JP7794559B2 - Management system and control method - Google Patents

Description

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

At production sites such as factories, it is common for material inventory management and usage status in the production process to be recorded in a database. Recording in the database is done automatically using information obtained from the operation of production equipment, or manually by workers. Using databases and other such records, managers can understand inventory management and usage status.

In order to record production history, input materials must be individually identified by management unit. One method for doing this is to assign a unique identifier (barcode) or an RFID (Radio Frequency Identifier) tag that uses a recording device such as an IC chip that can record small amounts of data to each management unit.

In addition, when using this type of database, the production history for each process or lot (batch) is managed so that the process history of processing and assembly for a specific material can be referenced, for example. Using such identifiers, individual material information is recorded and updated in the database, and a traceability system is built based on referencing information about that specific material.

In addition, rolls that have a long, cylindrically wound molded body (e.g., film) that can be pulled out from the outside of the roll as the molded body rotates around its central axis are pulled out from the top of the roll during use in the production process, and are processed into multiple work-in-progress or finished products through processes such as lamination, molding, and cutting. A unique circumstance in production management using rolls is that the management unit is prone to change (from "roll" to "meter" or "meter" to "sheet"). It is also common for multiple film materials with different standards or specifications to be fed into the same equipment.

A typical example of such a product is oral preparations (pharmaceuticals) filled into PTP sheets. The production and use of film materials is carried out through a division of labor system across multiple businesses. In this way, the supply chain for film materials is built by different businesses.

When materials are delivered between businesses, management information is passed on primarily through printed labels and transcription and registration into the receiving party's database. Data management is carried out by registering and recording information in independent databases created for each company or business. For this reason, visually checking and entering information on labels has remained the norm up until now, creating potential for errors in information registration and posing problems with real-time information updates. Furthermore, because identifiers and managed items are easily separated, there is a risk that identifiers may be lost, misidentified, or maliciously tampered with.

If these identifiers are lost, mixed up, or tampered with, information inconsistencies or time lags can occur, which can cause delays in ordering materials, especially for materials that are made to order. In such cases, production may be halted or plans may be changed while waiting for the delivery of film materials, and film material manufacturers may also be asked to shorten delivery times, which can have a significant impact.

This kind of uncertainty in information is interpreted as meaning that the quality of pharmaceutical products cannot be guaranteed, especially when it comes to medicines intended to treat illnesses. This directly leads to serious problems such as product recalls due to discrepancies between the labeling information and the contents, or a lack of assurance of stability, and a solution to this problem is desired.

In light of this background, technologies for attaching IC tags to cardboard tubes have been disclosed (see, for example, Patent Documents 1 and 2). Patent Document 1 discloses a technology in which the antenna element of an RFID tag is connected to a metal member extending in the circumferential direction of a cylindrical body. Patent Document 2 discloses a technology in which a non-contact IC tag is attached to an inner cylindrical body that fits into the inner peripheral surface of the end of the cardboard tube body.

JP 2017-065872 A Japanese Patent Application Laid-Open No. 2008-024504

The technologies disclosed in Patent Documents 1 and 2 require a complex paper tube structure, which increases costs, and the IC tag poses an obstacle to recycling the paper tube. Furthermore, the technologies disclosed in Patent Documents 1 and 2 simply involve attaching an IC tag to the paper tube, and do not mention any specific management methods using the IC tag.

Also, since rolls are consumed as film is pulled from one roll, it is difficult to manage inventory simply by number.

The present invention was made in light of these circumstances, and its purpose is to provide a management system and control method that can appropriately manage a roll that has a long, cylindrically wound formed body and that allows the formed body to be pulled out from the outside of the roll by rotating the formed body around its central axis.

To solve the above problems, the present invention provides a management system that includes a usage management device that manages the usage of a roll having a long, cylindrically wound molded body that can be pulled out from the outside of the roll by rotating the molded body around its central axis, and a roll management device that manages the roll. The usage management device includes an identification information acquisition unit that acquires identification information that identifies the roll from an identification unit provided on the molded body, a usage information acquisition unit that acquires usage information that indicates the usage status of the roll, a derivation unit that derives the remaining amount of the molded body from the usage information acquired by the usage information acquisition unit, and a provision unit that provides the roll management device with the type of the roll determined from the identification information acquired by the identification information acquisition unit and the remaining amount derived by the derivation unit.

Furthermore, in the above management system, the identification information acquisition unit may be able to acquire the identification information at any time via short-range wireless communication with the identification unit.

Furthermore, in the above management system, it may be impossible or virtually impossible to replace the identification unit or tamper with the identification information.

Furthermore, in the above management system, the identification unit may be provided integrally with the core of the roll, or may be provided near the central axis and covered by the film.

To solve the above problem, the present invention provides a control method for a usage management device in a management system including a usage management device that manages the usage of a roll having a long cylindrically wound molded body that can be pulled out from the outside of the roll by rotating the molded body around its central axis, and a roll management device that manages the roll.The usage management device acquires identification information that identifies the roll from an identification unit provided on the roll, acquires usage information that indicates the usage status of the roll, derives the remaining amount of the molded body from the acquired usage information, and provides the roll type determined from the acquired identification information and the derived remaining amount to the roll management device.

As described above, this invention provides a management device and management method that can appropriately manage a roll having a long cylindrically wound formed body that can be pulled out from the outside by rotating the formed body around its central axis.

