JP7553112B2 - Corrugated board management system - Google Patents

Description

This invention relates to a cardboard base paper management system, and in particular to a cardboard base paper management system for managing the inventory of base paper rolls used in cardboard manufacturing equipment.

Conventionally, inventory management has been carried out on rolls of base paper used in cardboard manufacturing equipment (see, for example, Patent Document 1).

The above-mentioned Patent Document 1 discloses that when manufacturing cardboard, two base paper rolls are set on each of five mill roll stands equipped in the cardboard manufacturing device. The above-mentioned Patent Document 1 discloses that, for used base paper rolls, the remaining base paper length is written directly on the base paper roll by the operator, or a barcode sticker (label) recording the remaining base paper length is affixed to the base paper roll.

Patent No. 3670626

Each base paper roll used in cardboard manufacturing is individually identified and managed for traceability in case a defect in the base paper is discovered. For this reason, although not described in the above Patent Document 1, cardboard manufacturers who operate cardboard manufacturing equipment have traditionally performed the task of attaching a label recording a control number to each new base paper roll when the new base paper roll arrives. The label attached to the new base paper roll is removed once it has been used in the cardboard manufacturing equipment. When the base paper roll is discharged from the cardboard manufacturing equipment and becomes scrap base paper, a new label recording the remaining length in addition to the control number is issued and re-attached to the base paper roll.

In this type of conventional base paper roll management operation, there is an issue with the task of attaching labels when new base paper arrives. That is, new base paper arrives in the early morning hours before cardboard production begins, so it becomes an early morning task for operators. Also, assuming that 100 rolls of new base paper arrive each day, the amount of work required to attach labels to each and every one of them is not small. Also, since it becomes necessary to print a large number of labels every day, costs and resource consumption are high.

As an alternative management method to labels, there is a method of attaching an RFIC tag recording data such as a management number and remaining length to the inside of the paper tube of the base paper roll. However, with RFIC tags, the management number can become unknown if a data error or physical damage occurs, and operators cannot check the tag from the outside unless the information is read. As a result, the above-mentioned labels are often attached at the same time, and the problem has not yet been solved.

This invention was made to solve the above problems, and one of the objects of this invention is to provide a cardboard base paper management system that makes it possible to omit the task of attaching labels when new base paper rolls arrive.

In order to achieve the above object, the inventors of the present application have conducted extensive research and have come up with the idea of using a base paper manufacturing number unique to the base paper manufacturer printed directly on the base paper roll of new base paper as a provisional management number instead of a label. That is, a cardboard base paper management system according to one aspect of the present invention is a cardboard base paper management system that manages base paper rolls supplied to a cardboard manufacturing device, and includes a server device that stores base paper manufacturing numbers in association with inventory information of the base paper roll, an imaging unit that photographs the base paper manufacturing number printed directly on the base paper roll when the base paper roll is used, and an information terminal that acquires the base paper manufacturing number from the photographed image of the base paper roll and performs allocation processing to identify the base paper roll to be supplied to the cardboard manufacturing device from the inventory information based on the acquired base paper manufacturing number.

In the cardboard base paper management system according to one aspect of the present invention, as described above, a photographing unit photographs the base paper manufacturing number printed on the base paper roll when the base paper roll is used, and an information terminal performs allocation processing to acquire the base paper manufacturing number from the photographed image of the base paper roll and identify the base paper roll to be supplied to the cardboard manufacturing device from the inventory information based on the acquired base paper manufacturing number. This allows the unique base paper manufacturing number printed on the base paper roll of the new base paper to be acquired from the photographed image, and the obtained base paper manufacturing number can be used to perform individual identification (allocation processing) of the base paper roll of the new base paper. Therefore, without attaching a label with a management number when the new base paper arrives, individual management of the base paper roll that ensures traceability in cardboard manufacturing can be performed. As a result, the early morning label attachment work for each new base paper roll can be omitted, reducing the operator's workload. Furthermore, by eliminating the need to print many labels on the base paper roll of the new base paper that arrives every day, costs and resource consumption can be reduced.

In the cardboard base paper management system according to the above aspect, preferably, a printing unit is further provided that outputs a label on which a management number assigned separately from the base paper manufacturing number and the remaining length are printed for the base paper roll dispensed from the cardboard manufacturing device, and the information terminal is configured to perform allocation processing based on either the base paper manufacturing number obtained from the image of the base paper manufacturing number or the management number obtained from the image of the label when the base paper roll of the leftover base paper is supplied. With this configuration, when the base paper roll of the new base paper is dispensed from the cardboard manufacturing device and becomes a base paper roll of the leftover base paper, the base paper roll can be individually identified using the label on which the management number and remaining length are printed. Here, the base paper manufacturing number is printed on the end surface of the base paper roll, and becomes unreadable when the base paper diameter is reduced to the printing point. Therefore, by making it possible to perform allocation processing for leftover base paper rolls using either the base paper manufacturing number or the label (control number), the base paper manufacturing number on the end surface can be read even when the label is touching the floor and the control number cannot be read, improving operator convenience.

In the cardboard base paper management system according to the above aspect, preferably, the information terminal is configured to display candidates for base paper rolls whose base paper manufacturing numbers are not registered and to accept the selection of the corresponding base paper roll from among the displayed candidates when the acquired base paper manufacturing number is not registered in the server device during the allocation process. With this configuration, even if the base paper manufacturing number acquired from the captured image is not registered in the inventory information of the server device, the operator using the information terminal can confirm and select it, thereby registering the base paper manufacturing number on the spot and enabling smooth allocation processing. In addition, when the allocation process is completed by selecting a candidate, the operator does not need to manually input the base paper manufacturing number into the information terminal one character at a time, which reduces the labor required for input work.

In the cardboard base paper management system according to the above aspect, the information terminal is preferably configured to perform a tilt correction process for a character string in a captured image, generate two types of character strings by image recognition: a character string after tilt correction and a character string rotated 180 degrees after tilt correction, and compare each generated character string with the base paper manufacturing number registered in the server device. With this configuration, the base paper manufacturing number can be obtained from the captured image regardless of the orientation of the base paper manufacturing number printed on the roll end surface rotated in the captured image. As a result, when photographing the base paper manufacturing number, the operator does not need to roll the heavy and large base paper roll to adjust the angle, or change the shooting angle to match the orientation of the base paper manufacturing number, so the operator's workload can be effectively reduced. The weight of the base paper roll is about several hundred kg to one thousand kg, depending on the width dimension and base paper type.

In the configuration further including the printing unit, preferably, the control number is printed on the label in the form of a barcode or two-dimensional code, and the information terminal is configured to obtain the control number by detecting the label area in the captured image and reading the code image contained in the detected label area. With this configuration, even when the control number is printed on the label in the form of a barcode or two-dimensional code, the control number can be obtained by simply photographing the label using the photographing unit in the same way as the base paper production number, without adding a dedicated reader device or the like. In other words, the photographing unit can obtain both the base paper production number and the control number, simplifying the configuration of the cardboard base paper management system.

In the cardboard paper management system according to the above aspect, the information terminal is preferably a portable information terminal with a built-in photography unit. With this configuration, a series of allocation processes such as photography, number reading, and matching with a server device can all be performed by a portable information terminal with a built-in photography unit, such as a tablet terminal or smartphone. This simplifies the configuration of the cardboard paper management system. Also, for the operator, convenience is improved because the device used for the allocation process is integrated into the portable information terminal.

In the above-mentioned configuration in which candidates for base paper rolls with unregistered base paper manufacturing numbers are displayed and the selection of the corresponding base paper roll from the displayed candidates is accepted, preferably, when the information terminal accepts the selection of the corresponding base paper roll from the displayed candidates, it is possible to accept the input of a photographed image of the base paper roll instead of the base paper manufacturing number, and when the input of the photographed image of the base paper roll is accepted, the photographed image of the base paper roll is associated with the inventory information of the base paper roll and stored in the server device. With this configuration, even if the base paper manufacturing number is unregistered in the inventory information of the server device and the base paper manufacturing number cannot be character-recognized from the photographed image, the photographed image can be used as a substitute for the base paper manufacturing number by storing image data of the base paper roll. In other words, when the base paper manufacturing number of the base paper roll is required, the operator (or base paper manufacturer) can identify the base paper manufacturing number from the photographed image, so that the traceability of the individual base paper rolls can be ensured. In addition, the number input work for this can be omitted, which also contributes to labor saving for the operator.

According to the present invention, as described above, it is possible to provide a cardboard base paper management system that can omit the task of attaching labels when new base paper rolls are received.

