numbers that are duplicated between records in the performance registration data M whose "status" is "dismantled" and records whose "status" is not "dismantled." The calculation unit 23 checks whether there is a serial number that is duplicated two or more times in the performance registration data M. If there is a serial number that is duplicated two or more times in the performance registration data M, the calculation unit 23 registers the same serial number as the serial number registered in the "individual management serial 1 (parent part)" field of the record containing the serial number whose "status" is not "dismantled" in the "individual management serial" field of the reintroduction counter EC. In addition, the calculation unit 23 registers a value obtained by subtracting one from the number of serial numbers included in the record whose "status" is not "dismantled" that are registered in the performance registration data M as the value of the "No." field corresponding to the serial number. The correspondence between "No." and serial numbers can be identified based on a combination of various data stored in the storage unit 22. For example, among the serial numbers of parent parts in the performance record registration data M, the serial number of a parent part to which a reused part is attached is registered in the reintroduction counter EC. The serial number of a child part of the parent part that is inserted as a reused part can be identified by a record in the performance record registration data M that registers information about the parent part to which the child part was attached before the disassembly work. When disassembly work occurs, the calculation unit 23 of the control device 20 identifies the serial number of a child part that will be generated after the disassembly work and that will be reused and reintroduced, by referring to the performance record registration data M. Here, the relationship between the serial number of the child part and the "No." in the BOM master (BOM master D13) can be identified by the relationship between the "No." and the "individual management serial" in the product master D7. Then, the serial number of the child part is registered in the record of the parent part in the performance record registration data M as information about the parent part to which the child part with the serial number of the child part was attached in the manufacturing process on the production line performed after the reintroduction work. Furthermore, the calculation unit 23 of the control device 20 registers the serial number of the parent part in the reintroduction counter EC. This establishes a correspondence relationship.The relationship between the serial number registered in the reinput counter EC and the "No." in the BOM master (BOM master D13) can be identified by the relationship between the "No." in the product master D7 and the "individual management serial number." In addition, which part in the reinput counter EC with the "No." is a reused or reinput part can be identified by the relationship between the record of the parent part in the performance registration data M and the "No." in the product master D7 and the "individual management serial number." In this way, the memory unit 22 stores information for individually identifying the workpieces and parts after disassembly. In addition, in this processing, the reinput counter EC essentially manages the number of times the "parent part serial number" is duplicated, but the "parent part serial number" may be excluded.

[0266] In the re-entry counter EC, an individual record is created for each workpiece that has been separated after the dismantling work. In the example shown in Fig. 46, workpieces with serial numbers "HS002", "MO002", and "HS002" are managed by individual records in the re-entry counter EC.

[0267] Furthermore, when reusable components are assembled together, the management in the reintroduction counter EC is integrated. FIG. 47 is a diagram showing an example of the reintroduction counter EC after the components that were managed separately in FIG. 46 are assembled together. For example, if a child part serial numbered "MO002" in FIG. 46 is assembled to a parent part serial numbered "HS002" in a manufacturing process on a production line that is performed again after disassembly, the record for "MO002" in FIG. 46 is deleted and integrated into "HS002" as shown in FIG. 47. In the record for "MO002" in FIG. 46, "1" was set in the "9" field of the "No." column, and "0" was set in the other fields. Therefore, while the field for "9" in the record for "HS002" in FIG. 46 was "0," the field in FIG. 47 is set to "1."

[0268] If a record including the individual management serial number of a workpiece before dismantling that was the subject of dismantling work is registered in the reintroduction counter EC, the value registered in the "No" field of that record is reflected in the number of reuses in the display area 152e in Fig. 41. On the other hand, if a record including the individual management serial number of a workpiece before dismantling that was the subject of dismantling work is not registered in the reintroduction counter EC, the number of reuses in the display area 152e in Fig. 41 will be 0.

[0269] Next, the "maximum number of reuses" will be described. A restriction may be set such that when the number of reuses reaches or exceeds a predetermined limit, only "discard" can be selected between "reuse" and "discard," and "reuse" cannot be selected. In this way, the condition for disposing of a workpiece or the like after disassembly may be met based on the number of reuses. In this case, the value of the limit number is, for example, 3, but it may also be 2 or less or 4 or more. Furthermore, the limit number may be common regardless of the type of workpiece or part, or may be set individually. Data indicating the limit number is stored in another storage device that can be referenced by the calculation unit 23, such as the memory unit 22.

[0270] In the embodiment, the limit on the number of times each workpiece, etc., can be reused is determined by the value registered in the "Upper Reuse Count" field of the BOM master D13. For example, in the records in the BOM master D13 where the "No." is "3" or "9," the "Upper Reuse Count" is 2, so the limit on the number of times the part assembly and motor ECU can be reused is 2. Also, in the records in the BOM master D13 where the "No." is "10" or "11," the "Upper Reuse Count" is 1, so the limit on the number of times the bracket and lever can be reused is 1. Also, in the record in the BOM master D13 where the "No." is "8," the "Upper Reuse Count" is 0, so the limit on the number of times the bolt can be reused is 0, meaning that it cannot be reused.

[0271] In the display control of the touch panel 152 described with reference to FIG. 41, the operation control unit 41 further displays a limit on the number of times that workpieces, etc., remaining after dismantling work can be reused. In FIG. 41, for example, the number of reuses for a "part assembly" is "1 / 2." This indicates that the number of times that the part assembly has been reused in the past is 1, and the limit on the number of times that the part assembly can be reused as defined in the BOM master D13 is 2. The other reuse counts displayed in FIG. 41 can be interpreted similarly. Note that items whose denominator (limit number of reuses) is 0 and items whose denominator and numerator (number of reuses) are equal are not reusable and are subject to disposal. Therefore, in the example shown in FIG. 41, the bracket, lever, and bolt are subject to disposal, and the reuse button BU1 cannot be selected. Furthermore, the bracket and lever are not included in the display on the reintroduction instruction display screen 152k illustrated in FIG. 42 because their denominator and numerator (number of reuses) are equal and they are subject to disposal. The operation control unit 41 performs display control to dispose of the workpieces etc. that have reached the limit of the number of times they can be reused, without allowing them to be reused.

[0272] Next, we will explain the special points regarding lot parts among the workpieces after dismantling.

[0273] As described above, the dismantling equipment 15 includes a reusable ID tag issuing unit 156. The reusable ID tag issuing unit 156 includes, for example, an image forming device (printer) that outputs a medium (such as paper) on which an ID to be assigned to each lot part is image-formed. The ID to be assigned to each lot part is generated by the calculation unit 23 randomly or according to a rule previously stored in the storage unit 22. The calculation unit 23 stores the generated ID in the storage unit 22. The calculation unit 23 also transmits information indicating the ID to the dismantling equipment 15 via the communication unit 21. The operation control unit 41 of the dismantling equipment 15 operates the reusable ID tag issuing unit 156 to image the ID included in the received information on a medium and output it. Lot parts removed from the workpieces before dismantling by the dismantling equipment 15 and re-inserted are managed in association with the medium and then re-inserted. The IDs of the re-inserted lot parts are managed based on the correspondence between the performance registration data M and the IDs stored in the storage unit 22. That is, by registering the ID of the re-input lot part in a field such as "Assembly Lot Part ID1" in the performance registration data M, the ID assigned to the lot part is associated with the serial number of the parent part to which the lot part with the assigned ID is assembled.

