Work process management device, work process management system, work process management method, and work process management program

Abstract

The work process management device (1A) includes a performance data reading unit (13) that attempts to read performance data for the current process, which is the process to be started for the work (W), and performance data for the previous process, which is the process preceding the current process for the work (W), from a database (16) that stores performance data for each process, which includes performance information showing the process performance of work (W) whose processes have been completed in the production line; and a performance determination unit (14) that diagnoses the process performance for the work (W) and determines whether or not there is an abnormality in the process performance, based on whether or not there is work performance information for the current process and whether or not there is work performance information for the previous process.

Description

Technical Field

[0001] The present disclosure relates to a work process management device, a work process management system, a work process management method, and a work process management program for managing work processes.

Background Art

[0002] In a production line where various operations are performed in a plurality of processes, preventing process skipping where the previous process is skipped in a series of multiple processes and preventing double processing where the same process is repeated are important management items for managing manufacturing quality. Conventionally, the management of work processes such as preventing process skipping or double processing has been managed by the operation of workers rather than by mechanical stops. For example, when a worker inputs a work piece into each process, the worker refers to a check sheet indicating the progress of the process to prevent process skipping, double processing, etc.

[0003] In the network system described in Patent Document 1, when a worker confirms that there is no process skipping and the product is a good product and inputs an OK signal, the assembly of the wire harness is advanced to the next process, thereby performing quality control between a plurality of work processes.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] However, in the technology of Patent Document 1 described above, there is a problem that human error may occur due to quality control by workers, and the accuracy of process management cannot be improved.

[0006] This disclosure has been made in view of the above, and aims to provide a work process control device that can improve the accuracy of process control. [Means for solving the problem]

[0007] To solve the aforementioned problems and achieve the objectives, the work process management device of this disclosure includes a performance data reading unit that attempts to read performance data for the current process, which is the process to be started for a workpiece, and performance data for the previous process, which is the process preceding the current process, from a database that stores performance data for each process, which includes workpiece performance information showing the process performance of workpieces whose processes have been completed in the production line. Furthermore, the work process management device of this disclosure includes a performance determination unit that diagnoses the process performance for a workpiece and determines whether or not there is an abnormality in the process performance, based on at least one of the presence or absence of workpiece performance information for the current process and the presence or absence of workpiece performance information for the previous process. At least one of the workpiece performance information for the current process and the workpiece performance information for the previous process includes at least one of the information obtained by measuring the workpiece and the information regarding the processing details of the workpiece. [Effects of the Invention]

[0008] The work process control device described herein has the effect of improving the accuracy of process control. [Brief explanation of the drawing]

[0009] [Figure 1] This figure shows the configuration of a work process management system equipped with a work process management device according to Embodiment 1. [Figure 2] This figure shows a first example of the data set of actual data stored in the database of the work process management device according to Embodiment 1. [Figure 3] This figure shows a second example of the data set of actual data stored in the database of the work process management device according to Embodiment 1. [Figure 4] This figure shows a third example of the data set of actual data stored in the database of the work process management device according to Embodiment 1. [Figure 5] A flowchart showing the processing procedure for the process performance determination process executed by the work process management device according to Embodiment 1. [Figure 6] FIG. for explaining first determination condition information used when the work process management device according to Embodiment 1 determines process results [Figure 7] FIG. for explaining the process executed by the work process management device according to Embodiment 1 when the status information is qualified [Figure 8] FIG. for explaining the process executed by the work process management device according to Embodiment 1 when the status information is unqualified [Figure 9] FIG. showing a configuration example of a database of the work process management device according to Embodiment 2 [Figure 10] FIG. for explaining second determination condition information used when the work process management device according to Embodiment 2 determines process results [Figure 11] FIG. showing a configuration example of a database of the work process management device according to Embodiment 3 [Figure 12] FIG. showing a configuration example of a database of the work process management device according to Embodiment 4 [Figure 13] FIG. showing performance data stored in the primary storage unit included in the work process management device according to Embodiment 4 [Figure 14] FIG. showing the configuration of a work process management system including the work process management device according to Embodiment 5 [Figure 15] FIG. showing a configuration example of a processing circuit when the processing circuit included in the work process management device according to Embodiments 1 to 5 is realized by a processor and a memory [Figure 16] FIG. showing a configuration example of a processing circuit when the processing circuit included in the work process management device according to Embodiments 1 to 5 is realized by dedicated hardware

Embodiments for Carrying Out the Invention

[0010] Hereinafter, a work process management device, a work process management system, a work process management method, and a work process management program according to embodiments of the present disclosure will be described in detail based on the drawings

[0011] Embodiment 1 FIG. 1 is a diagram showing the configuration of a work process management system including a work process management device according to Embodiment 1. The work process management system 100A of Embodiment 1 includes a work process management device 1A and data collection devices d1 to d6. The data collection devices d1 to d5 are respectively arranged in the manufacturing devices M1 to M5, and the data collection device d6 is arranged in the quality inspection device T6.

[0012] The work process management device 1A is a device that diagnoses the process results of the workpiece W for a production line that performs various operations on the workpiece W, which is a workpiece, in a plurality of processes, and determines whether there is an abnormality in the process results. The work process management device 1A determines the past process results of the executed processes on the workpiece W. That is, the work process management device 1A determines the past process results for the workpiece W for which the process is scheduled to start from now on. The work process management device 1A determines, for example, whether there is an abnormality in the processing order of the processes when the process scheduled to start from now on is executed.

[0013] A plurality of manufacturing devices and one or more quality inspection devices are arranged on the production line. FIG. 1 shows a case where the manufacturing devices M1 to M5 and the quality inspection device T6 are arranged on the production line. Note that the number of manufacturing devices arranged on the production line may be two to four, or six or more. Further, the devices arranged on the production line may be manufacturing devices and devices other than manufacturing devices. Hereinafter, the devices arranged on the production line such as the manufacturing devices M1 to M5 and the quality inspection device T6 may be referred to as production processing devices.

[0014] The manufacturing device M1 is a device that executes processing on the workpiece W in the first process. Similarly, the manufacturing devices M2 to M5 are devices that execute processing on the workpiece W in the second to fifth processes, respectively. The quality inspection device T6 is a device that executes quality inspection processing on the workpiece W in the sixth process. Note that a quality inspection device that executes quality inspection processing on the workpiece W for which the first to fourth processes have been executed may be arranged on the production line.

[0015] Manufacturing equipment M1 to M5 and quality inspection equipment T6 are arranged, for example, along a belt conveyor, and perform processing, quality inspection, etc., on workpieces W that are transported by the belt conveyor.

[0016] In the production line, each process is executed in the order of process 1, process 2, ..., process 6. That is, in the production line, processing of the workpiece W is performed in the order of manufacturing equipment M1, manufacturing equipment M2, ..., manufacturing equipment M5, and then quality inspection of the workpiece W is performed by quality inspection equipment T6. The workpiece W may be transported between each process by a belt conveyor or by an operator. Processes 1 through 6 may each include multiple sub-processes (small processes).

[0017] One process in a production line is the period from when a single production processing device starts processing until it finishes processing. For example, the first process is the period from when manufacturing device M1 starts processing until it finishes processing.

[0018] Each of the manufacturing devices M1 to M5 has a data acquisition device d1 to d5. The quality inspection device T6 also has a data acquisition device d6. Note that the data acquisition devices d1 to d5 may be located outside of the manufacturing devices M1 to M5. Furthermore, the data acquisition device d6 may be located outside of the quality inspection device T6.

[0019] Data acquisition devices d1 to d5 may be implemented by edge devices located in manufacturing devices M1 to M5, respectively. Furthermore, data acquisition device d6 may be implemented by an edge device located in quality inspection device T6.

[0020] Data acquisition devices d1 to d6 are devices that collect process performance data (hereinafter referred to as performance data) for workpiece W from manufacturing devices M1 to M5 or quality inspection device T6, respectively. The performance data collected by data acquisition devices d1 to d5 corresponds to the processing results of the machining process, and the performance data collected by data acquisition device d6 corresponds to the processing results of the quality inspection process.

[0021] Each performance data point corresponds to the processing result of a single process. The performance data collected by data collection devices d1 to d6 includes the process name, work identification information (which identifies workpiece W), and information indicating the performance of workpiece W. Hereinafter, the information indicating the performance of workpiece W may be referred to as work performance information. Work performance information may include multiple types of data items.

[0022] The work performance information for processes 1 through 5 is information about the workpiece W after processing, and the work performance information for process 6 is information about the quality inspection results of workpiece W. Below, we will explain the case in which the work process control device 1A mainly manages processes 1 through 5, but the work process control device 1A may also manage process 6.

[0023] The workpiece performance information for steps 1 through 5 may be information obtained by measuring or inspecting the condition of workpiece W, or it may be information regarding the processing details of workpiece W. The information obtained by measuring workpiece W is the measured value, which will be described later, and the information obtained by inspecting the condition of workpiece W is the condition information, which will be described later. In addition, the information regarding the processing details of workpiece W is the workpiece model name, which will be described later.

