JP2005128752A - Defect processing analysis device, defect processing analysis method, and defect processing analysis program - Google Patents

Abstract

By performing defect processing according to the importance of an article defect, it is possible to minimize the occurrence of defects and the cost of defect processing.
An apparatus for analyzing defect handling in overseas goods logistics, estimating the number of defects in goods that are being transported or unpacked while collecting defect occurrence information as needed, and unit prices and repairs of defective articles Determining the importance of a defect that has occurred based on the scale of the defect, such as the defect processing amount obtained by multiplying the cost and the estimated number of occurrence of the defect. By shortening the standard time, we will minimize the cost of defect handling. Further, the unpacking site selects the transportation means so as to minimize the distribution cost when replenishing the goods by predicting the inventory transition from the defect information acquisition to the defect countermeasure completion.
[Selection] Figure 1

Description

  The present invention relates to a defect processing analysis apparatus, a defect processing analysis method, and a defect processing analysis program, and in particular, a series of defect processing that obtains and analyzes information on defects occurring in articles, performs defect countermeasures, and performs expense settlement. The present invention relates to improvement of an apparatus, a method, and a program that are performed using a computer.

Conventionally, when a defect occurs in a product delivered to a customer, the following measures are taken. That is,
(1) The quality assurance department, which has received defect information from the customer, is responsible for the process that is expected to cause one or more defects based on the defect information (the “process” shown in the description is (For example, a department, a factory, a company, etc.) is sent fault information, and the cause of the fault is investigated and countermeasures are implemented.
(2) The process that receives the defect information investigates the cause of the defect while exchanging information with the customer and the contact department, and implements countermeasures.
(3) When the countermeasure for the cause of the defect is completed, the process that caused the defect reports a report summarizing the cause of the defect, the scope of the defect, and the countermeasure status to the counter department.
(4) The counter department explains the defect to the customer based on the report from the process that caused the defect.
(5) After that, the expense required for defect handling is settled through the accounting department.
That's it.

  The exchange of information related to malfunctions as described above is usually performed using a telephone, a fax, or the like, and is very inefficient.

  Therefore, a technique relating to a method and system for collecting information from a plurality of terminals connected to the Internet and analyzing the contents of defects has been devised. For example, Patent Document 1 below discloses an invention in which the occurrence of damage to automobiles or the like that occurs in the physical distribution process is obtained via the Internet, and the cause of the occurrence is quickly and accurately analyzed. According to such an invention, a logistics process in which it is important to grasp with higher accuracy visually by accumulating damage location information, other damage information (for example, the type and degree of damage), and logistics attribute information at the time of transportation. This makes it possible to quickly and accurately analyze the occurrence tendency and characteristics of the damage situation, damage location, etc.

  However, the visual information that the invention described in the following Patent Document 1 adopts with particular emphasis in actual article logistics is insufficient for analyzing article defects. For example, the causes of defects in automobile parts include not only surface flaws, chipping, and rust that can be visually detected, but also internal defects and distortions that are first discovered after being actually incorporated into a product. Such a defect is first clarified by a phenomenon such as generation of abnormal noise from the product or malfunction of the product.

  In order to minimize the occurrence of defects, early detection and countermeasures for defects are important. Until now, if a problem occurs, the process that caused the problem must bear the cost of handling the problem, so other processes (for example, the counter department, the inspection department, etc., and the delivery destination of goods) In all processes related to countermeasures against defects including customers, it was normal that the awareness of the parties would be low. For this reason, there has been a problem that sufficient information cannot be obtained from the customer, a delay in the inspection occurs in the inspection department, and a defective article flows out.

  In view of the above problems, the inventors created a new invention and filed an application of “Japanese Patent Application No. 2003-52768” (hereinafter referred to as “prior application invention”). The invention described in the invention of the prior application is capable of carrying out sufficient information transmission and prompt response in the event of a failure, and further providing a consciousness of the parties to all processes related to the failure response, It is possible to minimize the cost of handling defects. Specifically, the time required from the defect information acquisition to the completion of the defect countermeasure is calculated for each process, and the share cost for defect processing corresponding to the responsibility ratio is calculated. This calculation result makes it possible to clarify the location of responsibility, so that each process has a sense of ownership, and as a result, it is possible to minimize defective products and defect processing costs.

