JP7573458B2 - Foreign matter contamination check device, foreign matter contamination check method, and foreign matter contamination check program - Google Patents

Description

The present invention relates to a foreign matter contamination check device, a foreign matter contamination check method, and a foreign matter contamination check program.

Patent Document 1 discloses a technology that calculates the yield rate of a final product and manages costs by comparing the actual usage of multiple raw materials when manufacturing an actual final product with the usage amounts of multiple raw materials when manufacturing an initially planned final product.

JP 2018-133006 A

Manufacturers of food, cosmetics, and other products prevent waste in production costs by reusing the amount of ingredients remaining in the tanks used in the production of the product and the amount of ingredients that were not used in the next product. In this case, when manufacturing a specific product, there is a risk that the amount of ingredients different from the specified ingredients will be mixed in as foreign matter.

However, the manufacturing instruction management device described in the above-mentioned Patent Document 1 does not take into consideration the presence of foreign objects. For this reason, manufacturers have been hoping for a technology that can check for the presence of foreign objects when using payment amounts when manufacturing a specific product.

The present invention has been made in consideration of the above, and aims to provide a foreign matter contamination checking device, a foreign matter contamination checking method, and a foreign matter contamination checking program that can check for foreign matter contamination in products.

In order to solve the above-mentioned problems and achieve the object, the foreign matter contamination checking device of the present invention is a foreign matter contamination checking device equipped with a control unit, and the control unit is characterized by comprising: a calculation means for calculating a yield by dividing the sum of the actual quantity of products obtained in a certain manufacturing process and the paid amount, which is the actual quantity of products obtained in the manufacturing process preceding the certain manufacturing process minus the quantity of products used in the certain manufacturing process and is the remainder of the previous manufacturing process , by the quantity of raw materials used until the product is obtained in the certain manufacturing process; a confirmation means for confirming whether the yield exceeds a standard yield; and a notification means for outputting a notification of the possibility of foreign matter contamination if the yield exceeds the standard yield.

Furthermore, the foreign matter contamination checking method of the present invention is a foreign matter contamination checking method executed by a foreign matter contamination checking device equipped with a control unit, and is characterized by including a calculation step executed by the control unit to calculate a yield by dividing the sum of the actual quantity of products obtained in a certain manufacturing process and the paid amount, which is the actual quantity of products obtained in the manufacturing process preceding the certain manufacturing process minus the quantity of products used in the certain manufacturing process and is the remainder of the previous manufacturing process, by the quantity of raw materials used until the product is obtained in the certain manufacturing process; a confirmation step to confirm whether the yield exceeds a standard yield; and a notification step to output a notification notifying of the possibility of foreign matter contamination if the yield exceeds the standard yield.

In addition, the foreign matter contamination check program of the present invention is a foreign matter contamination check program to be executed by a foreign matter contamination check device equipped with a control unit, and is characterized by including a calculation step for calculating a yield by dividing the sum of the actual quantity of products obtained in a certain manufacturing process and the paid amount, which is the amount obtained by subtracting the quantity of products used in the certain manufacturing process from the actual quantity of products obtained in the manufacturing process preceding the certain manufacturing process and which is the remainder of the previous manufacturing process , by the quantity of raw materials used until the product is obtained in the certain manufacturing process; a confirmation step for confirming whether the yield exceeds the standard yield; and a notification step for outputting a notification notifying of the possibility of foreign matter contamination if the yield exceeds the standard yield.

The present invention has the effect of making it possible to check for foreign matter contamination of products.

FIG. 1 is a schematic diagram showing an overview in a block diagram of an example of the configuration of a foreign matter contamination check device. FIG. 2 is a diagram showing an example of a configuration master table in the configuration master. FIG. 3 is a diagram showing an example of a product master table in the product master. FIG. 4 is a diagram showing an example of a package quantity master table in the package quantity master. FIG. 5 is a diagram showing an example of a configuration master table in the configuration master. FIG. 6 is a diagram showing an example of a manufacturing instruction master table in the manufacturing instruction master. FIG. 7 is a diagram showing an example of an arrangement content master table in the arrangement content master. FIG. 8 is a diagram showing an example of a manufacturing instruction reception data table in the manufacturing instruction reception data. FIG. 9 is a diagram showing an example of a manufacturing instruction delivery data table in the manufacturing instruction delivery data. FIG. 10 is a diagram showing an example of a manufacturing performance reception data table in the manufacturing performance reception data. FIG. 11 is a diagram showing an example of a production performance delivery data table in the production performance delivery data. FIG. 12 is a diagram showing an outline of a procedure for creating a production performance table. FIG. 13 is a diagram showing a schematic diagram of the manufacturing process of a certain product. FIG. 14 is a flowchart showing an outline of the process executed by the foreign matter contamination check device. FIG. 15 is a diagram showing an example of a production instruction input screen for a packaging process for the planned production of a certain product and an example of production instruction input for the packaging process. FIG. 16 is a diagram showing an example of a production instruction input screen in a preparation process for a production plan of a certain product and an example of production instruction input in the preparation process. FIG. 17 is a diagram showing an example of a production performance table (plan) and production instruction contents. FIG. 18 is a diagram showing an example of a production performance input screen in a preparation process of the production performance of a certain product and an example of production actual situation input in the preparation process. FIG. 19 is a diagram showing an example of a production record input screen in a packaging process of a production record of a certain product and an example of production record input in the packaging process. FIG. 20 is a diagram showing an example of a production performance table (performance) and the contents of the production performance. FIG. 21 is a diagram showing an example of a production record input screen in the preparation process of the production record of a product in which additional oil and reduction may occur in the production record, and an example of production actual market input in the preparation process. FIG. 22 is a diagram showing an example of the production record reception data table in the production record reception data 106i in the case where the production record includes additional oil and reduction. FIG. 23 is a diagram showing an example of the production performance payout data table in the production performance payout data 106j in the case where additional oil and return are included in the production performance. FIG. 24 is a diagram showing an example of a production record input screen in a packaging process of the production record of a product in which additional oil and reduction may occur in the production record, and an example of production record input in the packaging process. FIG. 25 is a diagram showing an example of a production performance table (performance) and the production performance contents in the case where the production performance includes additional oil and reduction. FIG. 26 is a diagram showing an example of a production record input screen in a packaging process of a production record of a certain product and a production record input in the packaging process. FIG. 27 is a diagram showing an example of a production record table (record) and the production record contents of a certain product. FIG. 28 is a diagram showing an example of a production performance table at the time of document extraction.