FIG. 1 is a block diagram for explaining a configuration of a cardboard base paper management system according to an embodiment. FIG. 1 is a schematic diagram showing an example of a cardboard manufacturing apparatus. FIG. 2 is a schematic perspective view showing an example of a base paper roll stored in a base paper warehouse. FIG. 2 is a schematic perspective view showing a configuration for feeding a base paper roll into a cardboard manufacturing device. FIG. 11 is a diagram for explaining an example of information recorded as inventory information. 1A is a schematic perspective view of a base paper roll on which a base paper manufacturing number is printed, and FIG. 1B is a schematic view of an end face thereof. FIG. 2 is a block diagram for explaining a configuration of an information terminal. FIG. 13 is a diagram showing an example of a label. 11A and 11B are schematic diagrams showing a tilt correction process for a captured image. 13 is a schematic diagram showing an example of displaying a character string and a candidate for a base paper manufacturing number. FIG. FIG. 1 is a first flow chart showing a base paper roll allocation process by a cardboard base paper management system. FIG. 11 is a second flow chart showing the allocation process of the base paper roll by the cardboard base paper management system. FIG. 11 is a third flowchart showing the base paper roll allocation process by the cardboard base paper management system. FIG. 13 is a diagram showing an example of a lot display screen displayed by an information terminal. FIG. 13 is a diagram showing an example of a base paper list screen displayed on the information terminal. 1 is a diagram for explaining a comparison between a work flow in this embodiment and a work flow in a comparative example. FIG.

The following describes an embodiment of the present invention with reference to the drawings.

First, a cardboard base paper management system 100 according to one embodiment will be described with reference to Figures 1 to 10.

As shown in FIG. 1, the cardboard base paper management system 100 according to this embodiment (hereinafter referred to as the base paper management system 100) is configured as part of a production management system 200 for cardboard manufacturing or as a system that cooperates with the production management system 200. The production management system 200 is a system that manages the cardboard sheet manufacturing process using a cardboard manufacturing device (corrugator) 110.

The production management system 200 constitutes a network including the cardboard manufacturing equipment 110 and the corrugator management device 120. The corrugator management device 120 has the function of controlling the operation of the cardboard manufacturing equipment 110 and managing production lots. The base paper management system 100 is a system that manages the inventory of the cardboard base paper (base paper roll 1) supplied to the cardboard manufacturing equipment 110.

[Outline of the cardboard manufacturing equipment]
First, a description will be given of a cardboard manufacturing apparatus 110 that manufactures cardboard using base paper managed by the base paper management system 100 according to this embodiment. The cardboard manufacturing apparatus 110 is an apparatus that manufactures cardboard sheets using base paper wound into a roll (base paper roll 1).

As shown in FIG. 2, the cardboard manufacturing device 110 mainly comprises a roll stand 11, a splicer 12, a single facer 13, a double facer 14, a cutter 15, and a stacker 16. The cardboard manufacturing device 110 in FIG. 2 comprises five roll stands 11 and can manufacture cardboard by bonding up to five types of base paper (three liners and two cores). The liners are flat base paper provided on the surface and in the middle of the cardboard, and the cores are base paper that are corrugated into a wavy shape.

Each roll stand 11 holds two base paper rolls 1 in a rotatable manner. During the production of cardboard sheets, one of the base paper rolls 1 is used. The other base paper roll 1 is prepared in the roll stand 11 as a replacement when the base paper of one base paper roll 1 is completely consumed, or for the next production lot. A splicer 12 is provided for each roll stand 11, and performs paper splicing when the base paper roll 1 is switched. The single facer 13 forms a single-sided cardboard sheet by bonding the liner and the core. The double facer 14 bonds two single-sided cardboard sheets sent from the two single facers 13, respectively, and the liner to form three sheets, forming a two-layer (double) cardboard sheet. A heater 17 for heating the sheet is provided upstream of the single facer 13 and the double facer 14. In addition, a gluing machine 18 for gluing the sheet is provided upstream of the double facer 14. The two-layer (double) cardboard sheets that have been glued together are scored with creases (fold lines) and cut by the slitter scorer 19, cut to a specified length by the cutter 15, and then stacked and stored in the stacker 16.

The five roll stands 11 are provided for each type of base paper so as to supply a total of five types of base paper: a corrugated medium for stage A (A core), a back liner for the A core, a corrugated medium for stage B (B core), a back liner for the B core, and a common front liner. The back liner is the liner on the back side of the corrugated board, and the front liner is the liner on the front side of the corrugated board. In addition to two-stage A and B corrugated board, the corrugated board manufacturing device 110 can selectively manufacture one-stage A or B corrugated board. When manufacturing one-stage corrugated board, three roll stands 11 are in operation. When manufacturing two-stage corrugated board, five roll stands 11 are in operation. The order in which the types of corrugated board are manufactured is determined by the manufacturing lot managed by the production management system 200.

As shown in FIG. 3, the base paper roll 1 is a cylindrical roll of base paper of a specified width, and has an outer peripheral surface 2, which is the radial surface, and an end surface 3 in the winding axis direction. At the radial center of the base paper roll 1, there is a center hole 4 made of the inner surface of the winding paper tube, which penetrates the base paper roll 1 in the winding axis direction.

There are many types of base paper used in production, with different paper widths, weights, and qualities. In addition, the base paper roll 1 may be new base paper (unused base paper) or scrap base paper (base paper that has been used partway). As a result of the production of many different types of cardboard sheets, multiple rolls of new base paper and scrap base paper are stored as inventory for the same type of base paper. Such many types of base paper rolls 1 are stored in a base paper warehouse 8 (see Figure 1) in a production facility where a cardboard manufacturing device 110 is installed. During production, the type of base paper roll 1 corresponding to the production lot is removed from the base paper warehouse 8 by an operator (not shown) who operates a clamp lift 9 as shown in Figure 3, and is transported to a preparation position (see Figure 4) in front of each roll stand 11 of the cardboard manufacturing device 110.

As shown in FIG. 4, the base paper roll 1 transported to the preparation position is placed on a pair of rails 20 extending in a direction (Y direction) intersecting the base paper transport direction (X direction) shown in FIG. 2, and is transported to the roll stand 11 by a transport device 21 that can move in the Y direction between the pair of rails 20. The pair of rails 20 are inclined downward toward each other, and the base paper roll 1 is held at the middle position of the pair of rails 20. The transport device 21 engages (chucks) the lower part of the end surface 3 of the base paper roll 1 between the pair of rails 20 and transports the base paper roll 1. The base paper roll 1 is transported in the Y direction to a position aligned with the roll stand 11 in the X direction, and is chucked (attached) to the arm 11a of the roll stand 11 so that it can rotate around the winding axis. At the end of the day's work or the end of the production of a production lot, the base paper roll 1 is transported (discharged) from the roll stand 11 in the opposite direction to the Y direction by the transport device 21.

[Configuration of the cardboard containerboard management system]
Next, the configuration of the stencil paper management system 100 will be described. As shown in Fig. 1, the stencil paper management system 100 includes at least a server device 30, a photographing unit 46, and an information terminal 40. In the example of Fig. 1, the stencil paper management system 100 further includes a control device 50, a remaining length acquisition unit 60, a relay device 70, and a clamping terminal 80.

The corrugator management device 120, the server device 30, the control device 50, the remaining length acquisition unit 60, and the relay device 70 are connected to each other via a wired or wireless network. The information terminal 40 and the clamping terminal 80 can be connected to the network via the relay device 70 by wireless communication with the relay device 70. The wireless communication is, for example, a wireless LAN such as Wifi (registered trademark), and the relay device 70 is, for example, an access point for the wireless LAN.

The server device 30 may be a server device for the entire production management system 200, or may be a server device dedicated to the base paper management system 100 configured to cooperate with a higher-level server device 130 (see dashed double-dashed line) of the production management system 200. Here, an example will be described in which the higher-level server device 130 is not provided and the server device 30 of the base paper management system 100 is a server device shared with the production management system 200.

The server device 30 is composed of a PC (personal computer) equipped with a CPU (processor), a memory (main storage device), and a storage device (auxiliary storage device). The CPU executes the application program of the base paper management system 100, so that the PC functions as the server device 30 of the base paper management system 100. The server device 30 stores the base paper manufacturing number 31a (see FIG. 5) and the inventory information 31 of the base paper roll 1 in association with each other. The inventory information 31 is a record of management information for each base paper roll 1. As shown in FIG. 5, the inventory information 31 for one base paper roll 1 includes, for example, the base paper manufacturing number 31a, management number 31b, base paper type (weight) 31c, width dimension 31d, brand 31e (manufacturer name), initial length LS of the base paper roll 1, date and time of use 31f, remaining length LP, lot number 31g, delivery date 31h, etc.