[0024] The measurement and condition inspection of the workpiece W may not only be performed by the production processing equipment, but may also be performed by an operator or by an external device other than the production processing equipment. The following describes the case in which both the measurement and condition inspection of the workpiece W are performed for each process executed by the manufacturing equipment M1 to M5.

[0025] One example of work identification information is the serial number, which is set when workpiece W is introduced into the production line. The serial number is the manufacturing serial number. Data acquisition devices d1 to d6 input the process name and serial number into the performance data when a process is executed for workpiece W. In addition, data acquisition devices d1 to d6 input workpiece performance information into the performance data after the process for workpiece W is completed.

[0026] The performance data collected by data acquisition devices d1 to d5 includes, for example, data on processing results, while the performance data collected by data acquisition device d6 includes, for example, data on inspection results.

[0027] The performance data collected by data acquisition devices d1 to d5 includes information obtained from the workpiece W, such as measured values ​​of the workpiece W and condition inspection results, which are the results of condition inspections of the workpiece W. Examples of measured values ​​include length, weight, appearance, load, area, temperature, current value, torque, resistance value, and the thickness of the workpiece W after processing.

[0028] Once the processes performed by manufacturing equipment M1 to M5 are complete, the workpiece W is measured and its condition is inspected. When the processes performed by manufacturing equipment M1 to M5 are complete, data acquisition devices d1 to d5 collect the measured values ​​of the workpiece W and the condition information of the workpiece W after its condition has been inspected. When the processes performed by quality inspection device T6 are complete, data acquisition device d6 collects the quality inspection results of the workpiece W.

[0029] The completion of a process is defined as a state in which a measurement value can be obtained by measuring the workpiece W, or a state information can be obtained by inspecting the workpiece W. The state information of the workpiece W is information about the state of the workpiece W. The state information of the workpiece W indicates whether the state of the workpiece W after the completion of each process is in an acceptable or unacceptable state. The state information may be the result of the state inspection of the workpiece W after the completion of the process, or it may be the result of the measurement value judgment. If there are no problems with the measurement value judgment or the state inspection result, the state information indicating acceptance is included in the performance data. If there are problems with the measurement value judgment or the state inspection result, the state information indicating rejection is included in the performance data.

[0030] When data acquisition devices d1 to d5 collect condition information, manufacturing devices M1 to M5 perform a condition inspection on the workpiece W after processing is complete. Data acquisition devices d1 to d5 include the condition information corresponding to the condition inspection results from manufacturing devices M1 to M5 in the actual data.

[0031] The status information collected by data acquisition device d6 corresponds to the inspection results of the quality inspection process performed by quality inspection device T6. Data acquisition device d6 includes the status information corresponding to the inspection results of the quality inspection process performed by quality inspection device T6 in the actual data. Data acquisition devices d1 to d6 transmit the actual data to the work process management device 1A.

[0032] In the following explanation, if it is not necessary to distinguish between manufacturing equipment M1 to M5, any one of them may be referred to as manufacturing equipment Mx. Also, if it is not necessary to distinguish between data acquisition devices d1 to d5, the data acquisition device attached to manufacturing equipment Mx may be referred to as data acquisition device dx.

[0033] The work process management device 1A is, for example, a cloud computer. The work process management device 1A acquires actual data from the data acquisition device dx after the processing of the workpiece W by the manufacturing device Mx is completed.

[0034] The work process management device 1A acquires actual data from the data acquisition device dn after the processing of the workpiece W by the manufacturing device Mn (where n is one of 1 to 4) is completed. Then, when the manufacturing device M(n+1) starts processing the workpiece W, the work process management device 1A determines whether the processing of the workpiece W by the manufacturing devices Mn and M(n+1) is appropriate, based on the actual data from the manufacturing devices Mn and M(n+1) on the workpiece W.

[0035] The processing of workpiece W by manufacturing device Mn is the processing of the nth process, and the processing of workpiece W by manufacturing device M(n+1) is the processing of the (n+1)th process. For example, if there is no actual data for the nth process when starting the (n+1)th process, the work process management device 1A determines that the nth process has not been executed and is therefore inappropriate. Also, for example, if there is already actual data for the (n+1)th process when starting the (n+1)th process, the work process management device 1A determines that the (n+1)th process has already been executed and that executing the subsequent (n+1)th process is inappropriate.

[0036] Furthermore, the work process management device 1A acquires actual data from the data acquisition device d5 after the processing of the workpiece W by the manufacturing device M5 is completed. Then, when the quality inspection device T6 starts the quality inspection process on the workpiece W, the work process management device 1A determines whether the processing of the workpiece W by the manufacturing device M5 and the quality inspection process on the workpiece W by the quality inspection device T6 are appropriate, based on the actual data from the manufacturing device M5.

[0037] In this way, when a new process (hereinafter sometimes referred to as the current process) is executed, the work process management device 1A determines whether the processing or quality inspection process on the workpiece W in the new process is appropriate, based on the performance data of the previous process, which is the process immediately preceding the new process. The previous process is the process immediately preceding the current process, which is managed in the database 16 described later.

[0038] The work process management device 1A acquires actual data from the data acquisition device d1 after, for example, the processing of the workpiece W by the manufacturing device M1 is completed. In this case, when the manufacturing device M2 starts processing the workpiece W, the work process management device 1A determines whether the processing of the workpiece W by the manufacturing devices M1 and M2 is appropriate, based on the actual data of the first and second processes of the workpiece W.

[0039] When the work process management device 1A starts the processing of the (n+1)th process, if the actual data of the nth process does not include work performance information such as status information and measured values, it determines that the nth process is a skipped process. In other words, when the work process management device 1A starts the processing of the current process, if the actual data of the previous process does not include work performance information, it determines that the previous process is a skipped process.

[0040] Process skipping occurs when a specific process required for workpiece W is skipped and the next process is executed. In other words, process skipping occurs when the current process, which is the next process after the previous one, is performed on workpiece W for which the previous process has not been completed. To put it another way, process skipping occurs when a process is mistakenly assumed to have been performed in the previous process, and the previous process is skipped and the current process is executed instead. In a production line, process skipping can occur, for example, when the screw tightening process is skipped.

[0041] Furthermore, when the work process management device 1A starts the machining process of the (n+1)th process, if the actual data for the (n+1)th process includes workpiece actual data, it determines that the (n+1)th process is a double machining process where the same process is repeated. In other words, when the work process management device 1A starts the machining process of the current process, if the actual data for the current process includes workpiece actual data, it determines that the current process is a double machining process.

[0042] Double machining is the process of performing the same machining operation on a workpiece W. In other words, double machining is the process of repeating the same operation on a workpiece W that has already completed its operation in the current process. To put it another way, double machining is the process of performing the same machining operation even though the machining process has already been completed.

[0043] In a production line, there are cases where a workpiece W undergoes the same processing twice, such as applying the same paint treatment, the same welding treatment, or the same current testing treatment. For example, if workpiece W is scheduled to undergo welding only once, performing the welding treatment twice may reduce the strength of workpiece W. Similarly, if workpiece W is scheduled to undergo current testing only once, performing the current testing treatment twice may reduce the durability of workpiece W.

[0044] The work process management device 1A prevents the workpiece W from undergoing the same process twice by detecting the possibility of double processing. Therefore, the double processing in Embodiment 1 is a process that would result in two duplicate processes if the main process were to be executed as is, and at the time it is determined that double processing is occurring, the second processing step has not yet been executed.

[0045] Furthermore, in Embodiment 1, skipping a process is not limited to skipping the machining process in the previous process, but also includes skipping the quality inspection process in the previous process. Also, in Embodiment 1, double machining is not limited to performing two machining processes in the current process, but also includes performing two quality inspection processes in the current process.

[0046] The work process control device 1A determines that a workpiece W is skipping a process and decides to return it to the previous process as the course of action for that workpiece W, and instructs the production line to return the workpiece W to the previous process. As a result, the workpiece W determined to be skipping a process is returned to the production processing device of the previous process. For example, if the work process control device 1A determines that a process is skipping a process when starting processing by manufacturing device M(n+1), the workpiece W determined to be skipping a process is transported to manufacturing device Mn.

[0047] The work process control device 1A determines that a workpiece W requires two processing steps and decides to proceed to the next process, which is the next step after the current process, as the course of action for the workpiece W. It then instructs the production line to proceed to the next process. As a result, the workpiece W determined to require two processing steps is advanced to the production processing device of the next process. For example, if the work process control device 1A determines that a workpiece requires two processing steps when manufacturing device Mn starts processing, the workpiece W determined to require two processing steps is transported to manufacturing device M(n+1).

[0048] Furthermore, when the work process management device 1A starts the processing of the (n+1)th process, if the work performance information of the nth process includes status information, it determines a course of action for the workpiece W based on the status information. The course of action for the workpiece W based on the status information will be described later.

