INFORMATION MANAGEMENT SYSTEM AND INFORMATION MANAGEMENT METHOD

An information management method includes acquiring a component serial number identifying an individual of a target component used in each process and a unit serial number (or a product serial number) identifying an individual of an intermediate product (or a product) manufactured by the process according to work order of the process. The information management method includes registering the component serial number in a hierarchy of the target component in the acquired order in a BOM database, and registering the unit serial number (or the product serial number) in a hierarchy of the process in the acquired order in a BOP database.

CROSS REFERENCE TO RELATED APPLICATIONS

This nonprovisional application is based on Japanese Patent Application No.

2022-083558 filed on May 23, 2022, with the Japan Patent Office, the entire contents of which are hereby incorporated by reference.

BACKGROUND OF THE INVENTION

Field of the Invention

The present disclosure relates to an information management system and an information management method.

Description of the Background Art

Conventionally, a bill of material (BOM), a bill of process (BOP), and the like are used for product production management. For example, Japanese Patent Laying-Open No. 2018-36899 discloses a system that supports editing of the BOM.

SUMMARY OF THE INVENTION

In general, data regarding quality of an individual is accumulated for each individual of a product or an intermediate product. The data regarding the quality is accumulated in a database different from the BOM and the BOP. For example, the BOM, the BOP, and the data regarding the quality may be utilized for investigation of a defect cause of the product. However, the BOM, the BOP, and the data regarding the quality are distributed but not cooperated. Therefore, there is a problem that it is difficult to investigate the defect cause of the product.

The present disclosure has been made in view of the above problems, and an object of the present disclosure is to provide an information management system and an information management method capable of easily investigating the defect cause of the product.

According to an example of the present disclosure, an information management system includes a BOM database, a BOP database, a quality database, an acquisition section, and a registration section. The BOM database indicates a hierarchical structure of at least one component constituting a product. The BOP database indicates a hierarchical structure of at least one process producing the product. The quality database associates first identification information identifying an individual of an intermediate product or the product manufactured by the process with a quality data set regarding quality of the individual for each of the at least one process. The acquisition section acquires second identification information identifying an individual of a target component used in the process in the at least one component, and the first identification information corresponding to the intermediate product or the product manufactured in the process according to work order of the process from each of the at least one process. The registration section registers the second identification information in a hierarchy of the target component of the BOM database in the order acquired by the acquisition section in response to the acquisition of the second identification information from each of the at least one process. The registration section registers the first identification information in a hierarchy of the process of the BOP database in the order acquired by the acquisition section in response to the acquisition of the first identification information from each of the at least one process.

According to this disclosure, the first identification information and the second identification information are acquired according to the work order of the process. Then, the first identification information and the second identification information are registered in the BOP database and the BOM database in the acquired order. Consequently, the user checks the registration order of the first identification information and the second identification information in the BOP database and the BOM database, thereby easily specifying the intermediate product and the component constituting the target individual of the product. Furthermore, the user can specify a quality data set regarding the quality of each individual of the product or the intermediate product based on the quality database. Consequently, the user can use the first identification information of a defective individual as a key to specify the quality of the individual, the quality of the intermediate product constituting the individual, an individual of the component constituting the individual, and the like. Thus, the user can easily investigate the defect cause of the product.

In the above disclosure, the information management system further includes a search section configured to search the second identification information of each individual of the at least one component constituting a target individual of the product using the BOM database and the BOP database.

According to this disclosure, the user can easily specify the individual of the component constituting the defective individual by checking a search result by the search section.

In the above disclosure, the BOM database includes supply source data that associates the second identification information of the individual with third identification information identifying a supply source of the individual for each individual of at least one component. The information management system further includes an inquiry section configured to specify third identification information corresponding to the second identification information searched by the search section based on the BOM database, and transmit inquiry about quality of the individual indicated by the second identification information searched by the search section to a supply source indicated by the specified third identification information.

According to this disclosure, the user can easily check the quality of the individual of the component constituting a defective product.

In the above disclosure, the quality data set includes item data indicating each of a plurality of items. The information management system further includes: a provision permission database configured to indicate provision permission of each of the plurality of items to a supply destination of the product; and an answer section configured to generate answer information in response to receiving an inquiry about the quality of the target individual of the product from the supply destination, and transmit the generated answer information to the supply destination. The answer section reads the quality data set of the target individual from the quality database, and specifies at least one item permitted to be provided, based on the provision permission database. The answer section extracts item data corresponding to each of the at least one specified item from the read quality data set, and includes the extracted item data in the answer information.

