Management device, management method, and program

Abstract

Provided is a management device including: an accepting means that accepts input of a delivery date for each of a plurality of products ordered by a customer, said products being manufactured by undergoing a plurality of steps, including a step of punching out one or more components from sheet material; an acquisition means that acquires the man-hours required for each of the plurality of steps; a selection means that selects at least some of the plurality of components forming one or more products among the ordered products for which the punching step has not been completed, the selection being based on the man-hours and the delivery date; an instruction means that gives an instruction for preparing a layout of the selected components to a layout means that prepares a layout of indicated components on the sheet material for the punching step; a conveyance allocation means that allocates each of the selected components, which are obtained as a result of the punching step being performed on the sheet material on which the layout of the selected components was prepared by the layout means, to one of a plurality of conveying means that is to convey said component to the work area of a subsequent step after the punching step; and an output means that outputs the result of the allocation.

Description

Management device, management method, and program

[0001] The present invention relates to a management device, a management method, and a program technology.

[0002] There are known techniques for managing schedules for each process in a factory that manufactures products. For example, Patent Document 1 discloses a management device that makes it easy to view the schedule of work required to manufacture products, even when a large number of products are to be manufactured.

[0003] Patent Document 2 discloses a sheet metal process work support system that includes a display device that displays images of component plates cut out from raw material sheets and nesting layout diagrams in a database corresponding to the component plates cut out from the raw material sheets during the process of cutting and cutting out component plates from the raw material sheets.

[0004] Patent Document 3 discloses a placement data creation device that creates placement data for performing nesting, in which each target part to be manufactured is placed on available material, based on part data for multiple parts, including length as information about each part, in order to improve the yield rate, which indicates the ratio of leftover material to the base material, during the part cutting process.

[0005] Patent No. 7061402 Patent No. 5879725 Patent No. 6572356

[0006] The invention of Patent Document 1 merely presents a schedule of the entire manufacturing process to the user in an easy-to-read format. The invention of Patent Document 2 displays additional information and nesting layout diagrams corresponding to components within a component plate to a worker during the component cutting process, but this is merely for the convenience of the worker and does not extend to schedule management of the manufacturing process. The invention of Patent Document 3, however, is capable of selecting components and creating the most efficient layout diagram by taking into account the physical requirements of each component (length, shape, material type, etc.) when nesting components on a base material, but it only solves the general problem of improving yield efficiency by reducing the proportion of leftover materials.

[0007] In view of the above background, the present invention provides a technique for determining a nesting arrangement taking into consideration a process schedule, and for improving the workability and convenience of the manufacturing process.

[0008] One aspect of the present disclosure provides a management device having: a receiving means for receiving input of a delivery date for a product ordered from a customer for each of a plurality of products manufactured through a plurality of processes including a punching process in which one or more parts are punched out of a sheet metal; an acquiring means for acquiring the man-hours required for each of the plurality of processes; a selecting means for selecting at least some of the parts from a plurality of parts that constitute one or more ordered products for which the punching process has not been completed, based on the man-hours and the delivery date; an instructing means for instructing an allocating means that allocates the specified parts to the sheet metal for the punching process to allocate the selected parts; a transport allocation means for allocating each of the selected parts obtained from the punching process for the sheet metal to one of a plurality of transport means that transports the part to a work site for a subsequent process after the punching process by the allocation means; and an output means for outputting the results of the allocation.

[0009] The manufacturing method may further include a calculation means for calculating a latest start date for a punching process for one or more parts constituting each of the plurality of products using the man-hours and the delivery date, and the selection means may select at least some of the parts based on the latest start date.

[0010] The apparatus may further include a determination means for determining whether or not the allocation needs to be modified, and when the determination means determines that the modification is necessary, the instruction means may instruct the allocation means to modify the allocation.

[0011] The acquiring means may acquire the man-hours required for each of the plurality of processes from a database in which man-hours defined for each process are recorded.

[0012] The system may include a grouping means for dividing at least some of the parts into a plurality of groups, and a worker allocation means for allocating a plurality of workers to the plurality of groups for a specific process among the plurality of processes, wherein the database records the man-hours required for each process and each worker, and the acquisition means acquires from the database the man-hours required for the assigned worker to work on the specific process.

[0013] The plurality of conveying means may include a plurality of conveying means of different shapes or types, and the conveying allocation means may select one conveying means from the plurality of conveying means according to the conveying conditions of each of the some of the parts, and allocate the part to the selected conveying means.

[0014] The transport conditions may include conditions regarding at least one of the shape, size, weight, and whether or not care must be taken when handling the part.

[0015] The transport conditions may include conditions regarding subsequent processes subsequent to the punching process for the part and conditions regarding workers in the subsequent processes.

[0016] The plurality of transport means may include at least one of a dolly, a pallet, and an automated guided vehicle.

[0017] The system may have an access means for accessing a database in which the current positions of the plurality of transport means are recorded, and the transport allocation means may allocate the part to a transport means that is located at a specific position among the plurality of transport means.

[0018] Another aspect of the present disclosure provides a management method including the steps of: a computer receiving input of a delivery date for each of a plurality of products ordered from a customer, the products being manufactured through a plurality of processes including a punching process of punching one or more parts from a sheet material; a step of acquiring the man-hours required for each of the plurality of processes; a step of selecting at least some of the parts from a plurality of parts constituting one or more ordered products for which the punching process has not been completed, based on the man-hours and the delivery date; a step of instructing an allocation means that allocates the specified parts to the sheet material for the punching process to allocate the selected parts; a step of assigning each of the selected parts obtained from the punching process for the sheet material to one of a plurality of transport means that transports the part to a work site for a subsequent process after the punching process by the allocation means; and a step of outputting the results of the assignment.

[0019] Another aspect of the present disclosure provides a program for causing a computer to execute the steps of: accepting input of delivery dates for a plurality of products ordered from a customer for each of the plurality of products manufactured through a plurality of processes including a punching process of punching one or more parts from a sheet metal; acquiring the man-hours required for each of the plurality of processes; selecting at least some of the parts from a plurality of parts that constitute one or more ordered products for which the punching process has not been completed based on the man-hours and delivery date; instructing an allocation means that allocates the specified parts to the sheet metal for the punching process to allocate the selected parts; assigning each of the selected parts obtained from the punching process for the sheet metal to one of a plurality of conveying means that transports the part to a work site for a subsequent process after the punching process by the allocation means; and outputting the results of the allocation.

[0020] According to the present invention, it is possible to determine a nesting arrangement taking into consideration a process schedule, and to improve the workability and convenience of the manufacturing process.

[0021] 1 is a diagram illustrating an overview of processing in a management system according to related art. A diagram illustrating the system configuration of the management system 1. A diagram illustrating the functional configuration of the management system 1. A diagram illustrating the hardware configuration of a management device 10. A diagram illustrating the hardware configuration of a user terminal 20. A flowchart illustrating an overview of operations in the management system 1. A sequence chart illustrating a nesting allocation method in the management system 1. A diagram illustrating a product management database. A diagram illustrating welding work efficiency. A diagram illustrating a welding work / welding schedule. A diagram illustrating an overall process schedule. A diagram illustrating nesting arrangement. A flowchart illustrating a re-nesting method in the management system 1. A sequence chart illustrating a method of acquiring position information of a transport means in the management system 1. A diagram illustrating transport means and transport conditions. A sequence chart illustrating a method of allocating transport means in the management system 1. A diagram illustrating the result of transport means allocation. A diagram illustrating labels. A diagram illustrating movement of a transport means between processes.

[0022] 1. Overview FIG. 1 is a diagram illustrating an example of an overview of the processing of a management system according to related art. In this example, the management system refers to a system for managing each step (manufacturing step or manufacturing process) of a product that is manufactured through multiple steps. In this example, a product refers to an item manufactured in a factory or the like in response to an order from a customer. In this example, a product is made up of one or more parts. For the sake of convenience, a manufactured item related to a customer order and final delivery will be referred to as a product, and an item in an unfinished state will be referred to as a part. In this example, the management system has the following manufacturing process:

[0023] In step SS1, the management system receives an order for a product from a customer. In this example, when receiving an order, the management system acquires information about the customer and the product, such as the customer's name and address, as well as order information such as the product quantity, delivery date, specifications, instructions indicating the work instructions for the manufacturing process, and the number and type of parts. In this example, the delivery date includes the date by which the finished product must be delivered to the customer. In step SS2, the management system performs administrative processing based on the order information. From this point on, the process proceeds to manufacturing processing at a factory site (an example of a workplace), etc.