[0049] The work process management device 1A includes a process identification unit 11, a data acquisition unit 12, a performance data reading unit 13, a performance determination unit 14, a processing instruction unit 15A, and a database 16. The data acquisition unit 12 and the processing instruction unit 15A are connected to data collection devices d1 to d6. The processing instruction unit 15A may be located in a higher-level controller (not shown) of a production processing device located on the production line.

[0050] The data acquisition unit 12 acquires performance data from data collection devices d1 to d6 that shows the work performed on the workpiece W in each process. The performance data includes the process name, serial number, status information, and measured values. Of the performance data, the status information and measured values ​​are work performance information that shows the performance of the workpiece W and are used to determine the process performance. The performance data may also include the workpiece model name. In this case, the status information, measured values, and workpiece model name of the performance data are used to determine the process performance.

[0051] The workpiece model name is the model name of workpiece W, and corresponds to the processing performed on workpiece W. The production processing equipment executes the processing according to the recipe corresponding to the workpiece model name. Therefore, if the workpiece model names included in the actual data are different, the processing recipes are different. After processing is completed, the workpiece model name corresponding to the processing recipe is entered into the actual data. Even if it is the same workpiece W, if the processing performed differs due to differences in the process, the workpiece W after processing will be different. For this reason, the name of the workpiece model will also differ depending on the processing performed.

[0052] When a machining process corresponding to the machining machine name of workpiece W is performed on workpiece W, the machining machine name corresponding to workpiece W will also be entered into the performance data for workpiece W. On the other hand, when a different machining process that does not correspond to the machining machine name of workpiece W is performed on workpiece W, the performance data for workpiece W will also be entered into the performance data for workpiece W, with the name of the other machining machine not corresponding to workpiece W being entered.

[0053] The process name is the name of the process corresponding to the machining or quality inspection process on the workpiece W. The process name is an example of process identification information, which is information that identifies a process. The process identification information can be any information as long as it can identify the process. For example, the process identification information is the process number assigned to each process. Note that the process identification information may be information other than numbers, such as letters, as long as it can identify the order of the processes.

[0054] The serial number is the manufacturing serial number for workpiece W. The serial number is an example of workpiece identification information, which is information that identifies workpiece W. Workpiece identification information can be any information that can identify workpiece W. Workpiece identification information may be, for example, information on the date and time when workpiece W was first started. The measured values ​​are the measured values ​​of workpiece W after each process is completed.

[0055] The data acquisition unit 12 acquires actual data from the data collection device dx located on the manufacturing equipment Mx that has completed a process, when the first to fifth processes are completed. In other words, the data acquisition unit 12 acquires actual data for each process. The data acquisition unit 12 stores the acquired actual data in the database 16.

[0056] The data acquisition unit 12 stores actual data in the database 16 for each process in the order of the production line. That is, the data acquisition unit 12 stores actual data in the database 16 on a process-by-process basis. The data acquisition unit 12 stores actual data in the database 16 in such a way that the actual data is arranged in the order in which it was acquired.

[0057] Furthermore, when the workpiece W starts a new process, the data acquisition unit 12 receives a process start notification from the manufacturing equipment Mx or the quality inspection equipment T6. The process start notification includes the process name and serial number. Upon receiving the process start notification, the data acquisition unit 12 transmits it to the process identification unit 11. The process start notification may also be transmitted to the process identification unit 11 from the manufacturing equipment Mx or the quality inspection equipment T6.

[0058] Database 16 stores performance data, for example, for each process. That is, Database 16 stores one performance data for each process. Database 16 stores performance data obtained from the processes of the production line corresponding to each managed process, associating it with each managed process. In this way, Database 16 stores a process associating it with the performance data obtained from the process of the production line corresponding to that process. In other words, Database 16 does not store performance data obtained from any process other than the process of the production line corresponding to each managed process. That is, Database 16 does not store performance data obtained from any process other than the process of the production line corresponding to that process for each process. Note that Database 16 may be located outside the work process management device 1A.

[0059] The process identification unit 11 identifies the process name corresponding to the process start notification based on the process start notification. Specifically, the process identification unit 11 determines that the process name in the process start notification is the process name of the process that is about to be started. The process identification unit 11 notifies the performance data reading unit 13 of the serial number included in the process start notification and the identified process name.

[0060] For example, when the (n+1)th process is started, the process identification unit 11 receives a process start notification for the (n+1)th process from the manufacturing equipment M(n+1). In this case, the process identification unit 11 notifies the performance data reading unit 13 of the serial number and the process name of the (n+1)th process, which is information indicating the (n+1)th process. The process identification unit 11 may also be located in the data acquisition unit 12 or the performance data reading unit 13.

[0061] The performance data reading unit 13 reads performance data from the database 16 based on the serial number and the identified process name. The performance data reading unit 13 reads the performance data corresponding to the serial number and process name and transmits it to the performance determination unit 14.

[0062] When the performance data reading unit 13 receives a process name indicating the (n+1)th process, it attempts to read performance data corresponding to the (n+1)th process and its serial number, as well as performance data corresponding to the nth process (the process immediately preceding the (n+1)th process) and its serial number, from the database 16. The performance data reading unit 13 then transmits the read performance data for the nth and (n+1)th processes to the performance determination unit 14.

[0063] Furthermore, if the actual data reading unit 13 does not have work performance information for the nth process in the database 16, it will not send the actual data for the nth process to the actual determination unit 14. Also, if the actual data reading unit 13 does not have work performance information for the (n+1)th process in the database 16, it will not send the actual data for the (n+1)th process to the actual determination unit 14.

[0064] The performance determination unit 14 diagnoses the process performance of the workpiece W based on the received performance data for the nth and (n+1)th processes and determines whether or not there is an abnormality in the process performance. For example, the performance determination unit 14 determines whether or not a process is skipped or if the workpiece is processed twice, based on the performance data for the nth and (n+1)th processes. Specifically, if the performance determination unit 14 has not received workpiece performance information for the nth process, which is the preceding process among the nth and (n+1)th processes, and therefore there is no workpiece performance information, it determines that the preceding nth process is a process skip.

[0065] Furthermore, if the performance determination unit 14 has work performance information for the nth process and the (n+1th)th process, which is the later process, it determines that the current process, the (n+1st)th process, which is about to start, is a two-pass process. In other words, if the performance determination unit 14 has work performance information for the (n+1st)th process, it determines that the current process has already been executed, and that if the current process is executed again, it will be a two-pass process where the current process is repeated. The performance determination unit 14 determines a course of action corresponding to the determination result and transmits a course of action instruction corresponding to the course of action to the processing instruction unit 15A.

[0066] Furthermore, if the work performance information of the performance data includes multiple types of data items, the performance determination unit 14 may determine that work performance information exists if data is included in at least one of the data items of the work performance information, as this indicates that the process has performance. For example, if the data items of the work performance information are state information and measured values, the performance determination unit 14 may determine that performance data exists if data is stored in at least one of the state information and measured values. This allows the performance determination unit 14 to determine the process performance of work W based on the presence or absence of performance data, even if some data items in the work performance information are missing due to some malfunction.

[0067] Furthermore, the performance determination unit 14 may determine that work performance information exists if, in cases where the work performance information of the performance data includes multiple types of data items, data is included in all of the data items of the work performance information.

[0068] Furthermore, if the performance determination unit 14 finds that the performance data for the nth process, which is the preceding process among the nth and (n+1)th processes, includes status information, it determines a course of action for the workpiece W based on the status information and transmits a course of action corresponding to the course of action to the processing instruction unit 15A.

[0069] The performance evaluation unit 14 determines, for example, whether the workpiece W was sent to the current process despite the status information indicating it was unacceptable. If the status information indicates unacceptable, it could be due to processing defects or insufficient processing. Therefore, if the status information indicates unacceptable, the performance evaluation unit 14 determines, based on the measured values, whether the workpiece W is defective or insufficiently processed.

[0070] The performance evaluation unit 14, when the status information indicates a failure, determines that the workpiece W is under-processed if the measured value is within a specific range, and determines that it is poorly processed if it is outside the specific range. If the performance evaluation unit 14 determines that the workpiece W can be brought to an appropriate state by additional processing, it sends an instruction for additional processing to the processing instruction unit 15A. In this case, the performance evaluation unit 14 sends an instruction for additional processing to the processing instruction unit 15A that corresponds to the magnitude of the measured value.

[0071] Furthermore, if a processing defect occurs, the performance evaluation unit 14 will send instructions to the processing instruction unit 15A to take appropriate action, such as discarding, reprocessing, or repairing, because the workpiece W cannot be brought to an appropriate state even with additional processing.

[0072] The performance determination unit 14 determines, for example, that if a process and measurement value allows for reprocessing, it will allow for repair if a process and measurement value allows for repair, and that if a process has a defect in the quality of the workpiece W and neither reprocessing nor repair is possible, it will allow the workpiece to be discarded.

[0073] Furthermore, the performance determination unit 14 may determine that the measurement should be remeasured if the difference between the measured value and the allowable value of the measured value is less than or equal to a specific value. The action instruction that the performance determination unit 14 transmits to the processing instruction unit 15A is not limited to the action instruction described above and may be any action instruction.

