Sewing management system and sewing management method

Abstract

A sewing management system (1) comprises: a correlation data storage unit (61) for storing correlation data indicating a relationship between a plurality of sewing steps for sewing a sewn object (100) using a sewing machine (2), and an inspection level associated with an inspection step of the sewn object (100) that is carried out after the sewing steps; and an output unit (62) for causing an output device (13) to output the inspection level matched to the inspection step.

Description

Sewing management system and sewing management method

[0001] The present disclosure relates to a sewing management system and a sewing management method.

[0002] In the technical field related to the stitching management system, a stitching management system such as that disclosed in Japanese Patent Application Laid-Open No. 2003-122266 is known.

[0003] Japanese Patent Application Publication No. 2020-168056

[0004] The sewing object sewn in the sewing process is inspected in the inspection process. When there are multiple inspection processes, if the inspection level of each of the multiple inspection processes is uniformly high or low, there is a possibility that the inspection will not be carried out properly.

[0005] The present disclosure aims to properly inspect a sewing object.

[0006] The sewing management system according to the present disclosure includes a correlation data storage unit that stores correlation data indicating the relationship between a plurality of sewing processes for sewing an object to be sewn using a sewing machine and an inspection level for an inspection process for the object to be sewn that is carried out after the sewing processes, and an output unit that outputs the inspection level according to the inspection process to an output device.

[0007] According to the sewing management system according to the present disclosure, the sewing object is inspected appropriately.

[0008] FIG. 1 is a diagram schematically showing a sewing management system according to an embodiment. FIG. 2 is a hardware configuration diagram showing a management controller according to an embodiment. FIG. 3 is a functional block diagram showing a management device, a sewing machine, and an information terminal according to an embodiment. FIG. 4 is a diagram showing an example of correlation data according to an embodiment. FIG. 5 is a flowchart showing a sewing management method according to an embodiment. FIG. 6 is a diagram showing an example of correlation data displayed on a display device of a first information terminal according to an embodiment.

[0009] Hereinafter, embodiments of the present disclosure will be described with reference to the drawings, but the present disclosure is not limited to the embodiments. The components of the embodiments described below can be combined as appropriate. In addition, some components may not be used.

[0010] [Sewing Management System] FIG. 1 is a diagram schematically illustrating a sewing management system 1 according to an embodiment. The sewing management system 1 includes a management device 3 that manages a production process of a sewn product. The production process includes a sewing process in which a sewing object 100 is sewn using a sewing machine 2, and an inspection process in which the sewing object 100 sewn in the sewing process is inspected. The sewing machine 2 is an industrial sewing machine. The sewn product is produced in a production line that includes the sewing machine 2. A plurality of sewing machines 2 are installed in the production line. The production line is installed in a sewing factory. The sewing machines 2 operate in the sewing factory. The sewing object 100 is sewn by the sewing machine 2, thereby producing a sewn product. In the embodiment, the management device 3 is installed in the sewing factory. Note that the management device 3 may be installed outside the sewing factory.

[0011] In the sewing process, a sewing object 100 is sewn by a sewing machine 2 to produce a sewn product. An example of the sewing object 100 is fabric. An example of the sewn product is clothing. In the example shown in FIG. 1 , the sewing object 100 includes a first sewing object 100A for producing a T-shirt and a second sewing object 100B for producing a dress shirt.

[0012] A sewing factory is equipped with multiple types of sewing machines 2 according to their intended use. A sewing factory is equipped with multiple types of sewing machines 2 corresponding to the multiple sewing processes for producing sewn products. Examples of the types of sewing machines 2 include a lockstitch sewing machine for sewing together body parts, a button sewing machine for attaching buttons to body parts, and a pocket sewing machine for attaching pockets to body parts. Many types of sewing machines 2 are installed in one sewing factory. For ease of explanation, three sewing machines 2 are shown in FIG. 1. A first sewing machine 2A is used in a first process for producing sewn products. A second sewing machine 2B is used in a second process for producing sewn products. A third sewing machine 2C is used in a third process for producing sewn products. A sewing factory may be equipped with multiple sewing machines 2 of the same type.

[0013] A manager, workers, and inspectors work in a sewing factory. The manager manages the workers, inspectors, and sewing machine 2. The workers sew the sewing object 100 using the sewing machine 2 in the sewing process. The inspectors inspect the sewing object 100 sewn by the sewing machine 2 in the inspection process. Each of the manager, workers, and inspectors may be considered to be a user of the sewing machine 2. The manager may be one person or multiple people. The workers may be one person or multiple people. For example, one worker may operate multiple sewing machines 2. The inspectors may be one person or multiple people.

