JP4470596B2 - Traceability system - Google Patents

Description

  The present invention relates to a traceability system, and more particularly to a traceability system in which an IC tag is associated with time.

In recent years, the importance of traceability has been recognized mainly in the food industry against the backdrop of an increasing safety consciousness for consumers.
In building a traceability system, an IC tag (here, a wireless type, a non-contact type IC tag, an electronic tag, an RFID, a data carrier, a transponder, and a responder are collectively referred to as an IC tag) is used. Thus, how to link the information vertically divided for each processing process in the factory as information on the horizontal connection between the processes is an important key.
It is known from Patent Document 1 and Patent Document 2 that an IC tag having unique ID information is used for an article. The thing of this patent document 1 uses an IC tag for the manufacture management of the to-be-manufactured product on a process line, and the carry-out / delivery management of goods, and the thing of patent document 2 is the delivery management of a product, and work procedure. It is applied to confirmation. Further, the IC tag and the identification device itself are disclosed in Patent Document 3, and management of information related to changes in the environment experienced by the management target in distribution management including fresh food is described in Patent Document 4. ing.
JP-A-5-266030 JP 2001-349057 A Japanese Patent No. 3518394 Japanese Patent Laid-Open No. 2001-14504

Traceability is essentially used when a quality problem occurs. For example, when a customer complains, the central point is to quickly find the cause by referring to the traceability database, quickly determine how far the cause has affected, and take appropriate action. It becomes a utilization method.
Therefore, in normal times when quality problems do not occur, the use of traceability is small. For this reason, in building a traceability system, it is desirable to minimize changes to the current work and avoid an increase in the burden of on-site work.

Further, in each of the above-mentioned patent documents, since traceability information and quality management items such as machine maintenance information acquired so far are not registered in association with traceability information, it becomes a quick pursuit obstacle when pursuing the cause. It was. Therefore, in the traceability system construction, since information on the horizontal connection between processes is indispensable, it is often necessary to leave a new record.
However, in order to leave a new record, it is important how to incorporate traceability data collection into daily work as a part of quality control without increasing the work load on site as much as possible.

  An object of the present invention is to provide a system in which traceability can be constructed as an extension of daily quality control work.

A first aspect of the present invention is a storage device storing process passage information, manufacturing environment information, and inventory information, and an IC tag that reads an ID assigned to a moving container that is disposed at a passing point of the manufacturing process and passes. A reading device, a reading control device for instructing the IC tag reading device to read / control the ID, and a storage device connected to the reading control device and the storage device to store and retrieve information. In what has a computing device to execute,
An ID tag is attached to the moving container to give a unique ID to each moving container, and an IC tag reading device is disposed at each of the manufacturing process inlet and outlet, and the IC tag reading device allows the moving container. reads the ID, and you and saving the step-on and the time during unloading in the storage device to record both
An ID tag is attached to the workpiece to be put into the moving container, and it is judged whether or not the workpiece can be sorted by ID when the workpiece is put into the moving container. When the sorting is possible, the ID of the moving container and the moving container are put into the moving container. The ID of the workpiece to be processed is read and repeated until the input of the workpiece into one moving container is completed, and when the above classification is impossible, the ID of the moving container at the process inlet and the time at the time of charging are read. In the storage device, the contents of the workpiece are reset when the workpiece is completely loaded into the moving container .

The second of the present invention is provided with an indicator lamp at the entrance and exit of the manufacturing process, and an indicator lamp control device for controlling the indicator lamp based on a command from the arithmetic unit,
It is characterized in that the moving container removal command is given by turning on the indicator lamp via the indicator lamp control device.

A third aspect of the present invention is characterized in that the indicator lamp is composed of first, second and third colors of arbitrary colors.

According to a fourth aspect of the present invention, when the reading of the IC tag of the moving container that has arrived at the inlet of the manufacturing process is abnormal, the first color indicator lamp is lit to instruct rereading, and when the IC tag reading is normal, the second color is displayed. The indicator lamp is turned on at the same time for a predetermined period of time and the time is registered. After lighting for a fixed period of time, the third color indicator lamp is turned on for a fixed period of time, and whether the moving container is removed after the third color indicator lamp is turned on. If it is not removed, the second color indicator lamp is turned on and the ID of the moving container and the registration time are stored in the storage device.