FIG. 2 is a system configuration diagram illustrating the system configuration of a management system. FIG. 10 is a diagram showing an example of attaching a wireless tag to the core of a roll. FIG. 10 is a diagram showing an example of attaching a wireless tag to a coreless type roll. FIG. 10 is a diagram showing an example of attaching a wireless tag to the core of a roll. FIG. 1 shows a roll of film. FIG. 2 is a functional block diagram illustrating a functional configuration of a role management device. FIG. 10 is a diagram illustrating a specific example of a role database. FIG. 10 is a diagram showing a specific example of the entire database. FIG. 10 is a diagram illustrating a specific example of a product database. FIG. 2 is a functional block diagram showing the functional configuration of the production management device. FIG. 10 is a diagram showing a specific example of an individual database. FIG. 2 is a functional block diagram illustrating a functional configuration of the usage management device. FIG. 10 is a diagram illustrating a specific example of a specification database. FIG. 10 is a diagram illustrating a specific example of a usage status database. 10 is a flowchart showing a processing flow of the production management device. FIG. 10 is a diagram showing an example of a warning display. 10 is a flowchart showing a flow of processing by the usage management device. FIG. 10 is a diagram showing an example of a warning display. 10 is a flowchart showing a flow of processing by the usage management device. 10 is a flowchart showing a processing flow of a role management device. FIG. 10 is a diagram showing an example of a warning display. FIG. 10 is a diagram showing an example of a display of a remaining capacity of 0.

The present invention will now be described based on preferred embodiments with reference to the drawings. In the following embodiments, a film is used as an example of a molded article.

Figure 1 is a system configuration diagram showing the system configuration of the management system 1000. The management system 1000 is composed of a roll management device 100, a production management system 200, and a usage management system 300. The roll management device 100, the production management system 200, and the usage management system 300 can communicate with each other via a network 10.

The roll management device 100 and production management system 200 are managed by the roll manufacturer. The usage management system 300 is managed by the user who receives the rolls from the manufacturer and uses them. Note that the roll management device 100 may also be managed by a management company other than the manufacturer.

A production management system 200 is provided for each device that produces rolls. The production management system 200 includes a production management device 201 and a tag reader/writer 250. The production management device 201 and tag reader/writer 250 are capable of communicating with each other. In response to instructions from the production management device 201, the tag reader/writer 250 performs short-range wireless communication using RFID (Radio Frequency Identifier) technology with a wireless tag attached to the roll 270, recording information to the wireless tag and reading information from the wireless tag. The wireless tag is an example of an identification unit.

A usage management system 300 is provided for each device that uses a roll. The usage management system 300 includes a usage management device 301, a tag reader 350, and a scale 360. The usage management device 301 and tag reader 350 are capable of communication. The usage management device 301 and scale 360 are also capable of communication. In response to instructions from the usage management device 301, the tag reader 350 uses RFID technology to perform short-range wireless communication with a wireless tag attached to the roll 370 and reads information from the wireless tag. The scale 360 outputs the usage status of the roll 370 to the usage management device 301. Specifically, the scale 360 notifies the usage management device 301 of a counter value counted as the roll rotates using a rotary encoder. The usage management device 301 can obtain the usage status of the roll by accumulating the counter values.

Next, examples of attaching wireless tags will be explained using Figures 2A, 2B, and 3. First, rolls to which wireless tags can be attached include those with a structure in which the film is wound around a core (see Figures 2A and 3), and coreless types (see Figure 2B) in which there is no core and the film itself is wound up into a cylindrical shape. The core is a cylindrical or solid rod-shaped member, and its central axis coincides with the central axis of the film wound around the core to form a cylindrical shape.

Figures 2A and 3 show examples of attachment of a wireless tag. The roll 400 shown in Figure 2A has a structure in which a film is wound around a core. Figure 2A shows a central axis 401, a wireless tag 410, a film 420, and a core 430. In the case of roll 400, the wireless tag 410 is attached to the surface of the core 430 on which the film is wound (specifically, the side surface of the core 430).

The roll 405 shown in Figure 2B is a coreless roll that does not have a winding core and is composed of the film itself wound up into a cylindrical shape. Figure 2B shows the central axis 401, wireless tag 410, film 420, and innermost periphery 431. Here, innermost periphery 431 is the end where the film begins to be wound. In the case of roll 405, the wireless tag 410 is attached to the curved outer periphery of innermost periphery 431 of the cylindrically wound film.

The roll 407 shown in Figure 3 has a structure in which film is wound around a winding core. Figure 3 shows the central axis 401, wireless tag 440, tape 450, film 460, and winding core 470. In the attachment example shown in Figure 3, the wireless tag 440 is attached to winding start end stopper tape 450, which is affixed across the winding start end of film 460 relative to winding core 470 and the circumferential surface of the winding core, bonding the winding core 470 and film 460. The wireless tag 440 is attached to the surface (outer surface) of winding start end stopper tape 450 opposite the surface affixed to film 460 and winding core 470. The wireless tag 440 is covered by the portion of film 460 that overlaps with the winding start end relative to winding core 470.

In this way, the wireless tag is either integral with the roll core or located near the central axis and covered with film.