The base paper manufacturing number 31a is a unique number assigned by the base paper manufacturer that produced the base paper (base paper roll 1) to identify the individual product. Therefore, the numbering system (character type, number of digits) of the base paper manufacturing number 31a differs depending on the base paper manufacturer. However, the base paper manufacturing number 31a is a combination of alphanumeric characters, and the number of characters is within a certain range (generally about 7 to 11 digits).

As shown in Figures 6(A) and 6(B), the base paper manufacturing number 31a is printed directly on the end surface 3 in the winding axis direction of the base paper roll 1. Depending on the base paper manufacturer, the base paper manufacturing number 31a may also be printed on the outer peripheral surface 2 of the base paper roll 1.

The base paper manufacturing number 31a on the outer peripheral surface 2 is removed from the base paper roll 1 when the base paper roll 1 is used for the first time, by peeling off the outermost base paper. The base paper manufacturing number 31a on the end surface 3 becomes invisible as the diameter of the base paper roll 1 decreases to the printing position of the base paper manufacturing number 31a as the base paper is used. The base paper manufacturing number 31a is printed on the end surface 3 in a position close to the paper tube (center hole 4) so that the base paper manufacturing number 31a on the end surface 3 remains for as long as possible.

In addition to the base paper manufacturing number 31a, the base paper type (weighing), width dimension, initial length, brand, etc. are often printed on the base paper roll 1. Fig. 6(B) shows an example in which "ABCIH01238" is printed on the end surface 3 as the base paper manufacturing number 31a, "160g (/ ^m2 )" as the base paper type 31c, "170cm" as the width dimension 31d, and "5000m" as the initial length LS.

Returning to FIG. 5, the management number 31b is a unique identification number that the base paper management system 100 assigns to each base paper roll 1 for the purpose of managing each individual base paper roll 1. Because the management number 31b is a number that is assigned independently by the base paper management system 100, the numbering system can be determined arbitrarily.

The base paper type 31c is the type of base paper according to basis weight and paper quality, and is expressed by a symbol such as k5 (180 g/m ² ) or k6 (220 g/m ² ) or by grams. The width dimension 31d is the length of the base paper roll 1 in the winding axis direction. The width dimension 31d has standards at 50 mm intervals and is generally in the range of 850 mm to 2000 mm. The initial length LS is the total length of the base paper roll 1 of new base paper (unused state). The use date and time 31f is the date and time (time is not shown) when the base paper roll 1 was last used. The remaining length LP is the remaining length of the base paper roll 1 of the scrap base paper that has been used halfway. The lot number 31g is a number indicating the order of cardboard production, and is obtained from the corrugator management device 120. The delivery date 31h is the date when the base paper roll 1 was received.

Of the inventory information 31, the base paper type 31c, width dimension 31d, brand 31e, and initial length LS are determined and registered in the server device 30 when the base paper is ordered from the base paper manufacturer. If the base paper manufacturing number 31a is stated in the order confirmation email (order confirmation) sent in advance from the base paper manufacturer in response to the order of the base paper, the base paper manufacturing number 31a can be registered in advance in the server device 30 from the order confirmation email. In addition, the base paper manufacturing number 31a can be acquired and registered when the base paper roll 1 of the new base paper is used for the first time. The management number 31b is assigned by the server device 30 when the base paper is ordered or when the base paper roll 1 of the new base paper is used for the first time. The date and time of use 31f, lot number 31g, and remaining length LP are information that are assigned (updated) each time the base paper roll 1 is used in the cardboard manufacturing device 110. The remaining length LP is acquired from the production record of the corrugator management device 120 by the remaining length acquisition unit 60, which is a PC dedicated to acquiring the remaining length. When the use of the base paper roll 1 is finished, the server device 30 obtains the remaining length LP from the remaining length acquisition unit 60 and updates the inventory information 31.

Returning to FIG. 1, the photographing unit 46 is a camera having an image sensor such as a CMOS sensor or a CCD sensor. As will be described later, in this embodiment, the photographing unit 46 is incorporated in the information terminal 40. The photographing unit 46 may have a pixel count equal to or greater than that of a typical WEB camera. The photographing unit 46 may be provided separately from the information terminal 40. The photographing unit 46 is used to photograph the base paper manufacturing number 31a (see FIG. 6) printed on the base paper roll 1 when the base paper roll 1 is in use. Also, as will be described later, the photographing unit 46 is used to photograph the label 5 (see FIG. 4) attached to the base paper roll 1 of the remnant base paper when the base paper roll 1 of the remnant base paper is in use.

The information terminal 40 and the clamp terminal 80 have the function of displaying information to the operator using the base paper management system 100 and accepting information input from the operator.

The clamping terminal 80 is an information terminal used by an operator who operates the clamp lift 9 (see FIG. 3) to unload the base paper roll 1 from the base paper warehouse 8 (see FIG. 3). In the base paper warehouse 8, various base paper rolls 1 are stacked flat with the winding axis facing up and down. The unloading operation involves transporting the base paper rolls 1 corresponding to the production lot from the base paper warehouse 8 (see FIG. 3) to the preparation position (see FIG. 4) in front of each roll stand 11. The clamp lift 9 is a transport device equipped with a gripping clamp attachment on a forklift. The clamping terminal 80 (see FIG. 3) can be attached to and detached from the clamp lift 9 via a bracket. The number of clamping terminals 80 (for example, 2 to 3) is provided according to the number of operators.

The information terminal 40 is an information terminal used by operators who perform preparation work (allocation processing) to supply (input) the multiple base paper rolls 1 that have been transported to the preparation position of each roll stand 11 to the roll stand 11. For example, about three to four operators are in charge of the input preparation work to perform work on each of the five roll stands 11 (see Figure 2). Multiple information terminals 40 for input preparation are provided (three to four units) so that the operators can use them individually.

In this embodiment, the information terminal 40 is a mobile information terminal with a built-in photographing unit 46. Specifically, the information terminal 40 is a so-called tablet terminal, but may be a smartphone, a notebook PC, or the like. As shown in FIG. 7, the information terminal 40 includes a processor 41 such as a CPU, a storage unit 42 such as a memory (main storage device) and a storage device (auxiliary storage device), a communication unit 43 that performs wireless communication with the relay device 70, a display unit 44 such as a liquid crystal monitor, an input unit 45 such as a touch panel, and a photographing unit 46. The processor 41 executes a program (application software) stored in the storage unit 42 to function as the information terminal 40 for preparation for insertion. The information terminal 40 can access the inventory information 31 of the server device 30 via the relay device 70 by the communication unit 43. The clamp terminal 80 is also configured with the same hardware as the information terminal 40 shown in FIG. 7, so a description thereof will be omitted.

In this embodiment, the information terminal 40 is configured to acquire the base paper manufacturing number 31a from the photographed image 90 (see FIG. 8) of the base paper roll 1, and perform allocation processing to identify the base paper roll 1 to be supplied to the cardboard manufacturing device 110 from the inventory information 31 based on the acquired base paper manufacturing number 31a. Specifically, the base paper type 31c and width dimension 31d are specified in the manufacturing lot, and a base paper roll 1 whose base paper type 31c and width dimension 31d match the specifications can be used in that manufacturing lot. The allocation processing is a process of registering in the server device 30 which base paper roll 1 to be used among the individual base paper rolls 1 registered in the inventory information 31 (see FIG. 5) for the target manufacturing lot. The allocation processing updates the date and time of use, remaining length, etc. in the inventory information 31 of the used base paper roll 1 after use in the cardboard manufacturing device 110 (after production of the manufacturing lot is completed). Details of the allocation processing will be described later.

As shown in FIG. 1, a control device 50 is provided for each of the five roll stands 11 of the cardboard manufacturing apparatus 110 (a total of five control devices). Each control device 50 is connected to the server device 30 (network) by wire or wirelessly.

The control device 50 is configured as a PC equipped with a CPU (processor), memory (main storage device), and storage device (auxiliary storage device). The control device 50 is also connected to a display unit and an input unit. Specifically, the control device 50 is configured as a tablet terminal (see FIG. 4) with a built-in touch panel display as the display unit and input unit, but it may also be a notebook PC or a type of PC to which the display unit and input unit are externally connected.

The control device 50 is configured to display information about the base paper roll 1 attached to each arm 11a of the corresponding roll stand 11 while the cardboard manufacturing device 110 is in operation. The control device 50 is connected to a label printer 51 that prints labels 5 to be affixed to the base paper roll 1. The label printer 51 is an example of a "printing unit" in the claims.

