JP3686360B2 - Production line management system - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a production line management system.
[0002]
[Prior art]
Japanese Patent Laid-Open No. 10-254537 discloses a barcode reading device for reading an attached barcode when a part is put into a production line, and reading information from the barcode reading device, and based on the reading information, A component determination device that determines whether or not a component is a correct component that should be put into the production line, and a warning device that issues an alarm when the component determination device determines that the component is not a correct component Are disclosed.
[0003]
[Problems to be solved by the invention]
In the prior art, when the part determination device determines that the part is not correct, it simply issues an alarm and does not have a means to actively prevent the part from being put into the production line. There is a difficulty in reliably preventing erroneous insertion of components, such as being able to insert components. This prevention of erroneous input is particularly difficult in a production line in which various types of parts are switched in frequently.
[0004]
The problem of the present invention is that, in a production line that enables manual supply of materials, it is possible to throw out the material remaining in the middle of the production line when the production type is switched, and to input a new type of material, which can be mixed with different materials It is to prevent the misuse of the material used regardless of who works.
[0005]
[Means for Solving the Problems]
The invention of claim 1 is a production line management system that enables materials to be supplied from a hopper that is a material introduction unit into a production line, and in accordance with a production plan, information on the type of material to be supplied to the hopper that is a material introduction unit is registered. And a handy terminal equipped with a remaining amount counting means for paying out and counting the remaining amount of the material of the current production type existing within the range of the production line from the hopper as the material introduction unit , The remaining amount of material of the current production type was paid out of the production line from the hopper, which is the material introduction unit, on condition that the controller received the counting result of the remaining amount counting means when switching the type according to the production plan. things and recognizes der those to issue scraps bar code for managing the remaining material and outputs an instruction to supply the material of the new product type in the hopper .
[0007]
DETAILED DESCRIPTION OF THE INVENTION
The present invention is a production line management system, particularly a system for preventing erroneous input of materials or the like in production facilities.
[0008]
Here, the material refers to parts such as bottles and caps constituting the product to be produced.
[0009]
The filling and packaging line 10 shown in FIG. 1 includes a basket conveyor 11, an aligner 12 that supplies bottles to the basket at various points in the circulation path of the bottle conveyor 11, a filler 13 that fills the bottle with contents, and a bottle A pump assembly machine 14 that incorporates a pump, an overcap assembly machine 15 that incorporates an overcap into a bottle, and a labeler 16 that attaches a label to the bottle are arranged. Further, a carry-out conveyor 17 is connected to the exit side of the portion where the labeler 16 is disposed in the bag conveyor 11, and the carry-out conveyor 17 loads the product bottles taken out from the bag into the box. 18 is arranged.
[0010]
Hereinafter, the supply management system of each material of the bottle, the pump, the overcap, the label, and the inner box in the filling and packaging line 10 will be described.
[0011]
In addition, the controller 20 of the filling and packaging line 10 has pre-registered product information of bottles, pumps, overcaps, labels, and inner boxes to be used in the filling and packaging line 10 in accordance with the production plan.
[0012]
(Bottle)
A barcode corresponding to the product type is attached to the bottle and / or its packaging box, and the bottle is supplied from the packaging box to the hopper 22 that is the material introducing unit 21 and is fed from the hopper 22 to the aligner 12.
[0013]
The material introduction unit 21 normally closes the shutter 22A, and is set in an introduction impossible state.
[0014]
A barcode reader 23 is installed in front of the material introduction unit 21. The barcode reader 23 reads the barcode attached to the bottle and / or its packaging box to be supplied to the material introducing unit 21. At this time, a bottle randomly extracted from the packaging box may be used as a representative bottle, and a barcode attached to the bottle may be read.
[0015]
The controller 20 receives the reading information by the barcode reader 23 of the barcode attached to the bottle and / or its packaging box to be supplied to the material introduction unit 21, and compares this reading information with the product type information. Then, it is determined whether or not the bottle is a correct material to be supplied to the material introducing unit 21. When it is determined that the bottle is correct, the hopper 22 opens the shutter 22A to set the material introduction unit 21 in a state where it can be introduced. When it is determined that the bottle is not correct, the material is kept with the shutter 22A of the hopper 22 closed. The introductory state of the introduction part 21 is maintained.
[0016]
Accordingly, the type of bottle is confirmed based on the read information of the read barcode, and the shutter 22A is opened only when it is determined that the bottle is correct, and the bottle can be inserted. After loading the bottle, the operator confirms the completion of the bottle loading and closes the shutter 22A by operating the button. Thereby, it is possible to reliably prevent erroneous insertion of the next bottle.