[0074] The processing instruction unit 15A is, for example, an edge device of the work process control device 1A. The processing instruction unit 15A transmits the action instructions received from the performance determination unit 14 to the manufacturing device Mx or the quality inspection device T6. Upon receiving the action instructions, the manufacturing device Mx or the quality inspection device T6 executes the processing corresponding to the action instructions.

[0075] Figure 2 shows a first example of the set of actual data stored in the database of the work process management device according to Embodiment 1. The database 16 stores actual data for each process, thereby forming a set of actual data consisting of multiple actual data. Each actual data in the set of actual data is associated with, for example, the process name, serial number, status information, measured value, and workpiece model name.

[0076] Figure 2 shows the structure of the performance data set when database 16 stores performance data in the order in which the processes are completed. For example, when the first process with serial number "ABC123" is completed, the performance data for the first process with serial number "ABC123" is stored in database 16. Subsequently, when the second process with serial number "ABC123" is completed, the performance data for the second process with serial number "ABC123" is stored in database 16. In this way, performance data is stored in database 16 on a process-by-process basis.

[0077] Figure 3 shows a second example of the data set of actual work stored in the database of the work process management device according to Embodiment 1. In Figure 3, the configuration of the data set of actual work is shown when the database 16 stores actual work for each type of process. When a process is completed, the actual work is stored in the area of ​​the database 16 corresponding to that type of process. For example, the actual work data for the first process is stored in the area for storing the actual work data for the first process, in the order in which the processes were completed. In the configuration of the data set of actual work shown in Figure 3, actual work is stored in the database 16 on a process-by-process basis.

[0078] Figure 4 shows a third example of the performance data group stored in the database of the work process management device according to Embodiment 1. In Figure 4, the configuration of the performance data group is shown when the database 16 stores performance data for each serial number. When a process is completed, the performance data is stored in the area of ​​the database 16 corresponding to the serial number of that process. For example, the performance data for serial number "ABC123" is stored in the area that stores the performance data for serial number "ABC123" in the order in which the processes were completed. In the case of the performance data group configuration in Figure 4, performance data is stored in the database 16 on a process-by-process basis.

[0079] Thus, the database 16 can store performance data sets in various configurations depending on the production line. For example, by storing performance data sets as shown in Figure 2, the database 16 can store performance data in a short time. Also, by storing performance data sets as shown in Figure 3 or Figure 4, performance data can be retrieved in a short time.

[0080] Figure 5 is a flowchart showing the processing procedure for process performance determination performed by the work process management device according to Embodiment 1. When any process is completed on the production line, a process completion notification indicating the completion of the process is sent from the device that was executing the process to the work process management device 1A. Here, we will describe the case where the production processing device that was executing the process is manufacturing device M1, but the production processing device that was executing the process may be manufacturing devices M2 to M5 or quality inspection device T6.

[0081] When the manufacturing device M1 completes the first process, measurement and condition inspection are performed on the workpiece W that has completed the first process. The data acquisition device d1 collects the measured values ​​and condition information. After collecting the measured values ​​and condition information, the data acquisition device d1 transmits a notification of completion of the first process to the data acquisition unit 12 of the work process management device 1A. As a result, the data acquisition unit 12 receives the process completion notification (step S10). Upon receiving the process completion notification, the data acquisition unit 12 requests actual data from the data acquisition device d1. In response to the request from the data acquisition unit 12, the data acquisition device d1 transmits the actual data to the work process management device 1A. As a result, the data acquisition unit 12 receives the actual data, including the measured values ​​and condition information, from the data acquisition device d1 and acquires the actual data (step S20).

[0082] Note that the data acquisition device d1 does not need to send a process completion notification to the data acquisition unit 12. In this case, after collecting the measured values ​​and status information, the data acquisition device d1 sends the actual data including the measured values ​​and status information to the data acquisition unit 12.

[0083] When the data acquisition unit 12 acquires the actual data, it stores the actual data in the database 16 (step S30). When the first process is completed, the manufacturing device M1 transports the workpiece W to the manufacturing device M2 by a belt conveyor. When the workpiece W arrives, the manufacturing device M2 sends a notification to the work process management device 1A to start the second process before starting the second process for the workpiece W. As a result, the data acquisition unit 12 receives the process start notification (step S40). Even after sending the process start notification, the manufacturing device M2 does not start the second process until it receives an instruction to start the process from the work process management device 1A.

[0084] The manufacturing device M2 may send a process start notification to the work process management device 1A when the workpiece W arrives, or it may send a process start notification to the work process management device 1A immediately before starting the second process for the workpiece W. The manufacturing device M2 sends a process start notification to the work process management device 1A between the arrival of the workpiece W and the start of the second process.

[0085] The data acquisition unit 12 sends a process start notification to the process identification unit 11. Based on the process start notification, the process identification unit 11 identifies the name of the process that is about to start (in this case, the second process). The process identification unit 11 notifies the performance data reading unit 13 of the serial number included in the process start notification and the process name indicating the identified second process.

[0086] The performance data reading unit 13 queries the database 16 for performance data based on the serial number and the identified process name (step S50) and retrieves the performance data (step S60). Here, the performance data reading unit 13 attempts to retrieve performance data for the second and first processes of work W with the serial number included in the process start notification. That is, the performance data reading unit 13 attempts to retrieve the performance data for the identified process name and the performance data for the preceding process, which is the process one step before the identified process name. The performance data reading unit 13 transmits the retrieved performance data to the performance determination unit 14.

[0087] The performance determination unit 14 determines the process performance based on the presence or absence of performance data (step S70). The presence or absence of performance data corresponds to the degree of completion of the performance data. If performance data for the first process is available, the performance determination unit 14 determines that the first process is normal because the performance data for the first process is complete. If performance data for the first process is not available, the performance determination unit 14 determines that the first process is abnormal because the performance data for the first process is not complete. Also, if performance data for the second process is available when the second process is started, the performance determination unit 14 determines that the performance data for the second process is complete, and therefore, running the second process again would result in an abnormal process.

[0088] The performance determination unit 14 determines the process performance using, for example, the first determination condition information 110. In this case, the first determination condition information 110 is stored in advance within the performance determination unit 14 or in a storage device (not shown) of the work process management device 1A.

[0089] Figure 6 is a diagram illustrating the first judgment condition information used by the work process management device according to Embodiment 1 when determining process performance. In the first judgment condition information 110, the judgment condition, the judgment result when the judgment condition is met, and the action instruction for the judgment result are associated with each other.

[0090] In the first judgment condition information 110 here, the judgment condition, "when there is no work performance information for the previous process," the judgment result, "skip a process," and the instruction to the production line to take action, "execute the previous process," are associated with each other.

[0091] Furthermore, the judgment condition, "if there is work performance information for the current process," the judgment result, "double processing," and the instruction to the production line, "instruction to execute the next process," are linked together.

[0092] Furthermore, the judgment condition, "When there is work performance information for the previous process but no work performance information for the current process," is correlated with the judgment result, "Normal," and the action instruction for the production line, "Execute instruction for the current process."

[0093] The performance determination unit 14, if there is no work performance information for the previous process, determines that a process has been skipped based on the first determination condition information 110 and generates an action instruction indicating an execution instruction for the previous process. For example, suppose the current process, which is the process to be started for work W, is the (n+1)th process. In this case, the performance determination unit 14 determines that a process has been skipped if the work performance information for the nth process of work W is not stored in the database 16.

[0094] Furthermore, if there is work performance information for the current process, the performance determination unit 14 determines that it is a double process based on the first determination condition information 110 and generates an action instruction indicating an instruction to execute the next process. In other words, the performance determination unit 14 determines that it is a double process if the work performance information for the (n+1)th process of work W is stored in the database 16.

[0095] Furthermore, if there is work performance information for the previous process but no work performance information for the current process, the performance determination unit 14 determines that the process performance is normal based on the first determination condition information 110 and generates an action instruction indicating an execution instruction for the current process. In other words, the performance determination unit 14 determines that the previous process is normal if the work performance information for the nth process of work W is stored in the database 16 and the work performance information for the (n+1)th process of work W is not stored in the database 16.

[0096] Furthermore, if the performance determination unit 14 includes status information in the performance data for the nth process of workpiece W, it determines the process performance based on the status information. In this case, if the status information in the performance data for the nth process of workpiece W includes status information indicating "failure," the performance determination unit 14 determines that the workpiece is poorly processed or under-processed. On the other hand, if the status information in the performance data for the nth process of workpiece W includes status information indicating "pass," the performance determination unit 14 determines that the workpiece is processed normally. If the performance determination unit 14 determines that the workpiece is processed normally, it uses the first determination condition information 110 to determine the process performance.

[0097] The performance determination unit 14 generates an action instruction according to the determination result and transmits it to the processing instruction unit 15A. The processing instruction unit 15A transmits the action instruction according to the determination result to the production line (step S80).

