CN1299238C - Process management system - Google Patents

Abstract

A process management system comprises: manufacturing the terminal portion 13 n; a server apparatus 101 having a communication control apparatus 111 and a database apparatus 112 that stores process data in a centralized manner; the data reference terminal units 15n are connected to form a system via a network 100. The communication control device 111 includes: a buffer 111m for storing process data; a data input processing unit 112b for temporarily storing process data from the manufacturing terminal 13n in the buffer 111m and transmitting a notification signal indicating completion of reception of the process data to the manufacturing terminal 13 n; the data output processing unit outputs the process data of the buffer device 111m to the database device 112. The database device 112 includes: a database 112d for storing process data from the communication control device 111; a data input processing unit 112b for storing the process data in the database 112 d; the data output processing unit 112c processes and outputs the process data in the database 112d in response to a request from the data reference terminal unit 15 n.

Description

Process management system

technical field

The present invention relates to a process management system for managing various process data such as inspection results or adjustment data of products or semi-finished products obtained from each process of various work processes such as product manufacturing processes.

Background technique

As a conventional process management system, for example, what is described in Japanese Patent Application Laid-Open No. 11-320348 is known. The manufacturing process management system disclosed in this publication includes: a terminal unit that outputs various manufacturing data every predetermined period or every predetermined amount; and a host-side arithmetic processing unit that calculates various manufacturing data output from the terminal While processing in a prescribed file format, from the various manufacturing data, a prescribed data item with a high frequency of external read requests is extracted, and various calculations are performed according to the request from the outside; the host side database, It is used to store various manufacturing data in the form of files that have been processed by the host-side arithmetic processing unit; the server-side arithmetic processing unit is used to input the specified data items extracted by the host-side arithmetic processing unit, The predetermined data items are subjected to arithmetic processing, and various arithmetic processing is executed according to requests from the outside; the server-side database stores predetermined data items according to the arithmetic processing of the server-side arithmetic processing unit.

In this manufacturing process management system, while the server-side arithmetic processing unit stores data items with high frequency of read requests from the outside in the server-side database, the server-side arithmetic processing unit stores/stores data in the server-side database. Therefore, it is possible to perform a read operation independent of the host side in response to a read request from the outside. As a result, data can be read without hindering the calculation operation of the host-side calculation processing unit.

In the conventional process management system configured as above, since it is necessary to have dual equipment of the host side that stores various process data and the server side that performs data retrieval processing from the outside, there is a risk of increasing equipment investment or maintenance cost. question.

In addition, the processing is rather complicated because predetermined data items frequently requested from the outside are extracted, output to the server-side arithmetic processing unit, and stored in the server-side database. In addition, since the data items with low frequency of use are not registered in the server-side database, such data items cannot be retrieved from the server-side database, and must be extracted from the host-side database. Therefore, as a result, calculation and control operations on the host side are hindered, and manufacturing data sequentially input from the manufacturing terminal unit may not even be stored in the host side database.

In addition, as prior art related to the present invention, for example, what is described in Japanese Patent Application Laid-Open No. 2002-258931, which is a publication of Japanese Patent Application, is known.

As shown in FIG. 1 , this process management system includes a manufacturing management system 10 inserted between each process 1 and a plurality of terminals 2 in the manufacturing process. This manufacturing management system 10 has: a detection unit 11 that detects information about actual manufacturing results and abnormalities; a storage unit 12 that stores the information detected by the detection unit 11; The information is distributed to a specific terminal 2; the warning unit 14 sends warning information to the terminal 2 when the detection unit 11 detects abnormal information.

In this manufacturing management system, information about an abnormality is transmitted to a specific terminal 2 by a warning unit 14 . Therefore, in order to know the occurrence of an abnormality, it is necessary to confirm it in a specific terminal 2. If the manager is in a position far away from the specific terminal 2, he cannot know the occurrence of an abnormality, and it may be difficult to handle it quickly. sex. In addition, when an abnormality is detected, information about the abnormality is output from the process 1, and the information is detected by the detection unit 11. Although the abnormality can be detected, it is difficult to apply the process information that can be analyzed to determine the tendency of abnormality. , the problem of advanced detection methods that detect anomalies in advance.

In addition, although such a manufacturing process management system can detect the abnormality of the process 1, the cause of an abnormality etc. is specified based on the judgment of an operator, for example. Therefore, depending on the level of proficiency of the operator or the like, different work results may be produced.

In addition, in general, there are many unclear causal relationships between the information on the process abnormality and the information causing it, which makes it more difficult to identify the cause of the abnormality.

In addition, as prior art related to the present invention, for example, what is described in Japanese Patent Application Laid-Open No. 2002-91532, which is a publication of Japanese Patent Application, is known.

In this process management system, as shown in FIG. 2 , a plurality of data input terminals 50 a , 50 b , - , and a data reference terminal 30 are connected to a server device (data server device) 20 via a network 40 . The server device 20 has a database 21, and the server device 20 is provided with a data processing device 24 including a data input processing unit 22 and a data output processing unit 23 to store and view process data.

First, storage of process data is performed by an operator operating data input terminals 50a, 50b, ---. At this time, the operator accesses the data input processing unit 22 in the data processing device 24 of the server device 20 through the network 40, and calls the data input screen to the data input terminals 50a, 50b, ---. Make the necessary data entry. On the data input terminals 50a, 50b, ---, after the input data input from the screen is sent to the data input processing part 22 in the data processing device 24 of the server device 20 through the network 40, it is stored as process data to database 21.

In addition, an operator operates the data reference terminal 30 to browse process data. At this time, the operator accesses the data output processing unit 23 in the data processing device 24 of the server device 20 through the network 40, calls the data output screen on the data reference terminal 30, and inputs and references the process Conditions corresponding to the data. On the data reference terminal 30 , the reference conditions inputted on the screen are sent to the data output processing unit 23 in the data processing device of the server device 20 via the network 40 .

The data output processing unit 23 analyzes the reference conditions received from the data reference terminal 30, extracts the process data satisfying the reference conditions from the database 21, and then sends the process data to the data reference terminal 30 through the network 30 to be displayed on the data reference terminal 30. on screen.

In such a structured system, for example, the process data is stored by the server devices 20 shown in FIG. 2 in each department of the company that manages the manufacturing process. Therefore, the server devices 20 that store the process data are sometimes dispersed in physically different locations. multiple locations. Therefore, when an operator (user) wants to browse the target process data, he has to travel between the above-mentioned departments and browse the data in a plurality of server devices 20, so browsing the process data takes a lot of effort and time.

In addition, in the system configured in this way, since the physical limitation of the server device 20 (capacity limitation of the storage area, etc.) is not fully taken into consideration, in order to improve the management capability of the process data, in many cases, it is replaced with a higher-performance The hardware becomes the only way.

Contents of the invention

The problem to be solved by the present invention is to improve various disadvantages that occur when process data is centrally managed using a server device having a database.

The process management system of the present invention is characterized in that it is composed of the following parts: a manufacturing terminal unit having a first data input processing unit for inputting process data and a first data output processing unit for outputting process data; It has a communication control device and a database device that centrally stores process data, and is connected to the manufacturing terminal through a communication network; the data reference terminal, through a communication network, makes a read request for the process data stored in the database device. The communication control device has: a buffer device for storing process data; a second data input processing part temporarily storing the process data output from the manufacturing terminal part in the buffer device, and notifying the process data The signal that the reception has been completed is sent to the manufacturing terminal part; the second data output processing part outputs the process data stored in the buffer device to the database device. This database device has: a database, which saves the process data output from the communication control device; a third data input processing unit, which stores the process data in the database; Process data stored in the database is processed and output.

According to the above-mentioned process management system, since the database for storing process data and the communication control device for controlling the transfer of process data output from a plurality of manufacturing terminal parts to the database device are integrated into one server device, it is possible to reduce equipment, reducing the equipment investment or maintenance costs. In addition, while the output processing of process data from the manufacturing terminal can be performed at high speed at all times, the readout request processing of process data from the data reference terminal can be prioritized without hindering the writing process of process data. Both the process data write process and the read request process can be compatible.

In addition, in the above-mentioned process management system of the present invention, the above-mentioned communication control device may further include a data calculation processing unit that extracts a specific process data item, and for each process data item, either at regular intervals or every When the number is constant, calculation processing is performed to make the extracted process data items into a predetermined format, and the results of the calculation processing are stored in the database.

According to this process management system, since process data with high request frequency is aggregated in real time on the communication control device and stored in the database on the server device, read requests can be processed at a higher speed. In addition, process data that is not frequently requested from outside can be referred to in exactly the same way without performing complicated processing in advance.

In addition, in the above-mentioned process management system of the present invention, the above-mentioned communication control device may include the following parts: a data calculation processing unit that extracts a specific process data item, and for each process data item, either at regular intervals or Every time a certain number is reached, the operation processing is performed to make the extracted process data items into a predetermined form, and the operation processing results are stored in the above-mentioned database; An abnormal value is judged, and if the result is an abnormal value, the process data to be calculated is marked; a display processing unit performs a warning display for the marked process data.

According to this process management system, since the marked process data items are monitored on the communication control device and a warning is issued when the value exceeds the specified value, the data reference terminal does not need to request reading every time, and the process data can be efficiently processed. monitor.

In addition, in the process management system of the present invention described above, when the time required for storing the process data in the database exceeds a predetermined time, the third data input processing unit stops storing the process data in the database. At the same time, the database sends a signal notifying the suspension of the process data storage to the above-mentioned second data output processing unit, and when the second data output processing unit receives the signal notifying the suspension of the process data storage, The output of the process data in the device to the database device is interrupted for a predetermined time.

By doing so, since the load imposed on the database device by the process data storage process is reduced, it is possible to preferentially process the process data readout request process from the data reference terminal unit.

Description of drawings

Fig. 1 is a structural schematic diagram of a manufacturing management system as one of the prior art.

Fig. 2 is a schematic structural diagram of a manufacturing management system as another prior art.

Fig. 3 is a schematic structural diagram of the process management system of the present invention.

FIG. 4 is a schematic diagram of a second configuration example of a communication control device in the process management system shown in FIG. 3 .

Fig. 5 is a schematic diagram of a third configuration example of a communication control device in the process management system shown in Fig. 3 .

Fig. 6 is a schematic diagram of the first embodiment of the process management system of the present invention.

Fig. 7 is a schematic diagram of a second embodiment of the process management system of the present invention.

Fig. 8 is a schematic diagram of a third embodiment of the process management system of the present invention.

Fig. 9 is a schematic diagram of a fourth embodiment of the process management system of the present invention.

Fig. 10 is a diagram showing an example of an abnormality determination criterion for process data.

Fig. 11 is a schematic diagram of a fifth embodiment of the process management system of the present invention.

Fig. 12 is a schematic diagram of a sixth embodiment of the process management system of the present invention.

Fig. 13 is a schematic diagram of a seventh embodiment of the process management system of the present invention.

Fig. 14 is a schematic diagram of an eighth embodiment of the process management system of the present invention.

Fig. 15 is a schematic diagram of a ninth embodiment of the process management system of the present invention.

FIG. 16 is a schematic diagram of a data structure of a database storing process data.

FIG. 17 is a schematic diagram of process data extracted by a transmission data generation unit based on predetermined conditions from among process data stored in a database.

FIG. 18 is an explanatory diagram showing a situation in which the transfer data collection unit of the centrally managed server device performs data collection according to a preset sequence of data collection between server devices.

Fig. 19 is a schematic diagram of a tenth embodiment of the process management system of the present invention.

Fig. 20 is a schematic diagram of an eleventh embodiment of the process management system of the present invention.

Fig. 21 is a schematic diagram of an example of process data automatically output from equipment.

Fig. 22 is a schematic diagram (No. 1) of an example of a process data record on a process data table.

Fig. 23 is a schematic diagram of an example of an event data record on an event data table.

Fig. 24(a) is a schematic diagram of a state in which a part of the inspection data is out of the allowable range in the display example of the search result of the process data search unit.

FIG. 24( b ) is a schematic diagram showing a state where a part of the history of the inspection data is basically approaching one end of the allowable range in the display example of the search result by the process data search unit.

FIG. 24( c ) is a schematic diagram showing a state in which a part of the inspection data history is substantially continuously on the side of the set value within the allowable range in the display example of the search result by the process data search unit.

FIG. 25 is a schematic diagram showing an example display of search results searched by a process data search unit and an event data search unit.

Fig. 26(a) and (b) show the cause of the abnormality/change by comparing with the event data of the same content when a predetermined time has elapsed after a change occurs in the process and an abnormality or any change is found in the inspection data The schematic diagram of the search results of the process data search unit in the explanatory diagram at the time.