According to this disclosure, the answer information including the item data corresponding to the item permitted to be provided can be immediately answered.

According to another example of the present disclosure, an information management method uses a BOM database, a BOP database, and a quality database. The BOM database indicates a hierarchical structure of at least one component constituting a product. The BOP database indicates a hierarchical structure of at least one process producing the product. The quality database associates first identification information identifying an individual of an intermediate product or the product manufactured by the process with a quality data set regarding quality of the individual for each of the at least one process. The information management method includes first to third steps. In the first step, second identification information identifying an individual of a target component used in the process in at least one component and first identification information corresponding to an intermediate product or a product manufactured in the process are acquired according to work order of the process from each of at least one process. In the second step, the second identification information is registered in a hierarchy of the target component of the BOM database in the acquired order in response to the acquisition of the second identification information from each of the at least one process. In the third step, the first identification information is registered in the hierarchy of the process of the BOP database in the acquired order in response to the acquisition of the first identification information from each of at least one process. This disclosure also allows the user to easily investigate the defect cause of the product.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

With reference to the drawings, an embodiment of the present invention will be described in detail. The same or equivalent portion in the drawings is denoted by the same reference numeral, and the description will not be repeated. The following modifications described below may selectively be combined as appropriate.

FIG.1is a view illustrating an outline of an information management method according to an embodiment. As illustrated inFIG.1, in the information management method, information regarding production of a company2is managed using a BOM database51, a BOP database52, and a quality database60.

BOM database51indicates a hierarchical structure (tree structure) of at least one component constituting a product produced in company2. BOP database52indicates a hierarchical structure of at least one process producing the product.

Quality database60associates first identification information identifying an individual of the product or an intermediate product produced in company2with a quality data set regarding quality of the individual. The intermediate product includes a unit constituting the product. Hereinafter, it is assumed that a “unit serial number” is used as the first identification information identifying the individual of the intermediate product, and a “product serial number” is used as the first identification information identifying the individual of the product.

The quality data set indicates information about the quality of the individual of the product or the intermediate product, and includes data indicating directly the quality, and data indicating information indirectly regarding the quality of the product or the intermediate product. For example, the data directly indicating the quality of the product or the intermediate product includes inspection data indicating the quality of processing and data indicating a characteristic (a dimension, an electrical property, and the like) of the product or the intermediate product. For example, the data indicating the information indirectly regarding the quality of the product or the intermediate product includes facility data in a factory, history data of processing and assembling work, worker data indicating a worker name, a time stamp (a work start time stamp, a work end time stamp, and the like), processing method data, data indicating a material, and processing condition data.

The information management method includes following steps (1) to (3) in order to cooperate BOM database51, BOP database52, and quality database60.

Step (1): From each of at least one process of company2, second identification information identifying the individual of a target component used in the process and the unit serial number (or the product serial number) identifying the individual of the intermediate product (or the product) manufactured in the process are acquired according to work order of the process. Hereinafter, it is assumed that a “component serial number” is used as the second identification information.

Step (2): In response to acquisition of the component serial number from each of at least one process of company2, the component serial number is registered in the hierarchy of target components in the order of acquisition in BOM database51.

Step (3): In response to acquisition of the unit serial number (or the product serial number) from each of at least one process of company2, the unit serial number (or the product serial number) is registered in the hierarchy of the process in the order of acquisition in BOP database52.

In the example ofFIG.1, a component serial number “HA4354” of a target component “housing” used in a “housing unit assembling process” is acquired from the “housing unit assembling process”. Accordingly, in step (2), the component serial number “HA4354” is registered in the hierarchy of the component “housing” in BOM database51. Furthermore, a unit serial number “000003” is acquired from the “housing unit assembling process”. Accordingly, in step (3), the unit serial number “000003” is registered in the hierarchy of the “housing unit assembling process” in BOP database52.

Furthermore, in the example ofFIG.1, thereafter, a product serial number “MA0003” is acquired from a “motor assembling process”. In response, in step (3), a product serial number “MA00003” is registered in the hierarchy of the “motor assembling process” in BOP database52.

In step (1), the unit serial number (or the product serial number) and the component serial number are acquired according to the work order of the process. Furthermore, in steps (2), (3), the unit serial number (or the product serial number) and the component serial number are registered in BOP database52and the BOM database51, in the acquired order. Consequently, when the registration order of the unit serial number, the product serial number, and the component serial number is checked in BOP database52and BOM database51, the intermediate product and the component constituting the target individual of the product can be easily specified.