Below, an embodiment of a foreign matter contamination check device, a foreign matter contamination check method, and a foreign matter contamination check program according to the present invention will be described in detail with reference to the drawings. Note that the present invention is not limited to the present embodiment.

[1. Configuration]
An example of the configuration of a foreign matter contamination check device according to the present embodiment will be described with reference to Fig. 1 etc. Fig. 1 is a schematic diagram showing an overview in a block diagram of an example of the configuration of a foreign matter contamination check device.

The foreign matter contamination check device 100 shown in FIG. 1 is a commercially available desktop personal computer. Note that the foreign matter contamination check device 100 is not limited to a stationary information processing device such as a desktop personal computer, but may be a portable information processing device such as a commercially available notebook personal computer, PDA (Personal Digital Assistant), smartphone, or tablet personal computer.

The foreign matter contamination check device 100 includes a control unit 102, a communication interface unit 104, a memory unit 106, and an input/output interface unit 108. Each unit of the foreign matter contamination check device 100 is connected to each other so as to be able to communicate with each other via any communication path.

The communication interface unit 104 communicatively connects the foreign matter contamination check device 100 to the network 300 via a communication device such as a router and a wired or wireless communication line such as a dedicated line. The communication interface unit 104 has a function of communicating data with other devices via the communication line. Here, the network 300 has a function of connecting the foreign matter contamination check device 100 and the server 200 so that they can communicate with each other, and is, for example, the Internet or a LAN (Local Area Network). The data stored in the memory unit 106 may be stored in the server 200, for example.

An input device 112 and an output device 114 are connected to the input/output interface unit 108. The output device 114 may be a monitor (including a home television), a speaker, or a printer. The input device 112 may be a keyboard, a mouse, a microphone, or a monitor that works with a mouse to provide a pointing device function. In the following, the output device 114 may be referred to as the monitor 114, and the input device 112 may be referred to as the keyboard 112 or the mouse 112.

The storage unit 106 stores various databases, tables, files, etc. The storage unit 106 records computer programs that work with the OS (Operating System) to give instructions to the CPU (Central Processing Unit) to perform various processes. As the storage unit 106, for example, a memory device such as a RAM (Random Access Memory) or a ROM (Read Only Memory), a fixed disk device such as a hard disk, a flexible disk, an optical disk, etc. can be used. The memory unit 106 stores a configuration master 106a, a product master 106b, a package quantity master 106c, a configuration master 106d, a manufacturing instruction master 106e, an arrangement content master 106f, manufacturing instruction receipt data 106g, manufacturing instruction delivery data 106h, manufacturing performance receipt data 106i, and manufacturing performance delivery data 106j.

The composition master 106a stores the constituent molecules, composition distribution, yield, number required for a certain quantity, and the process of use for multiple raw materials and supplies used in manufacturing a certain product.

Figure 2 is a diagram showing an example of a configuration master table in the configuration master 106a. As shown in Figure 2, the configuration master table T1 holds raw material A, raw material B, and supplies as raw materials used in manufacturing a certain product, "product A." Furthermore, the configuration master table T1 holds raw material A in correspondence with "9 kg" of constituent molecules, "10 kg" of constituent distribution, "98.6%" of yield, "456.34" of the number required for a certain quantity, for example, the number of 500 kg owned, and "100" of the process of use.

Product master 106b stores the code of a product in association with the product, asset classification, and unit.

Figure 3 is a diagram showing an example of a product master table in product master 106b. As shown in Figure 3, in product master table T2, when the code of a certain product is "1", the product is stored as "Product A", the asset classification is "Product", and the unit is stored as "kg", in association with the code.

The package quantity master 106c stores the product, package and quantity associated with the code of a certain product.

Figure 4 shows an example of a package quantity master table in the package quantity master 106c. As shown in Figure 4, the package quantity master table T3 stores the product code "1" in association with "Product A", the package type "pieces", and the quantity "10".

The composition master 106d stores, for each parent product, the process of use, the child product, the constituent numerator, and the constituent denominator in association with each other.

Figure 5 is a diagram showing an example of a configuration master table in the configuration master 106d. In the configuration master table T4 shown in Figure 5, when the parent product is "Product A", the usage process is "100", the child product is "Raw material A", the numerator is "9 kg", and the denominator is "10 kg", all of which are associated with each other. As shown in Figure 5, the configuration master table T4 stores the following:

The manufacturing instruction master 106e stores a code in association with a product, process, order content code, and standard yield rate.

Figure 6 is a diagram showing an example of a manufacturing instruction master table in the manufacturing instruction master 106e. As shown in Figure 6, in the manufacturing instruction master table T5 of the manufacturing instruction master 106e, when the code is "1", the product is "Product A", the process is "100", the order content code is "20", and the standard yield rate is "99.5%".

The order details master 106f stores the order details name in association with a code.