The label printer 51 is configured to output a label 5 (see FIG. 8) on which the control number 31b, which is assigned separately from the base paper production number 31a, and the remaining length LP are printed for the base paper roll 1 dispensed from the cardboard manufacturing device 110. That is, in FIG. 4, when the base paper roll 1 identified by the allocation process is dispensed from the cardboard manufacturing device 110 due to the completion of the production lot, the server device 30 transmits the remaining length LP of the dispensed base paper roll 1 to the control device 50. The control device 50 controls the label printer 51 to print various information including the control number 31b and the remaining length LP. The output label 5 is affixed to the outer peripheral surface 2 of the dispensed base paper roll 1 by the operator.

Figure 8 shows an example of a label 5 output by a label printer 51. The label printer 51 outputs (issues) the label 5 by printing information on an adhesive label mount. In the example of Figure 8, the label 5 includes the management number 31b, remaining length information (remaining length LP), as well as the base paper type 31c, brand 31e, width dimension 31d, base paper manufacturing number 31a, and delivery date 31h. In this embodiment, the management number 31b is printed on the label 5 in the form of a barcode. The management number 31b may also be printed in the form of a two-dimensional code. The management number 31b can be read by the imaging unit 46 of the information terminal 40.

That is, the information terminal 40 is configured to obtain the management number 31b by reading the code image CI included in the label area AL in the captured image. The operator uses the photographing unit 46 of the information terminal 40 to photograph an image of the outer circumferential surface 2 of the base paper roll 1 including the label 5. The information terminal 40 detects the label area AL (see FIG. 8) in the photographed image by area-based matching (e.g., template matching). For this reason, a template image of the label 5 can be registered in advance in the storage unit 42 of the information terminal 40. The information terminal 40 reads the code image CI (see FIG. 8) included in the label area AL by a known barcode reading application. Alternatively, the operator can instruct barcode reading without detecting the label area AL by template matching, and the code image IC (see FIG. 8) can be read by a method in which the information terminal 40 detects the barcode (code image CI) in the image.

(Reading the base paper manufacturing number)
Next, a process for reading the base paper production number 31a printed on the base paper roll 1 using the information terminal 40 during the allocation process will be described. The information terminal 40 obtains the base paper production number 31a by extracting the character information printed on the base paper roll 1 from the photographed image 90 of the base paper roll 1 through image recognition.

First, as shown in FIG. 4, during the allocation process, the base paper roll 1 is placed in a preparation position near the roll stand 11 in a horizontal position with the outer peripheral surface 2 in contact with the ground. The end surface 3 on which the base paper manufacturing number 31a is printed is exposed horizontally. An operator photographs the end surface 3 of the base paper roll 1 using the photographing unit 46 of the information terminal 40. As a result, the information terminal 40 acquires a photographed image 90 of the end surface 3 including the base paper manufacturing number 31a, as shown in FIG. 9.

The rotation angle of the base paper roll 1 during shooting is arbitrary, and the angle of the shooting unit 46 facing the base paper roll 1 is not necessarily horizontal. The base paper production number 31a may be captured in the captured image 90 rotated at any angle.

Therefore, the information terminal 40 is configured to perform a tilt correction process on the character strings in the captured image 90, generate two types of character strings by image recognition: a character string after tilt correction and a character string rotated 180 degrees after tilt correction, and compare each of the generated character strings with the base paper manufacturing number 31a registered in the server device 30.

Specifically, the information terminal 40 first performs binarization processing on the captured image 90. The binarization processing makes the image of the character string clearer and removes unnecessary image elements. The binarization threshold can be changed, and a value appropriate for the usage environment is set. Figure 9 shows an image after binarization processing.

Next, the information terminal 40 performs a tilt correction process. Because character strings such as the base paper production number 31a are printed in a straight line, the information terminal 40 detects the tilt θ of the character string in the image. Based on the detected tilt θ, the information terminal 40 performs a tilt correction process that rotates the captured image 90 so that the character string coincides with the horizontal axis direction of the image. This results in a captured image 90 in which the character string coincides with the horizontal axis direction of the image. The captured image 90 on the right side of Figure 9 is an image of the image after the tilt correction process.

Next, the information terminal 40 performs character recognition processing on the captured image 90 after the tilt correction processing. The content of the character recognition processing is not particularly limited, and a known character recognition algorithm can be used. As a result, the character string printed on the end surface 3 of the base paper roll 1 is generated as character information. The information terminal 40 rotates the image 180 degrees and performs character recognition processing. As a result, as shown in FIG. 10, two character strings are generated: a character string 91a extracted by the initial character recognition processing (angle 0 degrees) and a character string 91b rotated 180 degrees.

Figure 10 shows an example in which the initial character string 91a is character-recognized in the correct orientation, and an example in which the character string 91b is character-recognized after being rotated 180 degrees. When the base paper manufacturing number 31a is rotated 180 degrees, it becomes a rotated image RF. When character recognition processing is performed on this rotated image RF, since each character is inverted, it can be recognized as a different character with a similar shape. For example, Figure 10 shows an example in which the inverted characters "A", "B", "C", "2", and "3" are character-recognized as "V", "8", "0", "7", and "C", respectively. Characters that are rotationally symmetric or close to rotationally symmetric ("8", "1", "0", "H", and "I") can be recognized as they are in the rotated image RF. Characters that could not be character-recognized due to inversion can be replaced with "spaces (blanks)". As a result, the character string 91b that is character-recognized in an inverted state is completely different from the actual base paper manufacturing number 31a. Depending on the orientation of the base paper production number 31a in the captured image 90 after tilt correction (the direction in which the image was captured), either the character strings 91a or 91b will be recognized in the correct orientation, and the other will be recognized in the inverted orientation.

Note that character strings other than the base paper manufacturing number 31a are also printed on the end surface 3 of the base paper roll 1. Therefore, the information terminal 40 searches through all character strings for character strings with a specified range of characters. As mentioned above, the base paper manufacturing number 31a is often around 7 to 11 characters, depending on the base paper manufacturer. The character number range of the character string to be searched can be changed, and an appropriate range can be set depending on the base paper manufacturer with which the company does business.

As a result of the above, the information terminal 40 acquires the character strings 91a and 91b that are included within the range of the specified number of characters as character strings that are highly likely to be the base paper manufacturing number 31a. The information terminal 40 displays the refined character strings 91a and 91b on the display unit 44. The information terminal 40 compares each generated character string with the base paper manufacturing number 31a registered in the server device 30, and identifies the data of the base paper roll 1 that has a matching number. This performs the allocation process.

In addition, in the allocation process, if there is no number that matches the acquired character strings 91a and 91b, the information terminal 40 displays the base paper manufacturing number 31a of the base paper roll 1 that can be used in the production lot from the inventory information 31 as a candidate 95 on the display unit 44. The information terminal 40 is configured to be able to accept correction of the character string or direct input of the base paper manufacturing number 31a. If the corrected character string matches the candidate 95, the information terminal 40 performs the allocation process for the base paper roll 1 of the candidate 95. Alternatively, without correction, the operator may allocate the candidate from among the candidates 95 by tapping (selecting and inputting) the number that matches the actual number.

Here, there may be cases where the base paper manufacturing number 31a is not registered in the inventory information 31 of the server device 30 because the base paper manufacturer did not provide it when ordering the base paper. In such cases, the data for the base paper roll 1 is registered in the inventory information 31 based on the order information, but the information for the base paper manufacturing number 31a is left blank because it has not been registered.

In this embodiment, the information terminal 40 is configured to display candidates 95 for base paper rolls 1 for which the base paper manufacturing number 31a is not registered in the inventory information 31 of the server device 30 in the allocation process, and to accept the selection of the corresponding base paper roll 1 from among the displayed candidates 95. In other words, the information terminal 40 displays the base paper rolls 1 for which the base paper manufacturing number 31a is not registered as candidates 95 on the display unit 44. The information terminal 40 then accepts the selection input of the character strings 91a and 91b, and the selection input of the candidate 95 for the base paper roll 1 that is not registered (blank). The information terminal 40 communicates with the server device 30 to register the selected character string as the base paper manufacturing number 31a in the inventory information 31 of the candidate 95 selected by the operator, and to perform the allocation process for the base paper roll 1.

In addition, if the character strings 91a and 91b are not correctly recognized and the correct base paper manufacturing number 31a of the photographed base paper roll 1 is not registered in the inventory information 31, the operator can select the unregistered (blank) candidate 95 and directly input the base paper manufacturing number 31a, or can select the unregistered (blank) candidate 95 and register the photographed image 90 in the inventory information 31.