[0098] In this way, the work process control device 1A can determine the past process performance for the workpiece W that is scheduled to start processing. As a result, the work process control device 1A can send corrective instructions to the production line according to the process performance. Therefore, the work process control device 1A can prevent inappropriate process processing such as skipping processes or double processing, and can perform appropriate processing and quality inspection processes on the workpiece W. As a result, the work process control device 1A can improve the accuracy of process control.

[0099] Next, we will describe the process executed by the work process management device 1A when the process performance is normal. Figure 7 is a diagram illustrating the process executed by the work process management device according to Embodiment 1 when the status information is satisfactory. Here, we will describe the case in which the work process management device 1A determines the process performance when starting the fifth process.

[0100] In the production line, once the fourth process is completed by the manufacturing device M4 (st1), the data acquisition device d4 transmits the actual data D4 indicating the completion of the fourth process to the work process management device 1A. This actual data D4 includes information indicating the process name "Fourth Process", information indicating the serial number such as "ABC123", information indicating the status such as "Pass", and information indicating the measured value such as "1.23mm".

[0101] When the work process management device 1A receives the actual data D4, it stores the actual data D4 in the database 16 (st2). After this, when the workpiece W, which has completed the fourth process, is transported and arrives at the manufacturing device M5 where the fifth process is executed (st3), the manufacturing device M5 sends a process start notification to the work process management device 1A.

[0102] The process identification unit 11 of the work process management device 1A identifies the name of the process to be started (in this case, the 5th process) based on the process start notification. The process identification unit 11 associates the name of the 5th process to be started with the serial number included in the process start notification and transmits it to the performance data reading unit 13.

[0103] The performance data reading unit 13 queries the database 16 for performance data of the fourth process, which is one process prior to the fifth process that is about to begin. Specifically, the performance data reading unit 13 uses the serial number and the process name of the fourth process as search keywords to query the database 16 for performance data corresponding to the serial number and the fourth process (st4a).

[0104] Furthermore, the performance data reading unit 13 queries the database 16 for performance data for the fifth process, which is about to begin. Specifically, the performance data reading unit 13 uses the serial number and the name of the fifth process as search keywords to query the database 16 for performance data corresponding to the serial number and the fifth process (st4b).

[0105] If the database 16 contains performance data D4 which includes the serial number and work performance information corresponding to the fourth process, the database 16 sends the performance data D4 to the performance data reading unit 13 as a data response (st5). In this way, if the database 16 contains performance data D4 which includes work performance information for the fourth process, the performance data reading unit 13 reads the performance data D4 for the fourth process from the database 16.

[0106] Furthermore, if the database 16 contains actual data including work performance information for the fifth process, the actual data reading unit 13 reads the actual data for the fifth process (not shown) from the database 16.

[0107] The performance determination unit 14 determines, for example, whether a process was skipped or whether processing was done twice, based on the read performance data. Here, it is assumed that the performance determination unit 14 has obtained the performance data D4 for the fourth process from the performance data reading unit 13, but has not obtained the performance data for the fifth process from the performance data reading unit 13.

[0108] The performance data D4 for the fourth process here includes status information and measured values, so the performance determination unit 14 determines that it is not a skipped process. Also, since the performance determination unit 14 has not acquired performance data for the fifth process, it determines that it is not a double process. Furthermore, since the status information here is "pass," the performance determination unit 14 determines that it is permissible to proceed with the fifth process (st6). The performance determination unit 14 also generates a processing instruction for the fifth process based on the measured value. For example, if the measured value is 1.23 mm, the performance determination unit 14 generates a processing instruction to use a 1.23 mm X-axis offset in the fifth process.

[0109] The performance determination unit 14 transmits processing permission information indicating permission for the fifth process, and a processing instruction using an X-axis offset of 1.23 mm, to the processing instruction unit 15A. The processing instruction unit 15A then transmits the received processing permission information and processing instruction to the manufacturing device M5 for the fifth process.

[0110] When the fifth process is completed by the manufacturing device M5 on the production line (st7), the manufacturing device M5 transmits performance data D5 to the work process management device 1A indicating that the fifth process has been completed. This performance data D5 includes information indicating the process name "Fifth Process", information indicating the serial number such as "ABC123", information indicating the status such as "Pass", and information indicating the measured value such as "6.23mm". When the work process management device 1A receives the performance data D5, it stores the performance data D5 in the database 16 (st8).

[0111] Furthermore, if the performance determination unit 14 has not obtained the performance data D4 for the fourth process from the performance data reading unit 13, it determines that a process has been skipped. In the case of a process skip, the workpiece W that has arrived at the manufacturing equipment M5 is transported to the manufacturing equipment M4, and the fourth process is executed at the manufacturing equipment M4. The work process management system 100A may also perform a process performance determination process in the fourth process and execute processing according to the determination result.

[0112] Furthermore, if the performance determination unit 14 has obtained performance data for the fifth process from the performance data reading unit 13, it determines that it is a double process. In the case of double processing, the workpiece W that has arrived at the manufacturing device M5 is transported to the quality inspection device T6, and the sixth process is executed in the quality inspection device T6. The work process management system 100A may also perform a process performance determination process in the sixth process and execute processing according to the determination result.

[0113] Figure 8 is a diagram illustrating the process executed by the work process management device according to Embodiment 1 when the status information is unacceptable. Here, as explained in Figure 7, we will describe the case in which the work process management device 1A determines the process performance when starting the fifth process.

[0114] Even if the process performance is abnormal, the processes st1 to st5 are executed in the same way as when the process performance is normal. Here, the performance determination unit 14 has obtained performance data D4, which includes work performance information for the fourth process, from the performance data reading unit 13, but has not obtained performance data, which includes work performance information for the fifth process, from the performance data reading unit 13.

[0115] The performance data D4 for the fourth process here includes status information and measured values, so the performance determination unit 14 determines that it is not a skipped process. Also, since the performance determination unit 14 has not obtained the performance data for the fifth process, it determines that it is not a double process. Furthermore, since the status information here is "failed", the performance determination unit 14 determines that it will not permit the processing of the fifth process (st6a).

[0116] If the performance evaluation unit 14 decides not to permit processing in the fifth process, it sends an action instruction (for example, discard, reprocess, etc.) corresponding to the fourth process which was determined to be "unacceptable" to the processing instruction unit 15A. The processing instruction unit 15A then transmits the received action instruction to the manufacturing equipment M4 for the fourth process or the manufacturing equipment M5 for the fifth process.

[0117] The processing instruction unit 15A, for example, sends a reprocessing instruction to the manufacturing device M4. As a result, the manufacturing device M4 transports the workpiece W to the device via a belt conveyor and performs reprocessing on the workpiece W. Alternatively, the processing instruction unit 15A sends a disposal instruction to the manufacturing device M5. As a result, the manufacturing device M5 sets the workpiece W to be discarded.

[0118] In a production line where a series of processes are executed, it is important to manage whether each process is executed in order. The work process management device 1A of Embodiment 1 manages the production line to prevent skipping processes and duplicate processing, thereby enabling the production line to execute a series of processes in order.

[0119] The performance determination unit 14 may also determine whether there are incorrect items or shortages. Incorrect items are when the workpieces W to be processed in each process are different from those planned, and shortages are when there are insufficient workpieces W to be processed in each process, or when the workpieces W have not been delivered as planned.

[0120] Here, we will explain the method for determining defective products and missing items. Database 16 stores actual data for each process, and the actual data reading unit 13 reads the actual data from database 16.

[0121] The performance determination unit 14 determines that workpiece W is out of stock if the scheduled workpiece model name is not included in the performance data read by the performance data read unit 13. The performance determination unit 14 may also determine that workpiece W is not out of stock if the performance data read by the performance data read by the performance data read by the performance data read by the unit 13 contains at least one of the following data: status information, measured value, and workpiece model name. Furthermore, the performance determination unit 14 determines that workpiece W is a different item if the workpiece model name included in the read performance data is different from the scheduled workpiece model name.

[0122] The work process management device 1A stores the workpiece model name corresponding to the serial number in advance in a storage device (not shown). That is, the work process management device 1A stores correspondence information indicating the correspondence between the serial number and the workpiece model name in a storage device. Based on this correspondence information, the performance determination unit 14 determines whether the workpiece model name included in the read performance data is the same as the original workpiece model name of workpiece W.

[0123] The performance determination unit 14 determines that a product is defective if, for example, in the third process, it reads "T2" instead of "T1" as the workpiece model name. The difference between "T1" and "T2" is, for example, a difference in the color scheme of the paint used in the painting process.

[0124] By the way, there is a method of monitoring the operating status of a production line using an OT (Operational Technology) network such as CC-Link (Control & Communication Link), and determining whether or not processes are skipped or double-processed based on the operating status. However, OT networks become difficult to connect when they span across production lines, buildings, or locations. Also, with OT networks, it is necessary to program each process individually, which requires a great deal of manpower and carries the risk of management omissions due to bugs.

[0125] On the other hand, the work process management device 1A of Embodiment 1 can determine process skipping, double processing, etc., based on the actual data stored in the database 16, so process performance can be easily determined with a simple configuration.