[0014] The management device 3 has a display device 4, an input device 5, and a management controller 6. The display device 4 displays display data. The display device 4 includes a flat panel display such as a liquid crystal display or an organic EL display. The input device 5 generates input data when operated by an administrator. The input device 5 may be operated by a worker or an operator. The input device 5 includes a touch panel (touch sensor) arranged on the display screen of the display device 4. The input device 5 may be a computer keyboard, a mouse, or a voice input device. The management controller 6 includes a computer system. The management controller 6 has at least one processor and a main memory that stores computer programs executable by the processor.

[0015] The sewing machine 2 has a sewing machine controller 8. The sewing machine controller 8 includes a computer system. The sewing machine controller 8 has at least one processor and a main memory that stores a computer program executable by the processor.

[0016] An inspector inspects the sewing object 100 in the inspection process. The inspection of the sewing object 100 includes an intermediate inspection in which the sewing object 100 has undergone some of the sewing processes, and a final inspection in which the sewing object 100 has undergone all of the sewing processes. The inspector carries an information terminal 11. Examples of the information terminal 11 include a tablet terminal or a smartphone. The information terminal 11 includes a display, an input device such as a touch panel, and a computer system. In the example shown in FIG. 1 , the intermediate inspection is an inspection process in which the sewing object 100 has undergone the second process. The final inspection is an inspection process in which the sewing object 100 has undergone the third process. The information terminal 11 includes a first information terminal 11A carried by an inspector who performs the intermediate inspection and a second information terminal 11B carried by an inspector who performs the final inspection.

[0017] The management device 3 is shared by a plurality of sewing machines 2 and information terminals 11 in a sewing factory. The number of management devices 3 is smaller than the number of sewing machines 2. The number of management devices 3 is smaller than the number of information terminals 11. The management device 3 can communicate with each of the sewing machines 2 and the information terminal 11. The management controller 6 of the management device 3 communicates with each of the sewing machine controllers 8 of the sewing machines 2 and the information terminal 11. The management controller 6, sewing machine controller 8, and information terminal 11 communicate wirelessly. The management controller 6, sewing machine controller 8, and information terminal 11 communicate wirelessly via a local area network (LAN). An example of a wireless LAN is Wi-Fi (registered trademark). The management controller 6, sewing machine controller 8, and information terminal 11 may also communicate wirelessly via a personal area network (PAN). An example of a wireless PAN is Bluetooth (registered trademark).

[0018] The management controller 6 transmits a control command to the sewing machine controller 8 of the sewing machine 2 based on input data generated by operating the input device 5 .

[0019] The sewing machine controller 8 transmits operation data of the sewing machine 2 to the management controller 6. The operation data of the sewing machine 2 includes operating conditions of the sewing machine 2. The operating conditions of the sewing machine 2 include stitch length, stitch pitch, stitch pattern, feed speed of the sewing object, number of stitches, thread tension, and presser foot pressure on the sewing object. The sewing machine controller 8 monitors the operating conditions of the sewing machine 2. The sewing machine 2 is provided with a sensor that detects the operating conditions of the sewing machine 2. Examples of the sensor include a tension sensor that detects thread tension and a presser foot pressure sensor that detects presser foot pressure on the sewing object. The sewing machine controller 8 can monitor the operating conditions of the sewing machine 2 by acquiring the detection data of the sensor. The sewing machine 2 also has a sewing machine motor for operating the needle bar and thread take-up. The sewing machine controller 8 can monitor the operating conditions of the sewing machine 2 by acquiring a drive signal of the sewing machine motor. The operation data of the sewing machine 2 also indicates the operating history of the sewing machine 2. The operation history of the sewing machine 2 includes at least one of the operation date and time of the sewing machine 2, the continuous operation time of the sewing machine 2, the cumulative operation time of the sewing machine 2, the type of sewing object sewn by the sewing machine 2, the number of stitches during sewing, error information that occurred in the sewing machine 2, and the operator who operated the sewing machine 2.