JP 2002-46823 A

  By the way, although the defect handling work has been greatly improved by the invention described in the invention of the prior application, the applicant has made further minimization of the defective product and the defect handling cost from the request for reduction of the distribution cost and the management cost in the industry. It was necessary to plan.

  Therefore, the inventor obtained the following knowledge by investigating and analyzing the work contents of the defect processing. In other words, in overseas logistics where it takes several weeks to several months from shipment to unpacking, if a continuous defect is discovered at the time of unpacking, it will be broken over a long period of time, including unpacked items and items in transit. There is a risk that the product continued to be shipped. In such a case, it is assumed that production must be stopped at overseas factories due to exhaustion of the inventory of goods. Therefore, if a defective article occurs, the scale of the defect is identified immediately and the addition of the article is performed. You will have to place an order.

  However, in the defect handling work so far, normally, the process that caused the defect has been performed in the order in which the defect information was received. Defect countermeasures by the defect generation process are tried to be carried out without delay within a preset standard time, but since there was no index indicating the scale and importance of defects when multiple defects occurred so far, Priority measures cannot be taken against more costly defects, and the true defect handling cost has not been minimized. In addition, since the scale of defects cannot be specified at the overseas factory side, there has been a situation in which additional items are ordered more than necessary using expensive transportation means such as airplanes, resulting in extra costs.

  Therefore, in the case where a failure occurs, the present invention clarifies the importance level and urgency level of the failure, and provides information such as the priority order for starting the failure to each process, thereby minimizing the cost of occurrence of the failure and the failure processing cost. It aims to make it easier.

  In addition, the present invention predicts the shortage time of goods by comparing defective product occurrence information with the consumption plan of goods in the process of unpacking goods at overseas factories, etc. Since the selection can be optimized, further cost savings can be realized.

  The defect processing analysis apparatus according to the present invention is obtained based on an article information acquisition unit that acquires article information including unique information of an article and defect information of a defect that has occurred in the article, and the same or similar defects that have occurred in the past. Standard time storage unit that stores the standard time for each process required from the acquisition of defect information to the completion of countermeasures, and the number of defects and normal number of items that have already been unpacked when a defect occurs in the shipped item By obtaining the defect occurrence rate from the number of defects acquired by the defect number acquisition unit and the number of defects of the article and the normal number acquired by the defect number acquisition unit, and by grasping the unpacked or in-transport quantity of the article A defect scale analysis unit that calculates a defect scale for the entire article, and a problem scale analysis unit that calculates the defect scale for the article based on the defect scale of the entire article calculated by the defect scale analysis unit. When the defect exceeds a predetermined threshold value which is predetermined as severity, characterized in that it comprises a critical defect countermeasure of shortening the time the standard time at a predetermined ratio.

  In addition, the defect processing analysis apparatus according to the present invention calculates the inventory transition of normal products from the day of defect occurrence of the article to the target date of completion of the defect countermeasure based on the standard time reduced, and the occurrence of a missing item. And an article replenishment ordering unit for selecting a transportation means for the article to be replenished so that the transportation cost is minimized based on the expected inventory quantity of the article.

  The defect processing analysis method according to the present invention is a method used when the management of the standard time for each process required from acquisition of defect information to completion of countermeasures is performed by a computer when a defect occurs in an article handled in the process. A step of storing article information including specific information of the article and defect information generated in the article in a storage unit, and countermeasures from acquisition of defect information obtained based on the same or similar defects that occurred in the past Searching the storage unit that stores the standard time for each process required to complete, extracting the corresponding standard time, and the number of defects of the article that has already been unpacked when a defect occurs in the shipped article The storage unit storing the normal number and the number of defects and the normal number of the article in which the defect has occurred, and the acquired number of defects of the article Calculating the defect occurrence rate from the normal number and searching the storage unit storing the unpacked or transported quantity of the article, and calculating the scale of the article A step of shortening the standard time by a predetermined ratio when a defect occurring in the article exceeds a predetermined threshold value determined in advance as an importance based on the overall defect scale It is characterized by performing.