[0024] In step SS3, the management system manages the punching process. In this example, the punching process is a process of punching one or more parts from a workpiece material (or simply a plate material) such as sheet metal, that is, cutting the plate material into various shapes. In this example, the punching process is performed using a press machine, a laser machine, or the like. More specifically, the punching process is divided into the following three processes.

[0025] In step SS31, the management system manages nesting. In this example, nesting refers to, for example, selecting one or more parts for one sheet of workpiece material and determining the placement of each part. In this example, the parts are selected based on, for example, acquired order information. The placement of parts for the sheet material is determined by a server (or system) dedicated to nesting. In this example, nesting is typically performed to optimize so-called "yield," such as the ratio of leftover material to the sheet material or the time-to-product (effectiveness). The placement determined here is also called nesting allocation.

[0026] In step SS32, the management system manages the process of punching parts from the plate material according to the nesting allocation. This corresponds to the punching process described above. In this example, in the punching process, first, a press or laser machine cuts the plate material into the shape of each part according to the nesting allocation described above. Second, workers in a factory or the like extract each cut part from the plate material. In this way, the management system can manufacture and process the basic parts.

[0027] The parts that have been punched in step SS33 are loaded onto a transport means such as a cart by a worker or the like. In this example, the transport means refers to a physical method for transporting and conveying parts to a location where a process subsequent to the punching process (post-process) is performed. In this example, the punched parts are assigned to a transport means in advance and transported to the next process. Next, the processes subsequent to the punching process will be described.

[0028] In step SS4, the management system manages the bending process. In this example, the bending process is a process in which parts punched in the punching process are processed into a three-dimensional (flat) shape using a press or the like. In this example, each process is managed by either worker inputting progress (using a keyboard or barcode) or automatic determination using a camera installed on-site. At least some of the processes are performed by workers. In step SS5, the management system manages the welding process. In this example, the welding process is a process in which parts manufactured in the previous process are joined together using a welding machine or the like to manufacture and process new parts (an example of a component). In step SS6, the management system manages the inspection process. In this example, the inspection process is a process in which the quality (condition), quantity, operation, and conformity with standards, etc., of the parts manufactured in the previous process are confirmed. In step SS7, the management system manages the painting process. In this example, the painting process is a process in which paint or the like is applied to the exterior of each part. In step SS8, the management system manages the assembly process. In this example, the assembly process is a process in which manufactured parts are combined according to assembly drawings and finished into a product. This is the general manufacturing process.

[0029] Finally, in step SS9, the management system can deliver the product to the customer through a shipping process in which the product (finished product) is sent to the destination based on the order information. Note that the operations shown in Fig. 1 in this example are merely an example, and generally, processes can be freely changed (added, deleted, or replaced) depending on the product specifications or the manufacturing equipment of the factory. Furthermore, for any process including those mentioned above, a process that takes place before that process in the chronological order is defined as a previous process, and a process that takes place after that process is defined as a subsequent process.

[0030] Here, the functions required for a management system that manages the entire manufacturing process include schedule management of all processes (deliveries), each process, and workers for multiple products handled in a factory, as well as improving the workability and convenience of each process and between processes. More specifically, for example, simply assigning nesting optimally for yield rate in step SS31 is not sufficient functionality. It is necessary to simulate in advance the delivery dates of multiple products (parts), the man-hours of downstream processes such as bending and / or welding for each part, and the schedules, work efficiency, and man-hours of workers involved in the downstream processes, and then perform nesting. In this example, man-hours refer to, for example, the work time defined for each process, i.e., the time required to process one part. Therefore, one of the objectives of the present invention is to perform nesting based on the man-hours and delivery dates of downstream processes for each part.

[0031] Furthermore, if nesting allocation is performed in step SS32 solely with the aim of optimizing yield and parts are removed from the plate material, there is a risk that the removed parts will accumulate at the exit of the removal process, depending on the equipment status of the transport means or the processing status of the subsequent process. To avoid this situation, optimal allocation must be performed in advance, taking into account the equipment status of the transport means, etc. More specifically, allocation based on the type of cart and type of part, the type of subsequent process, the location of the site, and the loading order is required to ensure efficient operation. Furthermore, product information and schedule (process) information must be clearly associated with each removed part, and a highly convenient operation that allows workers to understand this information is also required. These are other objectives of the present invention. The present invention is primarily characterized to achieve these objectives. Next, more specific configurations and operations of the present invention will be described in Chapters 2 and 3, respectively.

[0032] 2. Configuration Fig. 2 is a diagram illustrating an example of the system configuration of the management system 1. In this example, the management system 1 includes a management device 10, a server device 100, a user terminal 20, a pull-out device 30, a dolly 40, a camera, and a user terminal 90. In this example, the components of the system are connected in a composite manner via a network 9 as shown in Fig. 2. In this example, the network 9 is a computer network such as the Internet.

[0033] In this example, the management device 10 is an information processing device / server device in the management system 1. In this example, the management device 10 receives an order for a product from a user terminal 90, which is a customer terminal, and at that time, accepts the delivery date of the product. In this example, the management device 10 manages all processes and each process in a factory for manufacturing the ordered product. In this example, the management device 10 selects parts based on the man-hours and delivery date when managing the punching process of punching parts from a sheet material. The management device 10 also instructs allocation to a server device 100 (an example of an allocation means), which is a dedicated server that allocates the selected parts to the sheet material for the punching process.

[0034] In this example, the management device 10 assigns each of the parts obtained from the punching process to a cart 40, which is an example of a transport means for transporting the parts to a workplace of a subsequent process after the punching process. Furthermore, the management device 10 clearly associates product information, part information, and process information relating to the identification of each part or the subsequent process, and presents information including instructions to move the cart 40 assigned to the part to a worker on-site (or simply referred to as a user).

[0035] In this example, the server device 100 is a dedicated server that performs nesting allocation in the management system 1. The server device 100 is managed and operated, for example, by the manufacturer or distributor of the punching device 30. That is, in this example, the server device 100 is managed and operated by a business operator different from that of the management device 10. The server device 100 receives allocation instructions from the management device 10. The server device 100 allocates the specified parts to sheet materials for the punching process, that is, performs nesting. The server device 100 outputs data representing the generated nesting allocation to the management device 10.

[0036] Here, the user terminal 20, punching device 30, cart 40, and camera include devices or facilities installed at the site of each process in a manufacturing site such as a factory. In this example, the site of each process refers to a site that is divided into different processes, such as a punching site, a bending site, or a welding site.

[0037] In this example, the user terminal 20 represents a terminal operated by a user at the site. In this example, the user refers to a member of staff who works and manages each process at the site, and is generally located at all process sites (some users are not shown). In this example, for example, a user at a punching site punches parts from a plate material using a press, laser machine, or the like. The user also sorts the punched parts, loads them onto a cart 40, and transports them to a site of a subsequent process after the punching process. In this example, the user terminal 20 presents to the user at the site various information about each part acquired from the management device 10, including, for example, the correspondence between the carts 40 assigned to the parts and instructions for moving the carts 40. The user terminal 20 also has a printing device for printing labels that present various information to the user at the site for each part. In this example, the labels can be attached to the parts punched in the punching process to present various information to the user.

[0038] In this example, the punching device 30 includes a press machine / laser machine or the like for punching parts from the plate material in the punching process. The punching device 30 cuts out parts from the plate material based on a nesting layout diagram or the like obtained directly from the management device 10 or the server device 100.

[0039] In this example, the cart 40 (an example of a transport means) includes a moving means and a moving facility for transporting and conveying parts between the sites of each process. The cart 40 includes a pallet and an automatic guided vehicle (AGV) in addition to a general-purpose cart. The cart 40 can transmit its own position to the management device 10 via the network 9 and record it in a database.

[0040] In this example, the camera includes a photographing means for monitoring and recording the site for each process. In this example, the camera is used to monitor whether there are any abnormalities in the manufacturing process and to identify the location of the cart 40.

[0041] In this example, the user terminal 90 represents a terminal used by a customer. In this example, the user terminal 90 transmits to the management device 10 order information such as orders received from customers and product delivery dates.