Figure 7 shows an example of an arrangement content master table in the arrangement content master 106f. As shown in Figure 7, in the arrangement content master table T6, when the code is "10", the arrangement content name is stored in association with "Purchase".

Manufacturing instruction acceptance data 106g holds various information regarding the acceptance of manufacturing instructions entered by the operator via the manufacturing instruction input screen.

Figure 8 is a diagram showing an example of a manufacturing instruction receipt data table in manufacturing instruction receipt data 106g. As shown in Figure 8, in the manufacturing instruction receipt data table T7, when the product No. is "1", the product is "Product A", the process: arrangement details are "999: Packaging", and the planned quantity is "500 kg", all of which are stored in association with each other.

The manufacturing instruction delivery data 106h holds various information regarding the quantity of a certain product that is input by the operator via the manufacturing instruction input screen.

Figure 9 is a diagram showing an example of a manufacturing instruction issue data table in manufacturing instruction issue data 106h. As shown in Figure 9, in the manufacturing instruction issue data table T8, when the product No. is "1", the parent product is "Product A", the process: arrangement is "999: Packaging", the child product is "Product A", the process: arrangement is "100: Preparation", and the planned quantity is "500 kg", all of which are stored in association with each other.

The manufacturing performance acceptance data 106i holds various information regarding the manufacturing performance acceptance input by the operator via the manufacturing performance input screen.

Figure 10 is a diagram showing an example of a manufacturing performance receipt data table in manufacturing performance receipt data 106i. As shown in Figure 10, in the manufacturing performance receipt data table T9, when the product No. is "1", the product is "Product A", the process: arrangement details are "999: Packaging", the actual quantity is "490 kg", and the manufacturing lot is "Lot 002", and these are stored in association with each other.

The production performance distribution data 106j holds various information related to the production performance distribution input by the operator via the production performance input screen.

Figure 11 is a diagram showing an example of a production performance dispensing data table in the production performance dispensing data 106j. As shown in Figure 11, in the production performance dispensing data table T10, when the product No. is "1", the parent product is "Product A", the process: arrangement details are "999: Packaging", the child product is "Product A", the process: arrangement details are "100: Preparation", the actual quantity is "487 kg", and the dispensing lot is "Lot002", all of which are stored in correspondence with each other.

The control unit 102 is a CPU or the like that provides overall control of the foreign matter contamination checking device 100. The control unit 102 has an internal memory for storing control programs such as an OS, programs that define various processing procedures, required data, etc., and executes various information processing based on these stored programs. The control unit 102 includes a calculation unit 102a, a confirmation unit 102b, and a notification unit 102c.

The calculation unit 102a calculates the yield by dividing the sum of the actual quantity of a product obtained in a certain manufacturing process and the actual quantity of a product obtained in the manufacturing process prior to the certain manufacturing process minus the quantity of the product used in the certain manufacturing process by the quantity of raw materials used until the product is obtained in the certain manufacturing process. Furthermore, the calculation unit 102a divides the sum of the actual quantity of a product obtained in a certain manufacturing process and the actual quantity of a product obtained in the manufacturing process prior to the certain manufacturing process minus the quantity of the product used in the certain manufacturing process by the sum of the quantity of raw materials used, the additional amount indicating the additional amount of raw materials used in the manufacturing process prior to the certain manufacturing process, and the reduction indicating the quantity of a product used in a manufacturing process different from the certain manufacturing process.

The confirmation unit 102b confirms whether the yield exceeds the standard yield. Specifically, the confirmation unit 102b confirms whether the yield rate of a product obtained in a certain manufacturing process calculated by the calculation unit 102a exceeds the standard yield, for example, 99.5% (see FIG. 6).

If the yield exceeds the standard yield, the notification unit 102c outputs a notification informing of the possibility of contamination with foreign matter. The notification unit 102c also outputs a production performance table that associates the product with the quantity of raw materials used until the product is obtained in the manufacturing process, the planned number of products, the actual quantity, additional oil, reduction, quantity, and yield. The notification unit 102c also outputs the numerical value of the product yield. Furthermore, if the product yield exceeds the standard yield, the notification unit 102c outputs the product yield with emphasis. Furthermore, if a document extraction is instructed, the notification unit 102c outputs a production performance table for products whose product yield exceeds the standard yield.

[2. Overview of the procedure for creating a manufacturing performance table]
Next, an outline of the procedure for creating a production performance table will be described with reference to Fig. 12.

As shown in FIG. 12, first, an operator operates the input device 112 to input manufacturing instructions for a certain product, for example, chocolate, using composition master data (see, for example, composition master table T1 in FIG. 2) (step S1). In this case, the calculation unit 102a of the foreign matter contamination checking device 100 creates a manufacturing performance table (planned) (described later) based on the manufacturing instruction receipt data (see FIG. 8) and manufacturing instruction delivery data (see FIG. 9) input by the operator via the input device 112, and the notification unit 102c displays the manufacturing performance table (planned) created by the calculation unit 102a by outputting it to the output device 114 (step S2).

Then, the operator operates the input device 112 to input the manufacturing performance of a certain product (step S3). In this case, the calculation unit 102a of the foreign matter contamination check device 100 creates a manufacturing performance table (performance) described later based on the manufacturing performance receiving data (see FIG. 10) and manufacturing performance dispensing data (see FIG. 11) input by the operator via the input device 112, and the notification unit 102c displays the manufacturing performance table (performance) created by the calculation unit 102a by outputting it to the output device 114 (step S4). In this case, when the confirmation unit 102b confirms that the yield of a certain product included in the manufacturing performance table (performance) generated by the calculation unit 102a exceeds the standard yield, the notification unit 102c outputs a notification to the output device 114 notifying the possibility of foreign matter contamination. The notification to notify the possibility of foreign matter contamination will be described later.