  In addition, the defect processing analysis method according to the present invention calculates the inventory transition of normal products from the day of defect occurrence of the article to the target date of completion of defect countermeasures based on the standard time reduced, and the occurrence of a missing item. The method further comprises the step of selecting a transportation means of the article to be replenished so that the transportation cost is minimized based on the expected stock quantity of the article when the demand is predicted.

  The defect processing analysis program according to the present invention is a program for managing a standard time for each process required from acquisition of defect information to completion of countermeasure when a defect occurs in an article handled in the process, It is necessary to store the article information including the unique information of the article and the defect information generated in the article in the storage unit, and from the acquisition of the defect information obtained based on the same or similar defect that occurred in the past to the completion of the countermeasure. Searching the storage unit storing the standard time for each process and extracting the corresponding standard time, and when a defect occurs in the shipped item, the number of defects and normal number of the item already unpacked The storage unit storing the number of defects, the number of defects and the normal number of the article in which the defect has occurred, and the number of defects of the acquired article Calculating a failure occurrence rate from the constant and calculating a failure scale in the entire article by searching a storage unit storing the unpacked or transported quantity of the article; and the calculated entire article A step of shortening the standard time by a predetermined ratio when a defect occurring in the article exceeds a predetermined threshold value determined in advance as an importance based on the defect scale of It is made to perform.

  In addition, the defect processing analysis program according to the present invention calculates the inventory transition of normal products from the day of the defect occurrence to the target date for completion of the defect countermeasure based on the standard time reduced by the computer. The method further includes the step of selecting the transportation means of the article to be replenished so that the transportation cost is minimized based on the expected stock quantity of the article when the occurrence of the article is predicted.

  According to the present invention, it is possible to minimize the occurrence of troubles and trouble handling costs.

  Hereinafter, preferred embodiments of the present invention will be described with reference to the drawings. In the present embodiment, a part for assembling a vehicle as an article in which a problem has occurred is described as an example.

  FIG. 1 is a block configuration diagram illustrating an example of the defect processing analysis apparatus 10 according to the present embodiment. The defect processing analysis apparatus 10 according to this embodiment includes an intelligent database 20, a parts supplier information database 200, a quality defect information database 300, a report delay standard table 600, an accounting database 700, a shipping record information database 800, and a defect price database 900. , An importance determination table 1000 is provided. Further, the defect processing analysis apparatus 10 communicates with the unpacking base terminal 100, the parts manufacturer terminal 400, and the quality control section terminal 500 via the data communication network 50.

  The intelligent database 20 is a host computer that plays a central role in the failure processing analysis apparatus 10 according to the present embodiment, and exchanges information with each process. Regarding the exchange of information with each process, the contents, time, and the like are all stored in the intelligent database 20.

  The unpacking site side terminal 100 is a terminal installed at the unpacking site and is connected to the intelligent database 20 via the data communication network 50. This unpacking base terminal 100 has a user ID representing its own location. Therefore, when a user ID is specified from the intelligent database 20, it is possible to acquire defect information of parts from the unpacking base side terminal 100 corresponding to the user ID. In the unpacking site side terminal 100, information such as a defect management number, a shipment order, a part product number, a packaging factory, a defect classification code, a defect content, image data, audio data, and the like is registered as defect information of the part. It should be noted that these component defect information can be input on general-purpose word processor software or a WEB screen that the unpacking base terminal 100 has. Therefore, digital data such as image data and audio data can be transmitted as an attached file through an electric communication line.

  In the parts supplier information database 200, information on defects of parts that have occurred in the past and information on processes such as parts suppliers and parts manufacturers that have caused defects in the past are registered. Therefore, when the parts supplier information database 200 is searched from the intelligent database 20 using the part item number and defect content as key items, the defect information related to the same or similar defect that has occurred in the past, the component supplier that caused the problem, and the part The process of the manufacturer or the like can be referred to. Here, for example, when the part product number indicates the type of the part, the similar fault may be similar if a part of the part part number is identical, or the part part number is the same and the content of the fault It is good also as what is similar.

  In the quality defect information database 300, supplier information of parts is registered. The quality defect information database 300 is used to search for a process that causes the same defect when it is clear that the same defect has occurred in the past. In this case, the quality defect information database 300 can be searched from the intelligent database 20 using the part product number as a key item, and the parts supplier information can be acquired.