[0042] 3 is a diagram illustrating an example of the functional configuration of the management system 1. In this embodiment, the management device 10 includes a receiving unit 11, an acquiring unit 12, a selecting unit 13, an instructing unit 14, a transport allocation unit 15, an output unit 16, a calculating unit 171, a determining unit 172, a grouping unit 173, a worker allocation unit 174, an access unit 18, a storage unit 191, and a control unit 192. In this example, the storage unit 191 stores various types of data including, for example, a database. In this example, the control unit 192 performs various types of control.

[0043] In this example, the receiving means 11 receives input of delivery dates for products ordered from customers via the user terminal 90 for each of a plurality of products manufactured through a plurality of processes including a punching process for punching one or more parts from a plate material. The receiving means 11 records the received delivery dates in a database.

[0044] In this example, the acquisition unit 12 acquires the man-hours required for each of the plurality of processes from a database in which the man-hours defined for each process are recorded.

[0045] In this example, the selection means 13 selects at least some of the parts from among the multiple parts that make up one or more products for which the punching process has not yet been completed among the ordered products, based on the man-hours and delivery date.

[0046] In this example, the instruction means 14 instructs an allocation means (e.g., the server device 100) that allocates the specified parts to a sheet material for the punching process to allocate the selected parts (nesting allocation). In this example, the instruction is an instruction that includes the parts selected by the management device 10. In addition to the above-mentioned instructions, the instruction means 14 can output various information such as the size, quantity, and material of each part to the server device 100. Based on these instructions, the server device 100 performs nesting allocation.

[0047] In this example, the transport allocation means 15 allocates each of the selected parts obtained from the punching process for the plate material to which the parts selected by the allocation means are allocated to one of the multiple transport means that transports the parts to a work area of ​​a subsequent process after the punching process. In this example, the multiple transport means include multiple transport means of different shapes or types. In this example, the transport allocation means 15 selects one of the multiple transport means according to the transport conditions for each of the parts, and allocates the part to the selected transport means. In this example, the transport conditions include at least one of the shape, size, and weight of the part, and whether or not handling precautions are required. The transport conditions also include conditions for subsequent processes after the punching process for the part and for the workers in the subsequent processes. In this example, the multiple transport means include at least one of a cart, a pallet, and an automated guided vehicle.

[0048] In this example, the output means 16 outputs the allocation result to the user terminal 20. In this example, the output means 16 can output various data including a nesting layout diagram to the user terminal 20 and the punching device 30.

[0049] In this example, the calculation means 171 calculates the latest start date of the part punching process for each of one or more parts that make up each of multiple products using the man-hours and delivery dates. In this example, the latest start date includes a deadline by which the part punching process must be started at least on this day (or time) in order to meet the delivery date of the product. In this example, the selection means 13 selects at least some of the parts based on the latest start date.

[0050] In this example, the determining means 172 determines whether or not the allocation needs to be modified. In this example, if the determining means 172 determines that the modification is necessary, the instructing means 14 instructs the allocating means to modify the allocation.

[0051] In this example, the grouping unit 173 divides at least some of the parts into a plurality of groups, including groups according to products, groups according to parts, groups according to workers, and groups according to delivery dates or latest start dates.

[0052] In this example, the worker assignment means 174 assigns multiple workers to multiple groups for a specific process among multiple processes. Here, the database records the man-hours for each process and each worker. In this example, the acquisition means 12 acquires from the database the man-hours required for the assigned worker to perform the work of the specific process.

[0053] In this example, the access means 18 accesses a database in which the current positions of a plurality of transport means are recorded. In this example, the transport allocation means 15 allocates a part to a transport means that is located at a specific position among the plurality of transport means.

[0054] FIG. 4 is a diagram illustrating an example of the hardware configuration of the management device 10. In this example, the management device 10 is a computer or general-purpose server having a CPU (Central Processing Unit) 101, memory 102, storage 103, and a communication IF 104. The CPU 101 is a processor that performs various calculations according to programs. The memory 102 is a main storage device that functions as a work area when the CPU 101 executes a program, and includes, for example, RAM (Random Access Memory). The storage 103 is an auxiliary storage device that stores various data and programs, and includes, for example, an SSD (Solid State Drive) or an HDD (Hard Disc Drive). The communication IF 104 is a device that communicates with other devices according to a predetermined communication standard, and includes, for example, a NIC (Network Interface Card).

[0055] In this example, the programs stored in the storage 103 include a program (hereinafter referred to as the "server program") for causing a computer to function as a server in the management system 1. When the CPU 101 is executing the server program, the CPU 101, memory 102, storage 103, and communication IF 104 are examples of functions for operating the management device 10. The CPU 101 is an example of an acquisition means 12, a selection means 13, a transport allocation means 15, a calculation means 171, a determination means 172, a grouping means 173, a worker allocation means 174, an access means 18, and a control means 192. At least one of the memory 102 and the storage 103 is an example of a storage means 191. The communication IF 104 is an example of a reception means 11, an instruction means 14, and an output means 16. The server device 100 is a computer or a general-purpose server (not shown) having a hardware configuration similar to that of the above-described management device 10.

[0056] FIG. 5 is a diagram illustrating an example of the hardware configuration of the user terminal 20. In this example, the user terminal 20 is a computer having a CPU 201, memory 202, storage 203, communication IF 204, input device 205, and display device 206, and includes, for example, a smartphone, tablet, or personal computer. The CPU 201 is a processor that performs various calculations according to a program. The memory 202 is a main storage device that functions as a work area when the CPU 201 executes a program, and includes, for example, a RAM. The storage 203 is an auxiliary storage device that stores various data and programs, and includes, for example, an SSD or HDD. The communication IF 204 is a device that communicates with other devices according to a predetermined communication standard, and includes, for example, a wireless chip in the case of wireless communication. The input device 205 is a device for inputting information to the user terminal 20, and includes, for example, a touch screen, keyboard, mouse, or pointing device. The display device 206 is a device that displays information, and includes, for example, an organic electroluminescence (EL) display or liquid crystal display.

[0057] In this example, the programs stored in the storage 203 include a program (hereinafter referred to as a "client program") for causing a computer to function as a client in the management system 1. When the CPU 201 is executing the client program, the CPU 201, memory 202, storage 203, communication IF 204, input device 205, and display device 206 are examples of functions for operating the user terminal 20.

[0058] The user terminal 90 is a computer having the same hardware configuration as the above-described user terminal 20, and includes, for example, a smartphone, a tablet, or a personal computer (not shown). In this example, the user terminal 90 has the same client program as the above-described user terminal 20. The configuration of the management system 1 has been described above. Next, the operation of the management system 1 will be described.

[0059] 3. Operation Figure 6 is a flowchart illustrating an example of the outline of the operation of the management system 1. In this example, the management system 1 proceeds with processing in accordance with the following overall control (flow). In step S1, the management system 1 receives an order for a product from a customer. In this example, the management system 1 obtains the above-mentioned order information and records it in a database.

[0060] In step S2, the management system 1 simulates a schedule for the manufacturing process of multiple products based on the order information. In this example, simulation refers to determining the process for each part on the schedule based on the delivery date of the product. In this example, the management system 1 performs simulation based on the man-hours for each part and the delivery date of the product.

[0061] In step S3, the management system 1 performs nesting allocation. In this example, the management device 10 selects parts to be allocated to the plate based on the schedule determined by the simulation. The management device 10 instructs the server device 100 to perform the allocation. The server device 100 accepts the allocation instruction from the management device 10. The server device 100 performs nesting, allocating the selected parts to the plate.

[0062] In step S4, the management system 1 assigns a transport means to each nested part. In this example, the management system 1 determines in advance which part is to be loaded on which transport means, for example, based on the transport conditions and / or the position of the dolly 40.

[0063] In step S5, the management system 1 manages the punching process. In this example, for example, the punching device 30 installed on-site cuts out each part from the plate material based on the determined nesting allocation.

[0064] In step S6, the management system 1 loads the extracted parts onto the transport means. This process may be performed with the help of a user who is an operator, or using a robot hand or a belt conveyor, etc. At this time, each extracted part is loaded (or placed) onto the corresponding transport means based on predetermined information regarding which transport means it should be loaded onto (or whether it will be placed in a predetermined location without being loaded).

[0065] In step S7, the management system 1 moves the transport means to the site of the subsequent process, or removes the transport means and leaves it at the site. The transport means may be moved, for example, by a worker, or automatically by a transport robot or a belt conveyor.

[0066] In step S8, the management system 1 performs bending, welding, inspection, painting, and / or assembly at the site of the process after moving the parts, and finally ships the product to the customer's destination. At least part of the bending, welding, inspection, painting, and / or assembly processes may be performed manually by workers.