For example, the user can easily specify that the product with the product serial number “MA00003” registered third in BOP database52is manufactured from the intermediate product having the unit serial number “000003” registered third in BOP database52. Similarly, the user can easily specify that the intermediate product having the unit serial number “000003” includes the component having the component serial number “HA4354” registered third in BOM database51.

Furthermore, the user can specify a quality data set regarding the quality of each individual of the product or the intermediate product based on quality database60.

Accordingly, the user can use the product serial number of a defective individual as a key to specify the quality of the individual, the quality of the intermediate product constituting the individual, the individual of the component constituting the individual, and the like. Thus, the user can easily investigate the defect cause of the product.

FIG.2is a view illustrating a conventional system utilized to investigate a cause of a product defect. As illustrated inFIG.2, the company includes an enterprise resource planning (ERP) system3, a manufacturing execution system (MES)4, and a manufacturing management system5as a product production management system. Further, the company has a database group950including a BOM database, a BOP database, and a bill of equipment (BOE) database, and a quality database960indicating the quality of the product.

ERP system3monitors a production plan of management and component procurement along the production plan. The component is specified from the BOM database. ERP system3designates a component number, a delivery date, and a quantity to a supplier of the component, and orders the component.

MES4manages information required for a production operation of a factory such as a production schedule, a preparation, quality, a component stock, a product stock, maintenance, and a facility according to the production plan managed by ERP system3, and generates a production instruction based on these pieces of information. IVIES4manages these pieces of information using the BOP database and the BOE database.

Manufacturing management system5controls a processing assembly line, a process, and a facility using a programmable logic controller (PLC), a sensor device, and the like in accordance with the production instruction from IVIES4. In addition, a work instruction document required for manufacturing the product is produced using the BOM database and the BOP database and distributed to the worker.

Quality database960indicates facility data in the factory, a history of processing and assembling work, a time stamp, processing data, inspection data such as the quality of the product, the serial number, a lot number, and the like. These pieces of information are acquired from the facility, the worker, the PLC constituting manufacturing management system5, and the sensor device.

As illustrated inFIG.2, database group950including the BOM database, the BOP database, and the BOE database is not cooperated with quality database960indicating the quality of the product. That is, division of the information is generated. For this reason, it takes time and effort to investigate the defect cause.

<Overall Configuration of Information Management System>

FIG.3is a view illustrating a configuration example of an information management system of the embodiment. As illustrated inFIG.3, an information providing system8includes an information management system for each company. Information providing system8inFIG.3includes information management systems1A,1B, . . . . Information management systems1A,1B, . . . provide information to each other through the Internet. Hereinafter, when information management systems1A,1B, . . . are not particularly distinguished, each of information management systems1A,1B, . . . is referred to as an “information management system1”.

Information management system1A is disposed in a manufacturer that manufactures a product6A. Information management system1B is disposed in a component supplier that manufactures a product6B. Product6B is used as a component of product6A, and is delivered to the manufacturer in which information management system1A is disposed. Information providing system8can further include, in addition to information management systems1A,1B, information management system1disposed in another component supplier that supplies a component of product6A.

Information management system1of each company includes a server that manages information regarding a product produced by the company, and a manufacturing controller that controls production of the manufacturing. That is, information management system1A includes a server100A that manages the information regarding product6A and a manufacturing controller200A that controls the production of product6A. Information management system1B includes a server100B that manages the information about product6B and a manufacturing controller200B that controls the production of product6B. Hereinafter, in a case where servers100A,100B, . . . are not particularly distinguished, each of servers100A,100B, . . . is referred to as a “server100”. When manufacturing controllers200A,200B, . . . are not particularly distinguished, each of manufacturing controllers200A,200B, . . . is referred to as a “manufacturing controller200”. For example, servers100A,100B, . . . can communicate with each other through the Internet. For example, manufacturing controller200is implemented by the PLC.

<Hardware Configuration of Server>

FIG.4is a schematic diagram illustrating an example of a hardware configuration of a server of the embodiment. As illustrated inFIG.4, server100typically has a structure according to a general-purpose computer architecture. Specifically, server100includes a processor101such as a central processing unit (CPU) or a micro-processing unit (MPU), a memory102, a storage103, a display controller104, an input interface105, and a communication interface106. These units are data-communicably connected to each other through a bus.

Processor101expands various programs stored in storage103on memory102, and executes the programs, thereby implementing various pieces of processing of the embodiment.

Memory102is typically a volatile storage device such as a dynamic random access memory (DRAM), and stores the program and the like read from storage103.

Storage103is typically a non-volatile magnetic storage device such as a hard disk drive. Storage103stores a management program130executed by processor101. Management program130to be installed in storage103is distributed while stored in a memory card or the like.