[0126] As a result, the work process management device 1A can properly manage process performance and prevent skipped processes, double processing, etc. Furthermore, by mechanically preventing skipped processes, double processing, etc., the work process management device 1A can prevent defective workpieces W from being released.

[0127] Furthermore, since the work process management device 1A only needs to be connected to the data acquisition devices d1 to d6, connections across production lines, buildings, and other locations are easily made. In addition, the work process management device 1A does not require ladder programs for each process, and can reduce man-hours without generating bugs.

[0128] Furthermore, the performance data, which is traceability data stored in database 16, can be reused for purposes other than traceability, so no additional costs are incurred for acquiring the data when it is reused.

[0129] Furthermore, the work process management device 1A can output processing instructions (for example, the offset amount in the current process) based on the measured values ​​included in the performance data of the previous process, making it possible to adjust processing conditions and control the prohibition of processing under specific conditions.

[0130] In this embodiment, the work process management device 1A has a performance data reading unit 13 that attempts to read performance data for the current process and the previous process from the database 16. Then, the performance determination unit 14 diagnoses the past process performance for the workpiece W based on at least one of the presence or absence of workpiece performance information for the current process and the presence or absence of workpiece performance information for the previous process, and determines whether or not there is an abnormality in the process performance. As a result, the work process management device 1A can improve the accuracy of process management.

[0131] Furthermore, when the performance determination unit 14 starts the processing of the current process, if the performance data of the previous process does not include work performance information, it determines that the previous process is a skipped process, making it easy to determine if a process is skipped.

[0132] Furthermore, when the performance determination unit 14 starts the machining process of the current process, if the performance data of the current process includes workpiece performance information, it determines that the current process is a double machining process, making it easy to determine if a process is a double machining process.

[0133] Embodiment 2. Next, Embodiment 2 will be described using Figures 9 and 10. In Embodiment 2, the work process management device 1A determines the process performance using a different determination method than in Embodiment 1. The performance determination unit 14 of the work process management device 1A in Embodiment 2 determines the process performance using, for example, the second determination condition information 120, which will be described later.

[0134] The work process management device 1A of Embodiment 2 has the same configuration as the work process management device 1A of Embodiment 1. The database 16 of Embodiment 2 has pre-stored item information that associates the process name of the process performed on the workpiece W flowing through the production line with the serial number of the workpiece W.

[0135] Figure 9 shows an example of the database configuration of the work process management device according to Embodiment 2. The database 16 of Embodiment 2 has all the item information, which is a combination of process name and serial number, stored in advance. On the production line, the process corresponding to this combination is executed. Although Figure 9 shows the case where the item information of work W with serial number "ABC123" is stored in the database 16, the item information of work W with other serial numbers is also all stored in the database 16. In this way, the database 16 stores actual data in which the process name and serial number are stored in advance, and the status information and measured value fields are left blank. Note that the database 16 may also have a blank field for the work model name.

[0136] In Embodiment 2, the performance data reading unit 13 reads the performance data from the storage area where the performance data for the current process is stored, based on the serial number. The performance data reading unit 13 reads the performance data for the process with the smallest process number among the processes where the storage field for work performance information, such as status information, is blank. The performance data read by the performance data reading unit 13 corresponds to the planned storage location for the work performance information of the current process. That is, the location of the blank space in the performance data read by the performance data reading unit 13 is the planned storage location for the work performance information of the current process.

[0137] For example, if work performance information for processes 1 through 3 has been stored, the performance data reading unit 13 reads the performance data for process 4. This performance data contains the process name "process 4" and the serial number of workpiece W, while the work performance information storage field is left blank.

[0138] The performance determination unit 14 compares the process name identified by the process identification unit 11 with the process name read by the performance data reading unit 13. If the process name identified by the process identification unit 11 and the process name read by the performance data reading unit 13 are the same, the performance determination unit 14 determines that the process performance is normal.

[0139] If the process number of the process name identified by the process identification unit 11 (for example, process 4) is greater than the process number of the process name read by the actual data reading unit 13 (for example, process 3), the actual determination unit 14 determines that a process has been skipped.

[0140] The process name identified by the process identification unit 11 is the process name of the process that is about to start. Similarly, the process name read by the performance data reading unit 13 is also the process name of the process that is about to start, provided that the previous process has been completed. If the previous process has been completed, the work performance information should be stored in the performance data of the previous process when it was completed, and the performance data reading unit 13 will not read the process name of the previous process when the current process starts. If the performance data reading unit 13 reads the process name of the previous process in this situation, it means that the previous process has not been executed, and the performance determination unit 14 determines that the previous process has been skipped.

[0141] Furthermore, if the process number of the process name identified by the process identification unit 11 (for example, the 4th process) is smaller than the process number of the process name read by the actual data reading unit 13 (for example, the 5th process), the actual determination unit 14 determines that it is a double process.

[0142] The process name identified by the process identification unit 11 is the process name of the process that is about to start. Similarly, the process name read by the performance data reading unit 13 is also the process name of the process that is about to start, unless the current process is completed. If the current process is not completed, the performance data for the current process should not contain any work performance information, and the performance data reading unit 13 will not read the process name of the next process when the current process starts. If the performance data reading unit 13 reads the process name of the next process in this situation, it is because the current process has already been executed, and the performance determination unit 14 determines that it is a second machining operation for the current process.

[0143] In this way, the performance determination unit 14 determines that the process performance is normal if the area where the work performance information for the current process to be started is originally the area where the work performance information for the current process is to be stored. In other words, when the performance determination unit 14 stores the performance data for each process, it checks whether the area where the work performance information is stored is in a state where it can be stored without any problems.

[0144] For example, if the performance determination unit 14 attempts to store work performance information in the storage area for the fourth process, but the performance data reading unit 13 reads the performance data for the third process as the storage area, the unit determines that a process has been skipped.

[0145] Furthermore, if the performance determination unit 14 attempts to store the work performance information in the storage area for the fourth process, but the performance data reading unit 13 reads the performance data for the fifth process as the storage area, the unit determines that it is a double process.

[0146] The performance determination unit 14 of Embodiment 2 determines process performance using the second determination condition information 120. Figure 10 is a diagram illustrating the second determination condition information used by the work process management device according to Embodiment 2 when determining process performance.

[0147] In the second judgment condition information 120, the judgment condition, the judgment result when the judgment condition is met, and the action instruction for the judgment result are associated. In the second judgment condition information 120, the judgment condition, "when the planned storage location for work performance information is the storage field of the previous process," the judgment result, "skip a process," and the action instruction for the production line, "execution instruction for the previous process," are associated.

[0148] Furthermore, the judgment condition, "when the planned storage location for work performance information is the storage field for the next process," the judgment result, "double processing," and the instruction to the production line, "instruction to execute the next process," are linked together.

[0149] Furthermore, the judgment condition, "If the planned storage location for work performance information is the storage field for the current process," the judgment result, "Normal," and the action instruction for the production line, "Execute instruction for the current process," are linked together.

[0150] As mentioned above, the actual data read by the actual data reading unit 13 is the planned storage location for the work actual information of the current process. If the planned storage location for the work actual information is the storage field of the previous process, the actual determination unit 14 determines that a process is being skipped based on the second determination condition information 120 and generates an action instruction indicating an execution instruction for the previous process.

[0151] Furthermore, if the planned storage location for the work performance information is the storage field for the next process, the performance determination unit 14 determines that it is a double process based on the second determination condition information 120 and generates an action instruction indicating an instruction to execute the next process.

[0152] Furthermore, if the planned storage location for the work performance information is the storage field for the current process, the performance determination unit 14 determines that the process performance is normal based on the second determination condition information 120 and generates an action instruction indicating an execution instruction for the current process.

[0153] Furthermore, the work process management device 1A may permit the data acquisition unit 12 to store work performance information in the database 16 to store it in the correct storage location, and prohibit it from storing it in an incorrect storage location. For example, as explained in Figure 9, the database 16 has a storage field for the process name, a storage field for the serial number, and a storage field for work performance information.

[0154] When the work process management device 1A acquires actual data from the data acquisition device dx for each process, it can determine which process the actual data belongs to based on the process name. For this reason, the work process management device 1A attempts to store the work actual data in the storage location corresponding to the identified process name. In this case, the work process management device 1A compares the process for which the actual data acquired from the data acquisition device dx for each process belongs with the process for which the storage location was attempted.

[0155] The work process management device 1A permits the storage of work performance information if the process of the actual data acquired from the data acquisition device dx for each process is the same as the process of the storage location where storage was attempted, but does not permit the storage of work performance information if the processes are different. In other words, the work process management device 1A permits the data acquisition unit 12 to store work performance information if the process of the work performance information to be stored and the process associated with the planned storage location are the same, and prohibits the storage of work performance information if they are different. To put it another way, if the performance determination unit 14 determines that the process name of the process identified by the process identification unit 11 is the same as the process name read by the performance data reading unit 13, the data acquisition unit 12 is permitted to store the performance data corresponding to this process name in the database 16.