[0274] Figure 48 is a schematic diagram showing an example of workpieces and the like placed as reusable parts on a reusable pallet 153. In the example shown in Figure 48, workpiece PT1, part PT2, and lot parts PT3 and PT4 are placed on the reusable pallet 153. Of these, lot part PT3 is assigned a reusable ID tag ID1. Furthermore, lot part PT4 is assigned a reusable ID tag ID2. Reusable ID tags ID1 and ID2 are assigned reusable ID tags issued by the reusable ID tag issuing unit 156.

[0275] The reuse pallet 153 may be provided so that multiple types of workpieces generated during dismantling work can be individually placed on it. Fig. 49 is a schematic diagram showing a reuse pallet 153A provided so that multiple types of workpieces generated during dismantling work can be individually placed on it. The reuse pallet 153A is similar to the reuse pallet 153 shown in Fig. 48, except that it has dividers for separating the workpieces PT1, parts PT2, and lot parts PT3 and PT4 by type.

[0276] In the explanations with reference to FIGS. 33 to 49, the process for which separate rules for dealing with abnormalities are defined is only a portion of the multiple processes. However, this rule may also apply to all of the multiple processes. Also, a combination of a process ID and an NG code number that is commonly used across multiple processes may be used. For example, the process ID "PRCS00" in the disassembly mode data D12 may be applied to all processes (e.g., "P-22" and "P-25") for which individual process IDs are not registered in the disassembly mode data D12, as exemplified by "disassembly mode 5" in the disassembly master D14, in which disassembled workpieces are numbered "5," "6," "7," "8," "9," "10," or "11" (see BOM master D13). As in this example, a special ID (e.g., "PRCS00") that functions as a wildcard for the process ID may be used to define the disassembly work content that is common to multiple processes. Furthermore, rules for dealing with abnormalities occurring at each of the multiple processes may be individually defined. Alternatively, the process ID may function as a wildcard, and a common set of work content may be applied to processes for which no work content (dismantling mode) is defined for each process ID. Similarly to the "dismantling mode," additional work content may be defined for dismantling only, without dismantling. Data may be added to the dismantling mode data D12, dismantling master D14, procedure data D15, etc., so that work content for dismantling only is applied when an abnormality occurs in a particular process. Furthermore, the BOM master D13 may be provided independently of data B1, or the BOM master D13 may be provided as data including data B1. In other words, the BOM master D13 can fulfill all of the functions of data B1.

[0277] Next, we will explain the management of abnormalities that may occur when handling abnormal products. An abnormal product is, for example, a workpiece whose parent part is a serialized configuration registered in the "individual product management serial" field of a record in which the "status" field in the performance record registration data M is registered to indicate "abnormal completion." This is because, as a result of an abnormality occurring in one of multiple processes, a record corresponding to the individual product management workpiece status table T, performance record registration data M, and defective product management table U is registered, and the workpiece as an incomplete product managed in this way in the individual product management workpiece status table T, performance record registration data M, and defective product management table U is an abnormal product.

[0278] A rule is established so that a workpiece corresponding to a record in the individual management workpiece status table T with a "status" of "abnormal completion" is managed as if the equipment for the subsequent process of the workpiece is the dismantling equipment 15. Information indicating the rule is stored in a storage device accessible by the calculation unit 23, such as the memory unit 22, or such logic is pre-implemented in the calculation unit 23. This allows workpieces corresponding to records with a "status" of "abnormal completion," i.e., abnormal products, to be managed in the same manner as workpieces with a "status" of "normal completion" that are stuck without being moved to a subsequent process. Specifically, if the individual management serial reader 33 of the dismantling equipment 15 does not detect that a workpiece that is an abnormal product has been moved to the dismantling equipment 15 by reading the serial number of the workpiece, it is determined that an abnormality has occurred, that is, the movement of the workpiece that should be moved to the dismantling equipment 15 is being delayed.

[0279] The calculation unit 23 may be configured to operate the notification unit 37 when a predetermined time has elapsed or when a predetermined time has arrived after storing temporary data including first identification information that functions as identification information for an abnormal product (for example, a record in the individual management workpiece status table T where the "status" is "abnormal completion") in the storage unit 22. In this case, the predetermined time and data indicating the predetermined time are stored in the storage unit 22. As a specific example of operation, for example, in a production line where a rule is established that "an abnormal product must be moved to the dismantling equipment 15 within 15 minutes of its occurrence," the predetermined time is set to 15 minutes. Furthermore, by setting the time when workers are replaced on the production line as the predetermined time, it is possible to prevent "losing awareness of which products are abnormal" due to a change in workers.

[0280] The flow of various processes performed in the management system will be described below with reference to the flowcharts in FIGS.

[0281] 50 is a flowchart showing an example of the flow of processing performed by the calculation unit 23 as a production line operation start process. First, the ID of the "production item number" is acquired (step S1). Specifically, the ID is input by an administrator of the management system via the input unit 25, for example. The calculation unit 23 acquires the ID of the "production item number" indicated by the input.

[0282] Next, the calculation unit 23 acquires the process list D1 and the process sequence master D2 corresponding to the ID of the "production part number" acquired in step S1 (step S2). Specifically, the calculation unit 23 reads the process sequence master D2, extracts a record including the ID of the "production part number" acquired in step S1, and acquires the process ID registered in the field of the "column in which IDs indicating the chronological relationship between multiple processes are registered" included in the extracted record. In this way, the calculation unit 23 acquires the processes and the execution order of the processes for manufacturing the product corresponding to the production part number acquired in step S1. In addition, the calculation unit 23 reads the process list D1 and identifies the ID registered in the field included in the "production line" of the record including the process ID included in the record extracted from the process sequence master D2, thereby identifying the production line that can manufacture the product corresponding to the production part number acquired in step S1.

[0283] The calculation unit 23 also acquires the process master D3 and certified worker list D5 corresponding to the ID of the "production part number" acquired in step S1 (step S3). Specifically, the calculation unit 23 reads out the process master D3 and acquires an ID indicating the "lot part" to be assembled in the "process for manufacturing a product corresponding to the production part number" identified in step S2, i.e., the "lot part provided for manufacturing the product corresponding to the production part number." The calculation unit 23 also acquires the "number of the program selected by the program selection unit 38 in manufacturing the product corresponding to the production part number" from the process master D3. The calculation unit 23 also reads out the certified worker list D5 and acquires the "ID indicating the certified worker" included in the record including the ID of the "production part number" acquired in step S1 and the process ID of the "process for manufacturing a product corresponding to the production part number."