[0017]
An indicator lamp 23A is installed in the main body of the barcode reader 23 so that the determination result of the controller 20 and the current state of the material introduction unit 21 can be visually confirmed. The indicator lamp 23A is configured to light up or blink red, yellow, or blue from the top. Red indicates that the barcode reader cannot be used (blinking indicates a different product), and yellow indicates that the barcode reader can be used. Blue indicates that the barcode reader has confirmed correctly and the bottle is ready for introduction. As a result, it is possible to prevent the bottle from being misused and to work safely and reliably.
[0018]
Furthermore, when the operator has confirmed the completion of the insertion and has closed the shutter 22A, the operator is notified that the shutter 22A is open by an alarm buzzer or an alarm lamp after a certain period of time has elapsed. In a normal state, the shutter 22A is always closed to keep the material introducing portion 21 in an inoperable state. In addition, the barcode cannot be read when the shutter 22A is open.
[0019]
In place of the alarm buzzer or the like, the shutter 22A may be automatically closed after a certain time has elapsed.
[0020]
By counting the number of bottles inserted in this bottle charging cycle, it is possible to grasp the total number of times and the charging history for each bottle.
[0021]
Next, when the production type is switched according to the production plan of the filling and packaging line 10, the remaining amount of the bottle of the current production type existing within the range of the aligner 12 from the material introduction unit 21 is discharged out of the range and counted. Counting means 24 (not shown) is used. As the remaining amount counting means 24, a counter operated by an operator can be used.
[0022]
The controller 20 outputs an instruction to supply a bottle of a new production type to the material introduction unit 21 on condition that the count result of the remaining amount counting unit 24 transmitted from the wireless handy terminal or the like is received by the operator. At the same time, the remaining bottles are put together in a bag and an end material bar code is issued. The bar code is affixed to the bag so that it can be reliably used at the next re-loading so as not to waste.
[0023]
According to this embodiment, there are the following operations.
{Circle around (1)} The controller that reads the information read by the barcode reader 23 of the bottle to be supplied to the material introduction unit 21 and / or the barcode attached to the packaging box as a bottle to be supplied to the material introduction unit 21 according to the production plan. When it is determined that the bottle is not a correct bottle as a result of comparison with the product type information registered in No. 20, the material introduction unit 21 is maintained in an unintroducible state, and the introduction of the bottle into the aligner 12 is actively prevented. To do. Accordingly, it is possible to reliably prevent erroneous bottle insertion even in a production line in which various types of bottles are switched in frequently.
[0024]
(2) At the time of switching the product type according to the production plan, the controller 20 inputs that the remaining amount of the bottle of the current product type discharged from the material introduction unit 21 out of the range of the aligner 12 is counted by the remaining amount counting means 24. On this condition, the product change can be started. Accordingly, after the bottle of the current production type is dispensed to the range of the aligning machine 12 from the material introduction unit 21, the bottle of the new production type is introduced, and there is always only one type of bottle in the above range. Therefore, it is possible to reliably avoid the possibility of mixing different materials and to prevent erroneous use of the used bottle.
[0025]
(3) In the above item (2), when a bottle of a newly produced product is to be supplied to the material introduction unit 21, the product check in the above item (1) is performed using the barcode attached to the bottle, Repeated misuse can be prevented.
[0026]
(4) Collect the remaining bottles in a bag, issue a mill bar code, and attach the bar code to the bag so that it can be used without waste when the bottle of the product is re-introduced next time. .
[0027]
(pump)
The pump and / or its packaging box is also labeled with the same barcode as the bottle, and the pump is supplied from the packaging box to the hopper 32 (shutter 32A) as the material introduction unit 31 and is fed from the hopper 32 to the pump assembly machine 14. Is done.
[0028]
Also for the pump, the same barcode reader 33 and remaining amount counting means 34 (not shown) as in the bottle are prepared, and the same operations (1) to (3) as in the bottle are achieved.
[0029]
(Over cap)
The overcap and / or its packaging box is also provided with the same barcode as the bottle, and the overcap is supplied from the packaging box to the hopper 42 (shutter 42A) as the material introducing portion 41, and the overcap assembly machine from the hopper 42 15 is input.
[0030]
Also for the overcap, the same barcode reader 43 and remaining amount counting means 44 (not shown) as in the bottle are prepared, and the same operations (1) to (3) as in the bottle are performed. As the remaining amount counting means 44, a device that measures the remaining cap weight and converts the remaining cap number from the measurement result can be used.