  The parts manufacturer side terminal 400 and the quality control section terminal 500 are terminals installed in the process of manufacturing and supplying parts, and are connected to the intelligent database 20 via the data communication network 50. These terminals 400 and 500 can perform information communication from the occurrence of a failure to a countermeasure completion report between the intelligent database 20 and the unpacking base side terminal 100.

  The report delay standard table 600 is a device that stores a standard time for each process required from acquisition of defect information to completion of countermeasures obtained based on the same or similar defects that occurred in the past. This standard time can be set very finely in each process. For example, a failure cause investigation time in a production factory, an investigation time in a quality inspection department, or the like is set. This standard time can be changed as appropriate depending on the production status and changes in process personnel allocation, etc., and can be automatically corrected based on past results, or a proper review time can be set to always set an appropriate time. It has become.

  The accounting database 700 is responsible for receiving defect handling costs charged by the local entity on the side of the unpacking site where a defect has been found and causing damage, and is responsible for reimbursing the defect handling costs to the local entity. . Regarding defect handling costs, rework costs at the unpacking site, additional parts costs, scrap costs, transportation costs, and other expenses are registered in detail.

  The shipment record information database 800 is a device that stores the shipment record of parts shipped so far. The shipment record information database 800 can be searched from the part manufacturer side terminal 400, the quality control section terminal 500, and the like via the intelligent database 20, for example, the shipment status of a part in which a defect has occurred. Information can be acquired by a part manufacturer or a contact department of a part manufacturing factory. In addition, the shipment result information includes the status of the shipment parts at the present time. Location information such as whether or not they are in stock at the unpacking base, or whether they are in transit, and unpacked / unopened Status information such as packing can be obtained.

  The defect price database 900 is a device that stores a part unit price for each part and a cost generated when the part is reworked or discarded. By referring to this defect price database 900, it is possible to calculate a loss cost when a defect occurs.

  For each part, a management group that is classified according to the severity of the required quality of the part, an amount that is a threshold for determining the importance, and whether or not it is a defect that has occurred continuously The minimum number of continuity determination is determined. The importance determination table 1000 is a device in which these data are stored. The management group may be set by, for example, a method of setting the strictest group for a functional component such as an engine.

  Next, the processing of the defect processing analysis apparatus according to the present embodiment will be specifically described with reference to the flowcharts shown in FIGS. 2 is connected to A in FIG. 3, and B in FIG. 3 is connected to B in FIG. That is, FIGS. 2 to 4 show a series of processing flows of the present embodiment.

Article information acquisition unit (step 100)
In the present embodiment, first, component information including specific information of a component for each user ID and defect information of a defect that has occurred in the component is acquired from the unpacking base terminal 100 (step 100). When a component failure occurs, component failure information is input to the unpacking base terminal 100 by the person in charge of the local business entity. This part defect information includes information such as shipment order, part number, packaging factory, defect classification code, defect content, image data, audio data, and the like. It should be noted that these component defect information can be input on general-purpose word processor software or a WEB screen that the unpacking base terminal 100 has. Therefore, digital data such as image data and audio data can be transmitted as an attached file through an electric communication line. The person in charge of the local entity transmits this information to the intelligent database 20 when the part defect information is input. In the intelligent database 20 that acquired the component defect information, the component defect information can be referred to using the user ID as a key item.

Countermeasure recording unit (steps 110 to 210)
In the intelligent database 20, when the component defect information is acquired from the unpacking base terminal 100, a defect management number and a reception time are assigned to the component defect information and stored in the intelligent database 20 (step). 110).

  Thereafter, the intelligent database 20 is searched for defect information of the same classification (step 120). When defect information of the same classification exists, the quality defect information database 300 is searched using the part product number as a key item, and a process that may have caused the defective part is determined based on the part supplier information ( Step 135). On the other hand, if there is no defect information of the same classification, the part supplier information database 200 is searched using the part item number and the defect content as key items to acquire past similar defects and past part supplier information. This process is determined as a process in which a defective part may have occurred (step 130). If there is no similar defect in the past, all processes related to the production of the target part are targeted.

  As described above, the part defect information is transmitted from the intelligent database 20 in the process determined to have the possibility of causing the defect (step 140). Moreover, the intelligent database 20 memorize | stores the date which transmitted component malfunction information (step 150).

