JP2007157061A - System and method for producing product - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a production system of a product by which generation of a rejected product is prevented, product quality is stabilized and yield is improved in a production line of a manufactured product. <P>SOLUTION: In an inspection system of the product having: computers 4-7 for operation control provided to a preprocessing process and a work process, respectively; a computer 8 for inspection provided in an inspection process; computers 2, 3 for data collection which collect data of the computers 4-7 for operation control and a data base server 1 which stores the data collected by the computers 2, 3 for data collection, computers 21-25 for displaying inspection results are provided to the preprocessing process, the work process and the inspection process, respectively. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a production system and a production method in an industrial product production line.

In general, an industrial product production line is composed of a number of processes such as a pre-processing process, a processing process, a post-processing process, an inspection process, and an assembly process for unitizing products.
Production conditions are set for each process, and if processing is not performed under certain conditions, defects may occur. For this reason, it is common to add one identification number to each workpiece, download the machining conditions when the workpiece is machined from the production line, store it in a database server, and manage it.
In addition, inspection information at the time of inspection in the inspection process is similarly accumulated in the database server so that when a rejected product or the like occurs, the machining history of the workpiece can be followed. These accumulated data can be referred to by a browsing program and used for investigation of the cause of failure.
However, such a system is for investigation after the occurrence of a rejected product, and it takes time until the countermeasure is taken after the rejected product is generated. In addition, it is ideal to prevent rejected products.
As a technique for improving the above problems, Patent Document 1 and Patent Document 2 are known. In Patent Document 1, various state history data of a processing device is accumulated, and it is possible to quickly grasp the device state of a lot before and after a rejected product is generated. Further, Patent Document 2 proposes a system for accumulating equipment and quality data in the same manner and issuing a warning to a machining process when a rejected product occurs.
JP-A-2005-128676 Japanese Patent Laid-Open No. 9-50949

However, the technique described in Patent Document 1 is also a countermeasure after the occurrence of an abnormality, and it is difficult to prevent rejected products. Further, with the technique described in Patent Document 2, it is possible to take measures in the machining process when a rejected product is generated, but it has been difficult to prevent the rejected product.
An object of the present invention is to provide a product production system and a production method capable of preventing the occurrence of rejected products in an industrial product production line, stabilizing the product quality and improving the yield. is there.

In order to achieve the above object, the invention described in claim 1 is an operation control computer provided in each of the pre-processing step and the processing step, an inspection computer provided in the inspection step, and the operation control computer. In a product inspection system comprising a data collection computer for collecting data and a data base server for storing data collected by the data collection computer, the inspection results in the preprocessing step, the processing step, and the inspection step, respectively A display computer is provided.
According to a second aspect of the present invention, in the product production system according to the first aspect, the inspection result is reflected in a computer for displaying the inspection result of the machining process.
The invention according to claim 3 is characterized by a product production method including a step of displaying an inspection result in each of a preprocessing step, a processing step, and an inspection step, and a step of reflecting the result of the inspection step in the processing step.

  According to the present invention, in the product inspection system, the inspection result display computer is provided in each of the pretreatment process, the processing process, and the inspection process, thereby preventing the occurrence of rejected products in the industrial product production line. Product quality can be stabilized and yield can be improved.

Hereinafter, embodiments of the present invention will be described with reference to the drawings.
FIG. 1 is a configuration diagram of a product production system according to an embodiment of the present invention. Here, the configuration of the line is a pretreatment process, processing processes A to C, and an inspection process. Each process includes apparatus A to C (9 to 20). In other words, this means that three workpieces can be processed simultaneously.
In addition, each process is provided with operation control computers 4 to 7 for each device, and these computers 4 to 7 also serve to transfer workpiece machining conditions to the upstream side. A data collection computer 2 is provided on the upstream side of the operation control computers 4 to 7, and the machining conditions of the workpiece are collected at any time by this computer 2. The computer 2 also performs protocol conversion work.
Data collected by the data collection computer 2 is stored in a database (DB) server 1. The database server 1 duplicates data in order to prevent data damage.
In the inspection process, the inspection result is output from the inspection computer 8, and the data collection computer 3 performs data collection and protocol conversion in the same manner as in the machining process, and the data is stored in the database server 1. Each process is provided with inspection result display computers 21 to 25 and displays the inspection result in real time. It is also possible to browse past data.

Next, the work flow and data flow of the line by the production system of the present invention will be described.
First, work processing is performed in a pretreatment process. Processing conditions at this time (for example, temperature / humidity in the room, if the process uses liquid, liquid temperature, apparatus A, apparatus B, apparatus C, processing time, processing time, etc.) Management item) is written into the data memory of the operation control computer 4.
The data memory of the operation control computer 4 is referenced by the data collection computer 2 at regular intervals, and when it can be confirmed that the data has been updated, the data collection computer 2 acquires the processing condition data. When the data collection computer 2 obtains the data, it transfers the data to the database server 1 and stores it in the preprocessing step table.
When the pretreatment process is completed, the workpiece is transferred to the machining process A and processed. In this case as well, the processing conditions at that time (device A, device B, or device C were used for processing, measurement data of management items for manufacturing, etc.) are written in the data memory of the operation control computer 5. Include.