According to a fifth aspect of the present invention, a Web system is used for the process terminal device and the management terminal device in the manufacturing process.

As described above, according to the present invention, the IC tag attached to the moving container is recorded together with the time for each input / output of the process, whereby the traceability data can be acquired without giving the worker a particularly large awareness. In addition, since the association between the process of the time and the moving container ID is made from any direction, it is possible to search from both the ID and the time at the time of the traceability search, and the machine failure in the process, the maintenance history, and the traceability data. Because of this, it is possible to quickly find out the cause of trouble.
In addition, when the workpiece is put into the moving container, it is determined whether or not it is possible to classify by ID. When the sorting is possible, the ID of the moving container and the ID of the workpiece to be put into this container are read and the sorting is impossible. Read the ID of the moving container at the process inlet and the time at the time of charging, thereby associating the moving container with the workpiece. As a result, the relationship between the container ID and the workpiece can be associated with the ID or time as a key, thereby facilitating a traceability search.
Furthermore, with regard to registration when a container that is moving between processes is replaced, the status of normal reading of the IC tag can be confirmed by turning on the indicator lamp, and when the moving container can be removed within a certain time, Since the registration process of the moving container ID is possible, the container registration can be performed without complicated operation of the device.

  FIG. 1 shows a basic system configuration diagram of the present invention. Reference numeral 1 denotes a storage device that stores information serving as a traceability database. Reference numeral 2 is an arithmetic unit, and 3 is a reading / control device, which reads IDs and barcodes attached to moving containers or workpieces (hereinafter referred to as input materials) with respect to the barcode reader 4 and the IC tag reader 5. • Command control. The IC tag reader 5 is a wireless type. 6 is an input with a barcode attached, 7 is a moving container, and this container is a box-shaped or cart mounted on a conveyor, and is a wireless system to which a unique ID is assigned. The IC tag is held. 8 is an indicator lamp control device, 9 is an indicator lamp such as a rotating lamp, etc. This indicator lamp is given the meaning of blue, yellow, red, for example, 3 so that data registration and cancellation instructions to the worker can be made visually. Has a color. Therefore, when the visual instruction is unnecessary, the indicator light 9 and the indicator light control device 8 are not necessary.

FIG. 2 is a schematic system configuration diagram illustrating a fish canning factory as an example. A solid line surrounded by an outer frame is a factory, and a part surrounded by a solid line is a manufacturing process.
When the received raw materials are temporarily stored in their own warehouse, the number of stocks, names of raw materials, and the like are stored in the storage device 1 as inventory information A.
The raw material stored in the producer or warehouse is input as an input 6 into a moving container (cart) 7 having a wireless IC tag after being received. Here, the input 6 is an additive made up of fish, a seasoning, oil, and the like, which are the main raw materials, and each is charged into a different mobile container 7.
The main raw material after receiving is transferred to the seasoning / oil charging process D through the thawing process B, the carving / cutting process B, and the canning process C in the state where it is mounted in the moving container 7. The additive mounted on the moving container 7 is also transferred, and this additive is put into the main raw material. Subsequently, the product is shipped as a product through the enclosing process e and the boxing process.

  When a raw material is input, an ID that can be specified by the raw material manufacturer is recorded (a barcode issued by the raw material manufacturer, or an ID issued in-house and output to the barcode or the like is read). In addition, in the main process related to quality, wireless IC tag readers 5 are respectively arranged at the input port and the discharge port of the process, and the residence time in the process is measured. FIG. 3 shows such a state. A wireless IC tag reader 5 is provided at each of the process inlet and outlet, and the relationship between the ID of the moving container 7 and the input 6 is associated with ID or time as a key. .

In FIG. 2, in the steps a to c, the movement of the moving container 7 is read by the IC tag reader 5, and the passage time is stored in the storage device 1 as step passage information B. Further, when the input 6 in the moving container 7 is transshipped during the movement of the container between processes, it is stored in the storage device 1 as transshipment ID information C. In the processes C to E, the number of manufactured items, the input amount, and the manufacturing time information are stored in the storage device 1 as manufacturing environment information F together with sequencer information such as detected temperature signals and machine signals.
That is, in the process in the manufacturing process, the input IDs are stored in the storage device 1 in a state of being associated with each other as process passage information.