  Subsequently, in the process of receiving the part defect information, if it is determined that the actual part sending of the defective part and / or additional information is necessary for the cause investigation (step 160), the actual part sending and / or via the data communication network 50 is performed. Alternatively, a request for sending additional information is transmitted to the intelligent database 20 (step 170). Upon receiving the request for sending the actual product and / or sending additional information, the intelligent database 20 requests the unpacking base terminal 100 to send the actual product and / or sending additional information. At this time, the date when the sending request is made is stored (step 180). Upon receipt of the actual product and / or additional information from the local entity at the unpacking site, the intelligent database 20 stores the date (step 190) and requests the actual product and / or additional information to be sent. Send actual product and / or additional information to the process. In the process of receiving the actual product and / or the additional information, the date of receipt is stored in the intelligent database 20 via the data communication network 50 (step 200).

  The process of finding the cause and taking countermeasures through such exchange of information will report the result of the component failure investigation. In this case, the user ID and defect classification code from the process side terminals 400 and 500 are set as major items, and the cause analysis result, the time required for analysis, the defect report, the input level of the local reporter, etc. are stored in the intelligent database 20. It will be transmitted (step 210). The intelligent database 20 that has acquired this information calculates the responsibility ratio of the component defect based on the actual time taken from the acquisition of the defect information in each process stored so far until the completion of the countermeasure for the defect. (Step 210).

Standard time storage unit (step 220)
Next, a standard time for each process required from the acquisition of defect information to the completion of the countermeasure, which is obtained based on the same or similar defects that occurred in the past, is acquired (step 220). To obtain the standard time, the report delay standard table 600 in which the standard time for each process that has been involved in countermeasures for the trouble is registered is searched. In the report delay standard table 600, for example, trouble cause investigation time at the production factory, investigation time at the quality inspection department, and the like are set.

Defect number acquisition unit (step 230)
At the unpacking base, parts necessary for production are unpacked every day in the order of container arrival. When a defective part is found, the unpacking base at the unpacking base-side terminal 100 counts the number of parts defective on the day, parts. The normal number, shipping order, etc. are registered for each defect management number (step 230). It should be noted that information such as the number of defective parts, the number of normal parts, and the shipping order of the day input to the unpacking base terminal 100 is stored in the quality defect information database 300 and added to the information before the previous day.

Failure scale analysis unit (steps 240 to 290)
In the process that caused the defect, the quality defect information database 300 is referred to via the intelligent database 20 from the part manufacturer side terminal 400, the quality control section terminal 500, etc., and the number of part defects, the number of normal parts, etc. Is acquired (step 240). Further, the shipment manufacturer information terminal 800, the quality control section terminal 500, etc. are referred to the shipment performance information database 800 via the intelligent database 20, and the number of unpacked parts and parts being transported is acquired (step 250). ). This information can be obtained from the difference between the unpacked shipping order and the shipping order shipped up to that day, and it is possible to acquire the number of parts that have not been unpacked and in transit or the total quantity shipped. It is.

  Next, a component failure rate is calculated from the information obtained above (step 260), and the number of predicted component failures not yet unpacked / transported and the number of predicted component normalities are calculated (step 270). The component failure rate can be obtained from the proportion of the number of component failures in the unpacked shipping order. Then, by multiplying the component failure rate by the number of unopened / transported components, the predicted number of component failures not yet unpacked / transported and the predicted number of normal components can be calculated. Further, the failure prediction cost can be calculated by multiplying these results by the failure unit price of the part obtained by referring to the failure price database 900 (step 280).

  On the other hand, the actual number of defective parts is calculated by adding the number of defective parts on the current day and the previous day obtained in step 230 and step 240 (step 275), and further, the actual defect cost is calculated (step 285). If there is an actual value, the actual value of the defect is used. If there is no actual value at the present time, refer to the defect price database 900 to obtain the defect unit price of the part, and multiply the defect number actual result and the defect unit price. You may employ | adopt the value calculated | required by this.

  By adding the estimated defect cost and the actual defect cost obtained by the above processing steps, the estimated total defect cost is calculated (step 290).

Critical defect countermeasure section (steps 300 to 305)
Subsequently, it is determined whether or not the component defect is of high importance based on the estimated total defect cost calculated by the defect scale analysis unit (step 300). Such a determination is made by referring to the importance determination table 1000.