[0284] FIG. 51 is a flowchart showing an example of the flow of a process for checking certified workers. In the device 10, the worker ID is read by the worker ID reader 35. Specifically, each worker (e.g., workers H1, H2, H3, H4, H5, etc.) is given a worker ID and a medium (e.g., an ID card) that enables the worker ID to be read by the worker ID reader 35. As part of the process of starting up the device 10, each worker causes the worker ID reader 35 to read the medium, thereby causing the device 10 to acquire the worker ID. The operation control unit 41 transmits information indicating the worker ID acquired by the worker ID reader 35 as worker ID information to the control device 20 via the communication unit 31. The calculation unit 23 of the control device 20 receives the worker ID information via the communication unit 21 (step S11). The worker ID information includes information indicating the worker ID acquired by the worker ID reader 35 and the process ID of the process that uses the device 10 from which the worker ID was acquired.

[0285] The calculation unit 23 performs matching based on a combination of the worker ID indicated in the information received in step S11 and the process ID of the process using the device 10 from which the worker ID was acquired. The matching is performed between the worker ID and the "ID indicating the certified worker" included in a record in the certified worker list D5 acquired in step S3, which includes the ID of the "production part number" acquired in step S1 and the process ID of the "process for manufacturing the product corresponding to the production part number" (step S12). That is, in step S12, it is assumed that the process ID of the process using the device 10 from which the worker ID was acquired, included in the information received in step S11, matches the process ID of the "process for manufacturing the product corresponding to the production part number" in the certified worker list D5. When a record is described as a corresponding record in the certified worker list D5, it is assumed that this assumption is met.

[0286] If the worker ID indicated by the information (worker ID information) received in step S11 is included in the corresponding record in the certified worker list D5 through the comparison in step S12 (step S13; Yes), the calculation unit 23 determines that the equipment 10 has been started up by a certified worker and does not shut down the equipment due to an abnormality in the worker ID.

[0287] On the other hand, if the operator ID indicated by the information received in step S11 is not included in the corresponding record in the certified operator list D5 as a result of the comparison in step S12 (step S13; No), the calculation unit 23 determines that the device 10 has been started by an operator who is not a certified operator, and performs processing to stop the device due to an abnormality in the operator ID (step S14). Specifically, the calculation unit 23 generates a command to stop the device 10 (stop command) and transmits it to the device 10 via the communication unit 21. The operation control unit 41 of the device 10 receives the stop command via the communication unit 31 and stops the operation of the drive unit 36 ​​in response to the stop command. Here, the operation control unit 41 may cause the notification unit 37 to notify information indicating that the cause of the device 10 stopping is that the operator ID of a non-certified operator has been acquired by the operator ID reader 35.

[0288] 52 is a flowchart showing an example of the flow of the process for checking a program selected by the program selection unit 38. In the device 10, a program is selected by the operator using the program selection unit 38. The operation control unit 41 transmits information indicating the program number acquired by the program selection unit 38 to the control device 20 via the communication unit 31 as selected operation Prg. information. The calculation unit 23 of the control device 20 receives the selected operation Prg. information via the communication unit 21 (step S21). The selected operation Prg. information includes information indicating the program number and a process ID of a process using the device 10 equipped with the program selection unit 38 for which the program number was selected.

[0289] The calculation unit 23 performs a comparison based on a combination of the program number indicated by the information received in step S21 and the process ID of the process using the device 10 equipped with the program selection unit 38 for which the program number was selected. The program number is compared with the "value indicating the program number selected by the program selection unit 38 in the manufacture of the product corresponding to the production number" contained in a record in the process master D3 acquired in step S3, which includes the ID of the "production part number" acquired in step S1 and the process ID of the "process for manufacturing the product corresponding to the production part number" (step S22). That is, step S22 is based on the premise that the process ID contained in the information received in step S21 matches the process ID of the "process for manufacturing the product corresponding to the production part number" in the process master D3. The term "corresponding record" in the process master D3 is used to mean that this premise is met. In short, in this embodiment, step S22 is used to compare whether the program selected by the program selection unit 38 matches the program indicated by the value of the "appropriate Prg. selection No." in the process master D3.

[0290] If the program number indicated by the information received in step S21 (selected operation Prg. information) is included in the corresponding record in the process master D3 through comparison in step S22 (step S23; Yes), the calculation unit 23 determines that an appropriate program has been selected by the program selection unit 38 and does not stop the equipment due to an abnormality in the operation Prg.

[0291] On the other hand, if the program number indicated by the information received in step S21 is not included in the corresponding record of the process master D3 as a result of the comparison in step S22 (step S23; No), the calculation unit 23 determines that an incorrect program has been selected by the program selection unit 38, and performs processing to stop the equipment due to an abnormality in the operation Prg. (step S24). Specifically, the calculation unit 23 generates and transmits a command (stop command) to stop the equipment 10. The operation control unit 41 of the equipment 10 receives the command via the communication unit 31 and stops the operation of the drive unit 36 ​​in accordance with the command. Here, the operation control unit 41 may cause the notification unit 37 to notify information indicating that the cause of the stop of the equipment 10 is due to an error in the program selected by the program selection unit 38.

[0292] 53 is a flowchart showing an example of the flow of an identification tag reading check process. In the device 10, an operator reads the identification tag of the lot part using the assembly lot part ID reading unit 34. The operation control unit 41 transmits information indicating the ID of the lot part managed by the identification tag acquired by the assembly lot part ID reading unit 34 as lot identification tag data to the control device 20 via the communication unit 31. The calculation unit 23 of the control device 20 receives the lot identification tag data via the communication unit 21 (step S31). The lot identification tag data includes information indicating the ID of the lot part, information for narrowing down the lot parts such as the date and material, and the process ID of the process using the device 10 equipped with the assembly lot part ID reading unit 34 that read the identification tag.

[0293] The calculation unit 23 performs a comparison based on a combination of information indicating the ID of the lot part indicated by the information received in step S31 and the process ID of the process using the device 10 equipped with the assembly lot part ID reader 34 that read the identification tag. The information to be compared is the ID of the lot part and the "ID indicating the lot part used to manufacture the product corresponding to the production part number" contained in the record in the process master D3 acquired in step S3, which includes the ID of the "production part number" acquired in step S1 and the process ID of the "process for manufacturing the product corresponding to the production part number" (step S32). That is, in step S32, it is assumed that the process ID contained in the information received in step S31 matches the process ID of the "process for manufacturing the product corresponding to the production part number" in the process master D3. When a record is described as a corresponding record in the process master D3, it is assumed that this assumption is met. In short, in this embodiment, a check is performed in step S32 to see if the lot parts managed by the identification tag read by the assembly lot part ID reading unit 34 are lot parts given an ID registered as "assembly lot part ID*" in the process master D3.

[0294] If the ID of the lot part indicated by the information received in step S31 (lot identification tag data) is included in the corresponding record of the process master D3 as a result of the collation in step S32 (step S33; Yes), the calculation unit 23 determines that the identification tag of the appropriate lot part has been read by the assembly lot part ID reading unit 34, and sets the lot part counter LC. Specifically, the calculation unit 23 reads the incoming quantity master D4, and registers the combination of the assembly lot part ID and its incoming quantity corresponding to the lot identification tag data received in step S31 in the record of the lot part counter LC (step S35). Then, the calculation unit 23 sets the outgoing quantity of the record registered in step S35 to an initial value (0) (step S36).