[0031]
(label)
The label is carried in the form of a winding body, and a bar code corresponding to the product type is attached to the label constituting the winding body, and the label winding body is supplied to the mounting table 52 which is the material introduction unit 51. To be supplied.
[0032]
Here, the mounting table 52 is usually configured such that a material cannot be placed by protruding a protrusion from a horizontal upper surface.
[0033]
A barcode reader 53 is installed in front of the material introduction unit 51. The barcode reader 53 reads a barcode attached to the label winder that is to be supplied to the material introduction unit 51.
[0034]
The controller 20 receives the reading information by the barcode reader 53 of the barcode attached to the label winding body to be supplied to the material introduction unit 51, compares the reading information with the product type information, and compares the label information. It is determined whether or not the winding body is a correct label winding body to be supplied to the material introducing unit 51. When it is determined that the label winding body is correct, the protrusion on the upper surface of the mounting table 52 is lowered, and the material introduction unit 51 is set in a state where it can be introduced in a horizontal plane, and when it is determined that the label winding body is not correct. In this case, the material introduction part 51 cannot be introduced, for example, the protrusion remains protruding from the upper surface of the mounting table 52 or the upper surface of the mounting table 52 remains inclined.
[0035]
Therefore, only when the type of the label winder is confirmed based on the read information of the read barcode and it is determined that the label winder is a correct label winder, the protrusion on the upper surface of the mounting table 52 is lowered to form a horizontal plane, and the material introduction unit 51 is ready for introduction. After the label is attached, the operator confirms the completion of the label application, removes an unnecessary winding body, or detects that the label has disappeared from the material introduction unit 51, and automatically detects the upper surface of the table 52. The protrusion is raised so that the material introduction part 51 cannot be introduced. Thereby, it is possible to reliably prevent erroneous pasting of the next label.
[0036]
Furthermore, when the worker does not introduce the material even after a certain period of time has elapsed since the protrusion on the upper surface of the pedestal 52 has been lowered and the material introducing portion 51 is ready to be introduced, an alarm buzzer or an alarm lamp is used. Then, the operator is notified that the protrusion on the upper surface of the mounting table 52 remains lowered, and the setting of the winding body is urged. If the winding body is still not set, the protrusion is automatically raised after a predetermined time has elapsed, and in a normal state, the protrusion on the upper surface of the pedestal 52 is always raised so that the material introduction part 51 cannot be introduced. I try to keep it. In addition, the barcode cannot be read when the protrusion is lowered.
[0037]
In this label application cycle, the number of label application can be counted, and the total application frequency and application history for each label can be grasped.
[0038]
Next, when the production type is switched according to the production plan of the filling and packaging line 10, the remaining amount counting is performed such that the remaining amount of the label of the current production type existing within the range of the labeler 16 from the material introduction unit 51 is discharged and counted. Means 54 (not shown) is used. As the remaining amount counting means 54, a device that measures the remaining outer diameter of the label winder and converts the remaining number of labels from the measurement result can be used.
[0039]
At the same time, an end material bar code is issued to the remaining label, and this is affixed to the label and checked at the time of re-input.
[0040]
The controller 20 gives an instruction to supply a label winding body of a new production type to the material introduction unit 51 on condition that the operator has received the counting result of the remaining amount counting means 54 transmitted from the wireless handy terminal or the like. Output.
[0041]
According to this embodiment, there are the following operations.
(1) As a label winder to be supplied to the material introducing unit 51 according to the production plan, the barcode read on the bar code reader 53 attached to the label winder to be supplied to the material introducing unit 51 is a controller. As a result of comparison with the product type information registered in No. 20, if it is determined that the label winding body is not correct, the material introduction unit 51 is set in an incapable introduction state, and the introduction of the label into the labeler 16 is actively prevented. To do. As a result, it is possible to reliably prevent erroneous label insertion even in a production line in which a variety of labels are frequently switched in.
[0042]
(2) The fact that the remaining amount of the label of the currently produced product that was dispensed out of the range of the labeler 16 from the material introduction unit 51 was counted by the remaining amount counting means 54 was input to the controller 20 when the product was switched according to the production plan. The condition change can be started on the condition. Therefore, after the label of the current production type is dispensed in the range from the material introduction unit 51 to the labeler 16, the label of the new production type is input, and there is always only one type of label in the above range. Therefore, it is possible to reliably avoid the possibility of mixing different materials and to prevent erroneous use of the used label.