In other words, in this embodiment, when the information terminal 40 accepts the selection of the corresponding base paper roll 1 from among the displayed candidates 95, it can accept the input of a photographed image 90 of the base paper roll 1 instead of the base paper manufacturing number 31a. When the information terminal 40 accepts the input of the photographed image 90 of the base paper roll 1, it is configured to associate the photographed image 90 of the base paper roll 1 with the inventory information 31 of the base paper roll 1 and store it in the server device 30. In this case, the photographed image 90 can ensure the traceability of the individual base paper rolls.

In this way, when the new base paper roll 1 is supplied (used) to the cardboard manufacturing device 110, the information terminal 40 performs allocation processing using the base paper manufacturing number 31a (or the data of the photographed image 90) obtained from the photographed image 90 of the base paper manufacturing number 31a.

As for the base paper roll 1 of the scrap base paper, while the base paper manufacturing number 31a printed on the end surface 3 can be read, the allocation process of the base paper roll 1 can be performed in two ways: a method of acquiring the base paper manufacturing number 31a by photographing the end surface 3, and a method of acquiring the management number 31b by photographing the label 5 on which the management number 31b (barcode) is written. In other words, the information terminal 40 is configured to perform the allocation process based on either the base paper manufacturing number 31a acquired from the photographed image 90 of the base paper manufacturing number 31a or the management number 31b acquired from the photographed image of the label 5 when the base paper roll 1 of the scrap base paper is supplied (when used).

As shown in FIG. 4, the base paper roll 1 is placed sideways, so if the label 5 affixed to the outer peripheral surface 2 is located on the ground side, it may be necessary to roll the base paper roll 1 to a position where the label 5 can be photographed. However, since photographing the end surface 3 does not depend on the orientation of the base paper roll 1, this is very convenient for the operator.

As described above, the base paper management system 100 according to this embodiment is configured to perform allocation processing based on the base paper manufacturing number 31a by photographing the base paper manufacturing number 31a printed on the end surface 3 of the base paper roll 1, so there is no need to affix a label 5 recording the management number 31b to the base paper roll 1 of new base paper until it is dispensed after the first use. For this reason, in this embodiment, when the base paper roll 1 of new base paper arrives from the base paper manufacturer, the task of affixing a label 5 to the base paper roll 1 of new base paper is not performed.

[Allocation process of base paper management system]
Next, the flow of allocation processing in the base paper management system 100 according to this embodiment will be described with reference to Figures 11 to 13. When manufacturing cardboard, as a preparatory work, allocation processing of the base paper rolls 1 to be fed into each of a maximum of five roll stands 11 is performed by repeating the processing flow shown below.

As a premise, the process flows of Figures 11 to 13 start with a state in which a base paper roll 1 corresponding to a production lot has been delivered from the base paper warehouse 8 to the preparation position (see Figure 4). At the preparation position, multiple base paper rolls 1 corresponding to the production lot are arranged side by side. Then, the allocation process is executed by an information terminal 40 operated by an operator in charge of input preparation. In the following explanation, the processing operation of the information terminal 40 is executed by the processor 41 of the information terminal 40.

In step S1 of FIG. 11, the information terminal 40 displays a list of base papers in the production lot to be prepared on the display unit 44. Base papers in the production lot refer to base papers that can be used in that production lot.

Specifically, the information terminal 40 accepts the selection of the production lot to be prepared on the lot display screen 210 shown in FIG. 14. The lot display screen 210 displays information in a table format that specifies the base paper to be fed (prepared) into the cardboard manufacturing device 110 in each production lot. For example, the lot display screen 210 in FIG. 14 displays a list of production lots in the roll stand 11 of "A back (back liner for A core)", and displays that 1643 m of base paper with a paper width (width dimension) of 1700 mm, A stage, and C5 (160 g/m ² ) is to be used for the lot number "360". By selecting and inputting one of the five type selection buttons 211, the display can be switched to the production lot list of each roll stand 11 of "A core", "B core", "B back", and "front" other than "A back". Note that the selection input is to tap the corresponding part of the touch panel.

When the information terminal 40 receives a selection input for a row of any lot number, it displays the base paper list screen 220 shown in FIG. 15. FIG. 15 shows an example in which the row of lot number "360" is selected and input, resulting in a transition to the base paper list screen 220 for lot number "360". The base paper list screen 220 displays the inventory information 31 of all base paper that can be used in the production lot ("360") in the form of a list. In the base paper list screen 220, "No." is the row number in the list. "Selection" indicates that the base paper roll has been identified as the base paper roll to be used by the allocation process. The number in the "Selection" column indicates the order of insertion into the roll stand 11. "Classification" indicates whether the base paper roll 1 is new base paper or scrap base paper. "Management No." indicates the management number 31b of the base paper roll 1. "Manufacturing No." indicates the base paper manufacturing number 31a of the base paper roll 1. "Paper width," "Base paper," "Weight," and "Brand" respectively indicate the width dimension, base paper type, weight, and brand of the base paper registered in inventory information 31. "Remaining m" indicates the remaining length LP of the base paper registered in inventory information 31. In the case of new base paper, "Remaining m" matches the initial length LS.

The operator in charge of preparation can check the available base paper from the inventory information 31 by displaying the base paper list screen 220 for the corresponding production lot.

Next, the base paper roll 1, which is placed in the preparation position and is to be subjected to the current allocation process, is photographed. First, in step S2, the information terminal 40 accepts the selection input of the image type. The operator in charge of preparation inputs an instruction to the information terminal 40 as to whether to photograph the base paper manufacturing number 31a or the label 5. Usually, the operator selects to photograph the base paper manufacturing number 31a when performing the allocation process of the base paper roll 1 of new base paper, or when the base paper roll 1 is a remnant base paper but the label 5 is hidden on the ground side and difficult to photograph. When the base paper roll 1 is a remnant base paper and the label 5 can be photographed, the operator selects to photograph the label 5.

In step S3, the information terminal 40 determines whether to photograph the base paper production number 31a or the label 5 based on the user's selection input. If the base paper production number 31a is to be photographed, the information terminal 40 proceeds to step S4. If the label 5 is to be photographed, the information terminal 40 proceeds to step S19 (see FIG. 13), which will be described later.

When photographing the base paper manufacturing number 31a, in step S4, the information terminal 40 acquires a photographed image of the base paper manufacturing number 31a printed on the end surface 3 of the base paper roll 1. That is, when the operator points the photographing unit 46 of the information terminal 40 toward the end surface 3 and inputs a photographing operation, the information terminal 40 acquires the photographed image 90 by the photographing unit 46.

In step S5, the information terminal 40 performs binarization processing and tilt correction processing (see FIG. 9) on the captured image 90. The processing details are as described above.

In step S6, the information terminal 40 performs character recognition processing on the captured image 90 after the binarization processing and the tilt correction processing. As a result, the information terminal 40 generates a character string at the initial angle (0 degrees).

In step S7, the information terminal 40 rotates the captured image 90 after the binarization process and the tilt correction process by 180 degrees and performs the second character recognition process. As a result, the information terminal 40 generates a character string rotated by 180 degrees.

In step S8, the information terminal 40 searches for character strings within the set range of the specified number of characters from each acquired character string (0 degrees and 180 degrees). As a result, the information terminal 40 acquires two types of character strings 91a and 91b (see FIG. 10) corresponding to the base paper production number 31a from the captured image 90.

In step S9, the information terminal 40 compares the two acquired character strings 91a and 91b with the base paper production number 31a in the production lot that is the target of the allocation process. That is, the information terminal 40 compares the base paper production number 31a listed on the base paper list screen 220 (see FIG. 15) with the character strings 91a and 91b, and searches for items with matching numbers.

In step S10, the information terminal 40 determines whether or not either of the two acquired character strings 91a and 91b matches any of the base paper production numbers 31a in the target production lot (i.e., any of the base paper production numbers 31a registered in the inventory information 31).

If the character string matches the base paper manufacturing number 31a, the information terminal 40 performs an allocation process in step S14 to assign the item of the matching base paper manufacturing number 31a (base paper roll 1 identified by the base paper manufacturing number 31a) as the base paper roll 1 to be inserted into the roll stand 11 in the corresponding production lot.

On the other hand, if there is no base paper manufacturing number 31a that matches the two acquired character strings 91a and 91b in step S10, the information terminal 40 proceeds to step S11. Cases in which the character strings do not match include (a) a case in which the character string is misread, (b) a case in which the character string is correct but the base paper manufacturing number 31a is not registered, and (c) a case in which the character string is misread and the base paper manufacturing number 31a is not registered.

In step S11, the information terminal 40 displays the acquired character strings 91a and 91b and candidates 95 for the base paper roll 1 in the production lot on the display unit 44, as shown in FIG. 10. At this time, unlike the base paper list screen 220 in FIG. 15, the information terminal 40 does not display information such as width dimension, base paper type, basis weight, and remaining length, and displays a list of base paper production numbers 31a.