[0067] The above has described an overview of the operation of the management system 1. Note that Fig. 6 is merely an overview of an example of operation, and more specific details of the operation (sequence) are performed by the devices, terminals, equipment, facilities, etc. within the management system 1. Furthermore, the above-described operation is not technically inconsistent with the overview of the related art described in Fig. 1. Next, detailed operations will be described below.

[0068] 3-1. Nesting Allocation Method Figure 7 is a sequence chart illustrating a nesting allocation method in the management system 1. This sequence corresponds to the operations from order receipt to nesting allocation determination in steps S1 to S3 of the operations in Figure 6 described above. In step S101, the management device 10 accepts input of the delivery date of the ordered product from the customer via the user terminal 90. The information accepted includes various order information in addition to the delivery date of the product.

[0069] In step S102, the management device 10 records the received various data in a database. Here, the database for managing the products and parts recorded as data will be described.

[0070] FIG. 8 is a diagram illustrating a product management database. In this example, the product management database 1001 includes multiple records. Each record corresponds to one order. Each record includes a management ID, delivery date, product name / company name, delivery quantity, part name, part quantity, process / man-hours (minutes), and latest start date (excluding). In this example, the management ID includes ID information that can uniquely identify each order based on the order information. In this example, the delivery date includes information indicating the delivery date of the product, such as a date. In this example, the product name / company name includes unique information for identifying the product and the customer. These may also be ID information, etc. In this example, the delivery quantity includes information indicating the quantity of the product required for delivery. In this example, the part name includes unique names or identification information for each part that makes up the product. In this example, the part quantity includes information indicating the quantity of parts required to make up the product. In this example, the process / man-hours (minutes) includes information indicating the process for each part and the man-hours (minutes) required for each process. In this example, the latest start date (exclusion) includes information, such as a date, that indicates the deadline for the excluded process, calculated by calculating the man-hours for each process backward from the product's due date. Here, the product's due date for calculating the latest start date (exclusion) corresponds to the order information received from the customer. Meanwhile, the man-hours for each process are values ​​estimated (simulated) by the management device 10. Next, a method for estimating the man-hours for each process will be described.

[0071] Returning to FIG. 7 , in step S103, the management device 10 refers to various databases and simulates the man-hours for each process, i.e., the product schedule. Here, the various databases required for the simulation and the results of the simulated schedule will be described. The following description will take as an example a welding process performed manually by a human user, such as a worker.

[0072] FIG. 9 is a diagram illustrating welding work efficiency. In this example, the welding work efficiency database 2001 includes the worker name, company name / product name, and work efficiency. In this example, the welding work efficiency database 2001 is a master created in advance. For example, if the product is a repeat product that has been manufactured once, the work efficiency estimated from past performance is recorded as the master. In this example, the worker name includes information representing a member working in a factory or the like who performs welding work at the welding process site. In this example, the company name / product name includes information representing the name of the customer company assigned to the worker and the name of the product ordered by the customer. In this example, the work efficiency includes information representing, for example, the number of minutes (hours) a worker takes to weld one product, i.e., the man-hours. In this example, the work efficiency is calculated in advance based on the worker's performance. Note that even if the product is not a repeat product but is being manufactured for the first time, it may be assigned to any worker. In this case, instead of past performance, a numerical value calculated in advance based on the product work process and specifications detailing the process, taking into account the proficiency of the worker, etc., is recorded in the database. Note that the work efficiency may be set in advance not only for each product but also for each part that makes up the product. Next, a method for simulating the allocation and schedule of workers in a welding process will be described.

[0073] FIG. 10 is a diagram illustrating a welding operation / welding schedule. In this example, the welding operation database 3001 includes the priority, company name, product name, product quantity, product delivery date, part name, part quantity, assigned worker, and welding man-hours (minutes). In this example, the welding operation database 3001 represents a database that records the assigned worker and welding man-hours (minutes) for each product sorted by a predetermined priority (e.g., product delivery date and / or order date). In this example, the welding operation database 3001 assigns a worker to each product by comparing the work efficiency of each assigned worker based on the welding operation efficiency database 2001. The welding operation database 3001 also calculates and records the welding man-hours (minutes) for each assigned worker according to the quantity of each product. Note that in this example, the welding operation database 3001 may also record the welding man-hours (minutes) for each assigned worker for each product, calculated taking into account the quantity of each part. Next, a method for simulating a schedule for a welding process will be described.

[0074] In this example, welding schedule 3002 represents the result of allocating welding man-hours (minutes) for each worker recorded in welding work database 3001 to the schedule of each worker performing welding work. In this example, welding man-hours (minutes) are allocated based on the worker's working hours. In this example, assuming that the actual working hours are 8 hours per day (480 minutes, excluding breaks), 960 welding man-hours (minutes) for Product A, the highest priority, are allocated to the most recent schedule of worker Yamada for two full days, January 11th and January 12th. Similarly, welding man-hours (minutes) are allocated to the respective schedules of workers Tanaka and Sato. Note that this schedule allocation (simulation) result only relates to the welding process. In this example, the welding process is performed manually, so it can be considered an example of a bottleneck in the manufacturing process, i.e., a process that is prone to work stagnation and productivity declines (a process where errors in time prediction results are likely to occur). Therefore, this method was described here as a method for predetermining the welding process. Next, the simulation results for all product processes are described.

[0075] FIG. 11 is a diagram illustrating an example of a total process schedule. In this example, the total process schedule 3003 represents the total process schedule for each product. In this example, the total process schedule 3003 represents the result of a simulation in which a predetermined welding process schedule is used as a reference and the schedules for each other process are determined using a predetermined method. In this example, the man-hours for each process, including the welding process, are calculated using the above-mentioned method or another method. In this example, the man-hours for each process are calculated based on, for example, past performance data for repeat products or the work process in specifications, etc. Note that in this example, the schedule is determined for each product (or each part) rather than for each worker (because each process is not necessarily performed manually). As a result, the management device 10 can simulate a schedule for each product using the above-mentioned method. Finally, the execution date and time of the punching process in the simulated schedule—for example, "1 / 10" for product A—is recorded in the product management database 1001 as the latest start date (punching) for that product. Note that the latest start date (punching) may also be determined for each part.

[0076] Returning to FIG. 7 , in step S104, the management device 10 selects parts for nesting. In this example, the management device 10 selects at least some parts from among the ordered products for which the scraping process has not yet been completed, based on the latest start date (scraping). In this example, "based on the latest start date" refers to selecting parts with reference to the latest start date. For example, this includes selecting parts whose latest start date (scraping) falls within a predetermined period (e.g., the current day, the next working day, and the day after that). Alternatively, "based on the latest start date" includes selecting parts according to a priority order, given in descending order of latest start date (scraping) closest to the current date and time. As described above, the management device 10 can select parts based on the latest start date. The management device 10 may also set an upper limit for the number of parts to be selected based on the man-hours for the scraping process preset for each day, and select parts until the cumulative man-hours required for the selected parts reaches this upper limit.

[0077] In step S105, the management device 10 instructs the server device 100 to perform allocation. In this example, the management device 10 outputs an allocation instruction to the server device 100, which includes various information such as the identification information, size, quantity, and material of each selected part. Note that the various information may include information about the plate material to be allocated.

[0078] When the server device 100 receives the allocation instruction from the management device 10, it allocates each part included in the instruction to a plate, that is, performs nesting (step S106). In this example, nesting onto the plate is performed by a known method based on the viewpoint of yield, etc. Here, nesting will be described.

[0079] FIG. 12 is a diagram illustrating nesting arrangement. In this example, nesting arrangement data 4001 represents an example of nesting data in which selected parts are allocated to boards. In this example, board B1 represents a board (also called a large board) that serves as the base for parts for each product. In this example, part a1 represents a part for product A. In this example, parts for each product, product A, product C, and product D, are nested in board B1. These parts are examples of parts selected by the management device 10 based on the latest start date (omitted) in step S104. Here, the yield R1 shown in FIG. 12 is, for example, a ratio (%) representing the ratio of the total area of ​​the nested parts to the area of ​​board B1. In this example, the server device 100 calculates the yield of each board. The server device 100 allocates the specified parts to board B1 so as to optimize (e.g., maximize) the yield.

[0080] Returning to Fig. 7, in step S107, when the server device 100 completes the nesting allocation, it outputs the created nesting data to the management device 10. In this example, the management device 10 records the output nesting data in a database. Note that the management device 10 may also calculate the total or daily work time required for the punching process based on the output nesting data.