Figure 4 is a diagram illustrating the product form of roll 500. The roll 500 shown in Figure 4 is provided with a wireless tag 520 and is wound with a film. The core 510 in Figure 4 refers to the winding core or the innermost periphery. According to the attachment examples shown in Figures 2A, 2B, and 3, as shown in Figure 4, the wireless tag 520 is covered by the core 510 and the film 530, and therefore cannot be physically contacted from outside the roll 500. Therefore, it is impossible to replace the wireless tag 520 unless the film 530 is peeled all the way down to the core 510 or the core 510 is destroyed. Peeling off and replacing the film 530 requires rewinding, but because winding is impossible without using the manufacturer's equipment, it is virtually impossible to replace the wireless tag 520.

Furthermore, since the wireless tag 520 can only be recorded using a dedicated terminal (tag reader/writer 250 in this embodiment), it cannot be tampered with unless the dedicated terminal is used. Furthermore, since it is virtually impossible for others to use the dedicated terminal, tampering with the wireless tag 520 is also virtually impossible.

Figure 5 is a functional block diagram showing the functional configuration of the roll management device 100. The roll management device 100 includes a CPU (Central Processing Unit), memory, auxiliary storage device, etc., connected via a bus. By executing a roll management program, the device functions as a device including an input unit 110, a communication unit 111, a display unit 112, a roll information storage unit 141, a product information storage unit 142, an overall information storage unit 143, and a control unit 120. Note that all or part of the functions of the input unit 110, communication unit 111, display unit 112, roll information storage unit 141, product information storage unit 142, overall information storage unit 143, and control unit 120 may be realized using hardware such as an ASIC (Application Specific Integrated Circuit), a PLD (Programmable Logic Device), or an FPGA (Field Programmable Gate Array). The roll management program may be recorded on a computer-readable recording medium. Examples of computer-readable recording media include portable media such as flexible disks, optical magnetic disks, ROMs, and CD-ROMs, as well as storage devices such as hard disks built into computer systems. The role management program may also be transmitted via telecommunications lines.

The input unit 110 is configured using input devices such as a touch panel, a mouse, and a keyboard. The input unit 110 may be an interface for connecting the input device to the role management device 100. In this case, the input unit 110 generates input data (e.g., instruction information indicating instructions to the role management device 100) from an input signal input to the input device, and inputs the input data to the role management device 100.

The communication unit 111 is a network interface. The communication unit 111 communicates with the production management device 201 and the usage management device 301 via the network 10. The display unit 112 is an output device such as a CRT (Cathode Ray Tube) display, a liquid crystal display, or an organic EL (Electro Luminescence) display. The display unit 112 may also be an interface for connecting an output device to the roll management device 100. In this case, the display unit 112 generates a video signal from the video data and outputs the video signal to a video output device connected to the display unit 112.

The role information storage unit 141 is configured using a storage device such as a magnetic hard disk drive or semiconductor storage device. The role information storage unit 141 stores a role database. Figure 6A is a diagram showing a specific example of a role database. The role database is a database for managing individual roles. The role database is configured with the serial number, type ID, tag ID, customer ID, shipping date, start date of use, and end date of use.

The serial number is a number uniquely assigned to each individual product shipped, regardless of the product type. The type ID is an identifier that uniquely indicates the type of roll (product) indicated by the serial number. The tag ID is an example of identification information and is an identifier that is uniquely assigned to a wireless tag and is used to identify the wireless tag. The customer ID is an identifier that uniquely indicates the customer to whom the product indicated by the serial number will be delivered. The shipping date indicates the shipping date (YYYYMMDD) of the product indicated by the serial number. The usage start date indicates the date (YYYYMMDD) when the customer began using the product indicated by the serial number. If usage has not begun, NULL is recorded. The usage end date indicates the date (YYYYMMDD) when the remaining amount of film in the product indicated by the serial number reached 0.

In Figure 6A, for example, the product with serial number 10001 has a type ID of P111234, a tag ID of Af88012, a customer ID of C00105, a shipping date of April 22, 2020, a start date of use of April 25, 2020, and an end date of use of NULL.

The overall information storage unit 143 is configured using a storage device such as a magnetic hard disk drive or semiconductor storage device. The overall information storage unit 143 stores the overall database. The overall database is a database for managing the remaining amount of each roll for each customer. Figure 6B is a diagram showing a specific example of the overall database. The overall database is configured with customer ID, type ID, remaining amount, warning, and predicted end date.

The remaining amount indicates the current remaining amount of film in the roll indicated by the type held by the customer indicated by the customer ID. In this embodiment, the remaining amount is expressed in meters (m), which represents S. For example, if five rolls of the product indicated by the type, each with an unused film length of 100 m, are in stock, and the roll currently in use has 30 m of film remaining, the remaining amount is 530 m (= 5 x 100 + 30). In addition to the above units of meters, the remaining amount of film can also be expressed as the number of remaining pitches if the film has a periodic design or pattern, and this can be selected appropriately depending on the purpose. The remaining amount is updated when the product is delivered to the customer. For example, if a roll with an unused film length of 100 m is delivered, 100 is added to the remaining amount. In the following explanation, it is assumed that the unused film length for all rolls is 100 m.

The warning in Figure 6B indicates whether the remaining amount has fallen below the remaining amount warning value (production side) described below and a warning has been displayed on the display unit 112. If the warning is on, it indicates that a warning has been displayed on the display unit 112. If the warning is off, it indicates that a warning has not been displayed on the display unit 112. The predicted end date indicates the predicted date (YYYYMMDD) when the remaining amount will be 0. This predicted end date is derived when the remaining amount falls below a predetermined warning value. If the predicted end date has not been derived, NULL is recorded.