  In the importance level judgment table 1000, a management group classified according to the severity of the required quality of the part, an amount serving as a threshold value for the importance level judgment, and whether or not a defect has occurred continuously are determined. And the minimum number of continuity determinations to be stored. The management group, amount, and minimum continuity determination number are determined in advance for each part.

  For example, a functional part such as an engine has a strict threshold amount for a defect classification code related to quality such as abnormal noise or vibration, and an internal part has a strict threshold amount for a defect classification code such as dirt. It is preferable to change the weighting of importance for each part. In addition, with regard to important parts and expensive parts, by setting the minimum number of continuity judgments to be small, it is possible to position them as important problems even with a small defect scale.

  It should be noted that, depending on the occurrence of daily defects, the importance level is initially the normal rank, but there may be a case where the importance level is promoted to the important rank from a certain day. On the other hand, although the degree of importance may be demoted, in this embodiment, the importance rank is not dropped because there is a risk of confusion among the parties involved in each process. However, the present invention is not limited to this method.

  As a result of the determination steps described above, when the intelligent database 20 determines that the failure of the part that has occurred this time is an important failure, the standard time required to complete the countermeasure obtained by referring to the report delay table 600 is shortened by a predetermined rate. (Step 305). For example, when the initial standard required time is 10 days, the required time may be 7 days by uniformly reducing the time by 30%. When the importance rank of a defective part is promoted and the standard required time is shortened, the intelligent database 20 automatically sends an email to the person in charge of each process or the manager of the management department until the countermeasure is completed. Notify that the target time has been shortened.

  In addition, continuous defects will continue to occur until the countermeasures are completed, so the number of defective parts that will occur between the current day and the scheduled date for completion of the countermeasures is predicted, and the time is taken into account. It is also preferable to determine the rate of shortening. In addition, with regard to the importance rank, a plurality of ranks can be set.

Parts replenishment ordering section (steps 310 to 335)
On the unpacking site side, the part with the defect is basically discarded, so an additional order is made to supplement the replacement part. Here, in overseas logistics, if a shipping service with a low fare is used, a transportation system for one month to several months after ordering is required, which may affect production. In such a case, an air mail that can be replenished with additional parts in a few days is used, but in this case, a fare that is approximately 10 times that of the shipping service is required. turn into.

  Therefore, the parts replenishment ordering unit according to this processing step performs a process for minimizing the cost required for replenishing defective parts.

  The unpacking base terminal 100 has already acquired the actual number of defects and the predicted number of parts defects by referring to the intelligent database 20. In addition, since the quantity of defective parts that may occur between the current day and the planned date of completion of the countermeasure can be predicted, the unpacking base terminal 100 can obtain the quantity of parts to be additionally ordered.

  On the other hand, similarly, it is also possible to obtain the number of normal parts that have been unpacked, the normal number of parts that have not been unpacked / transported, and the expected number of normal parts to be used until the planned date of completion.

  Based on the results obtained above, the estimated consumption of parts and the availability of normal parts obtained from the production plan after that day are estimated from the expected acquisition of parts, that is, the inventory of normal parts to the countermeasure target date (step 310). If the inventory quantity of parts does not fall below a predetermined standard, it is determined that no shortage will occur, and all additional ordered parts will be arranged by shipping service (steps 320 and 330). On the other hand, when the inventory quantity of the parts falls below the predetermined standard, it is determined that the air mail is necessary, and the air mail is arranged (step 320, step 335). However, since orders placed by air mail should be minimized, for example, if the order unit is “box”, the order for the above shortage is determined by transferring from air mail to air mail in order starting from one box. The calculation (step 320) is repeated until a result is obtained that the inventory quantity of the part does not fall below a predetermined standard. By doing in this way, it becomes possible to suppress the cost concerning a countermeasure against malfunction to the minimum.