Fig. 26(c) is an explanatory diagram for identifying the cause of the abnormality/variation by comparing with event data of the same content when a predetermined time has elapsed after a change occurs in the process and an abnormality or any variation is found in the inspection data. In , a schematic diagram of the search results of the event data search unit.

Fig. 27 is a schematic diagram of a twelfth embodiment of the process management system of the present invention.

FIG. 28 is a schematic diagram of a processing flow for determining whether an abnormality or any variation is found in the history of inspection data shown in FIG. 24( a ).

FIG. 29 is a schematic diagram of a processing flow for determining whether an abnormality or any variation is found in the history of inspection data shown in FIG. 24( b ).

FIG. 30 is a schematic diagram of a processing flow for determining whether an abnormality or any variation is found in the history of the inspection data shown in FIG. 24( c ).

FIG. 31 is a second structural diagram of the data reference terminal 530 shown in FIG. 20 .

FIG. 32 is a schematic flowchart of extraction processing of candidate causes of abnormality/change.

FIG. 33 is a schematic flowchart of the process of extracting event candidate results.

Fig. 34 is a schematic diagram (No. 2) of an example of a process data record on a process data table.

Detailed ways

Embodiments of the present invention will be described below with reference to the drawings.

Fig. 3 is a schematic structural diagram of the process management system of the present invention. This process management system has: a plurality of manufacturing terminal units 131, 132, . Database device 112; a plurality of data reference terminal units 151, 152, . . .

The manufacturing terminal units 131 to 13n have (not shown): a data input processing unit that inputs various process data in real time or every predetermined period or every predetermined amount; and a data output processing unit that outputs the process data to server device 101 .

The communication control device 111 of the server device 101 has a buffer device 111m and a data management unit 111a. The buffer device 111m stores process data. The data management unit 111a has: a data input processing unit 111b that receives the process data output from the manufacturing terminal units 131 to 13n and stores them in the buffer device 111m; and a data output processing unit 111c that outputs the process data stored in the buffer device 111m. process data.

The database device 112 of the server device 101 has a database 112d and a data processing unit 112a. The database 112d stores process data output from the communication control device 111 . The data processing part 112a has: a data input processing part 112b, which receives the process data output from the communication control device 111, and stores it in the database 112d; The data search request aggregates, processes and outputs predetermined data based on the process data stored in the database 112d.

The data reference terminal units 151 to 15n are used to search and refer to process data stored in the database 112d.

The operation of the process management system of FIG. 3 will be described.

When inputting process data, when the data input processing parts of the manufacturing terminal parts 131-13n receive the process data output from the equipment control programs executed on the manufacturing terminal parts 131-13n, the data output processing of the manufacturing terminal parts 131-13n output to the server device 101 in real time.

Here, when the manufacturing terminal units 131 to 13n have a data input program for inputting process data, the manufacturing terminal units 131 to 13n receive instructions based on the input screen generated by executing the data input program at the data input processing unit, and every The process data input at a predetermined time or every predetermined amount is simultaneously output to the server device 101 through the network 100 by the data output processing unit. In these operations, immediately after the data output processing units of the manufacturing terminal units 131 to 13n output the process data, the data input processing units of the manufacturing terminal units 131 to 13n are in a waiting state for receiving data and are ready to acquire the next process data.

In the server device 101, when the data input processing part 111b of the communication control device 111 receives the process data output from the data output processing parts of the manufacturing terminal parts 131-13n, the process data is temporarily stored in the buffer device 111m in a prescribed format. At the same time, through the network 100, a notification of completion of reception is immediately sent to the manufacturing terminal units 131-13n.

The data output processing unit 111c of the communication control device 111 outputs the process data stored in the buffer device 111m to the database device 112 . Then, the data output processing unit 111c sequentially monitors whether there is process data not output to the database device 112 in the buffer device 111m, and outputs the process data to the database device 112 if there is process data not output to the database device 112 .

After the data input processing unit 112b on the database device 112 saves the process data in the database 112d, it transmits a storage completion notification to the data output processing unit 112c on the communication control device 111 . In addition, here, in order to process the process data reading request from the data reference terminal units 151 to 15n, when the load on the database device 112 is so high that the time required to save it in the database 112d is longer than a predetermined time, the data The input processing unit 112b transmits a storage suspension notification to the data output processing unit 111c of the communication control device 111 at the same time as the storage job is suspended.

When the data output processing unit 111c of the communication control device 111 receives the signal indicating the completion notification of storage from the data input processing unit 112b of the database device 112, the process data output to the database device 112 is deleted from the buffer device 111m. At the same time, it continues to monitor whether there are other unoutputted process data on the buffer device 111m. Also, upon receiving a signal indicating storage suspension notification from the data input processing unit 112b, the data output processing unit 111c interrupts output processing on the data output processing unit 111c for a predetermined time. During this interruption period, a predetermined amount of recording area for process data is secured in the buffer device 111m, so that when process data is output from the manufacturing terminal parts 131 to 13n, the data input processing part 111b can be stored on the buffer device 111m. A certain amount of process data is stored.

When the data reference terminal parts 151-15n request to read the process data stored in the database 112d, the output condition screen of the data output processing part 112c of the database device 112 is called and displayed on the data reference terminal parts 151-15n. 15n screen. The conditions for reading the process data designated by the data reference terminal units 151 to 15n by inputting them according to the output condition screen are sent to the data output processing unit 112c of the database device 112 in the server device 101 through the network 100 . The data output processing unit 112c analyzes the sent conditions, that is, the conditions for referring to the process data specified by the data reference terminal units 151 to 15n, and extracts and processes the process data from the database 112d according to the conditions, and transmits them through the network 100 , and the results are sent to the data reference terminal units 151 to 15n and displayed on the screen.

Moreover, while the data output processing part 112c performs the process which reads process data from the database 112d, the data input processing part 112b puts the process which saves process data in the database 112d into a waiting state. Here, when a predetermined time elapses after entering the waiting state, saving of data is stopped. By doing so, the processing of the data output processing part 112c for responding to the process data readout request from the data reference terminal part 151-15n is performed preferentially rather than the processing of the data input processing part 112b.

FIG. 4 is a schematic diagram of a second configuration example of the communication control device 111 in the process management system shown in FIG. 3 . This communication control device 111 includes a data calculation processing unit 111e in addition to the configuration shown in FIG. 3 . The data calculation processing unit 111e extracts, for example, the process data of a specific item such as a high frequency of read requests from the outside (data reference terminal units 151 to 15n) from the buffer device 111m, makes a predetermined format, and temporarily stores it in the buffer device. After step 111m, the data is output from the data output processing unit 111c. Accordingly, the above-mentioned specific process data is stored in the database 112d.

In addition, in the communication control device 111 of FIG. 4 , the data input processing unit 111b also receives the process data output to the server device 101 from the data output processing units on the manufacturing terminal units 131-13n, and stores them in a prescribed format in the Simultaneously with the buffer device 111m, a reception completion notification is immediately sent to the manufacturing terminal units 131 to 13n via the network 100 .

FIG. 5 is a schematic diagram of a third configuration example of the communication control device 111 in the process management system shown in FIG. 3 . This communication control device 111 includes a data calculation processing unit 111e, an abnormality determination processing unit 111f, and a display processing unit 111g in addition to the configuration of FIG. 3 . The abnormality determination processing unit 111f determines whether or not the data in the predetermined format created by the data calculation processing unit 111e is abnormal. The display processing unit 111g is used to display a warning on the data when the abnormality determination processing unit 111f determines that the data is abnormal.

In the communication control device 111 in FIG. 5, when the data input processing unit 111b receives the process data output from the data output processing units included in the manufacturing terminal units 131-13n, it stores it in the buffer device 111m in a prescribed format. Simultaneously with the process, a reception completion notification is immediately transmitted to the manufacturing terminal units 131 to 13n via the network 100 .

The data calculation processing unit 111e, for example, extracts the process data of a specific item from the buffer device 111m such as a high frequency of read requests from the outside (data reference terminal units 151 to 15n), makes a predetermined format, and temporarily stores it in the buffer device 111m. After processing, the data is output from the data output processing unit 111c. Accordingly, the above-mentioned specific process data is stored in the database 112d. The abnormality judgment processing part 111f judges whether the data obtained by the data calculation processing part 111e is abnormal, and displays a warning on the display processing part 111g if there is an abnormality.

Next, a specific embodiment using the first principle configuration of the process management system of the present invention described above will be described. Moreover, in each embodiment, the same code|symbol is attached|subjected to the same member and the same member as FIG. 3-5, and it corresponds to each other.

Fig. 6 is a schematic diagram of the first embodiment of the process management system of the present invention. The process management system of this embodiment has several manufacturing terminal parts 131-13n and 141-14n; the server apparatus 101; several data reference terminal parts 151-15n; and the network 100 which connects them.

A plurality of manufacturing terminal parts 131 to 13n and 141 to 14n are arranged in the production line 190 . The manufacturing terminal units 131 to 13n have the equipment control program 103a and the data management unit 103b. The equipment control program 103a is a program for inspecting or adjusting the products flowing on the production line 190 in the manufacturing terminal units 131 to 13n in real time or every predetermined time or every predetermined quantity. The data management unit 103b has a data input processing unit 103b1 that receives process data generated by executing the facility control program 103a and a data output processing unit 103b2 that outputs the process data to the server device 101 .

Moreover, the manufacturing terminal parts 141-14n have the data input program 104a and the data management part 103b. The data input program 104a is a program that executes a process for acquiring process data input on an input screen not shown every predetermined time or every predetermined number in the manufacturing terminal units 141 to 14n. The data management part 103b has the data input processing part 103b1 which receives the process data acquired by executing the data input program 104a, and the data output processing part 103b2 which outputs the process data to the server apparatus 101.

The server device 101 has a communication control device 111 and a database device 112 .

The communication control device 111 has a storage device 111d and a data management unit 111a. The process data is stored in the storage device 111d. The data management part 111a has: a data input processing part 111b, which receives the process data output from the manufacturing terminal parts 131-13n and 141-14n, and stores it in a storage device 111d as a buffer device; a data output processing part 111c, It is used to output the process data stored in the storage device 111d.

The database device 112 has: a database 112d that stores process data output from the communication control device 111; a data input processing unit 112b that receives process data output from the communication control device 111 and stores it in the database 112d; and WWW ( Word Wide Web) processing unit 112w. The WWW processing unit 112w has a data output processing unit 112c. The data output processing unit 112c has an output condition screen 112c1 for inputting data retrieval conditions from the data reference terminal units 151 to 15n, and aggregates, processes and outputs predetermined data based on the process data stored in the database 112d.

The WWW browsing software 150 is installed in the data reference terminal units 151 to 15n. When the WWW browsing software 150 is executed, it is possible to search and refer to process data on the data reference terminal units 151 to 15n.

The operation of the process management system shown in FIG. 6 will be described.

When the process data is output from the equipment control program 103a executed on the manufacturing terminal parts 131-13n, the data input processing part 103b1 in the data management part 103b receives the process data in real time, and at the same time, the data output processing part 103b2 outputs the process data to the server device 101 via the network 100 . In addition, in the manufacturing terminal units 141 to 14n, the data input processing unit 103b1 in the data management unit 103b receives the input displayed by the action of the data input program 104a being executed every predetermined time or every predetermined number. Simultaneously with process data input on the screen, the data output processing unit 103b2 outputs the process data to the server device 101 via the network 100 .

Here, when the server device 101 receives process data from the data output processing part 103b2 on the manufacturing terminal parts 131-13n or 141-14n, the data input process from the communication control device 111 located in the server device 101 via the network 100 The part 111b sends a notification signal of the completion of reception to the data management part 103b. After the data management part 103b receives the signal, it ends the processing of the data output processing part 103b2, and immediately makes the data input processing part 103b1 into a data reception waiting state. As a result, the manufacturing terminal units 131 to 13n and 141 to 14n are in a state where subsequent process data can be output.

In the communication control device 111 of the server device 101, when the data input processing unit 111b receives the process data output from the data output processing unit 103b2 of the manufacturing terminal units 131 to 13n or 141 to 14n, the process data is stored in a predetermined format. In storage device 111d. Simultaneously with this storage, the data input processing unit 111b immediately transmits a reception completion notification signal to the manufacturing terminal units 131 to 13n or 141 to 14n via the network 100 . The data output processing unit 111c of the communication control device 111 sequentially monitors whether there is process data not output to the database device 112 remaining in the storage device 111d, and outputs it to the database device 112 if there is process data not yet output.