[0156] Thus, if the performance determination unit 14 determines that the current process identified by the process identification unit 11 and the process read by the performance data reading unit 13 are the same process, the data acquisition unit 12 is permitted to store the work performance information of the current process in the database 16.

[0157] On the other hand, if the performance determination unit 14 determines that the process name identified by the process identification unit 11 is different from the process name read by the performance data reading unit 13, the data acquisition unit 12 is prohibited from storing the performance data corresponding to this process name in the database 16. In other words, if the performance determination unit 14 determines that the current process identified by the process identification unit 11 is different from the process read by the performance data reading unit 13, the data acquisition unit 12 is prohibited from storing the work performance information for the current process in the database 16.

[0158] In this way, the performance determination unit 14 compares the process for which performance data has been provided with the process for which the input of performance data is being attempted. If they are the same process, the data acquisition unit 12 inputs the work performance information; if they are different processes, it does not input the work performance information. In other words, the work process management device 1A can only update the performance data in the database 16 with work performance information for the same process as the process for which the performance data is provided.

[0159] Thus, the work process management device 1A of Embodiment 2 stores the process name and serial number in the performance data in advance, and determines whether to skip a process, perform double processing, or whether the process performance is normal based on the planned storage location of the work performance information for the current process.

[0160] The work process management device 1A determines that a process is being skipped if the planned storage location for the workpiece performance information of the current process is the storage field for the previous process, that it is being processed twice if it is the storage field for the next process, and that the process performance is normal if it is the storage field for the current process. In this way, the work process management device 1A can determine the process performance for the workpiece W that is scheduled to start processing, similar to Embodiment 1.

[0161] Embodiment 3. Next, Embodiment 3 will be described using Figure 11. The work process management device 1A of Embodiment 3 determines whether to skip a process or perform processing twice based on whether or not measured values ​​have been stored for a preset measurement item.

[0162] The work process management device 1A of Embodiment 3 prepares a list of measurement items to be measured in each process in advance, and stores the measured values ​​in the list of measured values ​​when a process is completed. The work process management device 1A compares the list of measurement items with the list of measured values, and determines that a process has been skipped if there are missing measured values ​​in the list of measured values, and determines that it is a double process if the measured values ​​have already been stored in the planned storage location.

[0163] Figure 11 shows an example of the configuration of the database of the work process management device according to Embodiment 3. The database 16 of Embodiment 3 is provided with a first storage area 61 and a second storage area 62.

[0164] The database 16 of Embodiment 3 stores performance data for each combination of process name and serial number. The first storage area 61 of the database 16 of Embodiment 3 stores pre-associated process names, serial numbers, and measurement items. That is, the first storage area 61 stores all process names executed on workpiece W on the production line, the serial number of workpiece W, and the measurement items for each process.

[0165] Figure 11 shows the case where the process name, serial number, and measurement items of workpiece W with serial number "ABC123" are associated and stored in the first storage area 61. Note that for workpieces W with other serial numbers, the process name, serial number, and measurement items are also pre-associated and stored in the first storage area 61, similar to the actual data group shown in Figure 11.

[0166] In the production line, when a process for workpiece W of "ABC123" is completed, the status information and measured values ​​of each process are associated and stored in the second storage area 62 corresponding to the first storage area 61. As a result, each completed process is associated with the process name, serial number, measurement item, status information, and measured value.

[0167] The performance data reading unit 13 reads performance data from the database 16 based on the serial number and the process name identified by the process identification unit 11. For example, when the (n+1)th process is started, the performance data reading unit 13 reads the performance data for the nth process and the (n+1)th process from the database 16.

[0168] The performance determination unit 14 determines the process performance of the workpiece W based on the performance data of the nth and (n+1)th processes received from the performance data reading unit 13. The performance determination unit 14 compares the measurement item and the measured value of the nth process. If the measurement value is not stored for the measurement item of the nth process, the performance determination unit 14 determines that a process has been skipped. Also, if the measurement value is stored for the measurement item of the (n+1)th process, the performance determination unit 14 determines that it is a double process. The second storage area 62 may also store the workpiece model name.

[0169] Thus, the work process management device 1A of Embodiment 3 determines whether to skip a process or perform processing twice based on whether or not measured values ​​have been stored for a preset measurement item. As a result, the work process management device 1A can determine the process performance for a workpiece W that is scheduled to start processing, similar to Embodiment 1.

[0170] Embodiment 4. Next, Embodiment 4 will be described using Figures 12 and 13. In Embodiment 4, a multi-stage storage unit consisting of a primary storage unit and a secondary storage unit (storage unit 162, which will be described later) is set up in the database 16, and the primary storage unit stores the latest process data for each workpiece W. The process data reading unit 13 then reads the latest process data from the primary storage unit.

[0171] Figure 12 shows an example of the configuration of the database of the work process management device according to Embodiment 4. The database 16 of Embodiment 4 is provided with a primary storage unit 161 and an accumulation unit 162.

[0172] Figure 13 shows the actual data stored in the primary storage unit of the work process management device according to Embodiment 4. In the database 16 shown in Figure 2, actual data is stored for each process, and the actual data reading unit 13 reads the actual data corresponding to the process (such as the actual data of the previous process) from the database 16.

[0173] The database 16 of Embodiment 4 stores the actual data for each process in a multi-stage storage unit consisting of a primary storage unit 161 and an accumulation unit 162. The database 16 of Embodiment 4 stores only the most recent actual data, which is the actual data for the most recent process, in the primary storage unit 161 for each workpiece W, and the actual data reading unit 13 reads the actual data from the primary storage unit 161.

[0174] When the data acquisition unit 12 stores the actual data for a new process in the database 16, it stores the actual data for the new process in the primary storage unit 161. The data acquisition unit 12 also stores the actual data stored in the primary storage unit 161 in the storage unit 162. In other words, the data acquisition unit 12 stores all the actual data in the storage unit 162 as well. As a result, the storage unit 162 stores all the actual data for each process, similar to the database 16 as explained in Figures 2 to 4.

[0175] When the data acquisition unit 12 acquires performance data for a new process of work W, it stores this new performance data for work W in the database 16 and deletes the outdated performance data for work W from the primary storage unit 161.

[0176] The performance data reading unit 13 transmits the performance data read from the primary storage unit 161 to the performance determination unit 14. The performance determination unit 14 compares the process read by the performance data reading unit 13 with the current process, which is the process identified by the process identification unit 11.

[0177] If the process read by the performance data reading unit 13 is two or more processes earlier than the process identified by the process identification unit 11, the performance determination unit 14 determines that a process has been skipped.

[0178] Furthermore, if the process read by the performance data reading unit 13 and the process identified by the process identification unit 11 are the same process or later, the performance determination unit 14 determines that it is a double process.

[0179] Furthermore, if the process read by the performance data reading unit 13 is one process prior to the process identified by the process identification unit 11, the performance determination unit 14 determines that it is normal.

[0180] As described above, the work process management device 1A of Embodiment 4 has a database 16 which includes a primary storage unit 161 and an accumulation unit 162, and the primary storage unit 161 stores the latest process data for each work W. As a result, the process data reading unit 13 can read the latest process data that has been executed from the primary storage unit 161, and the process determination unit 14 can determine the process performance based on the latest process performance data. Therefore, the work process management device 1A can easily determine the process performance.

[0181] Embodiment 5. Next, Embodiment 5 will be described using Figure 14. In Embodiment 5, the processing instruction unit is located outside the work process control device.

[0182] Figure 14 shows the configuration of a work process management system equipped with a work process management device according to Embodiment 5. Among the components in Figure 14, components that achieve the same function as the work process management system 100A of Embodiment 1 shown in Figure 1 are denoted by the same reference numerals, and redundant explanations are omitted.

[0183] The work process management system 100B of Embodiment 5 comprises a work process management device 1B, a processing instruction unit 15B, and data acquisition devices d1 to d6. The work process management device 1B includes a process identification unit 11, a data acquisition unit 12, a performance data reading unit 13, a performance determination unit 14, and a database 16. In the work process management system 100B, the processing instruction unit 15B is located outside the work process management device 1B.

[0184] The processing instruction unit 15B is connected to the work process control device 1B and data acquisition devices d1 to d6. The processing instruction unit 15B performs the same processing as the processing instruction unit 15A. The processing instruction unit 15B may also be located in a higher-level controller (not shown) of a production processing device located on the production line.

[0185] Thus, in the fifth embodiment, the work process management device 1B has a processing instruction unit 15B that performs the same processing as the processing instruction unit 15A. Therefore, similar to the first embodiment, the work process management device 1A can determine the process performance for the workpiece W that is scheduled to start processing.

[0186] The "preceding process" can be any process that takes place at least one step before the current process. If the preceding process is the process immediately preceding the current process, it can further reduce unnecessary processing.

[0187] Next, the hardware configuration of the work process management devices 1A and 1B will be described. The work process management devices 1A and 1B are implemented by processing circuits. The processing circuits may be a processor and memory that execute programs stored in memory, or they may be dedicated hardware.