[3. Product Process]
Next, the manufacturing process of a certain product will be described. Fig. 13 is a diagram showing a schematic diagram of the manufacturing process of a certain product.

There are two processes in the process of a certain product. Process 1 is the purchasing process. Specifically, the purchasing process is the process of putting raw materials into the equipment. Process 2 is the packaging process. Specifically, the packaging process is the process of removing and packaging the purchased raw materials.

For this reason, as shown in FIG. 13, when an operator manufactures a certain product, for example, chocolate, he/she first inputs the purchase process and packaging process for today's production schedule using the amount of raw materials to be used to manufacture chocolate, the additional oil, and the reduction ((A) of FIG. 13). Next, after manufacturing a certain product (chocolate), the operator inputs the purchase process and packaging process for the production results, including the volume (yield) and payment amount of the manufactured product (chocolate) ((B) of FIG. 13). In this case, there are cases where the volume of the manufactured product is mixed with something unplanned, that is, the yield rate exceeds the standard yield rate, specifically the standard yield rate of the manufacturing instruction master table T5 in the manufacturing instruction master 106e, for example, 99.5%, but the reason why this yield rate exceeds the standard yield rate will be described later. Next, the operator inputs the preparation process and packaging process for the next day's production schedule using the amount of raw materials to be used to manufacture chocolate, the additional oil, and the payment amount of a certain product (for example, chocolate manufactured the day before) as the reduction ((C) of FIG. 13).

Here, each term will be explained in detail.
Volume is the number of items received.
The amount of stock is the volume of the stock preparation process. Since the stock preparation process cannot be measured, the planned volume is the volume (received volume) (planned volume = volume (received volume)).
The paid amount is the amount of the product not used in the packaging process from the amount charged in the previous process. In other words, it is the remaining amount. In other words, it corresponds to the amount obtained by subtracting the amount of the product used in a certain manufacturing process from the actual amount of the product obtained in the manufacturing process before that manufacturing process.
A refund is the use of something that was not charged this time. Specifically, it is the amount paid for in the previous production run.
Additional oil is an additional package of ingredients used in the preparation process.
The yield can be expressed by the following formula (1).
Yield = (output + payment) ÷ (charged amount + additional oil + return) ... (1)

4. Processing Executed by the Foreign Matter Inclusion Check Device 100
Next, a description will be given of the processing executed by the foreign matter contamination check device 100. Fig. 14 is a flow chart showing an outline of the processing executed by the foreign matter contamination check device 100.

As shown in FIG. 14, first, the foreign matter contamination checking device 100 displays a manufacturing instruction input screen on the output device 114 (step S101), accepts manufacturing instruction input in response to the operator's operation of the input device 112 (step S102), and creates a manufacturing performance table (planned) and outputs it to the output device 114 (step S103).

Figure 15 shows an example of a manufacturing instruction input screen for a packaging process for the planned production of a certain product, and an example of manufacturing instruction input for the packaging process. The following describes the case of a certain product A weighing 500 kg (50 packages, 10 kg each).

As shown in FIG. 15, the manufacturing instruction input screen P1 includes a product item indicating the product number, a process item indicating the process, a product name input item indicating the product name, a shipment quantity input item indicating the shipment quantity, a receipt quantity item indicating the receipt quantity, a lot number item indicating the lot number, and each process table. The operator operates the input device 112 to input "500" in the receipt quantity item. As a result, the manufacturing instruction input screen P1 displays "1" in the product item, "999" in the process item, "Product A" in the product name item, "50" (pieces) in the shipment quantity item, and "20201225" in the lot number item, and various information is displayed in each process table. Specifically, the first process table displays the product as "Product A", the process as "100" and "Preparation", and the planned quantity as 500 (kg). Furthermore, the second process table displays the product as "Materials", the process as "999", "Purchase", and the planned quantity as 50 (pieces).

Figure 16 shows an example of a manufacturing instruction input screen and manufacturing instruction input in the preparation process for the planned production of a certain product. In the following, a case where raw materials A and B are used as raw materials for a certain product A will be described. Furthermore, raw materials A and B are set larger than the preparation amount to take into account the yield of raw material A in the preparation process.

As shown in FIG. 16, the operator operates the input device 112 to input 456 kg of raw material A and 51 kg of raw material B as the stock amounts for product A. As a result, the manufacturing instruction input screen P1 displays "1" in the product item, "100" in the process item, "Product A" in the product name item, "0" (pieces) in the quantity item, and "20201225" in the lot number item, and various information is displayed in each process table. Furthermore, the first process table displays the product as "Raw material A", the process as "999", "Purchase", and the planned quantity as 456 (kg). Furthermore, the second process table displays the product as "Raw material B", the process as "999", "Purchase", and the planned quantity as 51 (pieces). In this case, the foreign matter contamination checking device 100 generates manufacturing instruction receiving data (see FIG. 8), manufacturing instruction discharging data (see FIG. 9), and a manufacturing performance table (planned) based on the contents entered on the manufacturing instruction input screen P1 in each of the packaging process and the preparation process.

Figure 17 is a diagram showing an example of a production performance table (planned) and the contents of production instructions. As shown in Figure 17, the foreign matter contamination check device 100 creates a production performance table (planned) based on the production instruction receiving data and the production instruction dispensing data, and outputs it to the output device 114. In the production performance table (planned) table T10 shown in Figure 17, the product code is associated with the product name, the amount to be charged, the planned number, the actual number, the additional oil, the reduction, the payment amount, and the yield. In the production performance table (planned) table T10 shown in Figure 17, the amount to be charged is "507.00" (456 of raw material A1 + 51 of raw material B), and the planned number is "50". The amount to be charged is the total planned number of semi-finished products. The semi-finished products are defined as a product process that is not equal to 999.