[0295] On the other hand, if the ID of the lot part indicated by the information received in step S21 is not included in the corresponding record of the process master D3 as a result of the comparison in step S22 (step S33; No), the calculation unit 23 determines that an incorrect identification tag has been read by the assembly lot part ID reading unit 34, and performs processing to stop the equipment due to an abnormality in the lot part (step S34). Specifically, the calculation unit 23 generates and transmits a command to stop the equipment 10. The operation control unit 41 of the equipment 10 receives the command via the communication unit 31 and stops the operation of the drive unit 36 ​​in accordance with the command. Here, the operation control unit 41 may cause the notification unit 37 to notify information indicating that the cause of the stop of the equipment 10 is an error in the identification tag (lot part) read by the assembly lot part ID reading unit 34.

[0296] 51 to 53 does not result in the device 10 being stopped, each device 10 is brought into a state where it can perform the processes in and after FIG. 54, which will be described later. That is, the calculation unit 23 stops the device 10 when an abnormality that should stop the device 10 is detected, and permits the device 10 to start up otherwise. Note that before reading (before verification), the device 10 starts out in a state where startup is not permitted.

[0297] FIG. 54 is a flowchart showing an example of the flow of a one-cycle process start check process. First, the calculation unit 23 checks whether "information indicating the start of the process" has been input from the equipment 10 (step S41). The "information indicating the start of the process" includes the serial number of the individual item or workpiece read by the individual item management serial reading unit 33 and the process ID of the process using the equipment 10 equipped with the individual item management serial reading unit 33. The "information indicating the start of the process" is generated by the individual item management serial reading unit 33 or the operation control unit 41 in response to the serial number of the individual item or workpiece being read by the individual item management serial reading unit 33. The operation control unit 41 transmits the generated information to the control device 20 via the communication unit 31. The calculation unit 23 of the control device 20 receives the information via the communication unit 21 and accepts it as input of "information indicating the start of the process." When the individual item management serial number reading unit 33 reads the serial number of an individual item or workpiece, if the serial number corresponding to the parent part is read using the device 10 equipped with the individual item management serial number reading unit 33, it functions as "information indicating the start of a process." If the serial number of another part, such as the serial number of a child part assembled to the parent part, is read, it is distinguished from when the serial number of the parent part is read (e.g., treated as an error). Information indicating which part corresponds to the parent part in which process is included in the process master D3. If the parent part is the same throughout the entire process, the serial number of one parent part is registered in each record of the process master D3. If workpieces from multiple parallel processes converge to form a product, the serial numbers of the parent parts for each process are registered in the records of the process master D3.

[0298] The process ID included in the "information indicating the start of the process" is treated as the "ID of the started process" in the subsequent steps. Also, the serial number included in the "information indicating the start of the process" is treated as the "serial number of the input work" in the subsequent steps. The calculation unit 23 waits until the "information indicating the start of the process" is input from the device 10 (step S41; No).

[0299] When "information indicating the start of a process" is input from the device 10 (step S41; Yes), the calculation unit 23 acquires the "ID of the started process" and the "serial number of the inserted workpiece" from the "information indicating the start of a process" input in step S41 (step S42). The calculation unit 23 generates a new record (newly registered data) in the individual management workpiece status table T (step S43). Specifically, the calculation unit 23 registers the "serial number of the inserted workpiece" acquired in step S42 in the "individual management serial number" field of the generated new record. The calculation unit 23 also registers the "ID of the started process" acquired in step S42 in the "process ID" field of the generated new record. The calculation unit 23 also registers "inserted" in the "status" field of the generated new record. The calculation unit 23 also registers the initial value (0) as the value of the retention counter of the generated new record.

[0300] The distinction between "parent" (parent part) and "child" (child part) in the "individual item type" field of the newly generated record is made based on a predetermined process. The predetermined process is, for example, when the calculation unit 23 reads out the managed individual item serial master D6 and identifies the "individual item type" ("parent" or "child") associated with the "individual item management serial" that matches the "serial of the input workpiece" based on the correspondence relationship between the "individual item management serial" and the "individual item type" in each record of the managed individual item serial master D6.

[0301] The calculation unit 23 determines, based on the process sequence master D2, whether the "ID of the started process" is the first process among multiple processes included in the overall process for manufacturing the product assigned the ID of the "production item" acquired in step S1 (step S44). If it is determined that the "ID of the started process" is not the first process (step S44; No), the calculation unit 23 refers to the process sequence master D2 and acquires the process ID of the process immediately before the process assigned the "ID of the started process" (step S45). The calculation unit 23 determines whether another record in which the same serial number as the "serial number of the input workpiece" is registered has already been registered in the individual management workpiece status table T and satisfies a predetermined condition (step S46). The predetermined condition is that the process ID acquired in step S45 (the process ID of the process immediately before the process assigned the "ID of the started process") is registered in the "process ID" field of the other record, and the "status" of the other record is "normal completion."

[0302] If it is determined that no other records that satisfy the specified conditions have been registered in the individual management work status table T (step S46; No), the calculation unit 23 treats this as a process progress abnormality being detected (step S47) and performs processing corresponding to the process progress abnormality as described above (step S48).

[0303] On the other hand, if it is determined in step S46 that another record satisfying the predetermined condition has already been registered in the individual management workpiece status table T (step S46; Yes), the calculation unit 23 deletes the other record satisfying the predetermined condition from the individual management workpiece status table T (step S49). Then, the calculation unit 23 updates the "status" field of the new record (newly registered data) generated and registered in step S43 to "incomplete" (step S50). Also, if it is determined in step S44 that this is the first process (step S44; Yes), the process proceeds to step S50. In this case, before proceeding to the processing of step S50, the new record (newly registered data) generated in step S43 may be compared with the managed individual serial master D6 to determine whether the combination of the "individual management serial" and "process ID" in the newly registered data matches the combination of the "individual management serial" and "initial input process ID" in the managed individual serial master D6, and if they match, proceed to the processing of step S50, and if they do not match, proceed to the processing of step S47.

[0304] After the process of step S50, the calculation unit 23 performs a lot part counter check process (step S51), and ends the one-cycle start check process of the process.

[0305] 55 is a flowchart showing an example of the flow of the lot part counter check process. First, the calculation unit 23 determines whether the process given the process ID registered in the record whose status was updated in step S50 is a process that uses lot parts (step S61). If it is determined that the process does not use lot parts (step S61; No), the calculation unit 23 ends the lot part counter check process.

[0306] On the other hand, if it is determined in step S61 that the process uses lot parts (step S61; Yes), the calculation unit 23 refers to the lot part counter LC and determines whether the number of outgoing lot parts used in the process is equal to the number of incoming lot parts (step S62). Here, if the number of outgoing lot parts used in the process is not equal to the number of incoming lot parts (step S62; No), that is, if there are still lot parts remaining to be used in the process, the calculation unit 23 increments (+1) the number of outgoing lot parts used in the process (step S63). The value added to the outgoing number in the processing of step S63 corresponds to the number of lot parts assembled in the process. Note that, although the example shown here illustrates a case where the number of lot parts of one type assembled in one process is one, multiple lot parts of the same type may be assembled in one process. In that case, the incremented value corresponds to the number of each lot parts assembled in one process. Information indicating the number of parts of each lot to be assembled in one process is registered, for example, in the process master D3, but is not limited to this and may also be registered in independent data linked to the process master D3 (for example, the product master D7).