Display controller104is connected to a display device140, and outputs a signal displaying various pieces of information to display device140according to an internal command from processor101.

Input interface105serves as an interface for data transmission between processor101and an input device150such as a keyboard, a mouse, a touch panel, or a dedicated console. That is, input interface105receives an operation instruction given by the user operating input device150.

Communication interface106serves as an interface for data transmission between processor101and an external device (for example, manufacturing controller200and another server100). Management program130to be stored in storage103may be downloaded from a distribution server or the like through communication interface106.

When the computer having the structure following the general-purpose computer architecture is used, an operating system (OS) providing a basic function of the computer may be installed in addition to the application providing the function of the embodiment. In this case, the program of the embodiment may call a required module in a predetermined order and timing in program modules provided as a part of the OS to execute processing. That is, the program itself of the embodiment does not include the module as described above, and sometimes the processing is executed in cooperation with the OS.

Alternatively, some or all of the functions provided by the execution of management program130may be implemented as a dedicated hardware circuit.

<Hardware Configuration of Manufacturing Controller>

FIG.5is a block diagram illustrating a hardware configuration example of a manufacturing controller of the embodiment. As illustrated inFIG.5, manufacturing controller200includes a processor201such as a CPU or an MPU, a chip set202, a main memory203, a storage204, a control system network controller205, an information system network controller206, and a memory card interface208.

Processor201reads various programs stored in storage204, expands the various programs in main memory203, and executes the various programs, thereby implementing a control arithmetic operation controlling a control target. Chip set202controls the data transmission and the like between processor201and each component.

Storage204stores a system program210that implements basic processing and a user program211that implements the control arithmetic operation.

Control system network controller205controls data exchange with the control target through a control system network.

Information system network controller206controls the data exchange with external devices (including server100) through an information system network.

Memory card interface208is configured such that a memory card220is detachable, and can write data to memory card220and read various data (such as a user program) from memory card220.

Although the configuration example in which the required function is provided by processor201executing the program has been illustrated inFIG.5, some or all of these provided functions may be mounted using the dedicated hardware circuit (for example, the ASIC or the FPGA). In addition, a main part of manufacturing controller200may be implemented using hardware (for example, an industrial personal computer based on a general-purpose personal computer) according to a general-purpose architecture. In this case, the plurality of OSs having different uses may be executed in parallel using a virtualization technology, and the required application may be executed on each OS.

<Functional Configuration of Information Management System>

FIG.6is a view illustrating an example of a functional configuration of an information management system1A.FIG.7is a view illustrating an example of a functional configuration of an information management system1B.

The control target of manufacturing controller200A inFIG.6includes a plurality of processes manufacturing a motor as product6A (seeFIG.3). The motor is manufactured by combining a housing unit, an end cap unit, and a rotor unit. Accordingly, the control target of manufacturing controller200A includes a housing unit assembling process301, an end cap unit assembling process302, a rotor unit assembling process303, a motor assembling process304, and a motor inspection process305.

A code reader401and a laser marker411are provided in housing unit assembling process301. A code reader402and a laser marker412are provided in end cap unit assembling process302. A code reader403and a laser marker413are provided in rotor unit assembling process303. A code reader404and a laser marker414are provided in motor assembling process304. A code reader405is provided in motor inspection process305.

Each of code readers401to405reads a QR code (registered trademark) of a component, an intermediate product, or a product that has been conveyed to a corresponding process. The QR code indicates a serial number that identifies the component, the intermediate product, or the product. For example, code reader401reads the QR code marked on the housing conveyed to housing unit assembling process301, and outputs the component serial number indicated by the read QR code. Code reader405reads the QR code marked on the motor conveyed to motor inspection process305, and outputs the product serial number indicated by the read QR code.

Laser markers411to414mark the intermediate product or the product to be output from the corresponding process with the QR code (registered trademark). The QR code indicates a serial number identifying the intermediate product or the product. The QR codes marked by laser marker411to414are uniquely designated by manufacturing controller200A or the facility installed in the corresponding process. For example, laser marker414marks the product serial number on the motor manufactured by motor assembling process304.

Manufacturing controller200A includes an IO processing section21A that performs data input and output processing with the facility installed in the process. Processor201(seeFIG.5) included in manufacturing controller200A executes user program211, thereby implementing IO processing section21A.

For example, IO processing section21A outputs data indicating an operation instruction, data indicating the QR code to be marked on the intermediate product or the product, and the like to the facility installed in each process.