[0020] In this embodiment, the information terminal 11 has an identification device 15 that identifies the identification tag 101 attached to the sewing object 100 (see FIG. 3 ). The identification device 15 outputs identification data indicating the identification result of the identification tag 101. The identification tag 101 is attached to the sewing object 100 to identify the sewing object 100. The identification tag 101 includes a first identification tag 101A for identifying the first sewing object 100A and a second identification tag 101B for identifying the second sewing object 100B. The first identification tag 101A is attached to the first sewing object 100A. The second identification tag 101B is attached to the second sewing object 100B. The identification tag 101 is detachable from the sewing object 100. The identification tag 101 is exemplified by an RFID tag or a two-dimensional code tag on which a two-dimensional code is printed. The identification device 15 is exemplified by an RFID reader or a two-dimensional code reader. The two-dimensional code reader includes a camera provided in the information terminal 11. The information terminal 11 transmits identification data indicating the result of identification of the identification tag 101 by the identification device 15 to the management controller 6.

[0021] The management controller 6 collects operation data of each of the plurality of sewing machines 2. The management controller 6 causes the display device 4 to display the operation data of each of the plurality of sewing machines 2.

[0022] The inspector operates the input device of the information terminal 11 to input the inspection results of the sewing object 100 to the information terminal 11. The information terminal 11 transmits inspection data indicating the inspection results of the sewing object 100 to the management controller 6.

[0023] The management controller 6 transmits guidance data indicating the inspection items and inspection methods for the sewing object 100 to the information terminal 11. The guidance data is displayed on a display device 13 (see FIG. 3 ) of the information terminal 11. The inspector inspects the sewing object 100 while checking the guidance data displayed on the display device 13.

[0024] [Computer System] FIG. 2 is a hardware configuration diagram showing a management controller 6 according to an embodiment. The management controller 6 includes a computer system 1000. The computer system 1000 includes a processor 1001 such as a CPU (Central Processing Unit), a main memory 1002 including a nonvolatile memory such as a ROM (Read Only Memory) and a volatile memory such as a RAM (Random Access Memory), a storage 1003, and an interface 1004 including an input / output circuit. The functions of the management controller 6 are stored in the storage 1003 as a computer program. The processor 1001 reads the computer program from the storage 1003, loads it into the main memory 1002, and executes processing in accordance with the computer program. The computer program may be distributed to the computer system 1000 via a network.

[0025] Similarly, each of the sewing machine controller 8 and the information terminal 11 includes a computer system having a processor, a main memory, a storage, and an interface.

[0026] [Management Device, Sewing Machine, and Information Terminal] FIG. 3 is a functional block diagram showing the management device 3, sewing machine 2, and information terminal 11 according to an embodiment. As shown in FIG. 3, the information terminal 11 includes a terminal controller 12, a display device 13 such as a flat panel display, an input device 14 such as a touch panel, and an identification device 15. The input device 14 generates input data when operated by an inspector. The input device 14 may also be operated by a worker or a manager. The terminal controller 12 transmits the input data generated by operating the input device 14 to the management controller 6. The identification device 15 outputs identification data indicating the identification result of the identification tag 101 by the identification device 15. The terminal controller 12 transmits the identification data indicating the identification result of the identification tag 101 by the identification device 15 to the management controller 6. The display device 13 displays guidance data indicating the inspection items and inspection methods for the sewing object 100 transmitted from the management controller 6.

[0027] The management controller 6 includes a correlation data storage unit 61 and an output unit 62 .

[0028] The correlation data storage unit 61 stores correlation data indicating the relationship between a plurality of sewing processes for sewing the sewing object 100 using the sewing machine 2 and an inspection level for an inspection process for the sewing object 100 that is carried out after the sewing process. The correlation data is determined in advance. The correlation data is input to the management controller 6 from, for example, the input device 5. For example, an administrator operates the input device 5 to store the correlation data in the correlation data storage unit 61.

[0029] In the embodiment, the correlation data indicates the relationship between the sewing process, the inspection process, the sewing object 100, and the inspection level. As described with reference to FIG. 1 , in the embodiment, the sewing process includes a first process, a second process, and a third process. The inspection process includes an intermediate inspection and a final inspection. The intermediate inspection may include, for example, a first intermediate inspection that inspects the sewing object 100 after the first process, and a second intermediate inspection that inspects the sewing object 100 after the second process. The sewing object 100 includes a first sewing object 100A and a second sewing object 100B.