[0081] In step S108, when the management device 10 acquires the nesting data from the server device 100, the management device 10 confirms the data. In this example, confirming the data includes determining whether or not the acquired nesting data (an example of layout) needs to be modified. In one example, an actual person, such as a manager, visually examines the nesting data and determines whether or not the data needs to be modified, or whether or not re-nesting, such as by adding and / or deleting components, is necessary (an example of whether or not modification is necessary), based on various perspectives such as yield. The worker inputs the results of their determination into the management device 10. Based on this input, the management device 10 determines whether or not modification is necessary. If modification is necessary, the management device 10 can again instruct the server device 100 to re-allocate the nesting. Here, step S108 will be described in more detail.

[0082] 13 is a flowchart illustrating a re-nesting method in the management system 1. In step S11, the management device 10 acquires nesting data. In this example, the processing of step S11 corresponds to the processing of step S107 in FIG. 7. For the following operations, the management device 10 cooperates with a worker to proceed with the processing. Note that in this example, cooperation with a worker means that at least some of the decisions related to each step are made by a human (user), such as a worker.

[0083] In step S12, the management device 10 determines whether the yield of the acquired nesting data meets the criteria. In this example, the server device 100 allocates components to maximize yield. However, the yield may not meet the required level, for example, if the total area of ​​the selected components is significantly smaller than the area of ​​the workpiece B1. In this example, if the yield of a certain workpiece (e.g., 20%) is lower than the required yield (e.g., 70% or higher) (i.e., if the proportion of remaining workpieces is as high as 80%), it is preferable to add additional components to achieve a yield above the required level. In this example, if it is determined that the yield does not meet the criteria, the management device 10 reselects components (e.g., adds components). In this example, the reselection of components may be performed using the method described above (based on the latest start date) or a different method. Any method for adding components may be used. In this example, the management device 10 may refer to the schedule again and select components with sufficient time between nesting and processing. Furthermore, when re-nesting is to be performed after the re-selection of the parts, the management device 10 outputs a new allocation instruction to the server device 100 to cause the server device 100 to perform re-nesting. This allows the management device 10 to perform re-nesting by adding parts.

[0084] Here, we will provide some additional information about yield criteria. For example, consider a case where an instruction is given to allocate a total of 100 parts to the plates, but all 100 parts cannot fit on one plate, so 70 parts are allocated to plate B1 and 30 parts are allocated to plate B2.

[0085] In one example, the "yield" is the yield of all the multiple plate materials allocated in response to a single instruction, i.e., (total area of ​​100 parts) / (total area of ​​two plate materials). In this case, there is only one yield value, and whether or not the yield meets the standard is determined for all the multiple plate materials at once. Re-nesting is performed on all 100 parts and added parts.

[0086] In another example, "yield" refers to the yield for each of a plurality of plate materials. For plate material B1, the yield is (total area of ​​70 parts) / (area of ​​the plate material), and for plate material B2, the yield is (total area of ​​30 parts) / (area of ​​the plate material). In this case, there are two yield values ​​(for each plate material), and whether the yield meets the standard is determined individually for each of the plurality of plate materials. Re-nesting is performed on the parts (30 parts in this example) assigned to the plate material whose yield did not meet the standard (plate material B2 in this example) and the added parts.

[0087] The concept of part reselection includes both the addition and deletion of parts. Whether to adopt addition or deletion as part reselection is determined based on set conditions. For example, if the man-hours for the removal process have not reached the upper limit, adding a part is selected, and if the man-hours for the removal process have reached the upper limit, deleting a part is selected. Alternatively, if the period until the latest start date is shorter than the standard, adding a part is selected, and if the period until the latest start date is longer than the standard, deleting a part is selected. Note that these are only examples of items of the determination condition, and whether to adopt addition or deletion may be determined based on a condition that combines these items.

[0088] In step S13, the management device 10 determines whether a new order has been received. In this example, orders from customers are irregular. Therefore, if an order is received during nesting, the management device 10 can consider whether the newly ordered product is applicable to re-nesting. In this example, the management device 10, for example, references a database or the like to determine whether a new order has been received. If a new order has been received, the management device 10, for example, simulates the schedule again, similar to step S103 described above. The management device 10 selects parts for the newly ordered product based on the latest start date in the simulated schedule. The management device 10 allocates the selected parts to the target plate material via the server device 100. This allows the management device 10 to modify the nesting data and add parts to re-nesting.

[0089] In step S14, the management device 10 determines whether the man-hours for the punching process meet the criteria. In this example, the management device 10 determines whether the re-nested nesting data can be implemented within a specified period (e.g., within the same day) based on the judgment of the worker or a worker at the punching site. In this example, if the man-hours for the punching process do not meet the criteria, for example, if the worker determines that the man-hours for the punching process have increased as a result of re-nesting and are not an amount that can be implemented within the same day, the management device 10 deletes any parts (or plate materials) from the re-nested nesting data via the server device 100. This allows the management device 10 to perform re-nesting by deleting parts.

[0090] Returning to FIG. 7 , in step S109, the management device 10 outputs the nesting layout data 4001 described above, i.e., the nesting layout drawing (or simply the nesting drawing) for which allocation to the plate has been completed, to the punching device 30. As described above, the management system 1 can determine the nesting layout taking into account the process schedule. Next, an operating method for determining the allocation of transport means to each part nested in the plate will be described.

[0091] 3-2. Method for Acquiring Position Information of Transport Means FIG. 14 is a sequence chart illustrating a method for acquiring position information of transport means in the management system 1. Here, of the operations in FIG. 6 described above, the operation for acquiring position information of transport means will be described as a preliminary step to step S4. In this example, the position information (an example of the current position) is used when allocating parts removed in the punching process to transport means. Here, the following two types of processing are implemented for the processing in FIG. 14. The first is (A) processing in which the management device 10 acquires position information from a worker via the user terminal 20. The second is (B) processing in which the management device 10 acquires position information directly from the cart 40. First, processing (A) will be described.

[0092] In step SA201, the user terminal 20 receives input of position information of multiple carts 40 from the worker. In this example, the worker searches for an available cart 40 in advance to load the removed parts, and brings it to a predetermined position, for example, a location for the cart 40 to wait. In this example, the worker inputs into the user terminal 20 the identification information (cart ID) of the cart 40 that has been waited at the predetermined position as a transport means that can be used to allocate parts. Note that an empty cart 40 is basically used to load parts. Therefore, the worker also inputs into the user terminal 20 the usage status (availability) of the transport means.

[0093] In step SA202, the management device 10 acquires the position information of the cart 40 from the user terminal 20. In this example, the user terminal 20 transmits the position information of each cart 40 to the management device 10 in accordance with the input content received from the worker.

[0094] In step SA203, the management device 10 records the position information of the cart 40 acquired from the user terminal 20 in the database. In this example, the management device 10 updates the current position of the cart 40 in the database to the latest information. This allows the management device 10 to record the current positions of multiple transport means. Here, the database in which transport means are recorded will be described.

[0095] FIG. 15 is a diagram illustrating examples of transport means and transport conditions. In this example, a transport means database 5001 represents an example of a database showing the correspondence between each transport means and the transport conditions and location information for loading parts. In this example, the transport means database 5001 includes a dolly ID, name / type, transport conditions, location information, and usage status. In this example, the dolly ID includes ID information that uniquely identifies each transport means. In this example, the name / type includes information indicating the type and name of each transport means, such as a dolly, pallet, and AGV (automated guided vehicle). In this example, the transport conditions include, for example, the shape, size, and weight of the part, and whether or not handling precautions are required. In this example, the part shape includes information indicating the shape of the part itself, such as whether the part has a plain shape immediately after punching or whether a bent part can also be loaded. In this example, the size includes the maximum vertical width (X), maximum horizontal width (Y), and maximum height (Z). In this example, the maximum vertical width (X), maximum horizontal width (Y), and maximum height (Z) represent the maximum value (upper limit) of all the parts loaded on the transport means when the three sides of the loading section of the transport means are defined as the X-axis, Y-axis, and Z-axis, respectively. In this example, the maximum weight (total) represents the maximum total weight of all parts that can be loaded on the transport means. In this example, the presence or absence of handling precautions includes information indicating the compatibility of each transport means with the presence or absence of handling precautions previously defined for each part. In this example, the location information includes information indicating the current location of each transport means. The current location includes, for example, the name of the work process site, the name of a predefined area within the factory, coordinates, etc. In this example, the usage status represents information including whether the transport means is capable of loading parts in the punching process and whether the transport means is available. In this example, the location information and usage status are examples of data entered by the worker into the user terminal 20. As a result, the management device 10 can first determine that, among the transport means whose location information indicates the extraction site, the transport means whose usage status indicates that they are available are transport means that can load parts. Second, the management device 10 can select and assign a transport means that meets the transport conditions for each part from among the transport means that it has determined to be available.Next, the process (B) will be described.

