JP7729264B2 - Traceability management system and traceability management method - Google Patents

Description

The present invention relates to a traceability management system and a traceability management method.

Generally, products are manufactured through multiple manufacturing processes. For example, if a defective product is discovered, it can be discovered during the inspection process carried out after the manufacturing process. The parts used in products may be managed by lot, and in such cases, it is necessary to prevent defective products from being discarded as finished products and to identify the lot of the parts used in the defective products.

Note that Patent Document 1 can be cited as a document related to this application. According to the traceability management system described in Patent Document 1, the traceability management server generates, from the process traceability information received from the manufacturing management server, product configuration information indicating the components that make up the product manufactured in the manufacturing processes up to that point, and the relationships between the assembled components, as well as inter-process coordination information that associates the tag numbers attached to the assembled components with the product numbers and serial numbers of the assembled components.

Japanese Patent Application Laid-Open No. 2008-299721

When a defective product is discovered, a worker looks back in time from the date and time the product was removed from the manufacturing process, references the input parts list to identify the parts used, and searches for the lot of parts used in the defective product. Then, for example, they inspect the parts from that lot and identify the products that use parts from the searched lot. If this series of tasks were done manually, it would take a significant amount of time to narrow down the part lots and products. Furthermore, because a worker has to manually create an input parts list, it takes more man-hours than necessary.

The object of the present invention is to provide a traceability management system and method that, even if an abnormality is discovered in a finished product, can instantly confirm the part lot number by linking it to the finished product in which the abnormality was discovered.

The invention described in claim 1 is directed to a traceability management system for supplying parts to a parts supply lane, supplying the parts from the parts supply lane to a main lane, assembling the parts supplied via the main lane, and discharging a finished product from the main lane. A first creation unit creates first information linking a parts lot number with a part input date and time when the parts were input to the parts supply lane. A second creation unit issues an identification number for the part after input to the parts supply lane but before assembly, and creates second information linking the identification number with a part assembly date and time when the part was assembled, the date and time being synchronized with the part input date and time.

The third creation unit acquires the date and time of discharge of the finished product when the finished product is discharged from the main lane, and creates third information linking the identification number with the date and time of discharge of the finished product. The fourth creation unit creates fourth information linking the date and time of discharge of the finished product with the date and time of assembly of the part from the second information and the third information. The search unit searches for a part lot number corresponding to the date and time of input of the part in the first information for the date and time of assembly of the part in the fourth information. The fifth creation unit creates fifth information linking the date and time of discharge of the finished product with the identification number and the part lot number.

According to the invention of claim 1, the fifth creation unit creates fifth information linking the identification number and part lot number with the date and time of discharge of the finished product , so that, for example, the identification number related to the finished product can be quickly linked with the part lot number, and the part lot number can be calculated from the identification number. Even if an abnormality is discovered in the finished product, the part lot number can be instantly confirmed by linking it to the finished product in which the abnormality was discovered.

FIG. 1 is a diagram illustrating the configuration of a traceability management system according to a first embodiment. Computer-generated functional diagram FIG. 1 is a plan view schematically illustrating an example of the overall structure of a main lane and a parts supply lane. Diagram showing one step in the manufacturing process (part 1) A flowchart outlining the flow of a table generation method. An example of the first table An example of the second table Diagram showing one step of the manufacturing process (part 2) Diagram showing one step in the manufacturing process (part 3) An example of the third table FIG. 10 is an explanatory diagram of a method for generating a fourth table. FIG. 5 is an explanatory diagram of a method for generating a fifth table.

One embodiment of the traceability management system 1 will be described below with reference to the drawings. The traceability management system 1 shown in Figure 1 includes a computer 2 and a detection unit 3 connected to the computer 2.

The computer 2 includes a control unit 4, which is a processor (not shown), a storage unit 5, such as RAM, ROM, or non-volatile memory, and an I/O 6. Programs are stored in the storage unit 5, allowing the computer 2 to execute various programs. The computer 2 has a built-in clock function that is achieved by executing the programs stored in the storage unit 5, and functions as a date and time acquisition unit that acquires the current date and time.