[0030] In the embodiment, the inspection level refers to the tolerance for the target value (target state) of the sewing object 100. If the tolerance is small, the inspection level is high (strict). If the tolerance is large, the inspection level is low (lenient). For example, when a target position of a stitch is set, the inspection level is the tolerance for the amount of misalignment of the stitch from the target position. If the inspection level is high, the tolerance for the amount of misalignment is small. If the inspection level is low, the tolerance for the amount of misalignment is large. As an example, if the inspection level is high, the tolerance for the amount of misalignment is 0.5 mm. If the inspection level is high and the amount of misalignment exceeds 0.5 mm, the sewing object 100 is determined to be defective. If the inspection level is low, the tolerance for the amount of misalignment is 2.0 mm. If the inspection level is low and the amount of misalignment exceeds 0.5 mm but is 2.0 mm or less, the sewing object 100 is determined to be good. If the amount of misalignment exceeds 2.0 mm, the sewing object 100 is determined to be defective.

[0031] The output unit 62 displays the inspection level suited to the inspection process on the display device 13 of the information terminal 11. The display device 13 is an example of an output device that outputs the inspection level suited to the inspection process. As described above, the identification tag 101 for identifying the sewing object 100 is attached to the sewing object 100. The output unit 62 displays the inspection level on the display device 13 based on the identification data of the identification tag 101 by the identification device 15 and the correlation data stored in the correlation data storage unit 61.

[0032] [Correlation Data] FIG. 4 is a diagram showing an example of correlation data according to an embodiment. As shown in FIG. 4, in the embodiment, the correlation data shows the relationship between the sewing object 100, the inspection process carried out after the sewing process, the inspection items in the inspection process, and the inspection level. The sewing object 100 includes a first sewing object 100A for producing a T-shirt and a second sewing object 100B for producing a Y-shirt. The inspection process includes a first intermediate inspection carried out after the first process, a second intermediate inspection carried out after the second process, and a final inspection carried out after the third process. The inspection items include item A, item B, and item C. As an example, item A is the amount of deviation of a stitch from a target position. Item B is the amount of fraying of a thread. Item C is the amount of deviation of overlapping fabrics. Level 1 is the lowest inspection level, followed by level 2, and level 3 is the highest inspection level.

[0033] For example, the inspection level of the final inspection is high. For example, if the first or second sewing process is a process for manufacturing a lining, the inspection level of the first intermediate inspection or the second intermediate inspection may be low because the lining is a part that will not be visible after the sewn product is completed. The manager sets the inspection level in accordance with the inspection process that is carried out after the sewing process. The manager creates correlation data, as shown in FIG. 4 , that indicates the relationship between the sewing object 100, the inspection process that is carried out after the sewing process, the inspection items in the inspection process, and the inspection level. The manager operates the input device 5 to store the created correlation data in the correlation data storage unit 61.

[0034] 5 is a flowchart showing a sewing management method according to an embodiment. Hereinafter, as an example, a sewing management method when the first sewing object 100A is subjected to the first intermediate inspection will be described. The inspector who performs the first intermediate inspection carries the first information terminal 11A.

[0035] The first sewing object 100A that has completed the first process is sent to a first intermediate inspection. An inspector reads the first identification tag 101A attached to the first sewing object 100A with the identification device 15 of the first information terminal 11A. The terminal controller 12 transmits identification data indicating the identification result of the first identification tag 101A by the identification device 15 to the management controller 6. In the embodiment, an identifier (ID) is assigned to each of the multiple information terminals 11. The terminal controller 12 transmits the ID data of the first information terminal 11A to the management controller 6. The management controller 6 acquires the identification data of the first identification tag 101A and the ID data of the first information terminal 11A transmitted from the first information terminal 11A (step S1).

[0036] The first information terminal 11A is the information terminal 11 to be used for the first intermediate inspection. It is predetermined that the first information terminal 11A will be used for the first intermediate inspection. The management controller 6 can recognize that the first sewing object 100A will be subjected to the first intermediate inspection by acquiring the ID data of the first information terminal 11A. In other words, the management controller 6 can recognize that the inspection process for the first sewing object 100A is the first intermediate inspection by acquiring the ID data of the first information terminal 11A.

[0037] The output unit 62 transmits to the first information terminal 11A an inspection level suited to the inspection process of the first sewing object 100A based on the identification data of the identification tag by the identification device 15 and the correlation data stored in the correlation data storage unit 61 (step S2). The terminal controller 12 of the first information terminal 11A displays on the display device 13 the correlation data corresponding to the first sewing object 100A and the first intermediate inspection transmitted from the management controller 6.