Returning to FIG. 14, the description of step S104 and subsequent steps will be continued.
In step S104, a manufacturing performance input screen is displayed, and manufacturing performance is accepted in response to the operator's operation of the input device 112 (step S105). A manufacturing performance table (performance) is created and output to the output device 114 (step S106), and this process is terminated.

[4-1. When there is no oil addition or reduction]
First, the input of the production results in the case where there is no additional oil or reduction in the production results will be described. Fig. 18 is a diagram showing an example of the production results input screen in the preparation process of the production results of a certain product and the input of the production actual situation in the preparation process.

As shown in FIG. 18, the operator operates the input device 112 to input 456 kg of raw material A and 51 kg of raw material B as the stock amounts of product A used in the production results. As a result, the production results input screen P2 displays "1" in the product item, "100" in the process item, "product A" in the product name item, "0" (pieces) in the quantity item, "20201225" in the lot number item, and "100%" (i.e., "yield is 1") in the yield item, and various information is displayed in each process table. In addition, the first process table displays the product as "raw material A", the process as "999", "purchase", the planned quantity as 456 (kg), and the lot number as "20201225". In addition, the second process table displays the product as "raw material B", the process as "999", "purchase", the planned quantity as 51 (pieces), and the lot number as "20201225".

Figure 19 shows an example of the production performance input screen for the packaging process of a certain product's production performance and the production performance input for the packaging process.

As shown in FIG. 19, the operator operates the input device 112 to input the actual usage, not the direct payment amount, in the production results. Specifically, when the charge amount of product A is 500 kg and a payment amount of 13 kg is generated for the charge amount, the operator inputs 487 kg (charge amount 500 kg - payment amount 13 kg = 487 kg). Furthermore, when the charge amount of materials is 50 sheets, the operator inputs 49 sheets that were actually used. As a result, the production results input screen P2 displays "1" in the product item, "999" in the process item, "Product A" in the product name item, "49" (pieces) in the number of shipments item, "490" (kg) in the receipt item, "20201225" in the lot number item, and "99.2%" in the yield item, and various information is displayed for each process. The first process table displays the product as "Product A", the process as "100", "Preparation", the planned quantity as 500 (kg), the delivery quantity as "487 (kg), and the lot number as "20201225". The second process table displays the product as "Materials", the process as "999", "Purchase", the planned quantity as "50" (sheets), and the lot number as "20201225". In this case, the foreign matter contamination check device 100 generates the production performance receipt data (see FIG. 10), the production performance delivery data (see FIG. 11), and the production performance table (performance) based on the contents entered into the production performance input screen P2 in each of the packaging process and the preparation process.

FIG. 20 is a diagram showing an example of a production performance table (performance) and the production performance contents. As shown in FIG. 20, the foreign matter contamination check device 100 creates a production performance table (performance) based on the production performance receiving data and the production performance dispensing data, and outputs it to the output device 114. In the production performance table (performance) table T11 shown in FIG. 20, the product code is associated with the product name, the charge amount, the planned number, the actual number, the additional oil, the reduction, the payment amount, and the yield. In the production performance table (performance) table T11 shown in FIG. 20, the charge amount is "507.00" (456 of raw material A1 + 51 of raw material B), the planned number is "50", the actual number is "49", the payment amount is "13", and the yield is "99.2". Here, the yield is calculated by the following formula (2).
Yield = (Volume (49 x 10) + Payment amount (13))
÷ (charge amount (507) + additional oil (0) + reduction (0)) ... (2)

In this way, the operator can understand the stock amount, planned quantity, actual quantity, payment amount, and yield by checking the production performance table (actual result) T11.

[4-2. When additional oil and reduction are required]
Next, the manufacturing performance input in the case where there is additional oil and reduction in the manufacturing performance will be described. FIG. 21 is a diagram showing an example of a manufacturing performance input screen in the preparation process of the manufacturing performance of a product that may have additional oil and reduction in the manufacturing performance and an example of a manufacturing actual input in the preparation process. FIG. 22 is a diagram showing an example of a manufacturing performance reception data table in the manufacturing performance reception data 106i in the case where there is additional oil and reduction in the manufacturing performance. FIG. 23 is a diagram showing an example of a manufacturing performance delivery data table in the manufacturing performance delivery data 106j in the case where there is additional oil and reduction in the manufacturing performance. FIG. 24 is a diagram showing an example of a manufacturing performance input screen in the packaging process of the manufacturing performance of a product that may have additional oil and reduction in the manufacturing performance and an example of a manufacturing performance input in the packaging process.

First, as shown in FIG. 21, the operator operates the input device 112 to input 456 kg of raw material A and 51 kg of raw material B for product A used in the production record as the stock amount. As a result, the production record input screen P2 displays "1" in the product item, "100" in the process item, "Product A" in the product name item, "0" (pieces) in the quantity item, "20201225" in the lot number item, and "100%" (i.e., "yield is 1") in the yield item, and various information is displayed in each process table. In addition, the first process table displays the product as "Raw material A", the process as "999", "Purchase", the planned quantity as 456 (kg), and the lot number as "20201225". In addition, the second process table displays the product as "Raw material B", the process as "999", "Purchase", the planned quantity as 51 (pieces), and the lot number as "20201225".