[0188] Figure 15 shows an example of the configuration of a processing circuit when the processing circuit of the work process management device according to Embodiments 1 to 5 is implemented using a processor and memory. Since work process management devices 1A and 1B have similar hardware configurations, the hardware configuration of work process management device 1A will be described here.

[0189] The processing circuit 90 shown in Figure 15 comprises a processor 91 and a memory 92. When the processing circuit 90 consists of a processor 91 and a memory 92, each function of the processing circuit 90 is realized by software, firmware, or a combination of software and firmware. The software or firmware is written as a work process management program and stored in the memory 92. In the processing circuit 90, each function is realized by the processor 91 reading and executing the work process management program stored in the memory 92. In other words, the processing circuit 90 includes a memory 92 for storing a work process management program, which will ultimately be executed by the processing of the work process management device 1A. This work process management program can also be said to be a program that causes the work process management device 1A to execute each function realized by the processing circuit 90. This work process management program may be provided on a computer-readable recording medium on which the work process management program is recorded, or it may be provided by other means such as a communication medium.

[0190] The above work process management program can also be described as a program that causes the work process management device 1A to execute the processes in steps S10 to S80 of Figure 5. Furthermore, the work process management program for the work process management device 1B can also be described as a program that causes the work process management device 1B to execute the processes in steps S10 to S70 of Figure 5.

[0191] Here, the processor 91 is, for example, a CPU (Central Processing Unit), processing unit, arithmetic unit, microprocessor, microcomputer, or DSP (Digital Signal Processor). The memory 92 is, for example, a non-volatile or volatile semiconductor memory such as RAM (Random Access Memory), ROM (Read Only Memory), flash memory, EPROM (Erasable Programmable ROM), EEPROM (Registered Trademark) (Electrically EPROM), magnetic disks, flexible disks, optical disks, compact disks, minidiscs, or DVDs (Digital Versatile Discs).

[0192] Figure 16 shows an example of the configuration of a processing circuit when the processing circuit of the work process management device according to Embodiments 1 to 5 is implemented with dedicated hardware. The processing circuit 93 shown in Figure 16 may be, for example, a single circuit, a composite circuit, a programmed processor, a parallel programmed processor, an ASIC (Application Specific Integrated Circuit), an FPGA (Field Programmable Gate Array), or a combination thereof. The processing circuit 93 may be partially implemented with dedicated hardware and partially implemented with software or firmware. In this way, the processing circuit 93 can realize each of the above functions with dedicated hardware, software, firmware, or a combination thereof.

[0193] The configurations shown in the above embodiments are merely examples, and it is possible to combine them with other known technologies, combine different embodiments, and omit or modify parts of the configuration without departing from the gist of the invention. [Explanation of symbols]

[0194] 1A,1B Work process management device, 11 Process identification unit, 12 Data acquisition unit, 13 Actual data reading unit, 14 Actual judgment unit, 15A,15B Processing instruction unit, 16 Database, 61 First storage area, 62 Second storage area, 90,93 Processing circuit, 91 Processor, 92 Memory, 100A,100B Work process management system, 110 First judgment condition information, 120 Second judgment condition information, 161 Primary storage unit, 162 Storage unit, D4,D5 Actual data, M1~M5,Mn,M(n+1),Mx Manufacturing equipment, T6 Quality inspection equipment, W Work, d1~d6,dn,dx Data acquisition device.

Claims

1. A performance data reading unit attempts to read performance data for the current process, which is the process to be started for the workpiece, and performance data for the previous process, which is the process preceding the current process, from a database that stores performance data for each process, which includes performance information showing the process performance of workpieces whose processes have been completed in the production line. A performance determination unit diagnoses the process performance of the workpiece and determines whether or not there is an abnormality in the process performance, based on at least one of the presence or absence of workpiece performance information for the current process and the presence or absence of workpiece performance information for the previous process. Equipped with, At least one of the workpiece performance information for the current process and the workpiece performance information for the previous process includes at least one of the information obtained by measuring the workpiece and the information regarding the processing details of the workpiece. A work process management device characterized by the following features.

2. The aforementioned database stores the performance data for each process in the order of the production line. The preceding process is the process immediately preceding the current process. The work process management device according to feature 1.

3. The aforementioned database stores processes in association with actual data obtained from the processes of the production line corresponding to those processes. The work process management device according to feature 1.

4. The aforementioned database does not store actual data obtained from processes other than those on the production line corresponding to the process in question. The work process management device according to feature 1.

5. In the aforementioned performance data, work identification information that identifies the work, process identification information that identifies the process, and work performance information are associated with each other. The aforementioned performance data reading unit attempts to read performance data for the current process and the previous process from the database based on the work identification information and process identification information of the current process. The work process management device according to feature 1.

6. The aforementioned performance determination unit, If there is no work performance information for the preceding process, it is determined that the preceding process was skipped. If there is work performance information for the preceding process and there is no work performance information for the current process, the process performance is determined to be normal. The work process management device according to feature 1.

7. The aforementioned performance determination unit, If there is workpiece performance information for the current process, it is determined that it is a two-pass process. If there is work performance information for the preceding process and there is no work performance information for the current process, the process performance is determined to be normal. The work process management device according to feature 1.

8. The system further includes a processing instruction unit that transmits corrective action instructions to the production line in accordance with the results of the performance evaluation unit. The work process management device according to feature 1.

9. The aforementioned workpiece performance information includes status information indicating whether the workpiece passed or failed, which is the result of a condition inspection of the workpiece after processing. If the processing instruction unit determines that the status information indicates a failure, it transmits an instruction to the production line indicating the disposal, reprocessing, repair, or remeasurement of the workpiece. The work process management device according to feature 8.

10. The system further includes a data acquisition unit that acquires performance data of completed workpieces from the production line and stores it in the database. If it is determined that the current process and the process read by the performance data reading unit are the same process, the data acquisition unit is permitted to store the work performance information of the current process in the database. If it is determined that the current process and the process read by the performance data reading unit are different processes, the data acquisition unit is prohibited from storing the work performance information of the current process in the database. The work process control device according to feature 9.

11. The aforementioned database is A primary storage unit that stores the latest process data for each workpiece from the aforementioned performance data, A secondary storage unit that stores the entirety of the aforementioned performance data, It has, The aforementioned performance data reading unit attempts to read the performance data of the previous process and the current process from the primary storage unit. The work process management device according to feature 1.

12. The performance determination unit determines whether or not there is an abnormality in the process performance based on the presence or absence of work performance information of the previous process among the performance data of the latest process stored in the primary storage unit. The work process management device according to feature 11.

13. The performance determination unit determines that the work performance information exists if, when the work performance information includes multiple types of data items, at least one of the data items is included. A work process management device according to any one of claims 1 to 12.

14. The work identification information is the serial number of the work. The work process management device according to feature 5.

15. A data acquisition device that collects performance data including work performance information showing the process performance of workpieces whose processes have been completed on the production line, A database for storing the aforementioned performance data for each of the aforementioned processes, A work process management device that manages the processes of the production line based on the work performance information included in the performance data, It has, The aforementioned work process management device is A data reading unit attempts to read from the database the data of the current process, which is the process to be started for the workpiece, and the data of the previous process, which is the process preceding the current process for the workpiece. A performance determination unit diagnoses the process performance of the workpiece and determines whether or not there is an abnormality in the process performance, based on at least one of the presence or absence of workpiece performance information for the current process and the presence or absence of workpiece performance information for the previous process. Equipped with, At least one of the workpiece performance information for the current process and the workpiece performance information for the previous process includes at least one of the information obtained by measuring the workpiece and the information regarding the processing details of the workpiece. A work process management system characterized by the following:

16. The process management device performs a process data reading step in which it attempts to read the process data of the current process, which is the process to be started for the workpiece, and the process data of the previous process, which is the process preceding the current process for the workpiece, from a database that stores process data for each process, which includes process data showing the process performance of workpieces whose processes have been completed in the production line. The process management device performs a process performance determination step, which involves diagnosing the process performance of the workpiece based on the presence or absence of workpiece performance information for the current process and the presence or absence of workpiece performance information for the previous process, and determining whether or not there is an abnormality in the process performance. Includes, At least one of the workpiece performance information for the current process and the workpiece performance information for the previous process includes at least one of the information obtained by measuring the workpiece and the information regarding the processing details of the workpiece. A work process management method characterized by the following:

17. A data reading step that attempts to read the data of the current process, which is the process to be started for the workpiece, and the data of the previous process, which is the process preceding the current process for the workpiece, from a database that stores data of performance data for each process, which includes workpiece performance information showing the process performance of workpieces whose processes have been completed in the production line. A performance determination step that diagnoses the process performance of the workpiece and determines whether or not there is an abnormality in the process performance, based on at least one of the presence or absence of workpiece performance information for the current process and the presence or absence of workpiece performance information for the previous process, Have the computer run it, At least one of the workpiece performance information for the current process and the workpiece performance information for the previous process includes at least one of the information obtained by measuring the workpiece and the information regarding the processing details of the workpiece. A work process management program characterized by the following features.

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