[0038] 6 is a diagram showing an example of correlation data displayed on the display device 13 of the first information terminal 11A according to the embodiment. As shown in FIG. 6, the display device 13 displays correlation data corresponding to the first sewing object 100A and the first intermediate inspection, among the correlation data shown in FIG. 4. The inspector inspects the first sewing object 100A while checking the correlation data displayed on the display device 13. In the first intermediate inspection, the inspector inspects the first sewing object 100A for inspection items A, B, and C. The inspection level for item A is level 2, the inspection level for item B is level 1, and the inspection level for item C is level 1. The inspector inspects the first sewing object 100A for each of items A, B, and C according to the specified inspection levels.

[0039] The above has described the sewing management method when the first sewing object 100A is subjected to the first intermediate inspection. The same applies when the first sewing object 100A is subjected to the second intermediate inspection and the final inspection, and the same applies when the second sewing object 100B is subjected to the first intermediate inspection, the second intermediate inspection, and the final inspection.

[0040] [Effects] As described above, in the embodiment, the sewing management system 1 includes a correlation data storage unit 61 that stores correlation data indicating the relationship between a plurality of sewing processes for sewing the sewing object 100 using the sewing machine 2 and an inspection level related to an inspection process of the sewing object that is carried out after the sewing process, and an output unit 62 that outputs the inspection level according to the inspection process to the display device 13 that is an output device.

[0041] According to the embodiment, the sewing object 100 is inspected appropriately in each of the multiple inspection processes. If the inspection level of each of the multiple inspection processes is uniformly high, strict inspections of inspection processes or inspection items that can be inspected at a low level will result in reduced productivity of sewn products. If the inspection level of each of the multiple inspection processes is uniformly low, lenient inspections of inspection processes or inspection items that require a high level will result in the production of defective sewn products. By setting inspection levels appropriate for each of the multiple inspection processes and inspection items, appropriate inspections are carried out. Furthermore, because the inspection levels are displayed on the display device 13 as guidance data, variation in inspection levels among inspectors is reduced.

[0042] In the embodiment, the correlation data indicates the relationship between the inspection process, the sewing object 100, and the inspection level. This allows an appropriate inspection to be performed according to the sewing object 100. Also, in the embodiment, the correlation data indicates the relationship between the inspection process, the inspection items in the inspection process, the sewing object 100, and the inspection level. This allows an appropriate inspection to be performed according to the inspection items.

[0043] An identification tag 101 for identifying the sewing object 100 is attached to the sewing object 100. The output unit 62 outputs an inspection level based on the correlation data and the identification data of the identification tag 101 obtained by the identification device 15. As a result, the correlation data tailored to the sewing object 100 is displayed on the display device 13.

[0044] The present disclosure includes the following aspects. (1) A sewing management system including: a correlation data storage unit that stores correlation data indicating the relationship between a plurality of sewing processes for sewing a sewing object using a sewing machine and an inspection level for an inspection process for the sewing object performed after the sewing processes; and an output unit that causes an output device to output the inspection level suited to the inspection process. (2) The sewing management system described in (1), in which the correlation data indicates the relationship between the inspection process, the sewing object, and the inspection level. (3) The sewing management system described in (1), in which an identification tag for identifying the sewing object is attached to the sewing object, and the output unit outputs the inspection level based on identification data of the identification tag obtained by an identification device and the correlation data. (4) A sewing management method including: storing correlation data indicating the relationship between a plurality of processes for sewing a sewing object using a sewing machine and an inspection level for an inspection of the sewing object performed after the processes; and causing an output device to output the inspection level suited to the process.

[0045] This application is based on Japanese Patent Application No. 2023-187517, filed on November 1, 2023, the contents of which are incorporated herein by reference.

Claims

1. A sewing management system comprising: a correlation data storage unit that stores correlation data indicating the relationship between a plurality of sewing processes for sewing an object to be sewn using a sewing machine and an inspection level for an inspection process for the object to be sewn which is carried out after the sewing processes; and an output unit that causes an output device to output the inspection level corresponding to the inspection process.

2. The sewing management system according to claim 1, wherein the correlation data indicates a relationship between the inspection process, the sewing object, and the inspection level.

3. The sewing management system according to claim 1, wherein an identification tag for identifying the sewing object is attached to the sewing object, and the output unit outputs the inspection level based on the identification data of the identification tag by an identification device and the correlation data.

4. A sewing management method comprising: storing correlation data indicating the relationship between a plurality of steps for sewing an object to be sewn using a sewing machine and an inspection level for inspecting the object to be sewn after the steps; and outputting the inspection level corresponding to the steps to an output device.

Images