In step S12, the information terminal 40 performs control to accept a selection operation of a candidate 95 for the base paper roll 1, accept direct input of the base paper manufacturing number 31a (inputting the entire number or correcting the character string), or accept input for storing image data of the captured image 90.

That is, in the case of (a) erroneous reading of a character string, the information terminal 40 accepts the selection input (tap) of the corresponding candidate 95, or accepts direct input of the base paper manufacturing number 31a (inputting the entire number or correcting the character string). When a candidate 95 that matches the correct base paper manufacturing number 31a is displayed, the operator selects and inputs (tap) the corresponding candidate 95. Alternatively, the operator can check the base paper manufacturing number 31a on the end surface 3 of the photographed base paper roll 1 and directly input the correct number (correcting the character string or inputting the entire number).

(b) In a case where the acquired character string is correct but the base paper manufacturing number 31a is not registered in the server device 30, as shown in FIG. 10, the information terminal 40 accepts in step S12 an operation to select either the character string 91a or 91b, and a selection of the displayed candidate 95 for the unregistered base paper roll 1.

(c) In the case where the acquired character string is incorrect and the correct base paper manufacturing number 31a is not registered, the information terminal 40 accepts the selection of a candidate 95 for the unregistered base paper roll 1 and also accepts direct input of the base paper manufacturing number 31a from the operator (input of the entire string or correction of the character string), or accepts input of a photographed image 90 of the base paper roll 1 instead of the base paper manufacturing number 31a.

Although not shown in Figure 11, there is an exception to this rule, where the acquired character string is correct, but there is no matching number candidate 95 in the production lot, and there is also no candidate 95 with an unregistered number. In this case, the photographed base paper roll 1 may be a base paper roll 1 outside the production lot that was mistakenly shipped out, so the operator performs a specified error process.

In step S13, the information terminal 40 determines whether an item without a manufacturing number in the target lot (candidate 95 with an unregistered base paper manufacturing number 31a) was selected in step S12.

If an item without a manufacturing number (an unregistered candidate 95) is not selected (case (a) above), the information terminal 40 proceeds to step S14, and performs allocation processing with the base paper manufacturing number 31a of the candidate 95 for the selected candidate 95 with a registered number or a candidate 95 with a base paper manufacturing number 31a that matches the character string that was directly input (modified or input in full).

On the other hand, if an item without a manufacturing number (unregistered candidate 95) is selected (cases (b) and (c) above), the information terminal 40 proceeds to the processing of step S15 in FIG. 12 and determines whether or not the base paper manufacturing number 31a was acquired in step S12.

In the above case (b), the number selected and input by the operator out of the character strings 91a and 91b is acquired, so the information terminal 40 determines that the base paper production number 31a has been acquired and proceeds to step S16. In step S16, the information terminal 40 registers the selected character string as the base paper production number 31a in the data corresponding to the selected unregistered candidate 95 in the inventory information 31 of the server device 30, and performs allocation processing using the base paper production number 31a.

In the case of (c) above, even if direct input of the base paper manufacturing number 31a (all input or modification of the character string) is received, the information terminal 40 determines that the base paper manufacturing number 31a has been acquired, and proceeds to step S16. In step S16, the information terminal 40 registers the directly input character string as the base paper manufacturing number 31a in the data corresponding to the selected unregistered candidate 95 in the inventory information 31 of the server device 30, and performs allocation processing using the base paper manufacturing number 31a.

On the other hand, in the case of (c) above, if input of a photographed image 90 of the base paper roll 1 is received instead of the base paper manufacturing number 31a, the information terminal 40 determines that the base paper manufacturing number 31a has not been acquired, and proceeds to step S17.

In step S17, the information terminal 40 stores the captured image 90 of the base paper roll 1 in the server device 30 as image data. That is, the information terminal 40 associates the data of the captured image 90 of the base paper roll 1 captured this time with the data corresponding to the selected unregistered candidate 95 in the inventory information 31 of the server device 30, stores it in the server device 30, and performs allocation processing (without the base paper manufacturing number).

After the allocation process is performed in either step S16, step S17 or step S14 (see FIG. 11), the information terminal 40 proceeds to step S18 in FIG. 11.

When the allocation process is performed, in step S18, the information terminal 40 determines whether the allocation process has been completed for all base paper rolls 1 used in the production lot. If the information terminal 40 is to perform allocation process for base paper rolls 1 to be inserted into another roll stand 11, the information terminal 40 returns the process to step S2. When the allocation process has been completed for all base paper rolls 1, the information terminal 40 completes the allocation process for that production lot.

The above is the allocation process using the base paper manufacturing number 31a. Next, the allocation process using the management number 31b will be explained. That is, the process when photographing the label 5 in step S3 of FIG. 11 will be explained.

In this case, in step S19 of FIG. 13, the information terminal 40 acquires a captured image of the label 5 affixed to the outer peripheral surface 2 of the base paper roll 1 (hereinafter referred to as a "label captured image"). That is, when the operator points the photographing unit 46 of the information terminal 40 at the label 5 and inputs a photographing operation, the information terminal 40 acquires the label captured image using the photographing unit 46.

In step S20, the information terminal 40 detects the label area AL (see FIG. 8) from the label photograph image.

In step S21, the information terminal 40 performs a tilt correction process on the captured label image. The content of the tilt correction process is the same as the process performed on the captured image 90 of the base paper production number 31a. Note that since the barcode is originally expressed as a binary image, unlike step S5, the image is not binarized. Also, if the code image CI is a two-dimensional code that includes a position detection pattern, the reading process of the code image CI itself includes tilt detection (tilt detection can also be performed on tilted code images CI), so there is no need to perform a tilt correction process on the entire captured image 90.

In step S22, the information terminal 40 performs a process of reading the code image CI (see FIG. 8) in the detected label area AL. As a result, the information terminal 40 obtains the management number 31b from the barcode (code image CI).

In step S23, the information terminal 40 compares the acquired management number 31b with the management number 31b of the base paper roll 1 in the target production lot from the inventory information 31 of the server device 30. In step S24, the information terminal 40 judges whether or not a number matching the acquired management number 31b exists in the target production lot. If data of a number matching the acquired management number 31b exists, in step S25, the information terminal 40 performs allocation processing to set the base paper roll 1 with the number matching the acquired management number 31b as the base paper roll 1 to be used.

If there is no data with a number matching the acquired management number 31b, the photographed base paper roll 1 is a base paper roll 1 that was mistakenly shipped out of the production lot. Therefore, the information terminal 40 displays a predetermined warning in step S26. Then, the operator handles the error.

If the allocation process is performed in step S25, the information terminal 40 proceeds to step S18 (see FIG. 11) and repeats the allocation process if there is a next base paper roll 1.

As a result, for example, in a production lot of two-tiered cardboard with A and B columns, the allocation process is repeated up to five times in preparation for feeding the base paper rolls 1 into the five roll stands 11. When all allocation processes are completed, an operator begins the task of feeding the base paper rolls 1 into each roll stand 11. Each base paper roll 1 used in the production lot is fed sequentially into the five roll stands 11, and the production of cardboard by the cardboard manufacturing device 110 begins.

(Work flow after starting cardboard production)
When the production of cardboard boxes progresses and the use of the base paper roll 1 on one arm 11a of the roll stand 11 is finished, production is resumed by switching to the base paper roll 1 on the other arm 11a, and the base paper roll 1 on one side that has been used is discharged from the roll stand 11. When the base paper roll 1 is used up (when the remaining length LP = 0), the base paper roll 1 is discarded. When the base paper roll 1 has been used up to a certain point (when the remaining length LP > 0), a label 5 is output by the label printer 51, and the label 5 is affixed to the base paper roll 1 by an operator. If the discharged base paper roll 1 of the remaining base paper is not scheduled to be used, it is stored in the base paper warehouse 8.

Before the base paper roll 1 is dispensed, the operator in charge of preparing for insertion performs the allocation process for the next base paper roll 1. The operator sequentially performs the allocation process for the base paper rolls 1 arranged in the preparation position at any timing before the base paper roll 1 is dispensed. After the allocation process at the start of production, the insertion work of the allocated base paper rolls 1 is performed alternately for the arm 11a on one side and the arm 11a on the other side of each roll stand 11. Then, when the end of the current production lot approaches, the operator prepares for the production of the next lot. In this way, the base paper production work continues according to the production lot.

[Effects of this embodiment]
In this embodiment, the following effects can be obtained.