In Figure 6B, for example, for a customer with customer ID C00105, the remaining amount of film indicated by type ID P111234 is 10 m, a warning is already displayed on the display unit 112, and the predicted end date is May 30, 2020.

The product information storage unit 142 is configured using a storage device such as a magnetic hard disk drive or semiconductor storage device. The product information storage unit 142 stores a product database. Figure 7 shows a specific example of a product database. The product database is a database for recording product specifications. The product database is configured with a type ID, product name, production device ID, and remaining amount warning value (production side).

The type ID is an identifier that uniquely identifies the type of product. The product name is the product name of the product identified by the type ID. The production equipment ID is an identifier that uniquely identifies the production equipment that produces the product identified by the type ID. The remaining amount warning value (production side) indicates a predetermined warning value (m) for displaying a warning on the display unit 112. Note that the "production side" in the remaining amount warning value (production side) is intended to be distinguished from the remaining amount warning value (customer side), which will be described later. This remaining amount warning value is set appropriately depending on the roll consumption time and order lead time, etc. For example, if the consumption time for one roll is several tens of minutes, the remaining amount warning value may be set to a large value such as 2000 (20 rolls of 100 m each), and if the consumption time for one roll is several days, the remaining amount warning value may be set to a small value such as 20 (20% of 100 m).

In Figure 7, for example, a product with a type ID of P111234 has a product name of Film A, a production device ID of F01, and a remaining amount warning value (production side) of 20m. As a result, when the remaining amount of film on the delivered roll falls below 20m, a warning is displayed on the display unit 112.

The control unit 120 in FIG. 5 controls the operation of each unit of the roll management device 100. The control unit 120 is executed by a device equipped with a processor such as a CPU and RAM, for example. By executing a roll management program, the control unit 120 functions as a display control unit 121, a tag setting unit 122, and a remaining amount management unit 123.

The display control unit 121 controls all screens displayed on the display unit 112. The tag setting unit 122 manages setting information recorded on wireless tags by the production management system 200. The remaining quantity management unit 123 manages remaining quantities, warnings, predicted completion dates, etc. in the roll database.

Figure 8 is a functional block diagram showing the functional configuration of the production management device 201. The production management device 201 includes a CPU, memory, auxiliary storage device, etc., connected via a bus, and functions as a device including an input unit 210, communication unit 211, display unit 212, individual information storage unit 241, and control unit 220 by executing a production management program. Note that all or part of the functions of the input unit 210, communication unit 211, display unit 212, individual information storage unit 241, and control unit 220 may be realized using hardware such as an ASIC or FPGA. The production management program may be recorded on the computer-readable recording medium described above.

The input unit 210 is configured using input devices such as a touch panel, mouse, and keyboard. The input unit 210 may be an interface for connecting the input device to the production management device 201. In this case, the input unit 210 generates input data (e.g., instruction information indicating instructions to the production management device 201) from an input signal input to the input device, and inputs the data to the production management device 201.

The communication unit 211 is a network interface. The communication unit 211 communicates with the roll management device 100 via the network 10. The display unit 212 is an output device such as a CRT display, a liquid crystal display, or an organic EL display. The display unit 212 may also be an interface for connecting an output device to the roll management device 100. In this case, the display unit 212 generates a video signal from the video data and outputs the video signal to a video output device connected to the display unit 212.

The individual information storage unit 241 is configured using a storage device such as a magnetic hard disk drive or semiconductor storage device. The individual information storage unit 241 stores an individual database. Figure 9 is a diagram showing a specific example of an individual database. The individual database is a database for recording individual information, including information to be written to the wireless tags of rolls produced by the production management system 200. The individual database is configured with the serial number, type ID, tag ID, customer ID, and shipping date.

The serial number indicates the serial number of the roll produced by the production management system 200. The type ID indicates the type ID of the roll produced by the production management system 200. The tag ID is the tag ID of the wireless tag of the roll produced by the production management system 200. The customer ID is the customer ID that indicates the customer to whom the roll produced by the production management system 200 will be delivered. The shipping date indicates the shipping date of the roll produced by the production management system 200.

In the case of Figure 9, the production management system 200 produces a roll with serial number 100001 and type ID P11234, the tag ID of the produced roll is Af88012, and the produced roll will be delivered to a customer with customer ID C00105 on April 22, 2020.

The control unit 220 in FIG. 8 controls the operation of each unit of the production management device 201. The control unit 220 is executed by a device equipped with a processor such as a CPU and RAM. By executing the production management program, the control unit 220 functions as a display control unit 221, individual information acquisition unit 222, tag determination unit 223, and RW control unit 224.

The display control unit 221 controls the overall screen displayed on the display unit 212. The individual information acquisition unit 222 acquires information contained in the individual database from the roll management device 100. The tag determination unit 223 determines whether the tag ID of the wireless tag attached to the roll during production matches the tag ID shown in the individual database. The RW control unit 224 controls the tag reader/writer 250.