Computer 2 executes a program to monitor the manufacturing process of the product and builds database 7 by recording the management status of the manufacturing process in memory unit 5. Computer 2 builds relational database 7 in memory unit 5 by sequentially creating first table T1 through fifth table T5 in database 7.

As shown in FIG. 2, the computer 2 has the functions of a first creation unit 2a that creates a first table T1 as the first information, and a second creation unit 2b that creates a second table T2 as the second information. The computer 2 also has the functions of a third creation unit 2c that creates a third table T3 as the third information, and a fourth creation unit 2d that creates a fourth table T4 as the fourth information. The computer 2 also has the functions of a fifth creation unit 2e that creates a fifth table T5 as the fifth information.

Figure 3 shows a schematic diagram of a manufacturing system 10 that manufactures a particular product. In this manufacturing system 10, parts A, B, and C are supplied to multiple part supply lanes R1, R2, and R3, respectively. Once parts A, B, and C are supplied to main lane MR, parts A, B, and C are assembled at turnpoints Pa, Pb, and Pc, respectively, and a finished product CO is discharged from the main lane MR. In this manufacturing system 10, parts A, B, and C that make up the finished product CO are assigned part lot numbers for each lot, but no part identification numbers are assigned to individually identify parts A, B, and C. Furthermore, the finished product CO is discharged with a finished product serial number attached to it via a nameplate or an information code such as a QR code (registered trademark).

The aforementioned detection unit 3 detects assembly information for parts A, B, and C and the finished product CO, for example by detecting the passage of passing points on the main lane MR and, if necessary, detecting the in-process status of the workpiece W. The detection unit 3 is configured, for example, using a sensor that detects the movement of the workpiece W, and is installed so that it can detect the date and time when the workpiece W passes through turn points Pa, Pb, and Pc shown in Figure 3, and the date and time when the finished product CO is discharged.

The workpiece W is moved automatically, semi-automatically, or manually by a moving means such as a belt conveyor, and the computer 2 records and manages in the memory unit 5 the date and time when the workpiece passes through turn points Pa, Pb, and Pc at each assembly process location. In Figure 3, the workpieces W located at assembly process locations that are turn points Pa, Pb, and Pc are shown as workpieces Wa, Wb, and Wc.

Note that while Figure 3 simply illustrates a single belt conveyor as a single piece of equipment on the main lane MR, the main lane MR may be configured by connecting multiple pieces of equipment together, for example, the main lane MR may be configured with multiple pieces of equipment branching off into multiple branches. In such cases, it is a good idea to install a detection unit 3 at each of the multiple pieces of equipment, with pass points such as the entrance, exit, or intermediate assembly process locations as turn points Pa, Pb, and Pc, and manage the date and time. By obtaining the date and time that a workpiece W passed from each detection unit 3, the computer 2 can synchronize the date and time that the workpiece W installed on this multiple pieces of equipment was detected. This shows the function of the management unit 2g by the computer 2.

Next, a method for creating the tables T1 to T5 executed by the traceability management system 1 will be described with reference to FIG. 4 and subsequent drawings.
As shown in Fig. 4, parts A, B, and C are input into part supply lanes R1, R2, and R3, respectively. At this time, in S1 of Fig. 5, computer 2 creates a first table T1 by linking the part lot number with the part input date and time when parts A, B, and C are input into part supply lanes R1, R2, and R3, respectively. Fig. 6 shows an example of how the first table T1 is created.

Next, computer 2 issues the finished product serial number as an identification number until the parts reach the part assembly process where parts A, B, and C are first assembled after being fed into part supply lanes R1, R2, and R3, or at the first part assembly process, and creates second table T2 that links the finished product serial number with the part assembly date and time. Figure 7 shows an example of the created second table T2.

For example, it is advisable to issue a finished product serial number when the part assembly process in which the first part A is assembled is executed. In the example of this embodiment, the first part assembly process is the assembly process at turn point Pa, so it is advisable to issue a finished product serial number by the time part A reaches turn point Pa, or when part A reaches turn point Pa as shown in Figure 8. Here, a form in which the finished product serial number itself is issued is shown, but other types of identification numbers that can be linked to the finished product CO may also be issued. This identification number can be composed of various numbers and symbols, but it is desirable to configure it to include the finished product serial number assigned when the finished product CO is shipped, or to match the finished product serial number.