The data input processing unit 112b of the database device 112 transmits a storage completion notification signal to the data output processing unit 111c of the communication control device 111 when saving of the process data in the database 112d is completed. In addition, at this time, in order to process the reading request of the process data from the data reference terminal units 151 to 15n, when the load on the database device 112 is so high that it takes longer than a predetermined time to store the data in the database 112d, the database The data input processing unit 112b of the device 112 suspends the saving operation, and at the same time transmits a signal for notifying the storage suspension to the data output processing unit 111c of the communication control device 111 .

When the data output processing part 111c of the communication control device 111 receives the notification signal of the completion of saving from the data input processing part 112b of the database device 112, it deletes the output process data from the storage device 111d while continuing to monitor the process data stored in the storage device. Whether or not the next unoutputted process data still exists on 111d. Moreover, when the data output processing part 111c receives the signal of a storage suspension notification, it interrupts the output process in the data output processing part 111c for a predetermined time. During this interruption period, when process data is output from the manufacturing terminal units 131 to 13n and 141 to 14n, a predetermined amount of storage area for process data is reserved in the storage device 111d so that the data input processing unit 111b can A certain amount of process data is stored in the storage device 111d.

In order to read out the process data stored in the database 112d, the WWW browsing software 150 is executed on the data reference terminal parts 151-15n, the connection processing to the WWW processing part 112w on the database device 112 is performed, and the data is output to the processing part. The output condition screen 112c1 in 112c is displayed on the screen of the WWW browsing software 150 . The conditions for referring to the process data set on the output condition screen 112c1 on the screen of the data reference terminal units 151 to 15n are sent to the data output processing unit 112c in the database device 112 via the network 100 . The data output processing unit 112c analyzes the transmitted conditions, that is, the conditions for referring to the process data designated by the data reference terminal units 151 to 15n, extracts the process data from the database 112d according to the conditions, processes them, and transfers them to the data through the network 100. The results are sent to the data reference terminal units 151 to 15n and displayed on the screen.

In addition, while the data output processing part 112c performs the process of reading process data from the database 112d, the data input processing part 112b puts the process of saving process data in the database 112d into a waiting state. Here, when a predetermined time elapses after entering the waiting state, saving of data is stopped. By doing so, the process of the data output processing part 112c for responding to the read request of process data from the data reference terminal part 151-15n is performed preferentially rather than the process of the data input processing part 112b.

According to such an embodiment, since the process data reference process from the data reference terminal units 151 to 15n is executed in priority over the data output process from the communication control device 111, it is possible to implement the process data without impairing the responsiveness of the data reference terminal units 151 to 15n. In the state, refer to the process data. In addition, since the communication control device 111 immediately transmits the notification signal of the completion of data reception to the manufacturing terminal units 131-13n or 141-14n independently of the process data storage process, the manufacturing terminal units 131-13n or 141-14n The data output processing performed will not be overloaded, and the responsiveness can be improved. In addition, since these processes are collectively performed by a single server device 101, the equipment of the management system can be reduced in size and low in cost.

Fig. 7 is a schematic diagram of a second embodiment of the process management system of the present invention. The process management system in this embodiment is also composed of a plurality of manufacturing terminal units 131 to 13n, manufacturing terminal units 141 to 14n, a server device 101, and a plurality of data reference terminal units 151 to 15n connected through the network 100.

The server device 101 has a communication control device 111 and a database device 112 . The communication control device 111 has a storage device 111d and a data management unit 111a. The data management unit 111a has a data input processing unit 111b and a data output processing unit 111c. The database device 112 has a database 112d, a data input processing unit 112b, and a WWW processing unit 112w including a data output processing unit 112c.

In addition to the above, in this embodiment, the communication control device 111 further includes a data calculation processing unit 111e. The data operation processing unit 111e has a function of extracting process data items with a high frequency of read requests from the data reference terminal units 151 to 15n, and for each process data item or at regular intervals for the extracted process data items. Every time or when a certain amount is reached, calculation processing is performed to create a predetermined format (for example, a format representing a predetermined total result), and the processed data is stored in the database 112d.

Parts different from those shown in FIG. 6 in the operation of the process management system shown in FIG. 7 will be described.

In the server device 101, when the data input processing part 111b of the communication control device 111 receives the process data output from the data output processing part 103b2 (refer to FIG. The processing unit 111b stores the process data in the storage device 111d in a predetermined format, and immediately transmits and receives completion notification signals to the manufacturing terminal units 131-13n and 141-14n via the network 100.

The data calculation processing unit 111e always monitors the process data stored in the storage device 111d, for example, for the process data of a specific item extracted in advance, such as a high frequency of read request, for each process data or every predetermined time or every arrival When the number is constant, calculation processing is performed to create a predetermined format (for example, a format representing a predetermined total result), and the processed data is stored in the storage device 111d.

The data output processing unit 111c successively monitors whether there is process data not output to the database device 112 remaining in the storage device 111d or whether data in a predetermined format has been created in the data operation processing unit 111e, and if there is process data not output, it is output. to database device 112.

The data input processing unit 112b on the database device 112 transmits a storage completion notification signal to the data output processing unit 111c on the communication control device 111 after saving the process data in the database 112d is completed. In addition, at this time, in order to process the process data reading requests from the data reference terminal units 151 to 15n, when the load on the database device 112 is so high that the time required for saving in the database 112d is longer than a predetermined time, the database The data input processing unit 112b of the device 112 suspends the saving operation, and at the same time transmits a signal for notifying the storage suspension to the data output processing unit 111c of the communication control device 111 .

When the data output processing unit 111c of the communication control device 111 receives the notification signal of completion of storage from the data input processing unit 112b of the database device 112, it responds to the previously extracted data with a high frequency of external read requests. For a specific data item, the output data is deleted from the storage device 111d for the portion processed by the data calculation processing unit 111e. On the other hand, for data items other than the above-mentioned items, such as those whose request frequency is relatively low, the data is immediately deleted from the storage device 111d upon receiving the notification signal of completion of storage. Thereafter, the data output processing unit 111c continues to monitor the presence or absence of next unoutputted data.

In addition, when the data output processing unit 111c receives the notification signal of suspension of storage, it interrupts the output processing on the data output processing unit 111c for a predetermined time. During this interruption period, a predetermined amount of recording area for process data is secured on the storage device 111d so that when process data is output from the manufacturing terminal units 131 to 13n and 141 to 14n, the data input processing unit 111b can store the data in the storage device 111d. A certain amount of process data is stored on the device 111d.

In order to request to read the process data stored in the database 112d, the WWW browsing software 150 is executed on the data reference terminal parts 151-15n, the connection processing to the WWW processing part 112w on the database device 112 is performed, and the data is output to the processing part The output condition screen 112c1 in 112c is displayed on the screen of the WWW browsing software 150 . The conditions for referring to the process data set on the output condition screen 112c1 on the screen of the data reference terminal units 151 to 15n are sent to the data output processing unit 112c in the database device 112 via the network 100 .

The data output processing unit 112c analyzes the sent conditions, that is, the conditions for referring to the process data specified by the data reference terminal units 151-15n. For specific data items such as higher request frequency, extract the data processed in advance from the database 112d, for example, for data items other than the above items with lower request frequency, extract relevant process data from the database 112d come out. Thereafter, the process data extracted from the database 112d are processed according to the conditions, and the result is transmitted to the data reference terminal units 151 to 15n via the network 100, and displayed on the screen.

Moreover, while the data output processing part 112c reads the process data from the database 112d, the data input processing part 112b puts the process of saving process data in the database 112d into a waiting state. Here, when a predetermined time elapses after entering the waiting state, saving of data is stopped. By doing so, the processing of the data output processing part 112c for responding to the process data readout request from the data reference terminal part 151-15n is performed preferentially rather than the processing of the data input processing part 112b.

In such an embodiment, since the database 112d stores, for example, operations performed in a predetermined format (for example, a format representing a predetermined total result) for specific data items that are frequently requested from the outside, etc. As a result, it is therefore possible to quickly display on the data reference terminal sections 151 to 15n. Furthermore, since the specified data item calculation processing is performed on the above-mentioned specific data item, it is not necessary to select a predetermined data item from the huge database 112d on the database device 112 as an object of calculation processing, and the load on the server device 101 can be reduced. .

Fig. 8 is a schematic diagram of a third embodiment of the process management system of the present invention. In this embodiment, a data calculation processing unit 111e, an abnormality determination processing unit 111f, and a display processing unit 111g are added to the communication control device 111 in the first embodiment of the present invention shown in FIG. 6 .

The data calculation processing unit 111e is the same as that in the second embodiment of the present invention described above, and the communication control device 111 has the data calculation processing unit 111e. The data operation processing unit 111e has a function of extracting process data items with a high frequency of read requests from the data reference terminal units 151 to 15n, and for each process data item or at regular intervals of the extracted process data items, Or every time a certain amount is reached, calculation processing is performed to create a predetermined format (for example, a format representing a predetermined total result), and the processed data is stored in the database 112d. The abnormality judgment processing part 111f judges whether the result of the calculation process of the data calculation processing part 111e is abnormal, and marks the said process data based on a judgment result. The display processing unit 111g is used to display a warning for marked process data.

Parts different from those shown in FIG. 6 in the operation of the process management system shown in FIG. 8 will be described.

In the server device 101, when the data input processing part 111b of the communication control device 111 receives the process data output from the data output processing part 103b2 (refer to FIG. The processing unit 111b stores the process data in the storage device 111d in a predetermined format, and immediately transmits and receives completion notification signals to the manufacturing terminal units 131-13n and 141-14n via the network 100.

The data calculation processing unit 111e always monitors the process data stored in the storage device 111d, for example, for the process data of a specific item extracted in advance, such as a high frequency of read request, for each process data item or every predetermined time or every When a certain amount is reached, calculation processing is performed to create a predetermined format (for example, a format representing a predetermined total result), and the processed data is stored in the storage device 111d. Moreover, the abnormality judgment processing part 111f judges whether the calculation result of the data calculation processing part 111e is abnormal, and when it judges that it is abnormal, it makes the display processing part 111g display a warning. Here, when the data judged to be abnormal is stored in the storage device 111d in a predetermined format, it is flagged.

The data output processing unit 111c successively monitors whether there are process data not output to the database device 112 remaining in the storage device 111d or data in a predetermined format in the data operation processing unit 111e, and if there is process data not output, it is stored. output to the database device 112 .

When the data input processing unit 112b on the database device 112 finishes saving the process data in the database 112d, it sends a notification signal of saving completion to the data output processing unit 111c on the communication control device 111 . In addition, at this time, in order to process the process data reading requests from the data reference terminal units 151 to 15n, when the load on the database device 112 is so high that the time required for saving in the database 112d is longer than a predetermined time, the database The data input processing unit 112b of the device 112 suspends the storage operation, and at the same time transmits a notification signal of the storage suspension to the data output processing unit 111c of the communication control device 111 .

When the data output processing unit 111c of the communication control device 111 receives the notification signal of the completion of storage from the data input processing unit 112b of the database device 112, the frequency of external read requests extracted in advance, etc. For the above-mentioned specific data item, the output data is deleted from the storage device 111d for the part processed by the data operation processing unit 111e. On the other hand, for data items other than the above-mentioned items, such as those whose request frequency is relatively low, the data is immediately deleted from the storage device 111d upon receiving the notification signal of completion of storage. Thereafter, the data output processing unit 111c continues to monitor the presence or absence of next unoutputted data.

In addition, when the data output processing unit 111c receives the notification signal of suspension of storage, it interrupts the output processing on the data output processing unit 111c for a predetermined time. During this interruption period, a predetermined amount of recording area for process data is secured on the storage device 111d so that when process data is output from the manufacturing terminal units 131 to 13n and 141 to 14n, the data input processing unit 111b can store the data in the storage device 111d. A certain amount of process data is stored on the device 111d.

In order to request to read the process data stored in the database 112d, the WWW browsing software 150 is executed on the data reference terminal parts 151-15n, and the connection processing to the WWW processing part 112w on the database device 112 is performed, so that the data output processing part The output condition screen 112c1 in 112c is displayed on the screen of the WWW browsing software 150 . The conditions for referring to the process data set on the output condition screen 112c1 on the screen of the data reference terminal units 151 to 15n are sent to the data output processing unit 112c in the database device 112 via the network 100 .