Next, as shown in FIG. 24, the operator operates the input device 112 to input the actual amount used, not the amount directly paid, in the production results. Specifically, when the amount of product A charged is 500 kg and 20 kg of payment is generated for the charged amount, the operator inputs 480 kg (charge amount 500 kg - payment amount 20 kg = 480 kg) (process ≠ 999 and there is a planned amount). Furthermore, when the amount of materials charged is 50 sheets, the operator inputs 49 sheets that were actually used (asset classification = materials is not included). Furthermore, in the charging of product A (lot before the previous day), the operator inputs the planned amount of "0" (kg) and the actual amount of "5" (kg) (reduction) (process ≠ 999 and the planned amount is 0, which is counted to express the difference in lots). Furthermore, the operator inputs the planned amount of raw material A is "0" (kg) and the actual amount is "2" (kg) (additional oil) (asset classification = raw material and counted with planned amount 0).

As a result, the production performance input screen P2 will display "1" in the product name item, "999" in the process item, "Product A" in the product name item, "49" (pieces) in the quantity item, "490" (kg) in the receipt item, "20201225" in the lot number item, and "99.2%" in the yield item, and various information will be displayed in each process table.

The first process table displays the product as "Product A", the process as "100", "Preparation", the planned quantity as "500" (kg), the payout quantity as "480" (kg), and the lot number as "20201225". The second process table displays the product as "Materials", the process as "999", "Purchase", the planned quantity as "50" (sheets), and the payout quantity as "490" (kg). The third process table displays the product as "Product A", the process as "100", "Preparation", the planned quantity as "0" (kg), the payout quantity for reduction as "5" (kg), and the lot number as "20201224". The fourth table displays the product as "Raw material A", the process as "999", "Purchase", the planned quantity as "0" (kg), and the payout quantity for additional oil as "2" (kg).

In this case, the foreign matter contamination checking device 100 generates production performance receipt data (see FIG. 22), production performance delivery data (see FIG. 23), and a production performance table (performance) based on the contents entered on the production performance input screen P2 in each of the packaging process and the preparation process.

In addition, as shown in FIG. 24, the foreign matter contamination check device 100 creates a production performance table (performance) based on the production performance receipt data and the production performance delivery data, and outputs it to the output device 114.

FIG. 25 is a diagram showing an example of the production performance table (actual results) and the production performance contents when there is additional oil and reduction in the production performance. As shown in FIG. 25, the production performance table (actual results) table T30 holds the product name, the charge amount, the planned number, the actual number, additional oil, reduction, the payment amount, and the yield rate in correspondence with the product code. Specifically, the production performance table (actual results) table T30 shown in FIG. 25 holds the charge amount of "507.00" (456 of raw material A1 + 51 of raw material B), the planned number of "50", the actual number of "49", the additional oil of "2", the reduction of "5", the payment amount of "20", and the yield rate of "99.2". Here, the yield rate is calculated by the following formula (3).
Yield = (Volume (49 x 10) + Payment amount (20))
÷ (charge amount (507) + additional oil (2) + reduction (5)) ... (3)

In this way, the operator can check the production performance table (performance) T30 to understand the amount of stock, planned quantity, actual quantity, additional oil, reduction, payment amount, and yield.

[4-3. When foreign matter is present]
Fig. 26 is a diagram showing an example of a production record input screen in a packaging process of a production record of a certain product and a production record input in the packaging process. Fig. 27 is a diagram showing an example of a production record table (record) of a certain product and a production record content. For the sake of explanation, Fig. 26 and Fig. 27 will be used to explain a case where a foreign object is mixed in.

As shown in FIG. 26, the operator operates the input device 112 to input the actual amount used, not the amount directly paid, in the production results. Specifically, when the amount of product A charged is 500 kg and a payment of 30 kg is generated for the charged amount, the operator inputs 470 kg (charge amount 500 kg - payment amount 30 kg = 470 kg) (process ≠ 999 and there is a planned amount). Furthermore, when the amount of materials charged is 50 sheets, the operator inputs 49 sheets that were actually used (asset classification = materials is not included). Furthermore, in the charge of product A (lot before the previous day), the operator inputs the planned amount of "0" (kg) and the actual amount of "5" (kg) (reduction) (process ≠ 999 and the planned amount is 0, which is counted to express the difference in lots). Furthermore, the operator inputs the planned amount of raw material A is "0" (kg) and the actual amount is "2" (kg) (additional oil) (asset classification = raw material and counted with planned amount 0). Thereafter, when the operator presses the confirm button B1, the foreign matter contamination check device 100 warns that the yield rate exceeds the standard yield rate of the manufacturing instruction master. Specifically, the notification unit 102c of the foreign matter contamination check device 100 highlights the yield rate frame W1. For example, the notification unit 102c highlights the yield rate number in red or displays the number by blinking. Of course, the notification unit 102c may also cause the output device 114 to output an alarm.

As a result, the production performance input screen P2 will display "1" in the product name item, "999" in the process item, "Product A" in the product name item, "49" (pieces) in the quantity item, "490" (kg) in the receipt item, "20201225" in the lot number item, and "101.1%" in the yield item, with various information being displayed for each process.

The first process table displays the product as "Product A", the process as "100", "Preparation", the planned quantity as "500" (kg), the payout quantity as "470" (kg), and the lot number as "20201225". The second process table displays the product as "Materials", the process as "999", "Purchase", the planned quantity as "50" (sheets), and the payout quantity as "490" (kg). The third process table displays the product as "Product A", the process as "100", "Preparation", the planned quantity as "0" (kg), the payout quantity for reduction as "5" (kg), and the lot number as "20201224". The fourth process table displays the product as "Raw material A", the process as "999", "Purchase", the planned quantity as "0" (kg), and the payout quantity for additional oil as "2" (kg).

In this case, the foreign matter contamination checking device 100 generates production performance receipt data (e.g., see FIG. 22), production performance delivery data (e.g., see FIG. 23), and a production performance table (performance) based on the contents entered on the production performance input screen P2 in each of the packaging process and the preparation process.