The data memory of the operation control computer 5 is referenced by the data collection computer 2 at regular intervals. When it is confirmed that the data has been updated, the data collection computer 2 acquires the processing condition data. When the data collection computer 2 acquires the data, the data collection computer 2 transfers the data to the database server 1 and stores it in the machining step A table.
When the processing step A is completed, the workpiece is transferred to the processing step B and processing is performed. In this case as well, the processing conditions at that time (device A, device B, or device C, the measurement data of the management items in manufacturing, etc.) are written in the data memory of the operation control computer 6. .
The data memory of the operation control computer 6 is also referred to by the data collection computer 2 at regular intervals, and when it is confirmed that the data has been updated, the data collection computer 2 acquires the processing condition data. When the data collection computer 2 acquires the data, the data collection computer 2 transfers the data to the database server 1 and stores it in the machining step B table.
When the machining process B is completed, the workpiece is transferred to the machining process C and processed. In this case as well, the processing conditions at that time (device A, device B, or device C were used for processing, measurement data of management items for manufacturing, etc.) are written in the data memory of the operation control computer 7. Include.

The data memory of the operation control computer 7 is referred to by the data collection computer 2 at regular intervals, and when it is confirmed that the data has been updated, the data collection computer 2 acquires the processing condition data. When the data collection computer 2 obtains the data, the data collection computer 2 transfers the data to the database server 1 and stores it in the machining step C table.
When the process up to the machining step C is completed, the workpiece is transferred to the inspection step. In the inspection process, each inspection is performed by the inspection device 26, and the inspection data is transferred to the inspection computer 8. The inspection computer 8 makes a pass / fail determination based on the inspection data and outputs the result to the data collection computer 8. At this time, if it is a failure, a failure item is also output.
The data collection computer 3 refers to the inspection computer 8 at regular intervals, and if a pass / fail judgment result has been output, acquires this data and transfers it to the database server 1. The database server stores this data in the inspection result table.
Further, inspection result display computers 21 to 25 are disposed in each process, and inspection result histories are always displayed on these computers.

As the inspection result display method, each process as shown in FIG. 2 and a type displayed for each apparatus, a type displayed in time series as shown in FIG. 3, and a specific inspection as shown in FIG. The type for displaying the results can be selected.
As a result, in the case of the type shown in FIG. 2, when a number of rejected products occur frequently, a determination can be made immediately if a certain device is the cause. Further, when the non-defective product rate decreases only for a certain device, an alarm can be output to warn the operator. In the type of FIG. 3, when rejected products occur frequently, it can be determined whether or not the product has been concentrated in a certain time period, and the cause can be easily pursued. In the case of the type shown in FIG. 4, it can be used for prevention of rejected products when products that are acceptable but close to rejected products occur frequently. Moreover, when such a product occurs frequently, an alarm can be output to warn the worker.

2 to 4 exemplify table types, the same contents can be displayed in a graph. Furthermore, the inspection result display computers 21 to 25 are provided with a function for searching past data, so that data by date or lot can be referred to and used for cause analysis of rejected products.
Further, by installing the inspection result display computers 21 to 25 outside the line (for example, an office in a production area), the line information can be known from outside the line, which can be used for improving the yield. These retrieved data can be output in hardware by a printing device such as a printer. It can also be output as electronic data such as text data.

FIG. 5 is a configuration diagram of a conventional production system shown as a comparative example.
In the electrophotographic photosensitive member production line, the production system of the present invention shown in FIG. 1 was compared with the comparative example of FIG. In the case of the comparative example, it took about 30 minutes from the discovery of the quality trouble in the inspection process to the transmission of the information to the processing process. The amount of loss during this period is approximately 100,000 yen. In addition, when the cause of the trouble cannot be identified, the analysis sometimes takes more than one hour.
On the other hand, in the production system of the present invention, it is possible to take action when signs of quality trouble occur, and when trouble occurs, information is immediately transmitted to the machining process. Occurrence was minimized. Assuming a monthly trouble occurrence rate, a cost reduction of 1.2 million yen per year can be expected.

1 is a configuration diagram of a product production system according to an embodiment of the present invention. It is a figure which shows the example of a test result display. It is a figure which shows the example of a test result display. It is a figure which shows the example of a test result display. It is a block diagram of the production system of the product which concerns on a comparative example.

Explanation of symbols

  DESCRIPTION OF SYMBOLS 1 Database server, 2, 3 Data collection computer 4, 5, 6, 7 Operation control computer, 8 Inspection computer, 9-20 Pre-processing process apparatus, 21-25 Inspection result display computer, 26 Work inspection apparatus

Claims (3)

  An operation control computer provided in each of the pretreatment process and the processing process, an inspection computer provided in the inspection process, a data collection computer for collecting data of the operation control computer, and the data collection computer A product production system comprising a data base server for storing collected data, wherein a pre-processing step, a processing step, and an inspection step each include a computer for displaying an inspection result.   2. The product production system according to claim 1, wherein the inspection result is reflected on a computer for displaying the inspection result of the machining process.   A method for producing a product, comprising: displaying an inspection result in each of a pretreatment process, a processing process, and an inspection process; and reflecting the result of the inspection process in the processing process.

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