The data output processing unit 112c analyzes the transmitted conditions, that is, the conditions for referring to the process data specified by the data reference terminal units 151 to 15n. Here, for example, for a specific data item whose read request frequency is relatively high from the outside (data reference terminal units 151 to 15n), the pre-calculated data is extracted from the database 112d. For data items other than the above items, etc., the corresponding process data is extracted from the database 112d. Thereafter, the process data extracted from the database 112d are processed according to the conditions, and the result is transmitted to the data reference terminal units 151 to 15n via the network 100, and displayed on the screen.

Moreover, while the data output processing part 112c reads the process data from the database 112d, the data input processing part 112b puts the process of saving process data in the database 112d into a waiting state. Here, when a predetermined time elapses after entering the waiting state, saving of data is stopped. By doing so, the processing of the data output processing part 112c for responding to the process data readout request from the data reference terminal part 151-15n is performed preferentially rather than the processing of the data input processing part 112b.

In the above embodiment, the abnormality determination processing unit 111f of the communication control device 111 and the abnormality judgment processing unit 111f of the communication control device 111 are stored in the database 112d on the database device 112 by storing predetermined data items extracted in advance and having a high frequency of read requests from the outside. The data output processing unit 112c of the database device 112 can also share the predetermined data item, thereby improving its efficiency.

In addition, according to this embodiment, the data judged to be abnormal by the abnormality judgment processing unit 111f is marked on the communication control device 111 and stored in the storage device 111d. A warning can be notified without a readout request on the data reference terminal units 151 to 15n. Therefore, monitoring of process data can be performed efficiently.

Next, Fig. 9 will be described. This figure is a schematic configuration diagram of the fourth embodiment of the process management system of the present invention.

The process management system of this embodiment has: a server device 201; a mail server device 206; data input terminal devices 208a1-208an and 208b1-208bn consisting of one or more arbitrary numbers; The configured reference terminal devices 208c1 to 208cn are connected via a communication network 207 such as LAN (Local Area Network).

The server device 201 has: a database 202 that collectively saves process data; a data input processing unit 203 that performs a process of registering process data output from the data input terminal devices 208a1 to 208an, 208b1 to 208bn in the database 202; a data output processing unit 204, which, while urging the input of the conditions for referring to the process data registered in the database 202, generates an output screen 204a showing the processing results of the process data referred to according to the input reference conditions; and abnormal processing unit 205 . Here, the abnormality processing unit 205 has an abnormality determination unit 205a for analyzing whether the process data stored in the database 202 is abnormal, and when it is determined that the process data is abnormal, an e-mail describing the abnormality is created and sent to the mail server device 206. .

Each of the data input terminal devices 208a1 to 208an has a facility control program 209 that causes the data input terminal devices 208a1 to 208an to acquire process data from process equipment, and a data output processing unit 210 that transmits the acquired process data to the server device 201 .

Each of the data input terminal devices 208b1 to 208bn has: a data input program 211 that causes the data input terminal devices 208b1 to 208bn to display an input screen 211a prompting input of process data, and obtains process data input based on the display; and a data output processing unit 210 , which transmits the obtained process data to the server device 201 .

Each of the reference terminal devices 208c1 to 208cn calls and refers to the process data stored in the database 202 .

Next, the action of the process management system of this embodiment will be described.

Process data is input by data input terminal devices 208a1-208an, 208b1-208bn. The data input terminal devices 208 a 1 to 208 an acquire process data from the process equipment after executing the equipment control program 209 , and transmit the acquired process data from the data output processing unit 210 to the server device 201 . Furthermore, after executing the data input program 211, the data input terminal devices 208b1 to 208bn display the input screen 211a to urge input of process data, and the data output processing unit 210 transmits the process data input according to the display to the server device 201.

The data input processing unit 203 of the server device 201 receives these process data through the communication network 207 and stores them in the database 202 .

When the reference terminal devices 208c1 to 208cn refer to the process data stored in the database 202 and output them, first, they access the server device 201 through the communication network 207 . Furthermore, the output screen 204a generated by the data output processing unit 204 is called to the reference terminal devices 208c1 to 208cn. The output screen 204a includes a setting section for setting the conditions of the reference process data, and the conditions input by operating the reference terminal devices 208c1 to 208cn displayed on the output screen 204a are sent to the data via the communication network 207. Output processing unit 204.

The data output processing unit 204 extracts from the database 202 process data matching the reference conditions transmitted from the reference terminal devices 208c1 to 208cn. Furthermore, after processing the extracted process data such as totalization, it is sent to the output screen 204a of the reference terminal devices 208c1-208cn through the communication network 207, and the processed process data is displayed on the reference terminal devices 208c1-208cn. superior. Accordingly, it becomes possible to grasp desired process data from the reference terminal devices 208c1 to 208cn.

The abnormality processing unit 205 of the server device 201 analyzes the process data stored in the database 202 by the abnormality determination unit 205a at predetermined time intervals, for example, at certain time intervals or when a certain amount of data is reached.

FIG. 10 is a diagram showing an example of an abnormality determination criterion of process data. The figure (a) is an example in which it is judged as abnormal when there is data exceeding the range between the reference value 1 and the reference value 2 in the process data aggregated for an arbitrary time or number of data. The figure (b) is an example in which it is judged to be abnormal when data out of the range between the reference value 1 and the reference value 2 appears at least twice. The figure (c) is an example in which it is judged to be abnormal when the relative reference value data exceeds or falls below 7 consecutive times (this figure shows the case of being below).

In addition, in the case of process data that is judged to be pass/fail in a certain inspection, a reference value may be set for the total result of the pass rate or the number of failures, and it may be judged as abnormal when the total result is lower than the reference value. Here, these respective reference values are set in advance. In addition, the abnormality determination method of the abnormality processing unit 205 may adopt a method other than the method described above.

When the process data is judged to be abnormal, or when it is judged that there is a tendency to be abnormal, the abnormality processing unit 205 creates an electronic mail describing the content of the abnormality, and sends it to the mail server device 206 . In this abnormality warning email, notification destinations are classified by process data item, and the person in charge of each process can receive from the mail server device 206 an abnormality warning email of only necessary data items related to his responsibility.

Since such an embodiment automatically analyzes the process data centrally stored in the database 202 and issues a warning when an abnormality occurs, it is not necessary to directly monitor the process to detect the occurrence of an abnormality, enabling rapid processing. In addition, due to the occurrence of an abnormal transmission by e-mail, it is also possible to receive by an unspecified terminal or a portable terminal such as a mobile phone. Therefore, exception warnings can be received no matter where. In addition, by judging the abnormality of the process data group extracted within the range of time or data number, it is possible to issue a warning at the time when an abnormal tendency is found, so that effective countermeasures can be taken before the abnormality occurs.

Next, Fig. 11 will be described. This figure is a schematic configuration diagram of the fifth embodiment of the process management system of the present invention, and shows a block diagram of the server device 201 . In this embodiment, a setting unit 204 b is added to the output screen 204 a of the data output processing unit 204 to the server device 201 in the fourth embodiment shown in FIG. 9 . The setting unit 204b is used to set a method of abnormality determination by the abnormality determination unit 205a or to set a reference value for the abnormality determination.

In this embodiment, when receiving a request to refer to process data from the reference terminal devices 208c1 to 208cn, the data output processing unit 204 performs necessary summarization processing on the process data items to be referred based on the process data stored in the database 202 , and include the result of totalization processing in the output screen 204a. The output screen 204a graphically displays the process data, for example, as shown in the example of FIG.10 (a) - (c). The output screen 204a includes a setting screen as the setting unit 204b. When setting the data abnormality determination method or the reference value for abnormality determination, refer to the graph in FIG. Each process data item in the display of the output screen 204a of 208cn is displayed in total, while referring to the terminal devices 208c1-208cn, for example, which abnormality determination method in Fig. 10(a)-(c) is used, or Set the reference value for abnormality judgment in the abnormality judgment method adopted.

According to such an embodiment, while confirming the process data on the screens of the reference terminal devices 208c1 to 208cn, it is possible to set a reference value used as a criterion for abnormality determination in the abnormality determination unit 205a of the abnormality processing unit 205 . Therefore, appropriate abnormality determination criteria can be easily set for process data items whose values fluctuate frequently.

Next, Fig. 12 will be described. This figure is a schematic configuration diagram of the sixth embodiment of the process management system of the present invention, and shows a block diagram of the server device 201 . In this embodiment, a system abnormality processing unit 205 b is added to the abnormality processing unit 205 of the server device 201 in the fourth embodiment shown in FIG. 9 .

The system abnormality processing unit 205b is used for sending an e-mail describing the content of the abnormality to the mail server device 206 through the communication network 7 when an abnormality occurs in the process management system itself.

In this embodiment, for example, when an abnormality occurs in the data output processing unit 210 of the data input terminal devices 208a1-208an, and the data cannot be transmitted to the server device 201 due to the abnormality, the data output processing unit 210 calls the The system exception handling unit 205b of the exception handling unit 205 in the system. The system abnormality processing unit 205 b determines which part of the management system related to the process has an abnormality, and transmits an e-mail describing the abnormal state from the mail server device 206 .

For example, when an abnormality occurs on the data input terminal devices 208a1 to 208an, and the process data cannot be output to the server device 201 due to the abnormality, the abnormality determination unit 205a of the abnormality processing unit 205 may not be able to output the process data to the server device 201 regardless of whether there is an abnormality in the process. The analysis result of the data is not abnormal, so the warning does not occur. On the other hand, according to this embodiment, when any abnormality occurs in the process management system, the content of the abnormality can be notified by e-mail, and the abnormality in the process management system itself can also be quickly dealt with.

Next, Fig. 13 will be described. This figure is a schematic diagram of the seventh embodiment of the process management system of the present invention. A block diagram showing the server device 201 and the mail server device 206. In this embodiment, a warning device 212 is added to either or both of the server device 201 and the mail server device 206 in the fourth embodiment shown in FIG. 9 . Furthermore, a warning device 212 may be added to either or both of the server device 201 or the mail server device 206 in the fifth embodiment shown in FIG. 11 or the sixth embodiment shown in FIG. 12 .

The warning device 212 is used for issuing a warning to the abnormality when the abnormality processing unit determines that the abnormality is abnormal.

In this embodiment, when the abnormality processing unit 205 determines that there is an abnormality, at the same time as sending an e-mail describing the content of the abnormality from the mail server device 206, either one or both of the server device 201 and the mail server device 206 has a The warning device 212 gives a warning. This warning is performed, for example, by emitting a warning sound such as a buzzer sound, lighting a warning lamp, or displaying a warning on a screen.

Therefore, in this embodiment, when an abnormality occurs and the abnormality warning is notified by e-mail, even if the manager of the process management system cannot read the e-mail, as long as he is in a position where he can perceive the slave server device 201 or the mail server device 206 The manager can know the occurrence of the abnormality within the range of the warning sound, warning display, or warning light emitted by the warning device 212 provided.

Next, Fig. 14 will be described. This figure is a schematic configuration diagram of an eighth embodiment of the process management system of the present invention. In this embodiment, one or more mail reception terminal devices 208d1 to 208dn are added to the process management system in the fourth embodiment shown in FIG. 9 .

The mail receiving terminal devices 208d1 to 208dn are connected to the server device 201 and the mail server device 206 through the communication network 207, and receive electronic mails transmitted from the mail server device 206. In addition, each of the mail receiving terminal devices 208d1 to 208dn has the same warning device 212 as that in the fourth embodiment shown in FIG. 13 .

In this embodiment, when the abnormality processing unit 205 determines that there is an abnormality, the mail server device 206 transmits an e-mail in which the content of the abnormality is described and sent to the mail server device 206 by the abnormality processing unit 205 . This e-mail is received by mail receiving terminal devices 208d1 to 208dn. After this reception, a warning is issued by the warning device 212 included in the mail receiving terminal devices 208d1 to 208dn. This warning is performed, for example, by emitting a warning sound such as a buzzer, lighting a warning lamp, or displaying a warning on a screen.

In this embodiment, when an abnormality occurs and the warning is notified by e-mail, even if the manager cannot read the e-mail, as long as he is in the place where he can perceive the warning device 212 of the mail receiving terminal devices 208d1 to 208dn The manager can know the occurrence of the abnormality within the range of the warning sound, warning display, or warning light.

Next, Fig. 15 will be described. This figure is a schematic configuration diagram of the ninth embodiment of the process management system of the present invention.

The process management system shown in FIG. 15 is formed by connecting a plurality of server devices 320 , centralized management server devices 310 , and reference terminals 330 via a network 340 . And, basically, the server device 320 is installed in each branch (department) of the manufacturing industry to manage the process data by department, and the centralized management server device 310 is used to centrally manage A process data management device that stores (by department) process data. In addition, although not clearly shown in the figure, at least one data input terminal is connected under each server device 320, and a user or a device inputs process data through the data input terminal.