As described above, the cardboard base paper management system 100 of this embodiment includes an image capturing unit 46 that captures the base paper manufacturing number 31a printed on the base paper roll 1 when the base paper roll 1 is used, and an information terminal 40 that acquires the base paper manufacturing number 31a from the captured image 90 of the base paper roll 1 and performs allocation processing to identify the base paper roll 1 to be supplied to the cardboard manufacturing device 110 from the inventory information 31 based on the acquired base paper manufacturing number 31a. This allows the unique base paper manufacturing number 31a printed on the base paper roll 1 of the new base paper to be acquired from the captured image 90, and the acquired base paper manufacturing number 31a can be used to perform individual identification (allocation processing) of the base paper roll 1 of the new base paper. Therefore, it is possible to perform individual management of the base paper roll 1 of the new base paper with traceability in cardboard manufacturing without attaching a label 5 with the management number 31b when the new base paper arrives. As a result, it is possible to eliminate the need to apply labels to each new base paper roll 1 in the early morning, reducing the operator's workload. In addition, by eliminating the need to print many labels on the new base paper rolls 1 that arrive every day, it is possible to reduce costs and resource consumption.

The effect of the cardboard base paper management system 100 of this embodiment will be specifically described with reference to Figure 16. Figure 16 shows the flow of work of an operator, with the vertical direction indicating the flow of time. Also, flow F1 on the left side of Figure 16 shows the work flow when the cardboard base paper management system 100 of this embodiment is used, and flow F2 on the right side shows the conventional work flow (comparison example). The following flow explains the work flow in which a base paper roll 1 of new base paper is received, cardboard is manufactured using the base paper roll 1 of new base paper, and the base paper roll 1 of new base paper is discharged and stored as leftover base paper.

In the conventional flow F2 according to the comparative example, when a new base paper roll 1 arrives in the early morning hours before production starts (operation W21), an operator creates a label using a label printer and attaches it (operation W22). Once the label attachment is complete, the roll is stored in the base paper warehouse (operation W23). Thereafter, at the cardboard manufacturing stage, the process is as follows: base paper is removed from the base paper warehouse (operation W24), the label is read (operation W25), allocation processing is performed (operation W26), the base paper roll is inserted (operation W27), the scrap base paper is removed (operation W28), a label is created and an updated label is attached (operation W29), and the scrap base paper is stored (operation W30). Operation W22 of attaching the label when the roll arrives is performed in order to read the label in operation W25.

In flow F1 when using the cardboard base paper management system 100 of this embodiment, when a new base paper roll 1 arrives in the early morning hours before production begins (task W1), it is stored directly in the base paper warehouse (task W2). Then, at the cardboard production stage, the process goes as follows: base paper is removed from the warehouse (task W3), the base paper production number 31a is read (task W4), allocation processing is performed (task W5), the base paper roll is inserted (task W6), the scrap base paper is removed (task W7), the first label 5 is created and affixed (task W8), and the scrap base paper is stored (task W9).

Assuming that 100 rolls of new base paper are received per day, operation W22 in the comparative example requires printing and attaching labels 100 times. For this reason, operation W22 requires at least 20 to 30 minutes of work time each day in the early morning hours before production begins. In addition, costs are incurred in the form of consumable costs, taking into account the cost of one label and the printing cost per label, as well as labor costs for the early morning work, and resource consumption also increases.

In contrast, in the cardboard base paper management system 100 of this embodiment, in task W4, the base paper production number 31a is read for the initial allocation process, so there is no need to create and attach the label 5 to the base paper roll 1 of the new base paper (task W22 in flow F2). As a result, the burden on the operator can be reduced by reducing early morning work, and the costs and resource consumption associated with attaching the label 5 to the base paper roll 1 of the new base paper can be suppressed.

In addition, in this embodiment, as described above, the label printer 51 is further provided for outputting the label 5 on which the management number 31b and the remaining length LP, which are assigned separately from the base paper manufacturing number 31a, are printed on the base paper roll 1 discharged from the cardboard manufacturing device 110, and the information terminal 40 is configured to perform allocation processing based on either the base paper manufacturing number 31a acquired from the photographed image 90 in which the base paper manufacturing number 31a is photographed, or the management number 31b acquired from the label photographed image in which the label 5 is photographed, when the base paper roll 1 of the leftover base paper is supplied. As a result, when the base paper roll 1 of the new base paper is discharged from the cardboard manufacturing device 110 and becomes the base paper roll 1 of the leftover base paper, the base paper roll 1 can be individually identified using the label 5 on which the management number 31b and the remaining length LP are printed. Here, the base paper manufacturing number 31a becomes unreadable when the base paper diameter is reduced to the printed position. Also, if the label 5 faces the ground side, the label 5 cannot be photographed as it is. Therefore, by making it possible to perform allocation processing for the scrap base paper roll 1 using either the base paper production number 31a or the label 5 (management number 31b), the convenience of the operator performing the allocation processing can be improved.

In addition, in this embodiment, as described above, when the acquired base paper manufacturing number 31a is not registered in the server device 30 during the allocation process, the information terminal 40 is configured to display candidates 95 for base paper rolls 1 with unregistered base paper manufacturing numbers 31a and accept the selection of the corresponding base paper roll 1 from the displayed candidates 95. As a result, even if the base paper manufacturing number 31a acquired from the captured image 90 is not registered in the inventory information 31 of the server device 30, the operator using the information terminal 40 can confirm and select the base paper manufacturing number 31a, thereby registering the base paper manufacturing number 31a on the spot and performing smooth allocation processing. In addition, when the allocation process is completed by selecting a candidate, the operator does not need to manually input the base paper manufacturing number 31a character by character into the information terminal 40, which can reduce the labor required for input.

In addition, in this embodiment, as described above, the information terminal 40 performs a tilt correction process on the character string in the captured image 90, generates two types of character strings by image recognition: a character string after tilt correction and a character string rotated 180 degrees after tilt correction, and compares each generated character string with the base paper manufacturing number 31a registered in the server device 30. This makes it possible to obtain the base paper manufacturing number 31a from the captured image 90, regardless of the direction in which the base paper manufacturing number 31a printed on the roll end surface is rotated in the captured image 90. As a result, when capturing the base paper manufacturing number 31a, the operator does not need to roll the heavy and large base paper roll 1 to adjust the angle, or change the capture angle to match the direction of the base paper manufacturing number 31a, so the operator's workload can be effectively reduced.

In this embodiment, as described above, the control number 31b is printed on the label 5 in the form of a barcode or two-dimensional code, and the information terminal 40 is configured to detect the label area AL in the label photographed image and obtain the control number 31b by reading the code image CI contained in the detected label area AL. As a result, even when the control number 31b is printed on the label 5 in the form of a barcode or two-dimensional code, the control number 31b can be obtained by simply photographing the label 5 using the photographing unit 46 in the same way as the base paper production number 31a, without adding a dedicated reader device or the like. In other words, the photographing unit 46 can obtain both the base paper production number 31a and the control number 31b, so the configuration of the cardboard base paper management system 100 can be simplified.

In addition, in this embodiment, as described above, the information terminal 40 is a portable information terminal with a built-in photographing unit 46. This allows a series of allocation processes, such as photographing, reading the number, and checking against the server device 30, to be performed all by a portable information terminal with a built-in photographing unit 46, such as a tablet terminal or a smartphone. This simplifies the configuration of the corrugated board management system 100. Also, for the operator, convenience is improved because the equipment used for the allocation process is integrated into the portable information terminal.

In addition, in this embodiment, as described above, when the information terminal 40 accepts the selection of the corresponding base paper roll 1 from the displayed candidates 95 (see FIG. 10), it is possible to accept the input of the photographed image 90 of the base paper roll 1 instead of the base paper manufacturing number 31a, and when the input of the photographed image 90 of the base paper roll 1 is accepted, the photographed image 90 of the base paper roll 1 is associated with the inventory information 31 of the base paper roll 1 and stored in the server device 30. As a result, even if the base paper manufacturing number 31a is not registered in the inventory information 31 of the server device 30 and the base paper manufacturing number 31a cannot be character-recognized from the photographed image 90, the photographed image 90 can be used as a substitute for the base paper manufacturing number 31a by storing the image data of the photographed image 90 of the base paper roll 1. In other words, when the base paper manufacturing number 31a of the base paper roll 1 is required, the operator (or the base paper manufacturer) can identify the base paper manufacturing number 31a from the photographed image 90, so that the traceability of the individual base paper rolls can be ensured. This also saves operators the work of inputting numbers, which saves them time.

[Modification]
It should be noted that the embodiments disclosed herein are illustrative and not restrictive in all respects. The scope of the present invention is indicated by the claims, not by the description of the embodiments above, and further includes all modifications (variations) within the meaning and scope of the claims.