Expansion cost calculation unit (steps 340 to 370)
When the investigation of the cause of the defect and the countermeasure are completed, the local entity of the unpacking base makes a claim for the defect processing cost to the accounting database 700 (step 340). The accounting database 700 that has received the request for the defect processing cost settles the defect processing cost including the parts shipping cost and the cost at the shipping base (step 350). Thereafter, it is determined whether the current failure is a continuous failure or a sudden failure (step 360). This determination is performed based on the defect information of the parts acquired by the intelligent database 20 and the defect report of the defect cause process. As a method of verifying whether the occurrence has been continuous or sudden, the number of occurrences of the failure can be used as a determination condition. For example, a defect that has never occurred within a certain period can be determined to be a sudden occurrence. In this case, it is processed as a sudden abnormality, and the sharing of the defect processing cost is not performed. On the other hand, a failure that has occurred more than once or continuously within a certain period of time is determined to be a chronic failure, and sharing of the failure processing cost will be considered.

  If it is determined that the generated defects are continuous, the defect processing cost increased based on the defects expanded due to the countermeasure delay is calculated as the expansion cost (step 370).

Responsibility analysis unit (steps 380 to 395)
Subsequently, based on the actual time required for each process and the standard time corresponding to the process, the responsibility ratio for each process for the failure expanded by the countermeasure delay is analyzed. First, the delay time for each process is calculated by subtracting the standard time corresponding to that process from the actual time required for each process (step 380). It is determined whether or not adjustment is necessary for the calculation result (step 390). If adjustment is required, adjustment is performed according to individual circumstances (step 395). With this individual circumstance, it is possible to set conditions in advance, for example, taking into account natural disasters such as water damage caused by typhoons.

  By performing such processing, it is possible to clarify the responsibility ratio due to countermeasure delay for each process. For example, the responsibility ratio of the local entity at the unpacking base is 10%, the responsibility ratio of the cause process is 15%, and the responsibility ratio of the quality inspection process is 5%.

Sharing cost calculation unit (step 400)
Finally, the sharing cost for each process is calculated based on the responsibility rate analyzed in the above-described responsibility rate analysis unit (steps 380 to 395) and the defect processing cost calculated in the expansion cost calculation unit (steps 340 to 370). In addition, a sharing cost is charged for each process (step 400).

  The above processing classifies the responsibility for the local business unit at the unpacking site, the responsibility for the reception side, and the responsibility for the occurrence of the failure among the time taken from the discovery of the defective part to the failure analysis for each defect item. In addition, there is a fixed reporting delay allowance frame called standard time that takes into account the transportation system, etc. for each defect item, and the standard time from the occurrence of the defect to the completion of the countermeasure is exceeded for the part exceeding that allowance frame The responsibility ratio is weighted and calculated so that extra trouble costs are paid for each delayed process. By adopting the defect processing analysis apparatus and method according to the present embodiment, it is possible to clarify the location of responsibility, so that a sense of ownership develops in each process, resulting in minimization of defective products and defect processing costs. It is possible to plan.

  In the present embodiment, the article information acquisition unit, countermeasure recording unit, standard time storage unit, defect number acquisition unit, defect scale analysis unit, important defect countermeasure unit, parts replenishment ordering unit, expansion cost calculation unit, responsibility ratio analysis unit Although the case where an individual storage unit called a shared cost calculation unit is provided in the intelligent database 20 is illustrated, it is also possible to provide the same storage unit and perform the same function. Needless to say, the failure processing analysis method according to the present embodiment may be implemented in cooperation with birdware or as software.

  As described above, according to this embodiment, the number of parts in which a defect has occurred every day is obtained, and the contents are presented with an index such as “amount” for the process of implementing the countermeasure against the defect. Loss costs are visualized, awareness of failure prevention and early resolution is performed. In addition, for important defects, the target date for completion of defect countermeasures is shortened, so that it is possible to minimize the defect processing cost. Furthermore, for the replenishment of parts that have failed, it is possible to predict the inventory transition and select the means of transportation so that the minimum logistics cost is achieved, so that it is possible to minimize the cost of trouble handling. .

It is the block block diagram which showed one Example in the malfunction processing analyzer which concerns on this embodiment. It is a flowchart which shows the process of the malfunction processing analyzer which concerns on this embodiment. It is a flowchart which shows the process of the malfunction processing analyzer which concerns on this embodiment. It is a flowchart which shows the process of the malfunction processing analyzer which concerns on this embodiment.