Figure 10 is a functional block diagram showing the functional configuration of the usage management device 301. The usage management device 301 includes a CPU, memory, auxiliary storage device, etc., connected via a bus, and functions as a device including an input unit 310, communication unit 311, display unit 312, specification information storage unit 341, usage status storage unit 342, and control unit 320 by executing a usage management program. Note that all or part of the functions of the input unit 310, communication unit 311, display unit 312, specification information storage unit 341, usage status storage unit 342, and control unit 320 may be realized using hardware such as an ASIC or FPGA. The usage management program may be recorded on the computer-readable recording medium described above.

The input unit 310 is configured using input devices such as a touch panel, mouse, and keyboard. The input unit 310 may be an interface for connecting the input device to the usage management device 301. In this case, the input unit 310 generates input data (e.g., instruction information indicating instructions to the usage management device 301) from an input signal input to the input device, and inputs the data to the usage management device 301.

The communication unit 311 is a network interface. The communication unit 311 communicates with the role management device 100 via the network 10. The display unit 312 is an output device such as a CRT display, LCD display, or organic EL display. The display unit 312 may also be an interface for connecting an output device to the usage management device 301. In this case, the display unit 312 generates a video signal from the video data and outputs the video signal to a video output device connected to the display unit 312.

The specification information storage unit 341 is configured using a storage device such as a magnetic hard disk drive or semiconductor storage device. The specification information storage unit 341 stores a specification database. Figure 11 shows a specific example of a specification database. The specification database is a database for recording product specifications, etc. The specification database is configured with a type ID, product name, device ID used, and remaining amount warning value (customer side).

The type ID indicates the type ID of the role used in the usage management system 300. The product name is the product name of the product indicated in the type ID. The device ID used is an identifier that uniquely identifies the device that uses the product indicated in the type ID. The remaining amount warning value (customer side) indicates a predetermined warning value (m) for displaying a warning on the display unit 112.

This remaining amount warning value is set appropriately depending on the consumption time of the roll and the production lead time of the roll. For example, if the consumption time of one roll is several tens of minutes, the remaining amount warning value is set to a large value such as 2000 (20 rolls of 100m each), and if the consumption time of one roll is several days, the remaining amount warning value is set to a small value such as 20 (20% of 100m).

For example, a product with type ID P111234 has a product name of Film A, a device ID of f01, and a remaining amount warning value (customer side) of 20m. This means that when the remaining amount of film on the roll in use falls below 20m, a warning is displayed on the display unit 312.

The usage status storage unit 342 is configured using a storage device such as a magnetic hard disk drive or semiconductor storage device. The usage status storage unit 342 stores a usage status database. Figure 12 is a diagram showing a specific example of a usage status database. The usage status database is a database for recording the usage status of roles used in the usage management system 300. The usage status database is configured with type ID, remaining capacity, and warnings.

The type ID is the type ID of the roll held in stock in the usage management system 300. The remaining amount indicates the current remaining amount of film in the roll indicated by the type. For example, if five rolls indicated by the type are held in stock and the roll currently in use has 30m of film remaining, the remaining amount will be 530m (= 5 x 100 + 30). The remaining amount is updated when the product is delivered to the customer. For example, if 10 rolls are delivered, 1000 will be added to the remaining amount.

The warning indicates whether the remaining amount has fallen below the remaining amount warning value (customer side) and a warning has been displayed on the display unit 312. If the warning is on, it indicates that a warning has been displayed on the display unit 312. If the warning is off, it indicates that a warning has not been displayed on the display unit 312.

In the case of Figure 12, the usage management system 300 has a roll with type ID P111234 in stock, the current remaining amount is 10m, and a warning is displayed on the display unit 312.

The control unit 320 in FIG. 10 controls the operation of each unit of the usage management device 301. The control unit 320 is executed by a device equipped with a processor such as a CPU and RAM, for example. By executing the usage management program, the control unit 320 functions as a display control unit 321, a usage start information acquisition unit 322, a device determination unit 323, an R control unit 324, and a usage information acquisition unit 325.

The display control unit 321 controls the overall screen displayed on the display unit 312. The usage start information acquisition unit 322 acquires usage start information (type ID and device used ID). The device determination unit 323 determines whether the device used ID of the device being used matches the device used ID indicated in the usage start information. The R control unit 224 controls the tag reader 350. The tag reader 350 can acquire the tag ID at any time as long as a roll is set in the usage management system 300. The usage information acquisition unit 325 acquires usage information indicating the usage status of the roll. Specifically, the usage information acquisition unit 325 acquires the counter value of the rotary encoder as usage information.

The details of the processing will now be explained based on the above-described configuration. First, the processing of the production management device 201 will be explained. Figure 13 is a flowchart showing the processing flow of the production management device 201. When a roll with an attached wireless tag is set in the production management system 200, the production management device 201 acquires the tag ID using the tag reader/writer 250 (step S101).

The production management device 201 acquires production start information (serial number, type ID, customer ID, shipping date, and production equipment ID) corresponding to the acquired tag ID from the roll management device 100 (step S102). At this time, the roll management device 100 acquires the serial number, type ID, customer ID, and shipping date corresponding to the tag ID received from the production management device 201 in the roll database, acquires the production equipment ID corresponding to the acquired type ID from the product database, and transmits the serial number, type ID, customer ID, shipping date, and production equipment ID to the production management device 201.