As shown in FIG. 26, the foreign matter contamination check device 100 creates a production record table (actual results) based on the production record receipt data and the production record delivery data, and outputs it to the output device 114. In this case, as shown in FIG. 27, the production record table (actual results) table T41 holds the product name, the charge amount, the planned number, the actual number, the additional oil, the reduction, the payment amount, and the yield in correspondence with the product code. In the production record table (actual results) table T41 shown in FIG. 27, the charge amount is "507.00" (456 of raw material A1 + 51 of raw material B), the planned number is "50", the actual number is "49", the additional oil is "2", the reduction is "5", the payment amount is "30", and the yield is "101.1". Here, the yield is calculated by the following formula (4).
Yield = (Volume (49 x 10) + Payment amount (30))
÷ (charge amount (507) + additional oil (2) + reduction (5)) ... (4)

In this way, by checking the production performance table (performance) T41, the operator can grasp the charge amount, planned quantity, actual quantity, additional oil, reduction, payment amount, and yield, and can also grasp that the yield exceeds the standard yield (for example, the standard yield rate is 99.5% (see Figure 6)).

Furthermore, the operator can specify a condition for the foreign matter contamination check device 100 to extract forms whose yield rate exceeds the standard yield rate. For example, when the operator instructs the device 112 to extract forms, the notification unit 102c extracts and outputs production performance forms whose yield rate exceeds the standard yield rate (e.g., 99.5% (see FIG. 6)) from among multiple production performance forms. FIG. 28 is a diagram showing an example of a production performance table at the time of form extraction. As shown in FIG. 28, the notification unit 102c displays the production performance table T42 by outputting it to the output device 114.

According to the embodiment described above, the calculation unit 102a calculates the yield by dividing the sum of the actual quantity of the product obtained in a certain manufacturing process and the actual quantity of the product obtained in the manufacturing process prior to the certain manufacturing process minus the quantity of the product used in the certain manufacturing process by the quantity of the raw material used until the product is obtained in the certain manufacturing process, the confirmation unit 102b confirms whether the product yield exceeds the standard yield, and if the product yield exceeds the standard yield, the notification unit 102c outputs a notification notifying the possibility of foreign matter contamination, so that it is possible to check for foreign matter contamination in the product.

In addition, according to the embodiment, the calculation unit 102a divides the sum of the actual quantity of the product obtained in a certain manufacturing process and the actual quantity of the product obtained in the manufacturing process prior to the certain manufacturing process minus the quantity of the product used in the certain manufacturing process by the sum of the quantity of the raw material used, the additional amount indicating the added quantity of the raw material used in the manufacturing process prior to the certain manufacturing process, and the reduction indicating the quantity of the product used in a manufacturing process different from the certain manufacturing process. Therefore, even if the raw materials for the product are reused, it is possible to check for foreign matter contamination in the product.

In addition, according to the embodiment, the notification unit 102c outputs a production performance table that associates a product obtained in a certain manufacturing process with the quantity of raw materials used until the product is obtained in the certain manufacturing process, the planned number of the product, the actual quantity, additional oil, reduction, quantity (payment amount), and yield, so that the operator can intuitively grasp each quantity.

In addition, according to the embodiment, the notification unit 102c outputs the product yield value, allowing the operator to intuitively grasp the product yield.

In addition, according to the embodiment, if the yield exceeds the standard yield, the notification unit 102c outputs the yield with emphasis, so that the operator can intuitively grasp the presence of foreign matter in the product.

In addition, according to the embodiment, when the operator instructs the notification unit 102c to extract a report, the notification unit 102c outputs a manufacturing performance table for products whose product yield exceeds the standard yield, allowing the user to intuitively identify products that have been contaminated with foreign matter.

[5. Contribution to the United Nations-led Sustainable Development Goals (SDGs)]
This embodiment can contribute to improving business efficiency and promoting appropriate management decisions by companies, thereby making it possible to contribute to goals 8 and 9 of the SDGs.

In addition, this embodiment can contribute to reducing waste and promoting paperless and electronic systems, which can contribute to the achievement of SDGs goals 12, 13, and 15.

In addition, this embodiment can contribute to strengthening control and governance, making it possible to contribute to Goal 16 of the SDGs.

6. Other embodiments
The present invention may be embodied in various different embodiments other than those described above within the scope of the technical concept set forth in the claims.

For example, among the processes described in the embodiments, all or part of the processes described as being performed automatically can be performed manually, or all or part of the processes described as being performed manually can be performed automatically using a known method.

In addition, the processing procedures, control procedures, specific names, registered data for each process, information including parameters such as search conditions, screen examples, and database configurations shown in this specification and drawings may be changed as desired unless otherwise specified.

Furthermore, with regard to the foreign matter contamination checking device 100, each component shown in the figure is a functional concept, and does not necessarily have to be physically configured as shown in the figure.

For example, the processing functions of the foreign matter contamination check device 100, particularly the processing functions performed by the control unit, may be realized in whole or in part by a CPU and a program interpreted and executed by the CPU, or may be realized as hardware using wired logic. The program is recorded on a non-transient computer-readable recording medium that contains programmed instructions for causing the information processing device to execute the processes described in this embodiment, and is mechanically read by the foreign matter contamination check device 100 as necessary. That is, a computer program is recorded in a storage unit such as a ROM or HDD (Hard Disk Drive) for working with an OS to give instructions to the CPU and perform various processes. This computer program is executed by being loaded into a RAM, and works with the CPU to form the control unit.

This computer program may also be stored in an application program server connected to the foreign matter contamination checking device 100 via any network, and all or part of it may be downloaded as needed.