Further, when packaging is completed, an ID that can be specified by the company at the time of tracking is attached and shipped, and when trouble occurs for some reason at the shipping destination, in-house manufacturing information is understood based on this ID. Further, since the ID of the raw material used for manufacturing can be specified from the shipping ID, the ID can be transmitted to the raw material manufacturer, and a survey request can be made. Therefore, the shipment ID information is stored in the storage device 1 as the inventory information D together with the inventory information after packing.
Furthermore, the recipe change input by the management terminal is registered in the storage device 1 as recipe change history information E, and a traceability database is constructed by these pieces of information.

  As for the input of process passage information, it is desirable to input as simple as possible without affecting the actual work. For this purpose, an ID tag is attached to the moving container 7 so that each container has a unique ID. However, an ID is also issued to the input 6 to be put into each container, and this is recorded by a barcode reader or the like. While putting it into the moving container. The input time is recorded for an input without a clear delimiter such as an ID, and the relationship between the moving container ID and the input is associated with the ID or time as a key.

FIG. 4 is a specific processing flow for associating a container with an input.
In step S1, a unique ID is assigned to each moving container 7 in the factory, and the information is recorded on the IC tag. In S2, in the reading / control device 3 shown in FIG. 1, an input signal from the barcode reading device 4 is used to determine whether or not an ID is added to the input material that is put into the moving container to which the IC tag is attached. Based on this, if it is determined that the input can be classified by ID, an ID (barcode or wireless IC tag) reading command of the moving container 7 is given to the IC tag reading device 5 in step S3, Read. In S4, the operation of putting the input 6 into the moving container 7 is executed. At this time, the input ID is read, and this step is repeated until the input of the input into one container is completed.
On the other hand, if the ID classification is impossible in step S2, the process proceeds to step S5, where the reading / control device 3 controls the IC tag reading device 5 of, for example, the inlet container 7 in the first step. At the same time that an ID read command is given, the time when the container arrives at the process is commanded. In S6, when the container moves to the carry-out port of the first step, the ID of the moving container is read, and the ID is recorded together with the carry-out time. This reading and writing are repeated until the input or discharge of the input from one container is completed. As for the moving container ID, as soon as the input of the input is completed, the content of the input is reset (S7) and the container is reused.

As described above, the IC tag readers 5 are installed at the process inlet and outlet, and from the time when the moving container arrives at the process entrance and the time away from the process, the input container ID and the discharge container ID of the process container The association is performed to enable the association between the moving containers.
In general, the IC tag can be used by attaching an IC tag to each traceable object, writing information such as the passing time at the passing point of the process, and the process information written on the IC tag in the final process. It is conceivable to acquire. In this case, there are many problems such as restrictions on the writing speed to each IC tag and restrictions on the tag mounting position due to the size of the tag and the handling of metal objects. The above-mentioned problems can be solved by using the IC tag mainly for the association.

FIG. 5 shows a processing flow based on an instruction to an operator by data transmission between moving containers.
In this embodiment, when the movable container 7 arrives at the process inlet, it can be visually instructed whether the IC tag of the container has been read normally.
An indicator lamp 9 shown in FIG. 1 is disposed at each doorway of the process. As the indicator lamp 9, for example, red, blue and yellow rotating lights are used, and each rotating lamp is controlled via the arithmetic unit 2 and the indicator lamp control device 8.
Step S10 in FIG. 5 shows the installation state of the indicator lamp. In S11, when the movable container 7 arrives at the process inlet, the IC tag reading device 5 reads the IC tag attached to the container. The read information is sent to the arithmetic device 2 via the reading / control device 13 to determine the read information (S12). If the information is read normally, the information is read through the indicator control device 8 in step S14. The blue indicator lamp 9 is turned on or blinked, and at the same time, the time is recorded. If the reading is abnormal in S12, the red indicator lamp 9 is turned on or blinked in S13. When the red indicator light is turned on, the operator returns to S11 and performs registration again.