The production management device 201 determines whether the acquired production device ID matches the production device ID previously stored in the production management device 201 (step S103). If the production device IDs match (step S103: YES), the production management device 201 records the serial number, type ID, tag ID, customer ID, and shipping date on the wireless tag using the tag reader/writer 250 (step S104), and ends this process. After this, the film is wound.

If the production device IDs do not match (step S103: NO), the production management device 201 displays a warning on the display unit 212 (step S105) and ends this process. After this, no film is wound and the process ends. Figure 14 is a diagram showing an example of the warning display displayed in step S105. The warning display shown in Figure 13 displays the names of products that can be produced by this production management system 200. The warning display also indicates that a product different from the products that can be produced by this production management system 200 is recorded on the wireless tag.

As explained above, by associating the tag ID of a wireless tag with the production equipment ID, it is possible to prevent mistakes from occurring during the production process, such as accidentally manufacturing the wrong product.

Next, the processing of the usage management device 301 will be described. Figure 15 is a flowchart showing the processing flow of the usage management device 301. When the delivered roll is set in the usage management device 300, the usage management device 301 acquires the tag ID using the tag reader 350 (step S201). The usage management device 301 acquires usage start information (type ID and device ID used) corresponding to the acquired tag ID (step S202). Specifically, the usage management device 301 acquires the type ID corresponding to the tag ID from the roll management device 100, and acquires the device ID used corresponding to the acquired type ID from the specification database.

The usage management device 301 determines whether the acquired usage device ID matches the usage device ID previously stored in the usage management device 301 (step S203). If the usage device IDs match (step S203: YES), the usage management device 301 transmits a usage start notification indicating that use of the delivered product has begun to the role management device 100, along with the tag ID (step S204). As a result, the role management device 100 records the date on which the usage start notification was received as the usage start date in the role database.

The usage management device 301 updates the usage database by setting off the warning corresponding to the type ID in the usage database that is the same as the type ID of the set roll (step S205). The usage management device 301 initializes the total usage amount S, which is a parameter used to derive the usage status, to 0 (step S206), and ends this process. After this, film usage begins.

If the device IDs do not match in step S203 (step S203: NO), the usage management device 301 displays a warning on the display unit 312 (step S207) and ends this process. From this point on, the film will not be used until it is replaced with the correct product, and the process will end.

Figure 16 shows an example of the warning display displayed in step S207. The warning display shown in Figure 16 displays the names of products that can be used with the usage management system 300. The warning display also indicates that a product different from the products that can be used with the usage management system 300 is recorded on the wireless tag.

As explained above, by associating the tag ID of the wireless tag with the device ID used, it is possible to prevent the mistake of accidentally using the wrong product.

Next, processing related to the remaining amount will be explained. Figure 17 is a flowchart showing the processing flow of the usage management device 301. The usage management device 301 determines whether or not a notification has been received from the scale 360 (step S301). This notification from the scale 360 is a notification of the counter value of the rotary encoder. If a notification has been received from the scale 360 (step S301: YES), the usage management device 301 acquires the notified counter value C (step S302). The usage management device 301 updates the total usage amount S to a value obtained by adding k x C to the total usage amount S (step S303). Here, k is a coefficient used to convert the counter value C into meters.

The usage management device 301 updates the remaining amount R in the usage status database by subtracting the total usage amount S from the remaining amount R and setting the new remaining amount R as the value (step S304). The usage management device 301 determines whether the remaining amount R is 0 or less (step S305). If the remaining amount R is 0 or less (step S305: YES), the usage management device 301 transmits to the role management device 100 a message indicating that the remaining amount has become 0 along with the tag ID (step S310), displays a "remaining amount 0" indicating that the remaining amount has become 0 (step S311), and terminates this process.

If the remaining amount R is not 0 or less (step S305: NO), the usage management device 301 determines whether the remaining amount R is less than the remaining amount warning value (customer side) (step S306). If the remaining amount R is not less than the remaining amount warning value (customer side) (step S307: NO), the usage management device 301 ends this process. If the remaining amount R is less than the remaining amount warning value (customer side) (step S307: YES), the usage management device 301 determines whether a warning has been displayed (step S307). In step S307, if the warning in the usage database is on, a positive determination is made, and if it is off, a negative determination is made.

If a warning has already been displayed (step S307: YES), the usage management device 301 ends this process. If a warning has not already been displayed (step S307: NO), the usage management device 301 predicts the day when the remaining amount will be 0 (step S308), displays a warning (step S309), and ends this process. One method for predicting the day when the remaining amount will be 0 is to derive the average length L of use per day in advance, and set the date that is the remaining amount R/L days from today as the day when the remaining amount will be 0.

If no notification is received from the scale gauge 360 in step S301 (step S301: NO), the usage management device 301 determines whether the reporting time has arrived (step S312). The reporting time here is the time at which the remaining amount is reported to the roll management device 100, and is predetermined. In this embodiment, the reporting time is set to the hour, so the reporting time arrives 24 times a day. If the reporting time has arrived (step S312: YES), the usage management device 301 obtains the remaining amount R from the usage database and transmits the remaining amount R along with the roll type (type ID) to the roll management device 100 (step S313), and ends this process. Note that, as explained in step S205, the type ID in the usage database is determined from the identification information obtained from the identification unit provided on the roll.