Next, the operation of the process management system configured as described above will be described.

First, process data is input by an operator or equipment in a predetermined department of the company through a data input terminal not shown. The input process data is stored in the database 321 in the server device 320 of FIG. 15 .

FIG. 16 is a schematic diagram of the data structure of the database 321 storing process data. As shown in FIG. 16 , the database 321 is constituted by a plurality of process data 3211 . The process data 3211 has items of "product individual number", "product number", "date", "equipment number", "inspection item number", and "inspection data".

Here, the item "product individual number" indicates a number for specifying a product individual, and the individual can be specified by designating the product individual number from among products of the same category (such as a camera). The item "product number" indicates the category of the product, for example, "1" is a digital camera, "2" is a film camera, "3" is a tape recorder, etc. The item "Date" indicates the date on which the inspection was performed.

The item "device number" indicates the device to be checked. Moreover, for a product category, it is generally necessary to use multiple devices for inspection. Furthermore, there are cases where a plurality of devices are used even if they are of the same type. The data example of "device number" is as follows.

"1001"……………… Machine No. 1 with equipment type No. 10

"1103"………………The equipment type is No. 11 machine No. 3

The item "inspection item number" indicates an inspection item performed in the equipment indicated by the item "equipment number". Usually, in one device, multiple checks are performed.

The item "inspection data" indicates the inspection result value of the inspection item indicated by the item "inspection item number".

The transmission data generating unit 322 in the server device 320 extracts data satisfying a predetermined condition from the process data 3211 stored in the database, and compresses the extracted process data 3211 to reduce the size of the file (data). size.

That is, in the manufacturing process considered as the main target of this system, since a large amount of manufacturing data of tens of megabytes is stored in each server device 320, for example, a day, in order to reduce data extraction from these server devices 320 The burden on the centralized management server device 310 is that the transmission data generation unit 322 compresses the file (data) before data transmission to the centralized management server device 310 .

FIG. 17 is a schematic diagram of process data 3212 extracted in accordance with predetermined conditions from process data 3211 stored in the database 321 by the transfer data generation unit 322 . And, the data obtained by performing data compression on the process data 3212 extracted in this way is the data transferred to the centralized management server apparatus 310 . This compressed data is called transfer data.

In FIG. 17, when extracting from the process data 3211 stored in the database 321, the date is used as a predetermined condition. That is, the data list shown in FIG. 17 is obtained by referring to the item "date" in the process data 3211 of FIG. 16 and extracting data whose date is a predetermined value (here, "2003/8/14").

And, the transmission data obtained in this way is stored in a storage area not shown in the server device 320 .

The storage of the above-mentioned process data is performed in each division (section). That is, the above-mentioned storage processing is independently performed on the server device 320 of the branch. As a result, a plurality of transfer data are stored in storage areas not shown in the plurality of server devices 320 .

On the other hand, the transfer data collection unit 313 in the centralized management server device 310 is connected to the above-mentioned storage area of each server device 320, and stores the stored transfer data in a storage area not shown in the centralized management server device 310. middle. At this time, the distribution data collection unit 313 collects the distribution data from the plurality of server devices 320 based on the order of collecting data from the plurality of server devices 320 or information such as the collected distribution data. For example, when the delivery data collection unit 313 collects delivery data by date, the above-mentioned “collected delivery data” information indicates the date of the collection date, and the delivery data collection unit 313 collects the delivery data from the target server device 320. A storage area that collects files with a file name indicating the collection date. An example of the above-mentioned file name is shown below.

Example: 20031016.csv

FIG. 18 is an explanatory diagram of a situation in which the transfer data collection unit 313 of the centralized management server device 310 collects data according to a preset data collection sequence among the server devices 320 .

In the example of FIG. 18, under the centralized management server device 310, a server device 320a, a server device 320b, and a server device 320c are connected via a network. In the case of the figure, the transmission data collection part 313 collects transmission data in order of the server apparatus 320a, the server apparatus 320c, and the server apparatus 320b.

In this way, by setting the order of collecting and transmitting data between the server devices 320 connected to the centralized management server device 310, even in the case of processing a large amount of data such as process data in manufacturing (manufacturing), due to multiple The data of each server device 320 will not be transmitted to the centralized management server device 310 in parallel, and the transmitted data will not be registered together on the centralized management server device 310 side, so the burden on the centralized management server device 310 side can be reduced. .

In addition, when the transmission data collection unit 313 saves the transmission data in the storage area not shown in the central management server device 310, it will provide information on whether it can be stored normally in the storage area (that is, whether it can be collected normally). information) to the warning processing unit 315.

After the transmission data from each server device 320 is stored in a storage area not shown in the centralized management server device 310 by the transmission data collection part 313, the data stored in the centralized management server device 310 is stored by the transmission data registration part 312. The transfer data of the storage area is registered in the database 311 in the centralized management server device 310 . At this time, information on whether or not the database 311 can be registered normally is submitted to the warning processing unit 315 .

The warning processing unit 315 that has received the information of whether the collection and storage can be performed normally or whether the registration can be performed normally will send the result of whether the collection/storage of the transmission data or the registration of the transmission data to the database has been completed normally based on the information, and send an email, etc. The method is directed to an operator's terminal (for example, a not-shown data input terminal connected to each server device 320 ), and is issued as a warning.

In a system that transmits a large amount of data through the network, network disconnection, failure, etc. are fatal. In the case of such failures such as disconnection and failure, untransmitted data increases, and subsequent increase in transmission time becomes a major cause of congestion of the hard disks of each server device. In the present embodiment, as described above, the transfer of data and the success or failure of the login are transmitted to the operator terminal by electronic mail. Thereby, even in the case of data transmission and registration failure, the problem can be grasped early, and the above-mentioned problem (clogging of the hard disk (for example, the database 321 of the server device 320)) can be solved by the operator manually performing the data transmission and registration. wait).

In addition, the above-mentioned transmission data generation unit 322 or transmission data collection unit 313 is usually configured to be activated when the timing is reached, but when the operator's terminal receives an e-mail indicating that data collection or registration cannot be performed normally, transmission The data generation unit 322 or the transmission data collection unit 313 is activated according to an operator's instruction (that is, manually), for example, collects or registers data that has not been collected or registered due to an error in the collection or registration.

Moreover, the user of this system can access the database 311 in the centralized management server apparatus 310 by using the browser 331 in the reference terminal 330, and can browse process data.

In this way, according to the process management system of this embodiment, various countermeasures, management, and feedback can be efficiently taken by centrally managing and sharing the inspection data and adjustment data of products that were originally scattered in the manufacturing department, technical department, and design department. to the next batch of products and so on. Users of this system browse necessary data through the above-mentioned reference terminal 330, and can enjoy the following effects, for example.

・By specifying the product individual number, the data attached to the product individual can be browsed. Therefore, the inspection history of the individual product can be grasped, and it can be applied to problem analysis and the like.

· By viewing the maximum value, minimum value, average value, standard deviation, etc. of a certain inspection item from the process data, changes in the data can be confirmed, and various countermeasures can be formulated based on the ability to grasp the process based on this change.

・By using pass/fail information of inspection items, it is possible to grasp the fail rate, list of fail contents, etc., making daily management and countermeasures easier.

In addition, in this embodiment, there is such a structure that the transfer data collection unit 313 of the centralized management server device 310 collects process data registered in the database 321 in the server device 320 according to predetermined conditions (dates, etc.). The data extracted in 3211 may be any configuration in which the process data 3211 in the server device 320 is collected by the transmission data collection unit 313 without omission and part by part. All of these configurations have the effect of reducing the load of registration processing (processing related to registration processing, including previous collection, storage, etc.) of process data (transmission data) on the centralized management server device 310 side to the database 311 .

In this way, according to this embodiment, since the centralized management server device 310 connected to each server device 320 through the network 340 is newly installed, the process data scattered in each department is centrally managed through the centralized management server device 310, so the user does not need to spend money. With no effort or time, you can browse the process data of each department.

Therefore, since the transmission data generating unit 322 in the server device 320 generates transmission data part by part without omission in the process data in the server device 320, the transmission data is to be sent to the centralized management server. The transfer data collection unit 313 of the centralized management server device 310 collects the transfer data generated in this way, so that process data can be realized by a structure that does not impose an excessive load on each server device 320 or the centralized management server device 310. Unified management. And, if the transmission data collection part 313 of the centralized management server device 310 collects the transmission data from each server device 320 according to the data collection order between the server devices 320 set in advance, the burden on the centralized management server can be further reduced. The load of the device 310. In addition, based on the notification information such as e-mail sent to the operator terminal by the warning processing unit 315 in the centralized management server device 310, the operator manually executes the processing after the abnormal end of the collection etc. again, so the server device 320 In the storage resources of the server device 320 side, no untransferred data remains at any time, and the load on the storage resources of the server device 320 side can be reduced.

Next, Fig. 19 will be described. This figure is a schematic configuration diagram of the tenth embodiment of the process management system of the present invention.

In addition, in the description of this embodiment, the differences from the configuration of the ninth embodiment of the process management system shown in FIG. 15 will be mainly described.

In FIG. 19 , the process management system is formed by connecting a plurality of server devices 420 , centralized management server devices 410 , and reference terminals 430 through a network 440 . And, basically, the server device 420 is installed in each branch (department) of the manufacturing industry. In addition, although not shown in the figure, at least one data input terminal is connected to each server device 420, and the process data is generated by User or device input through data input terminals.

Next, the operation of the process management system configured as described above will be described.

First, process data is input by an operator or equipment in a predetermined department of the company through a data input terminal not shown. The input process data is stored in the database 421 in the server device 420 of FIG. 19 . In addition, the data structure of the process data is the same as that shown in FIG. 16 .

The transmission data generating unit 422 in the server device 420 extracts data satisfying predetermined conditions from the process data stored in the database 421 and compresses the extracted process data to reduce the file (data) size.

That is, in the manufacturing process considered as the main target of this system, since a large amount of manufacturing data of tens of megabytes is stored in each server device 420, for example, a day, in order to reduce data extraction from these server devices 420 The burden on the centralized management server device 410 is that the transmission data generation unit 422 compresses the file (data) before data transmission to the centralized management server device 410 .

And, the transfer data obtained in this way is stored in a storage area (not shown) in the server device 420 .

The storage of the above-mentioned process data is performed in each branch (each department). That is, the above-mentioned storage processing is independently performed on each server device 420 of the branch. As a result, a plurality of transfer data is stored in storage areas not shown in the plurality of server devices 420 .

Then, the data transfer unit 423 of the server device 420 transmits the transferred data to a storage area (not shown) in the centralized management server device 410 and stores the transferred data in the storage area in the centralized management server device 410 . And, at this time, information on whether or not it can be normally stored in the storage area (that is, information on whether or not it can be transmitted normally) is submitted to the warning processing unit 415 .

The transmission and storage processing of the transfer data by the data transfer unit 423 is independently performed in each server device 420 connected to the centralized management server device 410 via the network 440 . Therefore, in this modified example, the sequence information to be transmitted to the central management server as described above is not set for each server device 420 .

On the other hand, the transfer data registration unit 412 in the centralized management server device 410 registers the transfer data stored in the storage area in the centralized management server device 410 to the database 411 in the centralized management server device 410, and also notifies whether The information of normal registration is submitted to the warning processing unit 415 .

The warning processing unit 415 that has received the information of whether it can be sent and stored normally or whether it can be registered normally uses the result of whether the sending and saving of the transmission data or the registration of the transmission data in the database 411 is normally completed as the warning information according to the information, and uses Send to the operator's terminal (for example, a data input terminal connected to each server device) by means of e-mail or the like.

In a system that transmits a large amount of data through the network, network disconnection, failure, etc. are fatal. When failures such as disconnection and disconnection occur, untransmitted data increases, and subsequent increase in transmission time becomes a major factor such as congestion of the hard disk of each server device. In the present embodiment, as described above, the transfer of data and the success or failure of the login are sent to the operator terminal by electronic mail. Thereby, even in the case of data transmission and registration failure, the problem can be grasped early, and the above-mentioned problem (clogging of the hard disk (for example, the database 421 of the server device 420)) can be solved by the operator manually performing the data transmission and registration. wait).

In addition, the above-mentioned transmission data generation unit 422 or data transmission unit 423 is usually configured to be activated when the timing is reached, but when the operator's terminal receives an e-mail indicating that data transmission or registration cannot be performed normally, the transmission data The generation unit 422 or the data transfer unit 423 is activated according to an operator's instruction (that is, manually), and, for example, transmits or registers data that has not been transmitted or registered due to an error in the transmission or registration.