[0307] After processing in step S63, the calculation unit 23 determines whether the updated number of outgoing lot parts is equal to the incoming number of parts of the lot (step S64). Here, if the number of outgoing lot parts used in the process is not equal to the incoming number of parts of the lot (step S64; No), that is, if there are still parts of the lot to be used in the process, the calculation unit 23 ends the lot part counter check process.

[0308] On the other hand, if it is determined in step S64 that the number of outgoing lot parts is equal to the number of incoming lot parts (step S64; Yes), the calculation unit 23 generates a request to read the identification tag of the lot parts, transmits it to the device 10 of the process via the communication unit 21 (step S65), and ends the lot part counter check process. The device 10 operates in response to the read request as described above. That is, if it is determined by the process of step S63 that the count has progressed to the point where the remaining lot parts used in the process have reached 0, a read request is made in preparation for the repetition of the subsequent process.

[0309] Furthermore, if it is determined in step S62 that the number of outgoing lot parts is equal to the number of incoming lot parts (step S64; Yes), the calculation unit 23 performs a device stop process for the device 10 (step S66). Specifically, the calculation unit 23 generates a command (stop command) to stop the device 10 in the process in which the lot parts are to be assembled, and transmits the command to the device 10 via the communication unit 21. That is, even though the process in which the lot parts are to be assembled is about to start, it is determined that the process cannot be started because the remaining number of parts in the lot is zero. Therefore, as described above, the calculation unit 23 does not allow the process to proceed by the operation of the device 10 until a new identification tag for the lot parts is read by the assembly lot part ID reader 34 provided in the device 10 in the process. The operation control unit 41 of the device 10 stops the operation of the drive unit 36 ​​in response to the stop command. As described above, the operation control unit 41 may cause the notification unit 37 to notify information indicating that the device 10 is stopped due to waiting for the reading of the identification tag of the lot part. A command for such notification may be included in the stop command.

[0310] After processing step S66, the calculation unit 23 checks whether the number of output lot parts to be used has been updated to the initial value (0) (step S67), and waits until it is updated to the initial value (0) (step S67; No). Thereafter, when the number of output lot parts counter LC is updated to the initial value (0) by receiving lot identification slip data from the device 10 stopped in step S66 (step S67; Yes), the calculation unit 23 proceeds to processing step S63.

[0311] Fig. 56 is a flowchart showing an example of the flow of a process for checking the completion of one cycle of a process. First, the calculation unit 23 checks whether "information indicating the completion of the process" has been input from the device 10 (step S71). "Information indicating the completion of the process" refers to information contained in data transmitted from the device 10 to the control device 20, triggered by the completion of the process in the device 10 of the process that was started through the processing described with reference to Figs. 54 and 55. Unless an error occurs, the data contains a process ID indicating the process, the serial number of the workpiece manufactured in the process, and information indicating whether the process was "normally completed" or "abnormally completed," as described with reference to Fig. 20.

[0312] The process ID included in the "information indicating the completion of the process" is treated as the "ID of the completed process" in the subsequent steps. Also, the serial number included in the "information indicating the completion of the process" is treated as the "serial number of the manufactured work" in the subsequent steps. The calculation unit 23 waits until the "information indicating the completion of the process" is input from the device 10 (step S71; No).

[0313] When "information indicating the completion of the process" is input from the device 10 (step S71; Yes), the calculation unit 23 acquires the "ID of the completed process" and the "serial number of the manufactured work" from the "information indicating the completion of the process" input in step S61 (step S72). The calculation unit 23 generates a new record (newly registered data) in the individual management work status table T (step S73). Specifically, the calculation unit 23 registers the "serial number of the manufactured work" acquired in step S72 in the "individual management serial number" field of the generated new record. The calculation unit 23 also registers the "ID of the completed process" acquired in step S72 in the "process ID" field of the generated new record. The calculation unit 23 also registers "normal completion" or "abnormal completion" in the "status" field of the generated new record according to the "information indicating the completion of the process." The calculation unit 23 also registers the initial value (0) as the value of the retention counter of the generated new record. The calculation unit 23 also registers "parent" in the "individual type" field of the newly created record.

[0314] The calculation unit 23 determines whether another record in which the same serial number as the "serial number of the manufactured workpiece" acquired in step S72 is registered in the individual management workpiece status table T and satisfies a second predetermined condition (step S74). The second predetermined condition is that the process ID ("ID of the completed process") acquired in step S52 is registered in the "process ID" field of the other record and the "status" of the other record is "incomplete."

[0315] If it is determined that no other records that satisfy the second predetermined condition have already been registered in the individual management work status table T (step S74; No), the calculation unit 23 treats this as having detected an abnormality in the registered data (step S75) and performs processing corresponding to the abnormality in the registered data as described above (step S76).

[0316] On the other hand, if it is determined in step S74 that another record satisfying the second predetermined condition has already been registered in the individual management workpiece status table T (step S74; Yes), the calculation unit 23 deletes from the individual management workpiece status table T the record in which the process ID acquired in step S71 ("ID of the completed process") is registered in the "process ID" field and the "status" is "uncompleted" (step S77). Then, the calculation unit 23 updates the achievement registration data M according to the "information indicating the completion of the process" as described with reference to Figures 23 to 26 (step S78).

[0317] In this embodiment, after the process of step S78, the calculation unit 23 performs a retention counter check process (step S79), and ends the one-cycle start-up check process of the process.

[0318] 57 is a flowchart showing an example of the flow of the retention counter check process. The calculation unit 23 refers to the individual management workpiece status table T, and identifies a record (registered data) other than the newly registered data in which the same process ID as the newly registered data (record) registered in the individual management workpiece status table T in the process of step S73 is registered and in which "normal completion" or "abnormal completion" is registered in the "status" field, and increments (+1) the value of the "retention counter" of the identified record (step S81).

[0319] The calculation unit 23 determines whether or not registered data in which the value of the retention counter is equal to the stop threshold has been generated by the processing of step S81 (step S82). Here, if it is determined that registered data in which the value of the retention counter is equal to the stop threshold has been generated (step S82; Yes), the calculation unit 23 regards this as having detected a work retention abnormality (step S83), and performs processing corresponding to the work retention abnormality as described above (step S84).

[0320] If it is determined in step S82 that no registered data has been generated in which the value of the retention counter is equal to the stop threshold (step S82; No), the calculation unit 23 determines whether or not registered data has been generated in which the value of the retention counter is equal to the warning threshold by the processing of step S81 (step S85).Here, if it is determined that registered data has been generated in which the value of the retention counter is equal to the warning threshold (step S85; Yes), the calculation unit 23 treats this as having detected a work retention symptom (step S86) and performs processing corresponding to the work retention symptom as described above (step S87).

[0321] If it is determined in step S85 that no registered data has been generated whose value of the retention counter is equal to the warning threshold (step S85; No), after processing step S84 or step S87, the calculation unit 23 terminates the retention counter check process.