In addition, the program for executing the processing described in this embodiment may be stored on a non-transitory computer-readable recording medium, and may also be configured as a program product. Here, the term "recording medium" refers to a memory card, a USB (Universal Serial Bus) memory, a SD (Secure Digital) card, a flexible disk, a magneto-optical disk, a ROM, an EPROM (Erasable Programmable Read Only Memory), an EEPROM (registered trademark) (Electrically Erasable and Programmable Read Only Memory), a CD-ROM (Compact Disk Read Only Memory), an MO (Magneto-Optical disk), a DVD (Digital Versatile This includes any "portable physical media" such as a Blu-ray (registered trademark) Disc, and a Blu-ray (registered trademark) Disc.

A "program" is a data processing method written in any language or description method, and may be in any format, such as source code or binary code. Note that a "program" is not necessarily limited to a single configuration, but also includes a distributed configuration consisting of multiple modules or libraries, and a program that works in conjunction with a separate program, such as an OS, to achieve its function. Note that the specific configuration and reading procedure for reading a recording medium in each device shown in the embodiments, as well as the installation procedure after reading, can use well-known configurations and procedures.

The various databases stored in the memory unit are storage devices such as RAM, ROM, etc., fixed disk devices such as hard disks, flexible disks, and optical disks, and store various programs, tables, databases, and web page files used for various processes and providing websites.

The foreign matter contamination check device 100 may be configured as an information processing device such as a known personal computer or workstation, or may be configured as the information processing device to which any peripheral device is connected. The foreign matter contamination check device 100 may be realized by implementing software (including programs or data, etc.) that causes the device to realize the processing described in this embodiment.

Furthermore, the specific form of distribution and integration of the devices is not limited to that shown in the figures, and all or part of them can be functionally or physically distributed and integrated in any unit depending on various additions or functional loads. In other words, the above-mentioned embodiments can be implemented in any combination, or the embodiments can be implemented selectively.

The present invention is useful in industries where multiple raw materials are blended into products (e.g., the pharmaceutical, food, compounding, chemical, and cosmetics industries).

100 Foreign matter contamination check device 102 Control unit 102a Calculation unit 102b Confirmation unit 102c Notification unit 104 Communication interface unit 106 Memory unit 106a Configuration master 106b Product master 106c Package quantity master 106d Configuration master 106e Manufacturing instruction master 106f Arrangement content master 106g Manufacturing instruction acceptance data 106h Manufacturing instruction delivery data 106i Manufacturing performance acceptance data 106j Manufacturing performance delivery data 108 Input/output interface unit 112 Input device 114 Output device 200 Server 300 Network

Claims (8)

A foreign matter contamination check device including a control unit,
The control unit is
a calculation means for calculating a yield by dividing the sum of an actual quantity of a product obtained in a certain manufacturing process and a payment amount, which is the amount obtained by subtracting the usage quantity of the product used in the certain manufacturing process from the actual quantity of the product obtained in the manufacturing process preceding the certain manufacturing process, and which is the remainder of the previous manufacturing process , by the usage quantity of the raw material used until the product is obtained in the certain manufacturing process;
A means for checking whether the yield exceeds the standard yield;
a notification means for outputting a notification of the possibility of contamination if the yield exceeds the standard yield;
To have
A foreign matter contamination check device characterized by the above. The calculation means is
The sum is divided by the sum of the quantity of the raw material used, the additional oil indicating the additional quantity of the raw material used in the manufacturing process before the certain manufacturing process, and the reduction indicating the quantity of the product used in the manufacturing process different from the certain manufacturing process.
2. The foreign matter checking device according to claim 1. The notification means is
A production performance table is output in which the product is associated with the quantity of raw materials used in the manufacturing process until the product is obtained, the planned quantity of the product, the actual quantity, the additional oil, the reduction, the payment amount , and the yield.
3. The foreign matter checking device according to claim 2. The notification means is
Outputting the yield value.
4. The foreign matter contamination checking device according to claim 1, The notification means is
If the yield exceeds the standard yield, the yield is highlighted and output.
5. The foreign matter checking device according to claim 1, The notification means is
When a report extraction is instructed, a production performance report of the product whose yield exceeds the standard yield is output.
6. The foreign matter contamination checking device according to claim 1, A method for checking for foreign matter contamination, which is executed by a foreign matter contamination checking device having a control unit,
Executed by the control unit,
a calculation step of calculating a yield by dividing the sum of the actual quantity of a product obtained in a certain manufacturing process and the payment amount, which is the amount obtained by subtracting the usage quantity of the product used in the certain manufacturing process from the actual quantity of the product obtained in the manufacturing process preceding the certain manufacturing process, and which is the remaining amount of the previous manufacturing process , by the usage quantity of the raw material used until the product is obtained in the certain manufacturing process;
a verification step to check whether the yield exceeds the standard yield;
a notification step of outputting a notification of the possibility of contamination by a foreign object when the yield exceeds the standard yield;
containing,
A method for checking for foreign matter contamination, comprising: A foreign matter contamination check program to be executed by a foreign matter contamination check device having a control unit,
To be executed by the control unit,
a calculation step of calculating a yield by dividing the sum of the actual quantity of a product obtained in a certain manufacturing process and the payment amount, which is the amount obtained by subtracting the usage quantity of the product used in the certain manufacturing process from the actual quantity of the product obtained in the manufacturing process preceding the certain manufacturing process, and which is the remaining amount of the previous manufacturing process , by the usage quantity of the raw material used until the product is obtained in the certain manufacturing process;
a verification step to check whether the yield exceeds the standard yield;
a notification step of outputting a notification of the possibility of contamination by a foreign object when the yield exceeds the standard yield;
containing,
A foreign matter contamination check program that features:

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