After that, as shown in Figure 9, the workpiece W moves down the main lane MR, and parts B and C are assembled in sequence. The finished product CO, with all parts A, B, and C assembled, is then discharged from the main lane MR. When the finished product CO is discharged from the main lane MR, the computer 2 detects the date and time using the detection unit 3 to obtain the finished product discharge date and time, and creates a third table T3 that links the finished product serial number with the finished product discharge date and time. Figure 10 shows an example of the third table T3.

Next, computer 2 creates a fourth table T4 that links the finished product discharge date and time with the part assembly date and time from second table T2 and third table T3. Figure 11 shows an example of the fourth table T4, in which the finished product discharge date and time, part assembly date and time, and finished product serial numbers are linked together and generated in fourth table T4.

Next, computer 2 searches for the part lot number that corresponds to the part assembly date and time in fourth table T4 using the part input date and time in first table T1. This shows computer 2 functioning as search unit 2f. Next, computer 2 creates fifth table T5, which links the finished product serial number with the part lot number. Figure 12 shows an example of fifth table T5, in which the finished product serial number, part lot number, and finished product discharge date and time are linked together and generated in fifth table T5.

As noted in the Background Art and Problems to be Solved by the Invention sections, if an abnormality is discovered in a finished product CO, for example, attempting to manually determine the part lot number and finished product serial number would require a large amount of man-hours, which is undesirable.

In this embodiment, a fifth table T5 can be created that links finished product serial numbers with part lot numbers, making it easy to link these numbers together. In other words, the part lot number can be instantly determined from the finished product serial number by tracing back, making it easy to link the finished product serial number and part lot number of the relevant product. Therefore, even if an abnormality is discovered in a finished product CO, an operator or other person can check computer 2 and instantly confirm the part lot number linked to the finished product CO in which the abnormality was discovered.

In addition, in this embodiment, the finished product serial number itself is configured as an identification number, so the finished product serial number can be determined without much effort compared to when using other identification numbers linked to the finished product CO.

<Summary>
According to this embodiment, the computer 2 creates a first table T1 that links part lot numbers with the dates and times when parts are input to the part supply lanes R1, R2, and R3. After parts are input to the part supply lane R1, a finished product serial number is issued before part A is assembled, and a second table T2 is created that links the finished product serial number with the dates and times when the part is assembled.

The computer 2 then obtains the date and time the finished product CO is discharged when it is discharged from the main lane MR, and creates a third table T3 that links the finished product serial number with the date and time the finished product was discharged. Then, it creates a fourth table T4 that links the date and time the finished product was discharged with the date and time the part was assembled from the second table T2 and the third table T3.

Computer 2 also searches for the part lot number corresponding to the part assembly date and time in fourth table T4 using the part input date and time in first table T1, and creates fifth table T5 that links the finished product serial number with the part lot number. Computer 2 uses tables T1 to T5 to record and manage the in-process dates and times of each milestone process in each of tables T1 to T5 in database 7. This makes it easy to link part lot numbers with individual finished products CO.

(Other embodiments)
The present invention is not limited to the above-described embodiment, but can be implemented in various modifications and variations without departing from the spirit of the present invention. For example, the following modifications are possible:

In the above embodiment, a form was described in which the finished product serial number was assigned as an identification number during the manufacturing process, but as explained in the above embodiment, other identification numbers linked to the finished product CO may also be assigned during the manufacturing process. If other identification numbers are assigned during the manufacturing process, the finished product CO will ultimately be assigned a finished product serial number, but the finished product serial number may also be assigned when the finished product CO is discharged from the main lane MR. An information code may also be affixed when the finished product CO is discharged. The information code may record the date and time of passage through various manufacturing processes, measurement values during inspection processes, etc., along with the finished product serial number.

If an information code is assigned to each part from the time it is first inserted, the information code can be read by an information code reader at each turn point Pa, Pb, and Pc, and the date and time of reading can be stored and managed in database 7.