[0096] Here, in process (B), it is mainly assumed that the management device 10 acquires location information directly from the cart 40. This includes, for example, a case where a function for allowing the transport means to identify its own location information, such as a GPS (Global Positioning System) and a beacon, is implemented.

[0097] In step SB201, the management device 10 acquires location information from the cart 40. In this example, the cart 40 transmits its own location information within the facility to the management device 10 via the network 9 constantly or at predetermined timing / times / intervals.

[0098] In step SB202, the management device 10 records the position information acquired from the cart 40 in the database. In this example, the management device 10 updates the current position of the cart 40 in the database to the latest information. This allows the management device 10 to record the current positions of multiple transport means. Note that the operations from step SB201 to step SB202 are performed continuously or at a predetermined frequency.

[0099] In addition to the above-mentioned processes (A) and (B), the management system 1 may acquire location information and usage status of the transport means by implementing or combining a method of identifying the current location by photographing the cart parking area with a camera installed at each process site, or by installing sensors throughout the factory and detecting the transport means with the sensors. In addition to the usage status of the transport means, the system may also manage, for example, the load capacity (%), and for this purpose, implementation such as attaching a sensor to the transport means may be added.

[0100] 3-3. Method of Allocating Transport Means Figure 16 is a sequence chart illustrating a method of allocating transport means in the management system 1. Here, we will explain the operation of determining the allocation of transport means to each part nested in the plate material in step S4, among the operations shown in Figure 6 above. In step S301, the management device 10 obtains a nesting diagram from the database. In this example, the management device 10 obtains, for example, the nesting arrangement data 4001 described above. Here, it is assumed that each part included in the nesting arrangement data 4001 is assigned to a transport means.

[0101] In step S302, the management device 10 accesses a database in which the current positions of a plurality of transport means are recorded. In this example, the management device 10 can refer to the transport means database 5001 described above to acquire the transport conditions, position information, and usage status of the cart 40. In this example, the management device 10 can identify an available transport means based on the acquired position information and usage status, for example, whether a cart 40 located near the site of the punching process is available for use.

[0102] In step S303, the management device 10 refers to a schedule (e.g., the overall process schedule 3003) and acquires information about the subsequent process for each part and the workers involved in the subsequent process. This allows the management device 10 to acquire and link information about the subsequent process for each part in the nesting diagram. The acquired data is used to present the subsequent process for each part to the workers.

[0103] In step S304, the management device 10 assigns one of the carts 40 determined as available transport means to each part. In this example, the management device 10 selects one of multiple transport means for each part according to the transport conditions in the transport means database 5001 described above, and assigns the selected transport means to the part. In this example, the management device 10 assigns transport means to each part by, for example, determining whether the size of each part (particularly the length and width) is within the specified size of the transport means, starting with the parts assigned to the plate material by the management device 10. Alternatively, the heights of each part are added up and allocation is continued until a maximum height is reached. Alternatively, allocation is continued until the weight of each part reaches a maximum weight. Alternatively, allocation is performed by referring to a schedule and determining whether the shape of the part changes during the bending process, i.e., whether the transport means is compatible with parts whose three-dimensional shape changes during the bending process. Alternatively, allocation is performed based on whether the transport means is compatible with the presence or absence of handling precautions for each part. In this example, any method of assigning transport means may be used as long as it is based on transport conditions, a schedule, etc. Here, the allocation of conveyance means to each nested part will be described.

[0104] FIG. 17 is a diagram illustrating the results of conveyance means allocation. In this example, plate B1 represents a nesting diagram of each part to be punched in the punching process. Plate B1 includes the nesting arrangement data 4001 described above. In this example, an allocation database 6001 represents information on conveyance means and subsequent processes assigned by the management device 10 to each part in plate B1. In this example, the allocation database 6001 includes plate ID, product name, part name, cart ID, and subsequent process / scheduled implementation date / worker. Furthermore, in this example, the plate ID includes ID information for uniquely identifying the punching process (batch processing) of the plate and part to be punched based on the nesting arrangement data 4001 described above. In this example, the product name and part name include information for uniquely identifying the product and part punched in the punching process corresponding to the plate ID. In this example, the cart ID includes unique ID information for the conveyance means (cart 40) assigned by the management device 10 to each part. In this example, the subsequent process / planned implementation date / worker includes a list of whether or not there is a subsequent process after the punching process for each part (or each product), the planned implementation date for each process, and, if there is a worker in charge, information indicating the name of that worker. In this example, the management device 10 can manage, for each part, whether or not there is a subsequent process, the planned implementation date if there is one, and information about the worker. In this example, the allocation database 6001 may also include instructions for the cart 40 loaded with parts, such as a move instruction / remaining instruction corresponding to each subsequent process.

[0105] Returning to FIG. 16 , in step S305, the management device 10 outputs the allocation results to the user terminal 20. In this example, the allocation results include information in the nesting arrangement data 4001 and the allocation database 6001. In other words, the allocation results include information on parts to be removed / that have been removed by the removal process, as well as information on the transport means and subsequent processes assigned to each part. Note that the part removal process itself may be performed at any time as long as the nesting allocation and transport means assignment have been completed.

[0106] In step S306, the user terminal 20 prints the allocation results acquired from the management device 10 as a label. In this example, the user terminal 20 inputs necessary data from the allocation results into a predetermined format for printing labels. In this example, the user terminal 20 is connected to a predetermined printing device. In this example, the user terminal 20 uses the printing device to print labels that reflect various data. Here, the labels will be described.

[0107] FIG. 18 is a diagram illustrating an example of a label. In this example, label L1 represents a printed label reflecting various data. In this example, label L1 includes the plate material ID, part name, product name, cart ID, and subsequent process / scheduled implementation date / worker. Note that any data may be printed on label L1 as long as it is information that improves the worker's workability and convenience. In this example, a label is printed for each part. Various information is printed on the front side of the label. Note that the back side of the label may have a function that allows it to be attached (or removed) from the part, such as a sticker function. This allows the worker to attach the label to each part cut from plate material B1, for example, based on the information printed on the label.

[0108] Returning to Fig. 16, in step S307, the worker obtains the printed label from the user terminal 20 via the printing device.

[0109] In step S308, the worker attaches a label to each part. In this example, the parts are placed around the punching device 30 at the punching site after being cut (hollowed out) from the sheet metal. Therefore, the worker attaches the corresponding label to each part while referring to the information printed on the label, for example, according to the nesting diagram displayed on the user terminal 20 or the punching device 30. Note that once all the labels have been printed, the worker at the punching site may sort the transport means in a predetermined location by part or by worker in the subsequent process.

[0110] In step S309, the worker attaches a label to each part and then removes the part from the plate. At this stage, although each part has already been separated from the plate, the part still retains its position relative to the plate as represented in the nesting diagram, so the worker must remove the part from the plate.

[0111] In step S310, the worker loads the removed parts onto the cart 40 based on the label. In this example, once all the removed parts have been loaded onto the cart 40, the worker moves the cart 40 to the work site of the subsequent process based on the label or a previously notified schedule. Note that these movements may be performed based on instructions for the cart 40 loaded with parts, such as a movement instruction / remaining instruction corresponding to each subsequent process, in the allocation database 6001. In other words, the worker may use any method to determine how to operate the cart 40. Here, the movement of the transport means between processes will be described.