For example, in the above embodiment, an example was shown in which the photographing unit 46 was built into the information terminal 40, but the present invention is not limited to this. In the present invention, the photographing unit 46 may be provided separately from the information terminal 40, and the information terminal 40 may not have a photographing unit. In this case, the photographing unit 46 may be a camera device that can be carried by the operator. The photographing unit 46 may be fixedly installed or movably installed by a moving mechanism at a position facing the end surface 3 of the base paper roll 1 arranged at the base paper preparation position, for example.

In the above embodiment, the information terminal 40 is a mobile information terminal such as a tablet terminal or a smartphone, but the present invention is not limited to this. The information terminal 40 may be, for example, a PC fixedly installed near the base paper preparation position.

In the above embodiment, an example was shown in which the information terminal 40 used by the operator in charge of input preparation executes the allocation process, but the present invention is not limited to this. In the present invention, the clamping terminal 80 in charge of shipping may be the information terminal that executes the allocation process. In other words, when shipping from the base paper warehouse 8, the allocation process may be executed using the clamping terminal 80.

In the above embodiment, an example is shown in which a label printer 51 is provided to output a label 5 to the raw paper roll 1 of the scrap raw paper, but the present invention is not limited to this. In the present invention, the label printer 51 (printing unit) does not have to be provided. For example, when the raw paper roll 1 is dispensed, the operator may write the management number 31b displayed on the control device 50 directly on the outer surface 2 of the raw paper roll 1, or the operator may attach a label on which the management number 31b is transcribed. However, it is preferable to use the label printer 51 from the viewpoint of suppressing human errors such as mistranscription. Note that the printing unit may be configured with a general plain paper printer or an office multifunction printer instead of the label printer 51.

In addition, in the above embodiment, an example was shown in which the base paper manufacturing number 31a on the end surface 3 of the base paper roll 1 was photographed, but the present invention is not limited to this. If the base paper manufacturing number 31a is also printed on the outer peripheral surface 2 of the base paper roll 1, either the base paper manufacturing number 31a on the outer peripheral surface 2 or the base paper manufacturing number 31a on the end surface 3 may be photographed.

In addition, in the above embodiment, an example was shown in which allocation processing is performed based on either the base paper manufacturing number 31a or the management number 31b when supplying the base paper roll 1 for the second or subsequent times (remnant base paper), but the present invention is not limited to this. In the allocation processing for the base paper roll 1 for the second or subsequent times (remnant base paper), it may be limited to only the management number 31b without using the base paper manufacturing number 31a.

In the above embodiment, in step S2 of FIG. 11, the information terminal 40 accepts a selection input of an image type, and in step S3, depending on the accepted selection input, switches between performing character recognition of the base paper production number 31a and reading the barcode of the label 5. However, the present invention is not limited to this. In the present invention, it is not necessary to accept a selection input of an image type. For example, an operator may operate the information terminal 40 to take a photograph of the photographed image 90 or a label photographed image, and the information terminal 40 may automatically select whether to perform character recognition of the base paper production number 31a or read the barcode of the label 5 based on the photographed image.

In the above embodiment, in the allocation process, if the acquired base paper manufacturing number 31a is not registered, candidates 95 for base paper rolls 1 with unregistered base paper manufacturing numbers 31a are displayed and the selection of the corresponding base paper roll 1 from the displayed candidates 95 is accepted, but the present invention is not limited to this. In the present invention, the selection of candidates 95 is not performed, and for inventory information 31 with unregistered base paper manufacturing numbers 31a, the information terminal 40 may only accept registration by direct input of the base paper manufacturing number 31a, or the captured image 90 may be saved as image data.

In the above embodiment, two types of character strings are generated by image recognition: character string 91a after tilt correction in the photographed image 90, and character string 91b rotated 180 degrees after tilt correction, and each generated character string is compared with the base paper production number 31a. However, the present invention is not limited to this. An image recognition method may be used that extracts character strings from the photographed image 90 regardless of the angle of the character string in the photographed image 90 without performing tilt correction processing.

In the above embodiment, an example was shown in which the information terminal 40 was configured to obtain the management number 31b from the photographed label image, but the present invention is not limited to this. In the present invention, instead of obtaining the management number 31b from an image, the management number 31b may be obtained from the label 5 using a code reading device such as a barcode reader provided separately from the information terminal 40. In this case, the information terminal 40 may be configured to receive the management number 31b from the code reading device by wired communication or wireless communication.

In the above embodiment, an example is shown in which a control device 50 is provided for each of the five roll stands 11, but the present invention is not limited to this. In the present invention, a common control device 50 may be provided for multiple roll stands 11. For example, a total of three control devices 50 may be provided, such as one for the roll stand 11 for the A core and the roll stand 11 for the A core back liner, one for the roll stand 11 for the B core and the roll stand 11 for the B core back liner, and one for the roll stand 11 for the front liner.

In addition, in the above embodiment, the number of information terminals 40 is described as three to four, but the present invention is not limited to this. The number of information terminals 40 is not particularly limited, and may be one, two, or five or more.

In the above embodiment, the inventory of the base paper roll 1 is managed by the base paper manufacturing number 31a and the management number 31b printed on the label 5, but the present invention is not limited to this. The present invention may be applied to a configuration in which inventory is managed using an RFIC tag. The RFIC tag is attached to the inner surface of the center hole 4 of the base paper roll 1 (the inner surface of the paper tube). For example, the information terminal 40 can perform a process of writing the base paper manufacturing number 31a read from the photographed image 90 of the base paper roll 1 to the RFIC tag by communication. When the base paper roll 1 is stored in the base paper warehouse 8 in a flat stack as shown in FIG. 3, it is preferable to use the RFIC tag and the label 5 in combination. In a configuration in which the base paper warehouse 8 is an automated warehouse and the base paper roll 1 is individually identified and managed by communication with the RFIC tag, it is not necessarily necessary to use the label 5.

In addition, in the above embodiment, for convenience of explanation, the processing of the control device is explained using a flow-driven flowchart, but the present invention is not limited to this. In the present invention, the processing operation of the control device may be performed by event-driven processing in which processing is executed for each event. In this case, the processing may be performed completely event-driven, or event-driven and flow-driven may be combined.

REFERENCE SIGNS LIST 1 Base paper roll 5 Label 30 Server device 31 Stock information 31a Base paper production number 31b Management number 40 Information terminal 46 Photographing unit 90 Photographed image 91a Character string 91b Character string 95 Candidate 100 Corrugated board base paper management system 110 Corrugated board manufacturing device AL Label area CI Code image LP Remaining length

Claims (7)

A cardboard base paper management system that manages base paper rolls supplied to a cardboard manufacturing device,
A server device that stores the base paper manufacturing number and inventory information of the base paper roll in association with each other;
an imaging unit that images the base paper production number printed directly on the base paper roll when the base paper roll is in use;
and an information terminal that performs an allocation process to acquire the base paper manufacturing number from a photographed image of the base paper roll, and identify the base paper roll to be supplied to the cardboard manufacturing apparatus from the inventory information based on the acquired base paper manufacturing number. A printing unit is further provided for outputting a label on the base paper roll discharged from the cardboard manufacturing device, the label including a management number assigned separately from the base paper production number and a remaining length.
2. The cardboard base paper management system according to claim 1, wherein the information terminal is configured to perform the allocation process based on either the base paper manufacturing number acquired from the photographed image of the base paper manufacturing number or the management number acquired from the photographed image of the label when the base paper roll of scrap base paper is supplied. The cardboard base paper management system according to claim 1 or 2, wherein the information terminal is configured to display candidates for the base paper roll whose base paper manufacturing number is not registered and to accept the selection of the corresponding base paper roll from among the displayed candidates if the acquired base paper manufacturing number is not registered in the server device during the allocation process. The cardboard base paper management system according to any one of claims 1 to 3, wherein the information terminal is configured to perform a tilt correction process for character strings in the captured image, generate two types of character strings by image recognition: a character string after tilt correction and a character string rotated 180 degrees after tilt correction, and compare each of the generated character strings with the base paper manufacturing number registered in the server device. The control number is printed on the label in the form of a bar code or a two-dimensional code,
The cardboard sheet management system according to claim 2 , wherein the information terminal is configured to obtain the management number by reading a code image included in a label area in the captured image. The cardboard management system according to any one of claims 1 to 5, wherein the information terminal is a mobile information terminal with the built-in image capture unit. The information terminal includes:
When accepting the selection of a corresponding base paper roll from among the displayed candidates, input of a photographed image of the base paper roll can be accepted instead of the base paper production number,
4. The cardboard base paper management system according to claim 3, configured to, when an input of a photographed image of the base paper roll is accepted, associate the photographed image of the base paper roll with inventory information of the base paper roll and store it in the server device.

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