Moreover, the user of this system can access the database 411 in the centralized management server apparatus 410 by using the browser 431 in the reference terminal 430, and can browse process data.

In addition, in this embodiment, there is such a structure that the data extracted from the process data 3211 registered in the database 421 in the server device 420 according to predetermined conditions (dates, etc.) is sent to the data transfer unit of the server device 420 423 to the centralized management server device 410, but any configuration may be adopted in which the process data 3211 in the server device 420 is transmitted (sent) without omission and part by part by the data transfer part 423 . All of these configurations have the effect of reducing the load of the process data (transmission data) on the central management server device 410 side in the process data (transfer data) registration process (processing related to the registration process, including the process of saving to the storage area performed before, etc.) to the database 411. .

In this way, according to this embodiment, the centralized management server device 410 connected to each server device 420 through the network 440 is newly installed. Since the centralized management server device 410 centrally manages the process data scattered in each department, the user does not have to It takes effort or time to browse the process data of each department.

Furthermore, since the transmission data generation part 422 in the server device 420 has the structure which does not omit the process data in the server device 420, and generates transmission data part by part, this transmission data is for sending to the centralized management server The data transfer unit 423 of the server device 420 transfers (sends) the generated transfer data to the central management server device 410, so that the structure does not impose an excessive load on each server device 420 or the centralized management server device 410. , the unified management of process data can be realized. In addition, based on notification information such as e-mail sent to the operator terminal by the warning processing unit 415 in the centralized management server device 410, the operator manually re-executes the processing after the abnormal end such as the transmission of the transmission data. In the storage resource on the device 420 side, there is never any untransferred data left, and the load on the storage resource on the server device 420 side can be reduced.

Next, Fig. 20 will be described. This figure is a schematic configuration diagram of an eleventh embodiment of the process management system of the present invention.

In FIG. 20 , the process management system of this embodiment is configured by connecting a process management device 510 to at least one data input terminal 520 and at least one data reference terminal 530 via a network 540 . In addition, the data input terminal 520 and the data reference terminal 530 may be collectively referred to as a user terminal.

The process management apparatus 510 has the process data table 511 and the event data table 512, and basically functions as a database server apparatus which manages the data in these tables. The process data table 511 is composed of at least one process data record 5111 . Furthermore, the event data table 512 is composed of at least one event data record 5121 .

The data input terminal 520 is a terminal for inputting process data or event data by a user of the system or a device connected to the system. Process data or event data is input through the data input unit 521 . Then, the process data or event data input through the data input unit 521 is converted into a predetermined format, transmitted to the process management device 510 through the network 540 , and stored in the process data table 511 or the event data table 512 . The data input terminal 520 has the function of any one or both of process data input terminals and event data input terminals.

Furthermore, the process data can be broadly classified into data automatically output and input from equipment, and data input by a user (operator) from a process data input terminal. In addition, the process data input terminal may be used in connection with equipment for product manufacturing, or may be used integrated with the equipment. Basically, there are process data input terminals corresponding to the number of devices.

Regarding the event data, it is mainly considered that a user (operator) inputs it from an event data input terminal. Event data input terminals can be set at one location or at multiple locations.

Furthermore, the process management system in this embodiment is characterized in that process data such as adjustment results or inspection results obtained from each process of a product manufactured through a plurality of processes and intermediate products such as adjustment results or inspection results of semi-finished products or parts Abnormalities or any changes (hereinafter referred to as abnormalities/changes) that occur in data (hereinafter, adjustment data, inspection data, intermediate data, etc. are collectively referred to as process data), while detecting the abnormality/changes, the abnormality/changes are also determined. reason for the change. In this sense, the processing content of the data reference terminal 530 described below is the content related to the above-mentioned feature points.

The data reference terminal 530 is a terminal used by the user to detect the above-mentioned abnormality/change and specify the cause thereof. The process data retrieval unit 531 has an interface function for accessing the process data table 511 in the process management device 510 from the data reference terminal 530 side, and searches the process data record 5111 in the process data table 511 according to a predetermined retrieval condition to obtain the corresponding process data. Data record 5111. The event data search unit 532 has an interface function when accessing the event data table 512 in the process management device 510 from the data reference terminal 530 side, searches the event data record 5121 in the event data table 512 according to a predetermined search condition, and obtains the corresponding event Data record 5121. The search conditions for the search by the process data search unit 531 or the event data search unit 532 are input by the user through an input unit not shown. The search result of the process data search part 531 or the event data search part 532 is displayed on the display which is not shown in the data reference terminal 530, for example.

Moreover, in FIG. 20, the process management apparatus 510 and the data reference terminal 530 do not necessarily have to be connected via the network 540, For example, they may be integrated.

Next, the operation of the process management system shown in FIG. 20 will be described.

First, various process data input by the user or the device through the data input unit 521 of the user terminal 520 are converted into a predetermined format. Furthermore, it is sent to the process management apparatus 510 through the network 540, and is saved in the process data table 511 in the said process management apparatus 510.

In addition, various event data input by the user through the data input unit 521 of the user terminal 520 are converted into a predetermined format. Furthermore, it is sent to the process management apparatus 510 through the network 540, and is saved in the event data table 512 in the said process management apparatus 510. Here, the various event data refer to various change information in the process, for example, change information on the operator, the working method, and the lot.

Next, the user activates the process data retrieval unit 531 from the data reference terminal 530 based on predetermined retrieval conditions in order to investigate whether there is any abnormality or any variation in the process data obtained from each process of a product manufactured through a plurality of processes.

The process data search unit 531 on the data reference terminal 530 searches the process data record 5111 stored in the process data table 511 according to the search condition, and displays the search result on a display (not shown) of the data reference terminal 530 , for example.

The user refers to the search results of the process data search unit 531 displayed in this way, and if abnormalities or any changes related to the process are found in the search results, the user then activates the event data search unit 532 from the data reference terminal 530 . Furthermore, the event data record 5121 stored in the event data table 512 is searched by the event data search part 532, and the event data which can cause the above-mentioned abnormality/fluctuation are displayed.

Fig. 21 is a schematic diagram of an example of process data automatically output from equipment.

Then, the process data is automatically output from devices such as an inspection machine and an adjustment machine not shown in the figure, and is stored in the process data table 511 in FIG. 20 after undergoing predetermined conversion processing.

In Fig. 21, the process data before conversion is separated and stored by each mark "Model:", "Seria No.:", "DATE", and the mark "@" indicating the data start position of the inspection item. The data input unit 521 in FIG. 20 detects the mark "Model:", obtains the product name from the part immediately after it, and refers to the product master table (not shown) to obtain the product number corresponding to the product name. Also, the mark "Seria No.:" is detected, and the product individual number is obtained from the part immediately following it. Also, the mark "DATE" is detected, and the date and time are acquired from the subsequent part. In addition, the mark "@" is detected, and its subsequent part is interpreted as a storage part of data related to various inspections performed on the product.

The product is completed through multiple processes, during which, or after completion, a certain quality is maintained by carrying out prescribed inspections. The data related to each of the above-mentioned inspections constitutes the data of one inspection by the following parts: a mark indicating the name of each inspection item such as "inspection item 1", "inspection item 2", etc.; The inspection data portion of the measured value. The above-mentioned data of one inspection is arranged in each row according to the number of inspections performed on the product, and constitutes the inspection data on the product.

FIG. 22 is a schematic diagram of an example of a process data record 5111 on the process data table 511 .

As shown in FIG. 22, the process data record 5111 is created for each inspection item. For example, since the process data before conversion in FIG. 21 includes two inspection items "inspection item 1" and "inspection item 2", two process data records 5111 are correspondingly generated in the data before conversion. Moreover, the item "device number" shows the device which outputs process data (the data input terminal of FIG. 1 is connected to this device, or is integrated). For example, the equipment number "1001" indicates that the process data is output from machine No. 1 whose equipment type is No. 10.

Also, the item "inspection item" indicates an inspection number corresponding to the inspection item name of FIG. 21 . For example, by referring to the inspection item master not shown in the figure by the data input unit 521 in FIG. 20 , the name of the inspection item indicated by the mark "inspection item 1" in FIG. 21 is converted into the corresponding inspection number "1". Furthermore, inspection data (the numerical value part except the unit) "4.71" is extracted from the subsequent part of the same row as this label "inspection item 1". The above-described process of extracting inspection data from the subsequent portion of the same line is performed by the data input unit 521 every time the mark of the inspection item name is detected. In addition, "UP-NG" indicates that the allowable range (the standard value of the upper limit and the lower limit) of the inspection data with respect to the inspection result set for each inspection item exceeds the upper limit. In addition, "KO" is a unit of measurement set for an inspection item. These information are stored in the above-mentioned inspection item master table as inspection item information. Since the user can refer to them as needed, in the process data record, these information (in FIG. 21, "UP-NG", "LOW-NG") ", "KO", "nF") are omitted.

FIG. 23 is a schematic diagram of an example of an event data record 5121 on the event data table 512 .

Here, the event data is various change information related to a process, and is data that somewhat affects the results of adjustments and inspections performed on a product in each process. The event data includes event data on specific equipment, event data on the entire process, and the like. For example, since a "batch of changes" is a batch of changes on a specific device, it is event data about a specific device. On the other hand, "changes in the environment (temperature, humidity, etc.)" and the like have event data when specific equipment is used and throughout the entire process. When checking the event data by the event data search unit, each item shown in FIG. 23 can be designated as a search key. For example, when searching for event data is performed by specifying the period (the range of "date") and "equipment number" as keywords, event data that may be related to the manufacturing process of a plurality of products produced by the equipment is acquired as the search key. result.

In FIG. 23 , the event data record 5121 is composed of items such as "date", "time", "device number", "product number", "event ID", and "event details". In addition, event data is different from process data, and it is not very meaningful to specify the terminal of the input data. In this sense, the event data record 5121 does not contain the information of the original input terminal. In addition, the item "equipment number" is not information indicating the original input terminal, as will be described later.

The items "date" and "time" indicate the date and time at which the event occurred.

The item "event details" shows the details of various change information about the process. The item "Event ID" indicates an event ID corresponding to an event having the content of "Event Details".

The item "device number" indicates the number of the device to which the content of the item "event details" is implemented. And, when there are multiple target devices, the multiple devices are listed. In addition, the device is not limited, and when the content shown in "Event Details" is implemented, it will be blank.

The item "product number" shows the number of the product to which the content of the item "event details" is implemented. And, when there are a plurality of target products, the plurality of products are listed. In addition, it does not limit the product, and when the content in "Event Details" is implemented, it becomes a blank column.

The data input part 521 of the data input terminal (event data input terminal) 520 of FIG. No. "indicated by the product number. In addition, when performing the above-mentioned conversion, the data input unit 521 refers to an equipment master table and a product master table not shown in the figure.

In addition, in the figure, examples of the "event details" information include "adjustment of item 1 of device 1001" and "batch change". Here, the "adjustment of the item 1 of the equipment 1001" specifically includes "mold maintenance of the injection molding machine" and the like. In addition, the above-mentioned "lot change" may also affect the process data when considering the deviation of parts for each lot. In addition, "change of operator" can also be considered as an example of "event details". There is a possibility that the operating procedures and the like are different depending on the operator, and the "change of the operator" may also affect the process data. In this case, by investigating the operator, the cause of the abnormality or any fluctuation of the inspection data is specified.

The process data search part 531 in the data reference terminal 530 extracts the corresponding process data record from the process data table 511 based on the predetermined search condition input by the user. The extracted process data value information in the process data record is submitted to the graphing unit (not shown) together with the range of "date" in the search condition, and a predetermined graphing process is performed, and the search result is displayed on the data Refer to the display on the terminal 530.

Moreover, you may perform summation processing with respect to each process data value in the process data record extracted above by the totalization part which is not shown in figure. For example, various statistical quantities such as moving average, maximum value, minimum value, and standard deviation are calculated to calculate the pass rate or the number of rejects relative to the standard, and display the result on a display not shown in the data reference terminal 530 superior.

As a search condition at the time of search by the process data search part 531, for example, "the inspection data of the inspection B of the product A from October 1st to October 9th" etc. are specified. In addition, when specifying the search condition, the display method of the test data can also be specified. For example, specify "represent data in a line graph", etc.

24( a ), ( b ) and ( c ) are schematic diagrams each showing a display example of a search result by the process data search unit 531 .