Explanation of symbols

  DESCRIPTION OF SYMBOLS 10 Defect processing analyzer, 20 Intelligent database, 50 Data communication network, 100 Unpacking base side terminal, 200 Parts supplier information database, 300 Quality defect information database, 400 Parts manufacturer side terminal, 500 Quality control section terminal, 600 report delay standard table, 700 accounting database, 800 shipment record information database, 900 defect price database, 1000 importance determination table.

Claims (6)

An article information acquisition unit that acquires article information including unique information of the article and defect information of a defect that has occurred in the article;
A standard time storage unit for storing a standard time for each process required from acquisition of defect information to completion of countermeasures obtained based on the same or similar defects occurring in the past;
When a defect occurs in the shipped item, a defect number acquisition unit that acquires the number of defects and the normal number of the item that has already been unpacked;
Calculate the defect scale for the entire article by obtaining the defect occurrence rate from the defect number and normal number of the article acquired in the defect number acquisition unit and grasping the unpacked or in-transport quantity of the article. Fault scale analysis department to
Based on the defect scale of the entire article calculated by the defect scale analysis unit, the standard time is set to a predetermined ratio when a defect occurring in the article exceeds a predetermined threshold value determined in advance as an importance level. With the important defect countermeasures department that saves time,
A failure processing analysis apparatus comprising: In the trouble processing analyzer according to claim 1,
Based on the standard time shortened, calculate the inventory transition of normal products from the date of defect occurrence to the target date for completion of defect countermeasures, and the expected inventory quantity of the item when a shortage is predicted And an article replenishment ordering unit for selecting a transportation means for the articles to be replenished so as to minimize the transportation cost. When a defect occurs in an article handled in a process, a defect processing analysis method used when managing the standard time for each process required from acquisition of defect information to completion of the countermeasure by a computer,
Storing article information including unique information of the article and defect information generated in the article in a storage unit;
Searching the storage unit storing the standard time for each process required from the acquisition of defect information to the completion of countermeasures obtained based on the same or similar defects that occurred in the past, and extracting the corresponding standard time;
When a defect occurs in a shipped item, the storage unit storing the number of defects and normal number of the unpacked item is searched to obtain the number of defects and normal number of the item in which the defect has occurred. And steps to
Calculate the defect occurrence rate from the acquired number of defects and normal number of the article, and calculate the scale of the defect for the entire article by searching the storage unit that stores the unpacked or transported quantity of the article. And steps to
A step of reducing the standard time by a predetermined ratio when a defect occurring in the article exceeds a predetermined threshold value determined in advance as an importance based on the calculated defect scale of the entire article. When,
A defect processing analysis method characterized by executing a process including: In the defect processing analysis method according to claim 3,
Based on the standard time shortened, calculate the inventory transition of normal products from the date of defect occurrence to the target date for completion of defect countermeasures, and the expected inventory quantity of the item when a shortage is predicted And a step of selecting a transportation means for the articles to be replenished so as to minimize the transportation cost based on the above. A defect processing analysis program that manages the standard time for each process required from the acquisition of defect information to the completion of countermeasures when a defect occurs in an article handled in the process,
On the computer,
Storing article information including unique information of the article and defect information generated in the article in a storage unit;
Searching the storage unit storing the standard time for each process required from the acquisition of defect information to the completion of countermeasures obtained based on the same or similar defects that occurred in the past, and extracting the corresponding standard time;
When a defect occurs in a shipped item, the storage unit storing the number of defects and normal number of the unpacked item is searched to obtain the number of defects and normal number of the item in which the defect has occurred. And steps to
Calculate the defect occurrence rate from the acquired number of defects and normal number of the article, and calculate the scale of the defect for the entire article by searching the storage unit that stores the unpacked or transported quantity of the article. And steps to
A step of reducing the standard time by a predetermined ratio when a defect occurring in the article exceeds a predetermined threshold value determined in advance as an importance based on the calculated defect scale of the entire article. When,
A defect processing analysis program characterized by causing a process including In the defect processing analysis program according to claim 5,
On the computer,
Based on the standard time shortened, calculate the inventory transition of normal products from the date of defect occurrence to the target date for completion of defect countermeasures, and the expected inventory quantity of the item when a shortage is predicted A failure processing analysis program characterized by further causing a step of selecting a transportation means of articles to be replenished so as to minimize the transportation cost based on the above.

Images