[0322] Here, when the process is performed as shown in the flowchart of FIG. 56, the value of the retention counter is It is a "number indicating the number of times that after an intermediate product (work) is manufactured, other intermediate products that are manufactured in the same process as the last process that has been carried out in the manufacture of the work have completed their manufacture."

[0323] The retention counter check process may be performed after the process of step S51. In that case, in the process of step S81, "(the record of) newly registered data registered in the individual management work status table T in the process of step S73" is read as "(the record of) newly registered data whose status has been updated in the process of step S50." In this case, the retention counter value becomes "a numerical value indicating the number of times that, after an intermediate product (work) is manufactured, another intermediate product that is manufactured in the same process as the last process that has been performed in the manufacture of the work has started to be manufactured."

[0324] The stagnant counter check process may also be performed when the next process of a certain process is started (for example, after the process of step S51) or completed (for example, after the process of step S78). In this case, the record for which the stagnant counter value is incremented (+1) in the process of step S81 is data (other records) other than the newly registered data (records) in the individual management work status table T in which the immediately preceding process ID is registered, based on the process ID included in the newly registered data (records).

[0325] In addition, when the stagnation counter check process is performed at the timing when the next process after a certain process starts, the value of the stagnation counter becomes "a number indicating the number of times that other intermediate products manufactured in the same process as the last process that has been performed in the production of a certain intermediate product (work) have already started the next process."

[0326] In addition, when the stagnation counter check process is performed at the timing when the process following a certain process is completed, the value of the stagnation counter becomes "a number indicating the number of times that other intermediate products manufactured in the same process as the last process that has been performed in the manufacture of a certain intermediate product (work) have completed the next process before."

[0327] As described above, the embodiment is a management system in which a plurality of pieces of equipment (e.g., equipment 10 such as first equipment 11, second equipment 12, third equipment 13, fourth equipment 14, etc.) that are used sequentially in accordance with the order of a plurality of processes included in the overall process of manufacturing a product, an isolation facility (e.g., dismantling equipment 15) for isolating an abnormal product that is an incomplete product and has developed an abnormality in any of the processes, and a control device (e.g., control device 20) are communicatively connected, and the control device manages the operation of the plurality of pieces of equipment and products manufactured using the plurality of pieces of equipment. Here, an abnormal product is, for example, a workpiece whose parent part is a serialized configuration registered in the "individual management serial" field of a record for which "abnormal completion" is registered in the "status" field of the performance registration data M. The equipment of the embodiment includes an abnormality information generation unit (e.g., operation control unit 41) that generates management data including at least identification information of the abnormal product when an abnormality occurs in a process using the equipment (e.g., information transmitted from the equipment 10 so that the calculation unit 23 generates records in the individual management work status table T, performance registration data M, and defective product management table U), and a communication unit (e.g., communication unit 31) that can transmit the management data generated by the abnormality information generation unit to a control device. The isolation facility of the embodiment includes a reading unit (e.g., individual management serial reading unit 33 provided in the dismantling equipment 15) that reads the identification information of the abnormal product, and a communication unit (e.g., communication unit 31 provided in the dismantling equipment 15) that can transmit the read information read by the reading unit to a control device. The control device of the embodiment includes a communication unit (e.g., communication unit 21) capable of receiving management data transmitted from the device and read information transmitted from the isolation facility, a memory unit (e.g., memory unit 22) that stores the management data transmitted from the device, and a determination unit (e.g., calculation unit 23) that performs processing based on the management data and the information transmitted from the isolation facility. If read information is not transmitted from the isolation facility even when a predetermined condition is satisfied, the determination unit determines that an abnormality has occurred in the handling of the abnormal product. This makes it possible to determine whether an abnormality has occurred in the handling of the abnormal product based on whether read information has been transmitted from the isolation facility. In other words, it is possible to determine whether an abnormal product that should have been moved to an isolation facility has been moved to the isolation facility. Therefore, it is possible to detect an abnormality that has occurred in a product manufacturing process that includes multiple steps.It is also possible to detect whether appropriate measures (for example, moving to an isolation facility) are being taken against defective items (products, workpieces, parts, etc.) that have arisen due to an abnormality in the manufacturing process of a product that includes multiple processes.

[0328] The anomaly information generating unit also includes a generating unit (e.g., one or more of an individual management serial reader 33, an assembly lot part ID reader 34, a worker ID reader 35, and a program selector 38) that generates data indicating identification information corresponding to the operation of the equipment as management data. The memory unit stores data indicating pre-registered identification information. It includes a first reader (e.g., individual management serial reader 33) that reads first identification information (serial) assigned to each part used in manufacturing, and includes the first identification information read by the first reader and second identification information (e.g., a process ID) assigned in advance to the process in information indicating at least one of the start and completion of a process using the equipment. The memory unit stores temporary data (e.g., an individual management work status table T) that can individually identify intermediate products that have completed some of the multiple processes. The temporary data includes, for each intermediate product, first identification information (e.g., the serial number of the parent part) assigned to a part used in the production of the intermediate product (e.g., a "workpiece" in the embodiment), second identification information (e.g., a process ID) indicating the last process involved in the production of the intermediate product, and a retention count value. The first identification information functions as identification information for the abnormal product. The determination unit determines whether a predetermined condition is met based on the identification information included in the data transmitted from the device, the identification information stored in the storage unit, the retention count value, and a predetermined threshold. This makes it possible to determine whether an abnormality has occurred in one of multiple processes based on the retention count value. This makes it possible to detect an abnormality occurring in a product production process that includes multiple processes. It also makes it possible to detect when appropriate measures have not been taken for an abnormal item (product, workpiece, component, etc.). Retention time may be monitored instead of retention count, or both may be monitored. For example, when the production volume is extremely low, the retention count is unlikely to increment, making it difficult to detect retention of workpieces. In such cases, monitoring based on retention time is effective. In that case, a column containing passage time information is added to FIG.

[0329] The predetermined threshold value includes a first threshold value (stop threshold value) for stopping at least one of the plurality of devices used in the final process. The determination unit determines whether an abnormality has occurred in the handling of the abnormal product based on the value of the retention count and the first threshold value, and if it is determined that an abnormality has occurred in the handling of the abnormal product, stops at least one of the plurality of devices used in the final process. Therefore, when an abnormality has occurred in any of the plurality of processes based on the value of the retention count, the device can be stopped. As will be described later, retention detection may also use the time that has passed without action (the passage of a predetermined time) in addition to the counter.

[0330] Furthermore, at least one of the plurality of devices and the control device includes an alarm unit (e.g., alarm unit 37, alarm unit 24) that issues an alarm to the device operator. The predetermined threshold value includes a second threshold value (warning threshold value) for determining whether or not the alarm unit should operate. The determination unit determines whether an abnormality has occurred in the handling of the abnormal product based on the retention count value and the second threshold value, and activates the alarm unit if it is determined that an abnormality has occurred in the handling of the abnormal product. Therefore, if an abnormality is detected in any of the plurality of processes based on the retention count value, an alarm to that effect can be issued.