[0112] FIG. 19 is a diagram illustrating the movement of a transport means between processes. In this example, an inter-process movement model 7001 is an example of a model that schematically represents how a transport means loaded with each part moves between processes. In this example, the inter-process movement model 7001 is managed in a database or the like of the management device 10. In this example, the inter-process movement model 7001 has a process flow including a punching process, a bending process, a welding process, ... (omitted) ..., and a shipping process. In this example, the inter-process movement model 7001 represents the work for each process of the transport means represented by various cart IDs. In this example, the work for each process includes, for example, the work day, the loading and unloading, stacking, reloading, and reloading of each part, as well as movement instructions and remaining instructions for each transport means. In this example, a transport means indicated by a transport ID of "001" (hereinafter referred to as "transport means 001") loads, for example, parts c1 and c2 of product C and parts d1 and d2 of product D in the punching process. In this example, transport means 001 unloads only the parts of product D in the bending process on January 11th. Then, the process proceeds to the welding process, where transport means 001 unloads all the remaining parts of product C on January 11th. Furthermore, transport means 001 stacks the welded parts of product C in the welding process in the afternoon of January 12th. Then, transport means 001 passes through the inspection process and proceeds to the workplace of the subsequent process. A similar inter-process movement model is also provided for a transport means indicated by a transport ID of "002" in this example. Note that inter-process movement model 7001 merely represents one example of an inter-process movement model, and information about the parts and transport means for each process may be reflected in the inter-process movement model in any way. Furthermore, at least a part of these inter-process movement models may be shared with workers. This can improve the workability and convenience of the workers. In this example, the workers may freely manage the operation of the transport means using these inter-process movement models. In this example, if parts need to be added to the transport means in a certain process, an extra transport means may be prepared in advance for each process. Similarly, if the shape of a part changes due to a bending process or the like and replacement is required, a transport means optimal for the shape of the part after deformation may be prepared for each process.

[0113] As described above, the management system 1 can classify each part by transportation means such as a cart and present various information to the worker who moves the cart. This allows for appropriate operational management of removed parts, improving the workability of each process. It also improves convenience by preventing parts from being lost, parts whose whereabouts are unknown being left on-site, and workers from being unable to understand the subsequent process of a part. Furthermore, by using a model of the movement of transportation means between processes, the manageability and operability of transportation means, etc. are improved.

[0114] 4. Modifications The present invention is not limited to the above-described embodiment, and various modifications are possible. Some modifications will be described below. Two or more of the following features may be combined and applied.

[0115] (1) Management System 1 The hardware configuration and network configuration of the management system 1 are not limited to those exemplified in the embodiment. The management system 1 may have any hardware configuration and network configuration as long as the required functions can be realized. For example, multiple physical devices may cooperate to function as the management system 1. Note that the entities, configuration, and system structure shown in FIG. 2 are merely an example and merely represent an overview of the system. Therefore, the management system 1 may have a configuration in which, for example, a user terminal 20 manages each device via a network established for each site.

[0116] (2) Management Device 10 / Server Device 100 Some of the functions of the management device 10 may be implemented in another server. This server may be, for example, a physical server or a virtual server (including a so-called cloud). Furthermore, the correspondence between functional elements and hardware is not limited to that illustrated in the embodiment. For example, in the embodiment, at least some of the functions described as being implemented in the management device 10 may be implemented in another device or system. Conversely, at least some of the functions described as being implemented in another device or system may be implemented in the management device 10. In this example, the management device 10 may have at least some of the functions of, for example, the server device 100, the user terminal 20, the pull-out device 30, and / or the cart 40. For example, it may be configured to constantly acquire various data from each device. Furthermore, the management device 10 may perform nesting allocation processing on behalf of the server device 100. Furthermore, the server device 100 is not limited to that illustrated in the embodiment. At least some of the allocation means of the server device 100 may be implemented in the management device 10. This allows the management device 10 to perform the nesting allocation process described above.

[0117] (3) User Terminal 20 and User Terminal 90 The user terminal 20 and user terminal 90 are not limited to those illustrated in the embodiment. In this example, users (workers, customers, etc.) using each terminal use the management system 1 via their own terminals, but the above-described configuration and operation may be realized by any display screen, input device, and various UIs. Furthermore, the user terminal 20 may be configured to be connected to various devices in addition to the printing device. In this example, the user terminal 20 may have a device capable of imparting a sticker function to printed materials. This allows the sticker function to be imparted to the printed labels. Furthermore, the method of presenting various information to the worker is not limited to labels, and any method or means may be used.

[0118] (4) Punching Device 30 The punching device 30 is not limited to the example shown in the embodiment. In this example, the punching device 30 may be a press machine, a laser processing machine, a gas cutting machine, a plasma cutting machine, or the like. Furthermore, the punching device 30 may have any hardware configuration as long as it can achieve the required functions and operations. In this example, the punching device 30 may be configured to include a CPU for analyzing and processing the acquired nesting diagram, a memory or storage as a storage means for storing various data, a communication IF for communicating with each device, an input device for receiving various operations from the operator, and / or a display device for displaying various data.

[0119] (5) Carriage 40 (Transportation Means) The carriage 40 (transportation means) is not limited to the one exemplified in the embodiment. In this example, the carriage 40 may be a carriage, a pallet, a forklift, an automated guided vehicle, a belt conveyor, an elevator (elevator or lift), a transport robot (robot arm), or the like. Furthermore, the carriage 40 may have any hardware configuration as long as it can realize the required functions and operations. In this example, the carriage 40 may be configured to include a CPU for performing various data processing, such as calculating the current position of the carriage, simulating a movement path, or calculating the cargo occupancy rate, a memory or storage as a means for storing various data, a communication IF for performing communication processing with each device, an input device for receiving various operations from a worker, and / or a display device for displaying various data.

[0120] (6) Camera The camera (photographing means) is not limited to the one exemplified in the embodiment. The camera may have any hardware configuration as long as it can achieve the required functions and operations. In this example, the camera may have a CPU for executing various data processing, a memory or storage for storing various data, a communication IF for communicating with each device, an input device for receiving various operations from the worker, and / or a display device for displaying various data.

[0121] (7) Products and Parts The products and parts are not limited to those exemplified in the embodiments. In this example, the products may be any type, such as metal / non-metal products, plastic products, mechanical / electronic products, wooden products, and leather products. In this example, the parts may be any type, such as metal / non-metal parts, plastic parts, mechanical / electronic parts, wooden parts, and leather parts.

[0122] (8) Plate Material The plate material is not limited to those exemplified in the embodiment. In this example, the plate material may be any material, such as a metal plate, for example, a mild steel plate, a stainless steel plate, a surface-treated steel plate, an aluminum plate, or a copper plate. Alternatively, the plate material may be a wood material.

[0123] (9) Overview of Operation The flowchart shown in FIG. 6 merely shows one example of the operation, and the operation of the management system 1 and the management device 10 is not limited to this. Some of the illustrated operations may be omitted, the order may be changed, or new operations may be added. In this example, if a part is about to be removed by the removal device 30 in step S5, the allocation of transport means in step S4 may be performed a predetermined time after the nesting allocation in step S3. This allows the management system 1 to update the allocation to an optimal one depending on the status of the transport means.

[0124] (10) Nesting Allocation Method The sequence chart shown in FIG. 7 merely illustrates an example of the operation, and the operation of the management system 1 is not limited to this. Some of the illustrated operations may be omitted, the order may be changed, or new operations may be added. In this example, in step S103, the management device 10 may divide at least some of the parts into multiple groups, such as product groups or customer groups, before simulating the process schedule. Furthermore, the management device 10 may assign multiple workers to multiple groups for a specific process (e.g., a welding process) among multiple processes. This allows the management device 10 to assign a worker to each product group or customer group. This is implemented as a process for registering data in the welding operation database 3001. Note that any method may be used to assign workers to each part.

[0125] In this example, in step S104, the management device 10 selects parts in order of closest to the current date and time based on the latest start date for each part calculated by simulation, but the parts may be selected in any order. For example, the management device 10 may select parts based on the above-mentioned groups. In this example, if there are multiple parts with the same (simultaneous) latest start date, the management device 10 may, for example, preferentially select one of the parts, and may also select multiple parts classified into the same product group in order.

[0126] In this example, the processes from simulation to nesting performed by the management system 1 in steps S103 to S106 may be performed, for example, when an order is received. If nesting is performed when an order is received, the management system 1 can calculate in advance approximately how many plate materials will be used.

[0127] In this example, the process of checking the nesting data performed by the management device 10 and the worker, etc. in step S108 may be entirely (i.e., automatically) performed by the management device 10. In this example, the worker may input predetermined standards such as yield and control for when the standards are not met as a program, thereby changing the implementation so that checking the nesting data, correcting it, reselecting parts, resimulating, deleting parts, etc. are all performed by the management device 10.