In the indicator light control device 9, each lighting time of blue and yellow is determined in advance as a predetermined time. Therefore, in S15, when the blue lighting time reaches the predetermined time, the indicator light control device 8 turns on the yellow indicator light for a certain time instead of the blue lighting. The removal of the moving container is executed while the yellow indicator lamp is lit. In S16, it is determined whether or not the container is removed. If the removal of the container has not been executed after a certain period of time has elapsed since the yellow indicator lamp was lit, the blue indicator lamp is lit again in S17, and the ID of the container and the registration time recorded in step S14 are recorded. And it returns to S11.
In S16, when the moving container is removed, the process returns to S11, and this operation is repeated until the input or the unloading of the input from one container is completed.

When building a traceability system, it is important to integrate quality management work, including linkage with environmental observation data, linkage with change information such as machine maintenance, automatic output of form creation, and information linkage with quality control documents. Become. For this reason, the present invention employs a Web system for on-site terminals.
The Web interface is adopted not only in the management terminal that refers to traceability but also in the process terminal and the handy terminal. By adopting a Web system, it is possible to use a wireless LAN & Web browser-equipped PDA used in various PDAs (personal digital assistants) etc. for field terminals, so a system in a wireless environment with a high degree of freedom in arrangement can be constructed. .

Under such an environment, the process result input in each process is input while being associated with the process passage information. FIG. 6 is an example of the input screen, and the currently used quality record form, etc. It is composed based on the form.
Specifically, detailed work results such as oil temperature, product center temperature, and room temperature are recorded, but using a Web terminal capable of touch-type input as the recording means, the process is started from the time when input of the process work record is started. Association with the input is made. The temperature change information or the like is not directly related to the process work, but the information change with the process passage time can be performed by recording the temperature change with time.
Among each information, data such as counter information obtained from a manufacturing machine in the field can be acquired by pressing a data acquisition button on the Web browser screen. The machine acquisition data can be input manually, and when the acquisition device fails, it can be input manually. In addition, information such as machine maintenance and machine stop is also recorded along with the occurrence time.

FIG. 7 shows an example of the machine maintenance history information screen, in which traceability information is associated with the history of maintenance and the like, and is recorded so as to be able to elucidate a defect caused by a change in manufacturing conditions. For this purpose, selection items such as machine stoppages that can occur in the machines in each process, such as the reason for machine stoppage, are defined. In each process, machine maintenance information such as manufacturing equipment and the reason for machine stoppage are input over time. . At the time of the traceability search, a search for the reason for machine maintenance of the relevant process is also performed in accordance with the trace search of the target process. At the time of the search, if the processes are linked in time, the time is the time, and in the case of ID, the ID is charged and unloaded, and the next maintenance reason starts after the time of the machine maintenance reason. Select the matching item.
That is, at the time of the traceability search, the process result input for each work unit of each process, the reason for stopping the machine, the content of maintenance, and the trace information are referred to in association with each other.

  FIG. 8 shows an example of a cause pursuit search screen when a trouble occurs. When pursuing the cause, specify the product type, product name, shipping date, etc., and search in the upstream direction (raw material side) of the process in which the product was made, so that you can deal with defects that occurred in the manufacturing process. It is possible to search in the upstream direction from the moving container ID, intermediate product ID, etc. As the information for pursuing the cause, the data entered for each work unit of each process is referred to. As a result, trace information such as the status of work, the reason for machine stoppage, and the contents of maintenance is related, and the cause is pursued by linking the change in the manufacturing environment that has occurred in the process and the process passing information.

FIG. 9 shows a processing flow for pursuing the cause. It is defined in advance whether the connection between processes is performed by ID or time for each product, and how the process is traced for each product is defined (S20). When tracing by time, the product type, product name, and shipping date are designated in S21, and the ID of the final shipment is specified from the designated product and the shipping date. When searching using the ID as an index, the in-process ID is designated in S23, and the in-process ID is selected from the performance data in S24.
In S25, the search is started from the previous process targeted in the upstream direction or the downstream direction according to the definition of the process. In S26, it is determined whether the connection with the process is an ID or a time. In the case of an ID, in S27, the relationship between the process input and output IDs is searched. If the connection with the process is a time, in S28, the standard time is set based on the set process time such as the maximum time interval, the standard time interval, the minimum time interval, etc. A search is executed by selecting an arbitrary connection such as whether to use a minimum time and a maximum time width. Based on the search results in S27 and S28, the image is further expanded in the upstream or downstream direction, and the process proceeds to S25. The process is repeated until there are no more objects in the upstream and downstream directions. FIG. 10 is a related information display screen when the cause is pursued.