[0043]
(Inner box)
A bar code similar to that of the label winder is also attached to the inner box and / or its packing box, and the inner box is supplied from the packing box to the table 62 which is the material introduction unit 61, and from the table 62 to the inner box packaging machine 18. To be supplied. As with the mounting table 52, the mounting table 62 sets the material introduction part 61 in a state where it cannot be introduced, such as by projecting a protrusion from the upper surface of the incorrect inner box or converting the upper surface into an inclined surface.
[0044]
Also for the inner box, a bar code reader 63 and remaining amount counting means 64 (not shown) similar to those of the label winder are prepared, and the same operations (1) to (3) as in the label are performed.
[0045]
Although the bottles and caps in the filling line have been described above, the material here is not limited to these, and may be a raw material such as a surfactant.
[0046]
In the present invention, not only the automated line but also the pedestal 52 may be a standardized material supply gantry, and the gantry may be appropriately connected to the line. According to this, the management system of the present invention can be applied to a hand-packed line that enables line recombination for each application. That is, even in a hand-packed line where the equipment changes frequently and the input work changes, it is possible to reliably prevent erroneous material input by using the management system of the present invention.
[0047]
2 is an example in which the above-described mounting bases 52 and 62 are standardized. The material supply base 100 has wheels 101 and is movable, and has a protrusion 103 that protrudes from or sinks to the upper surface 102 of the base 100. In a normal state, the protrusion 103 protrudes, for example, 10 cm from the upper surface 102 by the spring 104. A material such as a label and an inner box is confirmed by a bar code reader (wireless type or the like). When the material is correct, the projection 103 is lowered from the upper surface 102 by pressurization of the cylinder 105, and the material can be placed on the upper surface 102. A sensor 106 detects the presence or absence of material on the upper surface 102. When the sensor 106 detects that the material has disappeared from the upper surface 102, the pressure of the cylinder 105 is released, and the protrusion 103 protrudes from the upper surface 102 by the spring 104. To do. Reference numeral 107 denotes an indicator lamp (patlight) that can visually check the determination result of the controller 20 and the current state of the material introducing portions 51 and 61. The indicator lamp 107 is configured to light up or flash red, yellow, or blue from the top. Red indicates a bar code reader unusable state (flashing or different type), and yellow indicates a bar code reader usable state. Blue indicates that the material has been successfully introduced by the barcode reader. According to such a material supply base 100, it becomes possible to deal with various materials.
[0048]
【The invention's effect】
As described above, according to the present invention, in a production line that enables manual supply of materials, at the time of switching between production varieties, it is possible to throw out the material remaining in the middle of the production line and input a new variety of material, The possibility of mixing different materials is avoided, and it is possible to reliably prevent misuse of materials used by anyone .
[Brief description of the drawings]
FIG. 1 is a schematic diagram showing a production line management system.
FIG. 2 is a schematic diagram showing a material supply platform.
[Explanation of symbols]
10 Filling and packaging line (production line)
20 Controller 21, 31, 41, 51, 61 Material introduction part 23, 33, 43, 53, 63 Barcode reader 24, 34, 44, 54, 64 Remaining quantity counting means

Claims (2)

A production line management system that enables materials to be supplied into the production line from a hopper as a material introduction unit ,
In accordance with the production plan, a controller that registers the product type information of the material to be supplied to the hopper as the material introduction unit,
A handy terminal equipped with a remaining amount counting means for counting out the remaining amount of the material of the current production type existing within the range of the production line from the hopper as the material introduction unit ;
The remaining amount of material of the current production type was paid out of the production line from the hopper, which is the material introduction unit, on condition that the controller received the counting result of the remaining amount counting means when switching the type according to the production plan. A production line management system that recognizes that it is a product and outputs an instruction to supply materials of new production varieties to the hopper and issues a bar code for managing the remaining material . A production line management system that enables materials to be supplied from a material supply stand into a production line,
In accordance with the production plan, a controller that registers the product type information of the material to be supplied to the material supply platform ,
A handy terminal having a remaining amount counting means for paying out and counting the remaining amount of the material of the current production type existing within the range of the production line from the material supply stand ;
The remaining amount of material of the current production type has been paid out of the range of the production line from the material supply platform on the condition that the controller has received the counting result of the remaining amount counting means when switching the type according to the production plan. A production line management system that recognizes and outputs an instruction to supply materials of a new production type to a material supply stand and issues a bar code for managing the remaining material .

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