If the reporting time has not arrived (step S312: NO), the usage management device 301 ends this process. In this way, the usage management device 301 provides the acquired tag ID and the derived remaining amount to the roll management device 100. This allows the roll management device 100 to display that only a small amount of product remains, which the production side can use as a reference when placing orders and planning production for the production of products, thereby enabling appropriate management of rolls.

Next, the processing of the role management device 100 will be described. Figure 18 is a flowchart showing the processing flow of the role management device 100. The flowchart shown in Figure 18 shows the processing when a remaining amount R (R ≠ 0) or a remaining amount of 0 is received from the usage management device 301.

The roll management device 100 determines whether it has received the remaining amount R (step S401). If it has received the remaining amount R (step S401: YES), it determines whether the remaining amount R corresponding to the tag ID is less than or equal to the remaining amount warning value (production side) (step S402). In step S402, the roll management device 100 first updates the remaining amount corresponding to the tag ID in the roll database with the remaining amount R. Next, the roll management device 100 obtains the type ID corresponding to the tag ID in the roll database, and obtains the remaining amount warning value (production side) corresponding to the obtained type ID from the product database. The obtained remaining amount warning value (production side) is compared with the remaining amount R.

If the remaining amount R is not less than the remaining amount warning value (production side) (step S402: NO), the roll management device 100 ends this process. If the remaining amount R is less than the remaining amount warning value (production side) (step S402: YES), the roll management device 100 determines whether a warning has been displayed (step S403). In step S403, if the warning in the role database is on, a positive determination is made, and if it is off, a negative determination is made.

If a warning has already been displayed (step S403: YES), the role management device 100 ends this process. If a warning has not already been displayed (step S403: NO), the role management device 100 predicts the day when the remaining amount will be 0 (step S404), displays a warning (step S405), and ends this process. One method for predicting the day when the remaining amount will be 0 is the method described in step S308 above.

If the remaining amount R has not been received in step S401 (step S401: NO), the role management device 100 determines whether a remaining amount of 0 has been received (step S406). If a remaining amount of 0 has not been received (step S406: NO), the role management device 100 terminates this processing. If a remaining amount of 0 has been received (step S406: YES), the role management device 100 records the date on which the remaining amount of 0 was received as the end-of-use date corresponding to the tag ID in the role database (step S407), displays a remaining amount of 0 to indicate that the remaining amount has reached 0 (step S408), and terminates this processing.

Figure 19 shows an example of the warning display displayed in step S405. The warning display shown in Figure 19 displays the delivery destination and the fact that only a small amount of the product being used by the delivery destination is remaining. The warning display also displays the predicted date when the remaining amount will be zero and the shipping date. The delivery destination is obtained by referencing the customer ID in the role database from a database (not shown) in which customer IDs and delivery destination names are associated. The shipping date is also obtained from the role database.

Figure 20 shows an example of the zero remaining quantity display displayed in step S408. The zero remaining quantity display shown in Figure 20 displays the delivery destination and the fact that the remaining quantity of the product used by the delivery destination has reached zero. The zero remaining quantity display also displays the shipping date.

As explained above, by displaying the delivery destination and the fact that there is only a small amount of product remaining at the delivery destination, the manufacturer can use this information as a reference when placing orders and planning production for the production of products, allowing for the proper management of rolls.

The rolls used in the above-described embodiment are consumed as film is pulled from one roll, making it difficult to manage inventory simply by number. However, by providing the remaining amount on one roll, as in this embodiment, inventory management not previously possible becomes possible. Furthermore, according to this embodiment, the remaining amount warning value can be set on both the production side and the customer side, allowing each to set a remaining amount warning value that is convenient for them. For example, on the production side, a remaining amount warning value can be set that takes into account the procurement lead time required to order materials to produce a product and production plans.

In the above-described embodiment, the length of film used is obtained using a rotary encoder, but this is not limited to this. For example, the length of film used may be obtained using the number of rotations of the roll. Also, the length of film used may be obtained using a design drawn on the film (for example, the periodic design or pattern described above).

In the above-described embodiment, wireless tags are attached to the core or near the central axis of rolls before delivery to customers, and a system is constructed in which the wireless tags are read by the customer. This makes it possible to minimize human intervention, streamlining work and improving the accuracy of production management and information transmission. It also makes it possible to grasp production status in real time while eliminating factors that could lead to human error.

Furthermore, as shown in Figure 1, by building a system that connects businesses such as the production side and the customer side, the production side can understand the customer's product usage status. By knowing the product usage status, the production side can reflect this in their production plans, making it possible to respond to unexpected short delivery times and incorporate rational processing, thereby improving customer satisfaction and profitability. In other words, it is possible to improve the cost and delivery time aspects of production management QCD.

In addition, for example, by using a remaining quantity warning value (on the production side) and having the production side start production when the remaining quantity falls below that warning value, the customer can essentially entrust inventory management to the production side, preventing human error such as forgetting to place an order.

The role database records products that have been shipped or will be shipped, making it easy to understand forecasts and predict orders. This makes it possible to predict the quantity of products to be shipped, allowing production to forecast product sales and trends.

In this embodiment, the remaining amount is reported on the hour, but the frequency and timing of reporting can be set as appropriate, for example, every minute or once a day. Furthermore, if it is set to report in near real time, for example every minute, it is possible to detect brief stops on the customer's side, which makes it possible to predict the occurrence of problems and respond to them quickly.