In each graph of FIG. 24 , an allowable range is set for each process data in the search result. In the figure, the dotted line of the standard value 1 indicates the upper limit of the allowable range, and the dotted line of the standard value 2 indicates the lower limit. The circles in the figure are all used to represent abnormalities or any changes in the process data, that is, to represent the irregular history in the history of the inspection data, (a) to indicate that a part of the inspection data (only one data at this time) is within the allowable range (b) means that within the allowable range, the inspection data is basically (for example, continuous) approaching one end (the upper limit value at this time); (c) means that within the allowable range, relative to the set specified value , to check that the data is basically (for example, continuous) continuously on one side (lower side at this time).

According to the graphical display example of the search results using Fig. 24 (a) to (c), or the display (output) example of the inspection result by other methods, the user can find out abnormalities or any changes in the process data, that is, , found an irregular history in the history of the above inspection data.

Next, the user activates the event data search unit 532 in the data reference terminal 530 . That is, the event data search unit 532 in the data reference terminal 530 extracts the corresponding event data record from the event data table 512 based on the predetermined search condition input by the user. The extracted event data records are displayed on a display (not shown) of the data reference terminal 530 .

In addition, the retrieval conditions of the event data retrieval unit 532 and the retrieval conditions of the process data retrieval unit 531 are basically set independently, but the retrieval conditions of the event data retrieval unit 532 may be automatically generated based on the retrieval conditions of the process data retrieval unit 531. . For example, the range of "date" in the search condition may be set to be the same as the search condition of the process data search unit 531, or the search start date may be advanced by a predetermined number of days.

FIG. 25 is a schematic diagram showing a display example of search results searched by the process data search unit 531 and the event data search unit 532 . The search results are displayed, for example, on the display of the data reference terminal.

In FIG. 25, the search result of the process data search part 531 is displayed graphically in the upper part of a screen. The search condition of the process data search unit 531 is, for example, "inspection data of inspection B of product A from October 1 to October 9". The horizontal axis of the graph showing the search results is "date time number". The "date and time number" is a serial number assigned to a date and time ("date" or "time"), and is a serial number temporarily assigned to a date and time in the search result data for each search. In this case, the allocation is: "October 1"→"1", "October 2"→"2", . . . , "October 9"→"9". In addition, the vertical axis of this graph is the value of the item "inspection data" in the search result data.

In the lower portion of the screen of FIG. 25 , event data included in the range of date and time numbers in the upper portion of the screen and the corresponding date and time numbers are simultaneously displayed. That is, in this case, in the search of the event data search unit 532 performed after the search of the process data search unit 531, the range of the “date” of the search condition is set to “10 1st to 9th October", similarly, date and time numbers "1" to "9" are assigned. In the drawing, within the range (period) of the date and time numbers "1" to "9", an event occurs only on the date and time (date at this time) indicated by the date number "6".

Furthermore, in the drawing, the process data and the event data related to the process data are simultaneously displayed on one screen, but the process data and the event data related to the process data may be displayed on different screens.

In addition, when the user specifies the cause of abnormality/change based on the display screen of the test result shown in FIG. 25, it is considered as follows.

The user compares and studies the retrieval results of the process data retrieval unit 531 (the upper part of the screen in FIG. 25 ) and the retrieval results of the event data retrieval unit 532 (see the lower part of the screen in FIG. 25 ). The event data having the latest date and time number preceding the changed inspection data is determined as the cause of the abnormality or any variation of the above-mentioned inspection data.

Also, the cause of an abnormality or any variation of the inspection data can also be determined by how the event that will be a candidate for the cause this time has an influence on the inspection data in the vicinity of the event, and other events having the same content as the event The cause can be determined by comparing the impact (eg, anomalies or any shifts) on the inspection data elsewhere.

(a), (b) and (c) in Fig. 26 illustrate that when an abnormality or any change is found in the process data after a predetermined period of time has elapsed after the process is changed, the abnormality is confirmed by comparing with the event data of the same content. / Diagram of the situation of the cause of change. (a), (b) is a figure which shows the search result of the process data search part 531, (c) is a figure which shows the search result of the event data search part 532. 26(a) and (b) on the horizontal axis/vertical axis and each item in FIG. 26(c) are the same as those in FIG. 25, and therefore description thereof will be omitted. In addition, in order to make it easy to understand visually, the primary search result of the process data search part 531 is divided and displayed in FIG.26(a) and FIG.26(b).

First, the user refers to the search result screen of the process data in FIG. 26( a ), and determines that a change in the process data is found after the date and time number "3". In addition, referring to the search result screen of the process data in FIG. 26( b ), it is judged that a change in the process data was found after the date and time number "16". Next, the user refers to the event data retrieval result screen in FIG. 26(c), and determines that events have occurred at date and time numbers "1" and "14". Furthermore, according to the event details of the date and time numbers "1" and "14" are the same as "event content 1", and according to the date and time number "3" of Figure 26(a) and the date and time number of Figure 26(b) "16" is the number two after the date and time numbers "1" and "14", and the data change pattern is similar, the following conclusions can be drawn: that is, the date and time numbers "1" and "14" The events that occurred were the cause of the anomalous shifts in datetime numbers "3" and "16".

In Fig. 26(c), if an event whose date and time number is "15" is further added, and the event is described in detail as "event content 2", the abnormality/change of the data with the date and time number "16" will be included in the The event of the previous date and time number "15" is determined as its cause, but by comparing the event of the date and time number "14" with the event of the same content (the event is described in detail as "event content 1", date and time number "1") Event) is compared, and the event that occurred at the date and time number "14" can be identified as the cause of the data abnormality/change of the date and time number "16". Therefore, even if the event with the latest date and time number before the date and time number at which the data abnormality/change occurred is not the cause of the data abnormality/change and the real cause may be overlooked, the real cause can be identified.

In addition, as described above, the process data retrieval unit 531 and the event data retrieval unit 532 may be independently activated by the user, and the event data retrieval unit 532 may be activated based on the retrieval results of the process data retrieval unit 531 .

In particular, when starting the event data search part 532 with reference to the search result of the process data search part 531, the event data search part 532 may be started automatically other than manual start by a user. In this case, the following cases (1) and (2) are considered.

(1) The process data is searched by the process data search unit 531 based on predetermined search conditions. Regardless of whether there is abnormality/change in the inspection data in the search result, the event data search unit 532 is then activated to search for event data. The search conditions of the event data search unit 532 can be automatically generated from the search conditions and search results of the process data search unit 531 .

(2) The process data is searched by the process data search unit 531 based on predetermined search conditions. It is determined whether or not abnormality/variation is found in the inspection data among the search results. When it is determined that an abnormality/change is found, the event data search unit 532 is activated to search for event data. The search conditions of the event data search unit 532 can be automatically generated from the search conditions and search results of the process data search unit 531 .

First, the case of (1) above, that is, the case where the event data search unit 532 is not activated based on the search result of the process data search unit 531 is the same as the case already described. Hereinafter, the case of (2) will be mainly described.

In the case of (2) above, that is, when it is determined that an abnormality/variation is found in the search results of the process data search unit 531, the event data search unit 532 is activated, the system must have such a judgment function: It is judged whether abnormality/change is found in the search result of the process data search part 531.

Fig. 27 is a schematic diagram of a twelfth embodiment of the process management system of the present invention. In addition, this embodiment is a modified example of the configuration of the process management system of the eleventh embodiment shown in FIG. 20 . In addition, in the following description, differences from the system shown in FIG. 20 will be mainly described.

FIG. 27 is a configuration in which an abnormality warning terminal 550 is added to FIG. 20 . The abnormality warning terminal 550 notifies (warns) relevant departments of the judgment result while judging abnormality or any change in the search result of the process data search unit 531. The abnormality warning terminal 550 is composed of an abnormality/change determination unit 551 and a warning processing unit 552 , and is connected to a data input terminal 520 , a data reference terminal 530 , and a process management device 510 through a network 540 .

The abnormality/variation judgment part 551 acquires and analyzes the process data record 5111 on the process data table 511 at predetermined timing, and judges whether abnormality or any fluctuation|variation has arisen in this process data record 5111. The warning processing unit 552 notifies the user terminal of warning information when it is determined by the abnormality/change determination unit 551 that an abnormality or any fluctuation has occurred in the process data. For example, the warning information is transmitted by e-mail, or data for displaying the warning information on the screen of the user terminal is transmitted, or the warning information is notified by lighting a warning light or buzzing.

The predetermined timing at which the above-mentioned abnormality/fluctuation determination unit 551 is activated is, for example, every fixed time (fixed period) or every time the number of process data records in the process data table 511 reaches a certain amount.

In addition, the analysis performed by the above-mentioned abnormality/variation determination unit 551 can be performed by an analysis program, for example.

Fig. 28, Fig. 29, Fig. 30 are process flowcharts for determining whether abnormality or any variation is found in the history of the inspection data shown in Fig. 24 (a) to (c).

First, FIG. 28 is a schematic diagram of a flow of processing for determining whether an abnormality or any variation is found in the history of inspection data shown in FIG. 24( a ) (hereinafter, simply referred to as "abnormality/variation determination processing").

In FIG. 28 , first, in step S101 , from the search results of the process data search unit 531 , the inspection data value corresponding to the process data with the smallest date and time number is acquired. And, in the inspection B of the product A which is the current target product, an allowable range with the upper limit being the standard value 1 and the lower limit being the standard value 2 is set for the inspection data value, and then, in step S102, the process data (inspection data ) is within the allowable range. Here, in the case of "process data ≤ standard value 1" and "process data ≥ standard value 2" ("No" in S102), the inspection data should be within the allowable range, and the process proceeds to step S103. In step S103, it is determined whether or not the process data has been completed. When the process data has been completed, a series of abnormality/change determination processing is terminated. Moreover, when the process data is not finished, in step S105, the next process data is acquired, and it returns to step S102.

In addition, in step S102, in the case of "process data>standard value 1" or "process data<standard value 2" (the determination result of S102 is "Yes"), the inspection data exceeds the allowable range, and the process proceeds to step S104. In step S104, it is determined that there is abnormal data in the process data (the inspection data value is data outside the allowable range), and a series of abnormality/fluctuation determination processing is ended.

FIG. 29 is a schematic diagram of a flow of processing for determining whether an abnormality or any variation is found in the history of inspection data shown in FIG. 24( b ) (hereinafter, simply referred to as "abnormality/variation determination processing"). In addition, this flow targets inspection B of product A, and in this inspection B, an allowable range with an upper limit of standard value 1 and a lower limit of standard value 2 is set for the inspection data value. Furthermore, in the following flow, it is assumed that the inspection data of each date and time code has been confirmed, and it is limited within the allowable range by predetermined processing performed in advance (for example, the processing shown in FIG. 5( a )). In addition, in the following flow of this process, it is assumed that the variables n and i have the following meanings.

n: When the process data (inspection data) continues to increase, the threshold for deciding whether to consider it as a data change

i: A counter that changes within the range of i where 0≤i≤n

In FIG. 29, first, in step S201, the first two pieces of data on the side with the smallest date and time number are acquired from the search results of the process data search unit. Then, in step S202, it is determined whether the process data (inspection data) is larger than the previous process data (previous inspection data) (that is, whether process data>previous process data holds).

In this step S202, when it is determined that the process data is not greater than the previous process data (that is, the process data≤the previous process data, the determination result in step S202 is "no"), enter step S206, and counter i is initialized as 0, and then go to step S207.

On the other hand, in step S202, when it is determined that the process data is greater than the previous process data (that is, the determination result in step S202 is "Yes"), in step S203, the counter i increments, and then, in step S204, in In the state where the process data is continuously increasing, it is determined whether the counter i is equal to the threshold value n, and the threshold value n is used to determine whether to regard this state as a data change. Here, when it is determined that they are equal (YES in step S204), in step S205, the continuous increase of the process data is regarded as data variation, and a series of abnormality/variation determination processing ends. On the other hand, in step S204, when it is determined that it is not equal (when the determination result in step S204 is "No"), in step S207, it is determined whether or not the process data has been completed. When it is determined that the process data has been completed (when the determination result in step S207 is "YES"), a series of abnormality/fluctuation determination processing is terminated. When it is determined that the process data has not been completed (when the determination result in step S207 is "No"), the next process data is acquired in step S208, and the process returns to step S202. And, at this moment, in step S202, carry out following setting:

Process data ← "previous process data" when step S202 was executed last time

The previous process data ← the "next process data" acquired this time in step S208 is compared.