The computer 2 method described in this disclosure may be implemented by a dedicated device provided by configuring a processor and memory programmed to perform one or more functions embodied in a computer program. Alternatively, the computer 2 and method described in this disclosure may be implemented by a dedicated device provided by configuring a processor with one or more dedicated hardware logic circuits. Alternatively, the computer 2 and method described in this disclosure may be implemented by one or more dedicated devices configured by combining a processor and memory programmed to perform one or more functions with a processor configured with one or more hardware logic circuits. Furthermore, the computer program may be stored as instructions executed by the computer 2 on a non-transitory tangible storage medium readable by the computer 2.

While the present invention has been described with reference to the above-described embodiment, it is understood that the present invention is not limited to that embodiment or structure. The present invention also encompasses various modifications and variations within the scope of equivalents. In addition, various combinations and forms, as well as other combinations and forms including one, more, or less than one element, are also within the scope and spirit of the present invention.

In the drawing, 1 indicates a traceability management system, 2 indicates a computer, 2a indicates a first creation unit, 2b indicates a second creation unit, 2c indicates a third creation unit, 2d indicates a fourth creation unit, 2e indicates a fifth creation unit, 2f indicates a search unit, 2g indicates a management unit, 3 indicates a detection unit, 4 indicates a control unit, 5 indicates a memory unit, T1 indicates a first table (first information), T2 indicates a second table (second information), T3 indicates a third table (third information), T4 indicates a fourth table (fourth information), and T5 indicates a fifth table (fifth information).

Claims (6)

A traceability management system for supplying parts to part supply lanes (R1 to R3), supplying the parts from the part supply lanes to a main lane (MR), assembling the parts supplied in the main lane, and discharging a finished product from the main lane, comprising:
a first creating unit (2a) that creates first information (T1) that links a part lot number with a part input date and time when the part is input to the part supply lane;
a second creation unit (2b) that issues an identification number after a part is input to the part supply lane and before the part is assembled, and creates second information (T2) that links the identification number with a part assembly date and time at the time of assembling the part, the date and time of which is synchronized with the part input date and time;
a third creation unit (2c) that acquires the discharge date and time of the finished product when the finished product is discharged from the main lane and creates third information (T3) that links the identification number with the discharge date and time of the finished product;
a fourth creation unit (2d) that creates fourth information (T4) that links the finished product discharge date and time with the part assembly date and time from the second information and the third information;
a search unit (2f) for searching for the part lot number corresponding to the part installation date and time of the fourth information from the part input date and time of the first information;
a fifth creation unit (2e) that creates fifth information (T5) that links the identification number and the part lot number with the date and time of discharge of the finished product ;
A traceability management system with A traceability management system as described in claim 1, wherein the identification number includes a finished product serial number used to manage the finished product. The main lane is configured with a plurality of facilities,
3. The traceability management system according to claim 1, further comprising a management unit (2g) for synchronizing the date and time managed among the plurality of facilities. A traceability management method for supplying parts to a parts supply lane, supplying the parts from the parts supply lane to a main lane, assembling the parts supplied by the main lane, and discharging a finished product from the main lane, comprising:
a step in which a first creation unit creates first information (T1) linking a part lot number with a part input date and time when the part was input into the part supply lane;
a step in which a second creation unit issues an identification number after a part is input to the part supply lane and before the part is assembled, and creates second information (T2) linking the identification number with a part assembly date and time at the time of the part assembly, the date and time of which is synchronized with the part input date and time;
a step of acquiring a discharge date and time of the finished product when the finished product is discharged from the main lane by a third creation unit, and creating third information (T3) linking the identification number with the discharge date and time of the finished product;
a fourth creation unit creating fourth information (T4) linking the finished product discharge date and time with the part assembly date and time from the second information and the third information;
a searching unit searching for the part lot number corresponding to the part installation date and time of the first information with respect to the part installation date and time of the fourth information;
a step in which a fifth creation unit creates fifth information (T5) linking the identification number, the part lot number , and the finished product discharge date and time ;
A traceability management method with The traceability management method according to claim 4, wherein the identification number includes a finished product serial number used to manage the finished product. The main lane is configured with a plurality of facilities,
6. The traceability management method according to claim 4, wherein the management unit synchronizes the dates and times managed among the plurality of facilities.