Furthermore, by updating remaining quantities at a fixed frequency, it is possible to prevent discrepancies between management documents and actual usage, for example, which makes inventory management easier, smooths out procurement arrangements and deliveries, and evens out waiting losses and busy/unstable periods in the production process of custom-made products, contributing to cost reductions. As a result, supply chain management can be strengthened.

In the above-described embodiment, the film used as an example of a molded body is a long, flexible resin molded body (resin molded body). The resin molded body is not limited to a film as long as it is long, flexible, and can be rolled up into a cylindrical shape. The molded body is long, flexible, and formed in a continuous, elongated shape. In addition to a film, the molded body can also be a long, flexible resin cylindrical body (a cylindrical molded body for making bags, a hose, etc.), a resin string, or a resin strip that is significantly thicker than a film.

The roll management device 100 may be managed by a management company other than the manufacturer. In this case, the management company may sell wireless tags, tag readers and tag writers, collect and manage various data, and provide information on product sales trends to the manufacturer. The management company may also sell tag readers, collect and manage various data, and handle automatic ordering to customers. Establishing such a management company allows the management company to earn revenue on its own, while allowing the manufacturer to focus on production.

The above describes in detail an embodiment of the present invention with reference to the drawings, but the specific configuration is not limited to this embodiment and includes designs that do not deviate from the gist of the present invention.

10...Network, 100...Roll management device, 110, 210, 310...Input unit, 111, 211, 311...Communication unit, 112, 212, 312...Display unit, 120, 220, 320...Control unit, 121, 221, 321...Display control unit, 122...Tag setting unit, 123...Remaining amount management unit, 141...Roll information storage unit, 142...Product information storage unit, 200...Production management system, 201...Production management device, 222...Individual information acquisition unit, 223...Tag determination unit, 224...RW control unit, 241...Individual information storage unit, 250...Tag reader/writer, 27 0...roll, 300...usage management system, 301...usage management device, 322...usage start information acquisition unit, 323...device determination unit, 324...R control unit, 325...usage information acquisition unit, 341...specification information storage unit, 342...usage status storage unit, 350...tag reader, 360...measurement device, 370...roll, 400...roll, 410...wireless tag, 420...film, 430, 470...core, 440...wireless tag, 450...tape, 460...film, 500...roll, 510...core, 520...wireless tag, 530...film, 1000...management system

Claims (6)

a usage management device for a roll user, which manages the usage of a roll having a long cylindrically wound formed body, the formed body being able to be pulled out from the outside of the roll by rotating the formed body about its central axis;
a roll management device that can communicate with the usage management device via a network and manages the rolls for a roll manufacturer;
A management system including:
The usage management device
a tag reader that is attached to the molded body and that reads information from a wireless tag that records a customer ID of the roll user and a type ID that identifies the roll;
a measuring device for measuring the amount of the compact unwound from the roll;
a calculation unit that calculates the current remaining amount of the formed body on the roll based on the remaining amount stored in a database corresponding to the customer ID and the type ID read by the tag reader and a notification from the scale gauge;
a providing unit that provides the customer ID and the type ID acquired by the tag reader and the current remaining amount derived by the deriving unit to the roll management device via the network,
the roll management device has an information storage unit that stores the database in which the customer ID, the type ID, and the remaining amount of the roll are recorded;
A management system characterized in that the role management device compares the customer ID and type ID provided from the providing unit with information in the database, and updates the remaining amount in the corresponding database with the current remaining amount provided from the providing unit. The management system according to claim 1 , wherein the tag reader is capable of acquiring the information at any timing by short-range wireless communication with the wireless tag. 3. The management system according to claim 1, wherein the wireless tag is impossible or substantially impossible to replace or to falsify the information . The management system described in any one of claims 1 to 3, wherein the wireless tag is either integrally provided with the core of the roll or provided near the central axis and coated on the molded body. a usage management device for a roll user, which manages the usage of a roll having a long cylindrically wound formed body, the formed body being able to be pulled out from the outside of the roll by rotating the formed body about its central axis;
a roll management device that can communicate with the usage management device via a network and manages the rolls for a roll manufacturer;
A management system including:
The usage management device
a tag reader that is attached to the molded body and that reads information from a wireless tag that records a customer ID of the roll user and a type ID that identifies the roll;
a measuring device for measuring the amount of the compact unwound from the roll;
a calculation unit that calculates the current remaining amount of the formed body on the roll based on the remaining amount stored in a database corresponding to the customer ID and the type ID read by the tag reader and a notification from the scaler;
a providing unit that provides the customer ID and the type ID acquired by the tag reader and the current remaining amount derived by the deriving unit to the roll management device via the network,
the roll management device has an information storage unit that stores the database in which the customer ID, the type ID, the remaining amount of the roll, and the production side remaining amount warning value are recorded;
The roll management device compares the customer ID and type ID provided by the provider with the information in the database, updates the corresponding remaining amount in the database with the current remaining amount provided by the provider, obtains the production side remaining amount warning value in the database corresponding to the customer ID and type ID, compares the obtained production side remaining amount warning value with the current remaining amount, and issues a warning if the current remaining amount falls below the production side remaining amount warning value. The management system described in claim 5, characterized in that the roll management device issues the warning when the current remaining amount falls below the production-side remaining amount warning value, calculates a predicted end date when the remaining amount of the formed body on the roll will be zero based on the current remaining amount, and displays the predicted end date.