[0331] Furthermore, the determination unit activates the notification unit when a predetermined time has elapsed or a predetermined time has arrived after storing temporary data including the first identification information that functions as identification information for the abnormal product in the storage unit, so that when an abnormality is detected in any of the multiple processes, a notification to that effect can be issued.

[0332] The device also includes an addition unit (e.g., sensing unit 39, input unit 42) that adds additional information about the abnormality that occurred in the abnormal product (e.g., the process ID of the NG-occurring process and NG code) to the management data. Therefore, information about the abnormality that occurred in the abnormal product can be managed. Note that the addition unit may be integrated with the above-mentioned generation unit (e.g., one or more of the individual management serial reader 33, assembly lot part ID reader 34, worker ID reader 35, and program selector 38).

[0333] The isolation facility also includes work equipment (e.g., each component of the dismantling equipment 15) that performs work to reintroduce the abnormal product into one of the multiple processes. The memory unit stores display data for displaying and outputting work content according to the additional information. The communication unit of the control device transmits the display data to the work equipment. The communication unit of the isolation facility receives the display data. The work equipment includes a display unit (e.g., touch panel 152) that can display the display data. Therefore, work can be performed to reintroduce the abnormal product into one of the multiple processes. The content of the work can also be guided by the display. Furthermore, in the embodiment, the content of the work can be recorded (such as what was discarded).

[0334] The storage unit also stores correspondence data (for example, one or more records included in the BOM master D13) that indicates the correspondence between parts that can be re-entered due to work content corresponding to the additional information and the processes to which those parts are to be re-entered. The communication unit of the control device transmits the correspondence data to the work equipment. The communication unit of the isolation facility receives the correspondence data. The display unit further performs a display based on the correspondence data (for example, display of the re-entry instruction display screen 152k). This makes it possible to guide the user to the re-entry destination of parts that arise after work. It also makes it possible to prevent the release of defective products due to processing errors. Furthermore, in the embodiment, the re-entry history can be managed at the same time.

[0335] Furthermore, if a reusable part is a part for which identification information cannot be individually assigned, an output unit (for example, the above-mentioned reusable ID tag issuing unit 156) is provided that generates and outputs dedicated identification information. The storage unit stores the dedicated identification information. Therefore, identification information can be assigned to the part to be reusable. The reusable ID tag may include information indicating the number of times the part has been reused.

[0336] Furthermore, the embodiment is a management system in which a plurality of devices (e.g., devices 10 such as a first device 11, a second device 12, a third device 13, and a fourth device 14) that are used sequentially according to the order of a plurality of processes included in an overall process for manufacturing a product are communicably connected to a control device (e.g., control device 20), and the control device manages the operations of the plurality of devices and the products manufactured using the plurality of devices. The devices of the embodiment include a generation unit (e.g., one or more of an individual management serial reader 33, an assembly lot part ID reader 34, a worker ID reader 35, and a program selection unit 38) that generates data indicating identification information (e.g., a serial number, an assembly lot part ID, and a worker ID) according to the operation of the devices, and a communication unit (e.g., communication unit 31) that can transmit the data generated by the generation unit to the control device. The control device includes a communication unit (e.g., communication unit 21) capable of receiving data transmitted from the equipment, a memory unit (e.g., memory unit 22) that stores data indicating pre-registered identification information (e.g., process list D1, process sequence master D2, process master D3, input quantity master D4, certified worker list D5, managed individual serial master D6, product master D7, individual managed work status table T, performance registration data M, lot part counter LC, etc.), and a determination unit (e.g., calculation unit 23) that determines whether an abnormality has occurred in any of the multiple processes based on the identification information included in the data transmitted from the equipment and the identification information stored in the memory unit. This makes it possible to determine whether an abnormality has occurred in any of the multiple processes based on the movement of the identification information transmitted from the equipment and the identification information previously stored in the memory unit of the control device. Therefore, it becomes possible to detect abnormalities that have occurred in a product manufacturing process that includes multiple processes.

[0337] The generating unit further includes a first reading unit (e.g., an individual management serial reading unit 33) that reads first identification information (serial number) assigned to each component used in the manufacturing process, and includes the first identification information read by the first reading unit and second identification information (e.g., a process ID) previously assigned to the component in information indicating at least one of the start and completion of a process using the equipment. The storage unit stores temporary data (e.g., an individual management workpiece status table T) that can individually identify intermediate products that have completed some of the multiple processes. The temporary data associates, for each intermediate product, first identification information (e.g., the serial number of the parent component) assigned to the component used in the manufacturing of the intermediate product (e.g., a "workpiece" in the embodiment), second identification information (e.g., a process ID) indicating the last process involved in the manufacturing of the intermediate product, and a retention count value. The determining unit determines whether an abnormality has occurred in any of the multiple processes based on the retention count value and a predetermined threshold. An increase in the retention count suggests that a certain intermediate product is in a state where the next process cannot be started for some reason. This makes it possible to determine whether an abnormality has occurred in any of the multiple processes based on the value of the retention count, thereby making it possible to detect an abnormality that has occurred in a manufacturing process for a product that includes multiple processes.

[0338] Furthermore, according to the embodiment, it is possible to further detect an abnormality in which an "abnormally completed" workpiece is left unattended without being moved to the dismantling equipment 15. This makes it possible to prevent problems (for example, confusion with "normally completed" workpieces) from occurring due to the "abnormally completed" workpieces being left unattended.

[0339] Furthermore, the predetermined threshold value includes a first threshold value (stop threshold value) for stopping at least one of the plurality of devices used in the last process, and the determination unit determines whether to stop at least one of the plurality of devices used in the last process based on the value of the stay count and the first threshold value. Therefore, the device can be stopped when an abnormality is detected in any of the plurality of processes based on the value of the stay count.

[0340] Furthermore, at least one of the plurality of devices and the control device includes a notification unit (e.g., notification unit 37, notification unit 24) that notifies the device operator, and the predetermined threshold value includes a second threshold value (warning threshold value) for determining whether or not to operate the notification unit, and the determination unit determines whether to operate the notification unit based on the value of the stagnation count and the second threshold value. Therefore, when an abnormality is detected in any of the plurality of processes based on the value of the stagnation count, a notification to that effect can be issued.

[0341] Furthermore, the generation unit includes a second reading unit (e.g., assembly lot part ID reading unit 34) that reads second identification information (e.g., an identification tag with an assembly lot part ID such as LPART001) that is assigned to lot-managed parts (e.g., lot parts) that include multiple identical parts on a lot-by-lot basis. The data indicating the identification information includes information (e.g., process master D3) that can identify a process in which multiple identical parts assigned the second identification information are used. When the determination unit receives data including the second identification information from one device, it determines whether the device is an device in a process in which multiple identical parts are used with the second identification information. Therefore, for parts that are difficult to assign individual identification information to, such as lot-managed parts, it is possible to determine whether the process in which the part is used is appropriate, i.e., whether there is an abnormality.