FIG. 11 shows an example of an influence spread range display screen. When the cause becomes clear, the input that caused the cause is designated and a downstream search is performed to clarify the influence spread range. In the downstream search, the downstream search is performed using the target product type, the process, the target time in the process, the raw material ID, the in-process ID, and the like as keys. From the search result screen obtained in the downstream search, by selecting the input and process work that caused the cause, it is set as the downstream search condition as it is. This makes it possible to smoothly perform a series of processes such as pursuing the cause, finding the result, specifying the spread range, and collecting.
The traceability system according to the present invention also has a manufacturing instruction function for the site. FIG. 12 shows the work instruction display screen, and an instruction for work to be performed in the process today is issued from the arithmetic unit to a work terminal on site. The worker selects the instruction and erases the work from the work list, thereby clarifying the work to be performed on that day.

The block block diagram which shows embodiment of this invention. 1 is a schematic system configuration diagram of the present invention. Explanatory drawing at the time of the input / output of a process. The processing flowchart of traceability data acquisition of a moving container. The instruction | indication process flow figure to the operator in the data transfer between moving containers. The results information input screen figure. Machine maintenance history information screen diagram. Cause search screen diagram. Cause pursuit search processing flow diagram. The related information display screen when pursuing the cause. Influence influence range display screen diagram. Work instruction display screen diagram.

Explanation of symbols

1 Storage device
2. Arithmetic unit
3. Reading / control device
4. Bar code reader
5 ... IC tag reader
6 ... Input (workpiece)
7 ... Moving container
8 ... Indicator light control device
9 ... Indicator

Claims (5)

A storage device for storing process passage information, manufacturing environment information, and inventory information, an IC tag reader for reading an ID assigned to a moving container disposed at a passing point of the manufacturing process, and the IC tag A reading control device for instructing the reading device to read and control the ID, and an arithmetic device connected between the reading control device and the storage device to store and retrieve information from the storage device are provided. In things,
An ID tag is attached to the moving container to give a unique ID to each moving container, and an IC tag reading device is disposed at each of the manufacturing process inlet and outlet, and the IC tag reading device allows the moving container. reads the ID, and you and saving the step-on and the time during unloading in the storage device to record both
An ID tag is attached to the workpiece to be put into the moving container, and it is judged whether or not the workpiece can be sorted by ID when the workpiece is put into the moving container. When the sorting is possible, the ID of the moving container and the moving container are put into the moving container. The ID of the workpiece to be processed is read and repeated until the input of the workpiece into one moving container is completed, and when the above classification is impossible, the ID of the moving container at the process inlet and the time at the time of charging are read. The traceability system is configured to be stored in the storage device and to reset the content of the workpiece upon completion of the loading of the workpiece into the moving container . Provide an indicator lamp at the entrance and exit of the manufacturing process, and provide an indicator lamp control device for controlling the indicator lamp based on a command from the arithmetic unit,
2. The traceability system according to claim 1, wherein an instruction to remove the moving container is issued by turning on the indicator lamp via the indicator lamp control device . 3. The traceability system according to claim 2, wherein the indicator lamp is composed of first, second and third colors of arbitrary colors . When the reading of the IC tag of the moving container arriving at the inlet of the manufacturing process is abnormal, the first color indicator lamp is lit to instruct rereading, and when the IC tag reading is normal, the second color indicator lamp is predetermined. The time is registered at the same time as lighting for a certain period of time, and after the lighting for a certain period of time, the third color indicator lamp is lit for a certain period of time. 4. The traceability system according to claim 2, wherein the second color indicator lamp is turned on to store the ID of the moving container and the registration time in the storage device when there is not . 5. The traceability system according to claim 1, wherein a Web system is used for the process terminal device and the management terminal device in the manufacturing process .