[0128] The flowchart shown in FIG. 13 merely illustrates one example of the operation, and the operation of the management device 10 is not limited to this example. Some of the illustrated operations may be omitted, the order may be changed, or new operations may be added. In this example, any decision may be used as a trigger to execute re-nesting, such as adding a part, modifying the nesting, or deleting a part / plate, in steps S12 to S14. In this example, the management device 10 may determine the re-nesting execution content based on the operational status of the transport means (cart 40) or the number of parts remaining at the removal site. Furthermore, the management device 10 may implement at least some of the operator's decisions as a function expressed in a program or the like. This allows the management device 10 to automatically determine the re-nesting execution content (instructions) without waiting for the operator's decision.

[0129] (11) Method for Acquiring Location Information of Transportation Vehicles The sequence chart shown in FIG. 14 merely illustrates one example of the operation, and the operation of the management system 1 is not limited to this. Some of the illustrated operations may be omitted, the order may be changed, or new operations may be added. In this example, any method may be used to acquire the location information and usage status of transportation vehicles. In addition to the above-described cameras and sensors, any device that acquires the location information and usage status of transportation vehicles may be introduced or implemented in the management system 1 and / or management device 10. Furthermore, any data representing the location information and usage status recorded in the database may be used. Alternatively, the management system 1 may not manage the location information of transportation vehicles. In other words, the management system 1 may not record the location information of transportation vehicles in the database. In this case, an operator may visually check and use available transportation vehicles.

[0130] (12) Method for Allocating Transport Means The sequence chart shown in FIG. 16 merely illustrates an example of the operation, and the operation of the management system 1 is not limited to this. Some of the illustrated operations may be omitted, the order may be changed, or new operations may be added. In this example, in step S304, the management device 10 may select a transport means based on transport conditions, including conditions regarding subsequent processes after the punching process and the workers involved in those processes, and allocate the parts to the selected transport means. This allows the management device 10 to allocate parts to transport means for each process and worker involved in the subsequent process after the punching process, thereby improving workability and convenience. Furthermore, any type of data representing the transport conditions may be recorded in the database. Furthermore, if the transport means is a robotic arm, for example, in step S305, allocation data from various databases may be output to a control device on the arm. In this example, the arm can load parts onto a cart according to the output data.

[0131] (13) Database The database (or the data itself) of the management system 1 shown in Figures 8, 9, 10, 11, 15, and 17 is not limited to the example shown in the embodiment. In this example, any type of data may be registered in the database, such as customer information, order information, product specifications, schedule information, and drawing data. The layout of the database is not limited to the one shown in the figure, and data may be managed in any layout. The data output by the management device 10 to each device may be any type of data registered in the database.

[0132] (14) AI With regard to the configurations and operations exemplified in the embodiments, AI and machine learning functions may be implemented in the management system 1. In this example, with regard to the implementation of AI in the management system 1, for example, functions for determining and proposing an optimal nesting arrangement related to the operations of the present invention, allocating a transport means to parts cut out in the punching process, and other functions for managing the schedules of processes and workers may be implemented.

[0133] (15) Blockchain With respect to the configuration and operation exemplified in the embodiment, blockchain technology may be applied to the management system 1. In this example, with respect to the application of blockchain technology to the management system 1, for example, data registered in a database may be recorded on a blockchain network. This makes it possible to protect various types of data in a manner that prevents them from being deleted or rewritten. In addition, any type of data may be recorded on the blockchain network.

[0134] (16) Others The various programs executed by CPU 101, CPU 201, etc. may be provided by downloading via a network such as the Internet, or may be provided in a state recorded on a computer-readable non-transitory recording medium such as a DVD-ROM. Note that each processor may be, for example, an MPU (Micro Processing Unit) or a GPU (Graphics Processing Unit) instead of a CPU.

[0135] 1... management system, 10... management device, 100... server device (allocation means), 20... user terminal, 30... removal device, 40... cart (transport means), 90... user terminal, 9... network, 11... reception means, 12... acquisition means, 13... selection means, 14... instruction means, 15... transport allocation means, 16... output means, 171... calculation means, 172... determination means, 173... grouping means, 174... worker allocation means, 18... access means, 191... storage means (DB), 192... control means, 101... CPU, 102... memory, 103 ...storage, 104...communication IF, 201...CPU, 202...memory, 203...storage, 204...communication IF, 205...input device, 206...display device, 1001...product management database, 2001...welding work efficiency database, 3001...welding work database, 3002...welding schedule, 3003...total process schedule, 4001...nesting arrangement data, 5001...transport means database, 6001...allocation database, 7001...inter-process movement model, B...plate material, R...yield (rate), L...label

Claims

1. A management device having: a receiving means for receiving input of a delivery date for each of a plurality of products ordered from a customer for which the products are manufactured through a plurality of processes including a punching process of punching one or more parts from a sheet metal; an acquiring means for acquiring the man-hours required for each of the plurality of processes; a selecting means for selecting at least a portion of a plurality of parts constituting one or more ordered products for which the punching process has not been completed, based on the man-hours and the delivery date; an instructing means for instructing an allocating means, which allocates the specified parts to the sheet metal for the punching process, to allocate the selected parts; a transport allocation means for allocating each of the selected parts obtained from the punching process for the sheet metal to which the selected parts have been allocated by the allocation means, to one of a plurality of transport means for transporting the selected parts to a work site for a subsequent process after the punching process; and an output means for outputting the results of the allocation.

2. The management device according to claim 1, further comprising a calculation means for calculating a latest start date for a punching process for one or more parts constituting each of the plurality of products using the labor hours and the delivery date, and wherein the selection means selects at least some of the parts based on the latest start date.

3. A management device as described in claim 1, further comprising a decision means for deciding whether or not the allocation needs to be modified, and when the decision means decides that the modification is necessary, the instruction means instructs the allocation means to modify the allocation.

4. The management device according to claim 1, wherein said acquisition means acquires the man-hours required for each of said plurality of processes from a database in which man-hours defined for each process are recorded.

5. The management device according to claim 4, further comprising: a grouping means for dividing the at least some of the parts into a plurality of groups; and a worker allocation means for allocating a plurality of workers to the plurality of groups for a specific process among the plurality of processes, wherein the man-hours are recorded in the database for each process and for each worker, and the acquisition means acquires from the database the man-hours required for the assigned worker to perform the work of the specific process.

6. The management device according to claim 1, wherein the plurality of conveying means includes a plurality of conveying means differing in shape or type, and the conveying allocation means selects one conveying means from the plurality of conveying means in accordance with the conveying conditions of each of the parts, and allocates the part to the selected conveying means.

7. The management device according to claim 6, wherein the transport conditions include at least one of conditions regarding the shape, size, weight, and whether or not the part requires special handling.

8. The management device according to claim 6, wherein the transport conditions include conditions related to a subsequent process subsequent to the punching process for the part and a worker in the subsequent process.

9. The management device according to claim 6, wherein the plurality of transport means includes at least one of a dolly, a pallet, and an unmanned transport vehicle.

10. The management device according to claim 1, further comprising an access means for accessing a database in which the current positions of the plurality of transport means are recorded, and the transport allocation means allocates the part to a transport means located at a specific position among the plurality of transport means.

11. A management method comprising the steps of: receiving input of a delivery date for each of a plurality of products ordered from a customer for which the products are manufactured through a plurality of processes including a punching process of punching one or more parts from a sheet metal; acquiring the man-hours required for each of the plurality of processes; selecting at least some of the parts from among a plurality of parts constituting one or more ordered products for which the punching process has not been completed, based on the man-hours and the delivery date; instructing an allocation means that allocates the specified parts to the sheet metal for the punching process to allocate the selected parts; allocating each of the selected parts obtained from the punching process for the sheet metal to which the selected parts have been allocated by the allocation means, to a transport means among a plurality of transport means that transports the part to a workplace of a subsequent process after the punching process; and outputting the results of the allocation.

12. A program for causing a computer to execute the following steps: receiving input of the delivery date of each of a plurality of products ordered from a customer for which the products are manufactured through a plurality of processes including a punching process of punching one or more parts from a sheet metal; acquiring the man-hours required for each of the plurality of processes; selecting at least some of the parts from among a plurality of parts constituting one or more ordered products for which the punching process has not been completed, based on the man-hours and the delivery date; instructing an allocation means that allocates the specified parts to the sheet metal for the punching process to allocate the selected parts; allocating each of the selected parts obtained from the punching process for the sheet metal to which the selected parts have been allocated by the allocation means, to a transport means among a plurality of transport means that transports the part to a workplace of a subsequent process after the punching process; and outputting the results of the allocation.

Images