[0342] Furthermore, the generation unit generates process information indicating the progress of the process. The process information is generated in response to the start or completion of a process using the device. In terms of the correspondence with the flowcharts shown in FIGS. 56 and 57, the process information generated in response to the start of the process is, for example, the "information indicating the start of the process" mentioned in the process of step S41, which leads to the process of step S51. Furthermore, the process information generated in response to the completion of the process is, for example, the "information indicating the completion of the process" mentioned in the process of step S71, which leads to the process of step S78. When the determination unit receives data including second identification information from one device, it sets a counter (e.g., a lot component counter LC) that counts the number of used lot management components given the second identification information, counts the number of used lot management components used by the device in units of the second identification information in response to the reception of data including process information from the device, and, when the number of used lot management components (output number) becomes equal to the predetermined number of components in the lot (input number), it performs processing to request the second reading unit to read new second identification information. Therefore, it is possible to determine whether the number of lot management parts used is appropriate, that is, whether there is an abnormality.

[0343] Furthermore, the generation unit includes a third reading unit (e.g., worker ID reading unit 35) that reads third identification information (e.g., certified worker ID) given to a worker. The data indicating the identification information includes information (e.g., certified worker list D5) that can individually identify the third identification information given to a certified worker who is permitted to use a device for each of a plurality of processes. When the determination unit receives data including the third identification information from one device, it determines whether the third identification information corresponds to a certified worker for the process using that device. Therefore, it can determine whether the worker in charge of the process is a proper certified worker, i.e., whether there is an abnormality in which a worker who is not a certified worker is in charge of the process.

[0344] Furthermore, the generation unit includes a selection unit (e.g., program selection unit 38) that generates fourth identification information (e.g., "selection operation Prg. information" mentioned in the process of step S21 in the flowchart of FIG. 52) indicating a program selected by an operator from among multiple programs selectable by each device. Data indicating the identification information includes data indicating a program suitable for product manufacturing (e.g., process master D3). When the determination unit receives data including the fourth identification information from one device, it determines whether the program corresponds to a program suitable for product manufacturing. Therefore, it can determine whether the program selected in the process is appropriate, that is, whether there is an abnormality in which an inappropriate program is selected. Note that, upon acquisition of the "production part number" ID in the process of step S1, the control device 20 may transmit information indicating a program suitable for product manufacturing to the device 10, and the program applied to the device 10 may be automatically switched.

[0345] The method of assigning a serial number to each part is arbitrary. For example, a circuit may be provided to generate a serial number and assign it to each part, and the circuit may sequentially or randomly generate a character string that functions as a serial number and assign it to each part, and then record the assigned number in various data such as the managed individual serial master D6. Such serial numbers are generated within a range that complies with predetermined rules so that each part can be identified by country, facility (factory, etc.), and line, and there is no duplication.

[0346] Furthermore, the number of parts in a lot does not have to be fixed (unchangeable). If it is assumed that the number of parts varies, the information that can be acquired by reading the identification tag includes information indicating the number of parts in the lot that will be introduced in response to the reading of the identification tag. The calculation unit 23 sets and manages the number of parts in accordance with this information. [Explanation of symbols]

[0347] 10 equipment 15 Demolition equipment 20 Control device 21 Communications Department 22,32 Storage part 23 Arithmetic section 24,37 Information Department 25 Input section 31 Communications Department 33 Individual control serial reading unit 41 Motion control section 152 Touch Panel

Claims

1. A management system in which a plurality of devices that are used in sequence according to the order of a plurality of processes included in an overall process for manufacturing a product, an isolation facility for isolating an unfinished product that has developed an abnormality in any of the plurality of processes, and a control device are communicatively connected, and the control device manages the operation of the plurality of devices and products manufactured using the plurality of devices, The device comprises: an abnormality information generating unit that generates management data when an abnormality occurs in a process using the device; a communication unit capable of transmitting the management data generated by the abnormality information generation unit to the control device, The isolation facility comprises: a reading unit that reads the identification information of the defective product; a communication unit capable of transmitting the read information read by the reading unit to the control device, The control device a communication unit capable of receiving the management data transmitted from the device and the read information transmitted from the isolation facility; a storage unit that stores the management data transmitted from the device; a determination unit that performs processing based on the management data and information transmitted from the isolation facility, The anomaly information generation unit a first reading unit that reads first identification information given to each of the parts used in the manufacturing; information indicating at least one of the start and completion of the process in which the abnormality occurred, the first identification information, and second identification information previously assigned to the process, are included in the management data; the storage unit stores temporary data that can individually identify intermediate products that have completed some of the plurality of processes; the temporary data includes a record in which the first identification information given to a part used in the production of the intermediate product, the second identification information indicating the last process involved in the production of the intermediate product, and a retention count value are associated with each of the intermediate products; The value of the retention count is a numerical value indicating a predetermined number of times, The predetermined number of times is a numerical value indicating the number of times that another intermediate product manufactured in the same process as the last process has started or completed the next process before the last process, or the number of times that another intermediate product manufactured in the same process as the last process has started or completed production after the intermediate product in question has been manufactured, the first identification information functions as identification information for the defective product, a threshold value for stopping at least one device among the plurality of devices used in the last process is set as a first threshold value; The determination unit, when the management data is transmitted from the device, sets the retention count of the record associated with the first identification information included in the management data to 0, and when the predetermined number of times increases thereafter, updates the retention count of the record in accordance with the increase, and when the value of the retention count is equal to the first threshold value, determines that a predetermined condition has been satisfied, and when the read information is not transmitted from the isolation facility even when the predetermined condition is satisfied, determines that an abnormality has occurred in the handling of the abnormal product. Management system.

2. When it is determined that an abnormality has occurred in the handling of the abnormal product, at least one of the plurality of devices used in the final process is stopped. The management system according to claim 1 .

3. At least one of the plurality of devices and the control device includes a notification unit that notifies an operator of the device, The determination unit operates the notification unit when the value of the stay count is equal to a second threshold value; the second threshold is a threshold for determining whether or not the notification unit should operate, and is a threshold smaller than the first threshold; The management system according to claim 1 or 2.

4. The determination unit operates the notification unit when a predetermined time has elapsed or a predetermined time has come after the temporary data including the first identification information that functions as identification information for the defective product has been stored in the storage unit. The management system according to claim 3 .

5. The device includes an adding unit that adds additional information about the abnormality that occurred in the abnormal product to the management data. The management system according to any one of claims 1 to 4.

6. the isolation facility is equipped with work equipment for performing work to reintroduce the abnormal product into any one of the plurality of processes, the storage unit stores display data for displaying and outputting work content corresponding to the additional information; the communication unit of the control device transmits the display data to the work equipment; a communication unit of the isolation facility receiving the display data; The work equipment includes a display unit capable of displaying the display data. The management system according to claim 5 .

7. the storage unit stores correspondence data indicating a correspondence between parts that can be re-entered due to work content corresponding to the additional information and processes to which the parts are to be re-entered; the communication unit of the control device transmits the correspondence data to the work equipment; a communication unit of the isolation facility receiving the correspondence data; The display unit further performs a display based on the correspondence data. The management system according to claim 6.

8. an output unit that generates and outputs the dedicated identification information when the re-insertable part is a part to which the identification information cannot be individually assigned; The storage unit stores the dedicated identification information. The management system according to claim 7.

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