In addition, in the above description, the fact that the inspection data (process data) continuously increases n times is taken as the condition of data fluctuation, but the condition of data fluctuation is not limited to this. For example, it can also be regarded as the case where the inspection data has continuously decreased n times, or the history of the inspection data is gradually approaching the upper limit or lower limit of the allowable range as a data change. For this case, it can also be replaced by the corresponding process , automatically perform "determination of abnormality or any change processing".

FIG. 30 is a schematic diagram of a flow of processing for determining whether abnormality or any variation is found in the history of inspection data shown in FIG. 24( c ) (hereinafter, simply referred to as “abnormality/variation determination processing”). Furthermore, this flow targets inspection B of product A, and in inspection B, an allowable range with an upper limit of standard value 1 and a lower limit of standard value 2 is set for the inspection data value. Furthermore, in the flow below, it is assumed that the inspection data of each date and time code has been confirmed to be within the allowable range through predetermined processing performed in advance (for example, the processing shown in FIG. 24( a )). In addition, in the following flow of this process, it is assumed that the variables n, i, and j have the following meanings.

n: When the process data (inspection data) is continuously on the side of the preset value (setting value), determine whether to regard it as a threshold value of data fluctuation.

i, j: A counter that fluctuates within the range of 0≤i, j≤n, i is the counting number of process data values on one side of the set value, and j is the number of process data values on the other side of the set value Count the number.

In FIG. 30 , first, in step S301 , the inspection data value corresponding to the process data with the smallest date and time number (starting process data) is acquired from the search results of the process data search unit. Next, in step S302, it is determined whether or not the process data acquired in step S301 is larger than a preset value (setting value).

In step S302, when it is determined that the process data is greater than the set value, in step S303, counter i is incremented and counter j is initialized. Furthermore, go to step S305. On the other hand, in step S302, when it is determined that the process data is not greater than the set value, that is, when the process data ≤ the set value, proceed to step S304, and increment the counter j while initializing the counter i. Furthermore, go to step S305. That is, in this case, the counter i counts the cases where the process data is continuously located above the set value, and the counter j counts the cases where the process data is continuously located below the set value.

In step S305, when the process data is continuously located on one side of the set value, it is determined whether the threshold n for determining whether the state is regarded as a data fluctuation is equal to the above-mentioned counter i, or whether the above-mentioned threshold n and the above-mentioned counter j are equal. Is it equal. When the above-mentioned threshold value n is equal to the above-mentioned counter i, it means that the process data is above the set value n times. In this process, in step S306, it is determined that there is data variation, and a series of abnormality/change determination processing ends. On the other hand, when the above-mentioned threshold n is equal to the counter j, it means that the process data has n times below the set value. In this process, in step S306, it is judged that there is a data change, and a series of abnormal/change judgments is ended. deal with.

On the other hand, in step S305, when the above-mentioned threshold value n is not equal to the above-mentioned counter i, and the above-mentioned threshold value n is not equal to the counter j, it means that no data change has been detected until the process data of the current processing object. S307, determine whether the process data has ended. If the process data has been completed, a series of abnormality/change determination processing is terminated. If the process data is not finished, then in step S308, the next process data is obtained, and the process returns to step S302.

In addition, in the above description, the fact that the inspection data (process data) is continuously on the side of the set value is regarded as the data fluctuation condition, but the data fluctuation condition is not limited to this. For example, in the history of inspection data, the situation that the ratio of inspection data on one side is significantly higher than that on the other side can also be regarded as a data change. In this case, it can also be replaced by the corresponding process, automatically "Processing for judging abnormalities or any changes" is carried out in a timely manner.

As described above, according to the present embodiment, in the case of the stereotype analysis shown in each flow described above, since the abnormality/fluctuation determination unit 551 analyzes the process data at a predetermined timing, the process data search unit 531 is manually activated by a user such as a process manager. , to retrieve/display the process data, it is not necessary to judge the abnormality or any change, and the abnormality or any change of the process can be quickly dealt with. Furthermore, if the process data input into the process data table 511 through the network 540 is always obtained and analyzed, it is possible to deal with abnormalities or any changes in the process more quickly.

In addition, in the above description, when the causal relationship between the process data and the event data is estimated, the user issues a search command to the process data search unit 531 to execute the process data search, and also issues a search command to the event data search unit 532 to execute the event data. In the data search, the search results of the process data search unit 531 and the event data search unit 532 are compared, and when abnormalities/changes in data are found in the search results of the process data search unit 531, the event causing the cause can be specified (estimated). In this case, operations other than retrieval of process data or event data are performed by the user. When the abnormality/change determination part 551 mentioned above is added, the abnormality/change in the search result of process data can also be detected automatically.

Hereinafter, the case where the search result of process data and the search result of event data are compared automatically is demonstrated.

FIG. 31 is a schematic diagram of a second configuration example of the data reference terminal 530 shown in FIG. 20 .

In FIG. 31 , the data reference terminal 580 has a process data search unit 581 , an event data search unit 582 , an abnormality/fluctuation determination unit 583 , and a causal relationship estimation unit 584 .

The process data search unit 581 and the event data search unit 582 are activated in a predetermined order specified by the user. The causal relationship estimation unit 584 functions as a cause candidate extraction unit or a result candidate extraction unit according to the above-mentioned predetermined procedure.

First, the cause candidate extraction process will be described. In this process, the process data search unit 581 is activated based on predetermined conditions, and the process data search is executed. Next, the event data retrieval unit 582 is activated based on the conditions corresponding to the above-mentioned predetermined conditions, and the retrieval of event data is executed. The abnormality/change judgment part 583 judges whether the abnormality/change of process data was found in the search result of the process data search part 581 or not. The causality estimation unit (causal candidate extraction unit) 584 extracts event data that can be the cause of the process data being judged to be an abnormality/change position from the search results of the event data search unit 582 .

Next, the result candidate extraction process will be described. In this process, the event data search unit 582 is activated based on predetermined conditions, and event data is searched. Next, the process data search part 581 is activated based on the condition corresponding to the said predetermined condition, and the search of process data is performed. The abnormality/change judgment part 583 judges whether the abnormality/change of process data was found in the search result of the process data search part 581 or not. The causality estimation unit (result candidate extraction unit) 584 extracts process data that can be a result of the search result of the event data search unit 582 from the position determined to be abnormal/fluctuated in the process data.

Hereinafter, the process of extracting each of the cause candidate and the result candidate will be described with reference to the flowcharts in FIGS. 32 and 33 .

FIG. 32 is a schematic flowchart of extraction processing of candidate causes of abnormality/change.

In FIG. 32 , first, in step S11 , the user designates an equipment name and a period as search conditions, and the process data search by the process data search unit 581 is executed. The search condition of the process data search unit is, for example, "process data (inspection data) input from the device 1001 between October 1 and October 9".

Next, in step S12, a device name and a period are specified, and event data search by the event data search unit 582 is executed. The search condition of the event data search unit is, for example, "events that occurred in the device 1001 between October 1 and October 9". Moreover, the retrieval condition of the event data retrieval part 582 may be designated by a user, and the retrieval condition of the event data retrieval part 582 may be automatically generated from the retrieval condition of the process data retrieval part 581. In this case, the period is set to a period corresponding to the period of the process data search unit 581 (setting is made to match, or the period of the event data search unit 582 is advanced by a predetermined period, etc.). In addition, limitations such as "equipment" are added as necessary.

Furthermore, in step S13, the (next) process data which identified the process item name is taken out from the search result of step S11. In step S14, it is determined whether abnormality/variation is found in the process data extracted in step S13.

In step S14, when it is judged that no abnormality/change is found, the process returns to step S13, and the next process data whose product name and process item name are specified are extracted from the search result in step S11.

On the other hand, in step S14, when it is judged that abnormality/change is found, proceed to step S15, and find out the abnormality/change cause of the process data that can become the current product name and process item name from the search result of event data in step S12 Event data (candidate causes) for .

Next, in step S16, it is determined whether or not the above-described processing of steps S13 to S15 has been performed for all the data in the search results performed by the process data search unit 581 in step S11. When all the data have been processed, a series of candidate cause extraction processing ends. In addition, when not processing all data, it returns to step S13.

FIG. 33 is a schematic flowchart of the process of extracting event candidate results.

In FIG. 33 , first, in step S21 , the content and period of an event are specified as search conditions, and the search by the event data search unit 582 is executed. The search condition of the above-mentioned event data search unit 582 is, for example, "an event whose content is 'content 1' and occurred between October 1st and October 9th".

Next, in step S22, a period is designated as a search condition, and search by the process data search part 581 is performed. The search condition of the said process data search part 581 is, for example, "the process data between October 1st - October 9th". In addition, the search conditions of the process data search unit 581 may be designated by the user, or may be automatically generated based on the search conditions of the event data search unit 582 . At this time, the set period is a period corresponding to the period of the event data search unit 582 (setting is made to match, or the period of the process data search unit 581 is delayed by a predetermined period, etc.).

Furthermore, in step S23, the search results in step S22 are classified for each facility, and in each facility, it is determined whether abnormalities/changes are found in the process data for all processes of all products.

In step S24, a result (candidate result) that can be caused by event data among the search results by the event data search unit 582 in step S21 is extracted from the positions determined as process data abnormalities/changes in step S23.

In this way, by extracting candidate results, it is possible to statistically understand what kind of abnormality/fluctuation in inspection data is caused by an event having a certain content. If such information of "event-corresponding abnormality/change" is made into data, for example, when specifying a candidate cause, appropriate reference can be made, which is very useful.

In addition, in the above description, as an example of the inspection data, the case where the inspection result is a numerical value has been dealt with, but the inspection result does not necessarily have to be a numerical value, for example, it may be determined as "OK" or "NG". At this time, as shown in FIG. 34 , in the item “inspection data” of the process data record 111, determination results “OK” and “NG” are stored. The determination result may be numerically stored such that "0" is stored if it is "OK", and "1" is stored if it is "NG".

The methods for judging abnormalities/changes in such process data are listed below:

・When NG occurs, it is regarded as abnormal.

·When the specified period or the specified amount of data is reached, the pass rate of the inspection result is calculated, and if the pass rate is lower than the predetermined value, it is regarded as an abnormality/change.

・If the NG content is more than the preset number and occurs continuously, it will be regarded as an abnormality/variation.

In addition, this invention is not limited to the said embodiment, Various improvement and a change are possible in the range which does not deviate from the summary of this invention.

Claims (4)

1. a Working procedure management system is characterized in that,

By constituting with the lower part:

Make terminal part, it has first data input handling part that carries out the input of operation data and first data output processing part of carrying out the output of operation data;

Server unit, it has the data library device of communication control unit and centralized stores operation data, is connected to described manufacturing terminal part by communication network;

Data are with reference to terminal part, and it reads request by communication network to the operation data that are stored in the described data library device,

Described communication control unit has:

Snubber assembly, it is used to store the operation data;

Second data input handling part, when it will store on the described snubber assembly from the operation data of described manufacturing terminal part output temporarily, the signal that the reception of notifying described operation data has been finished sent to described manufacturing terminal part;

Second data output processing part, its operation data with described snubber assembly stored output to described data library device,

Described data library device has:

Database, it is preserved from the operation data of described communication control unit output;

The 3rd data input handling part, it stores the operation data into described database;

The 3rd data output processing part, it is processed and exports the operation data that are kept in the described database according to from the request of reading of described data with reference to terminal part.

2. Working procedure management system as claimed in claim 1 is characterized in that,

Described communication control unit also has the data operation handling part, this data operation handling part is extracted specific operation data item out, to each operation data item or at regular intervals or during every some, carry out the operation data item of extracting out is made the calculation process of prescribed form, and the result of this calculation process is stored in the described database.

3. Working procedure management system as claimed in claim 1 is characterized in that,

Described communication control unit also has:

The data operation handling part, it extracts specific operation data item out, to each operation data item or at regular intervals or during every some, carry out the operation data item of extracting out is made the calculation process of prescribed form, and this calculation process result is stored in the described database;

Unusual judgment processing portion, it is judged the exceptional value among the calculation process result of described data operation handling part, when this result is exceptional value, the operation data as operand is carried out mark;

Display process portion, it carries out showing at the warning of the described operation data that have been labeled.

4. Working procedure management system as claimed in claim 1 is characterized in that,

Described the 3rd data input handling part is storing the operation data into the time required in the described database when exceeding schedule time, termination is stored the operation data into this database, meanwhile, the signal that notice operation data storage is ended sends to described second data output processing part

When described second data output processing part receives the described signal of notice operation data storage termination, the operation data that are stored in the described snubber assembly are carried out the interruption of stipulated time to the output of described data library device.

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