IO processing section21A acquires at least one item data regarding the quality of the intermediate product or the product manufactured by each process from each process. The item data indicates a value, a content, and the like of the item regarding the quality. The serial number (the unit serial number or the product serial number) of the corresponding individual is added to the at least one item data. For example, IO processing section21A receives data (time stamp) indicating the time when code reader401to405read the QR code, data indicating a processing condition, data indicating a processing method, and data indicating the quality as item data.

Furthermore, IO processing section21A operates as an acquisition section that acquires the component serial number identifying the individual of the component used in the process and the unit serial number (or the product serial number) identifying the individual of the intermediate product or the product manufactured in the process according to the work order of the process from each process. Specifically, every time the code reader installed in each process reads the QR code of the component, IO processing section21A acquires the component serial number indicated by the QR code. Each time the laser marker installed in each process marks the QR code on the intermediate product or the product, IO processing section21A acquires the unit serial number or the product serial number indicated by the QR code.

For example, every time the individual of the housing unit is manufactured by housing unit assembling process301, IO processing section21A acquires the component serial number identifying the individual of the component used for the individual of the housing unit and the unit serial number identifying the individual of the housing unit from housing unit assembling process301. In addition, IO processing section21A acquires the product serial number marked on the individual of the motor from motor assembling process304each time the individual of the motor is manufactured.

The control target of manufacturing controller200B inFIG.7includes a plurality of processes manufacturing the housing as product6B (seeFIG.3). The housing is used as the component of the motor that is product6A. Specifically, the control target of manufacturing controller200B includes a sheet metal press punching process306, a housing molding process307, and a housing inspection process308.

A code reader406and a laser marker416are provided in sheet metal press punching process306. A code reader407and a laser marker417are provided in housing molding process307. A code reader408is provided in housing inspection process308.

Each of code readers406to408reads the QR code of the component, the intermediate product, or the product that has been conveyed to the corresponding process. The QR code indicates a serial number that identifies the component, the intermediate product, or the product. For example, code reader406reads the QR code marked on a metal plate conveyed to sheet metal press punching process306, and outputs the component serial number indicated by the read QR code. Code reader408reads the QR code marked on the manufactured housing, and outputs the product serial number indicated by the read QR code.

Laser marker416,417marks the QR code on the intermediate product or the product to be output from the corresponding process. The QR code indicates a serial number identifying the intermediate product or the product. The QR code marked by laser marker416,417is uniquely specified by manufacturing controller200B or the facility installed in the corresponding process.

Manufacturing controller200B includes an IO processing section21B that performs the data input and output processing with the facility installed in each process. Processor201(seeFIG.5) included in manufacturing controller200B executes user program211, thereby implementing IO processing section21B.

For example, IO processing section21B outputs the data indicating the operation command, the data indicating the QR code to be marked on the intermediate product or the product, and the like to the facility installed in the process.

IO processing section21B acquires at least one item data regarding the quality of each individual of the intermediate product or the product manufactured by the process from each process. The item data indicates a value, a content, and the like of the item regarding the quality. The serial number (the unit serial number or the product serial number) of the corresponding individual is added to the at least one item data. For example, IO processing section21B receives the data (work start time stamp) indicating the time when code reader406to408reads the QR code, the data indicating the processing condition, the data indicating the processing method, the data indicating the value of the parameter (dimension or the like) representing the quality, and the like as the item data.

Furthermore, IO processing section21B operates as an acquisition section that acquires the component serial number identifying the individual of the component used in the process in at least one component from each process, and the unit serial number (or the product serial number) identifying the individual of the intermediate product or the product manufactured in the process according to the work order of the process. Specifically, IO processing section21B acquires the component serial number indicated by the QR code every time the code reader installed in each process reads the QR code of the component. Each time the laser marker installed in each process marks the QR code on the intermediate product or the product, IO processing section21B acquires the unit serial number or the product serial number indicated by the QR code.

For example, IO processing section21B acquires the component serial number identifying the individual of the metal plate and the unit serial number identifying the individual of the metal piece from sheet metal press punching process306each time the metal piece is punched out from the metal plate. In addition, IO processing section21B acquires the product serial number marked on the individual of the housing from housing molding process307every time the individual of the housing is manufactured.

As illustrated inFIGS.6and7, servers100A,100B have the similar functional configuration. That is, server100A inFIG.6includes a registration section10A, a data analysis section11A, an inquiry and answer section12A, a database group50A, a quality database60A, and a provision permission database70A. Server100B inFIG.7includes a registration section10B, a data analysis section11B, an inquiry and answer section12B, a database group50B, a quality database60B, and a provision permission database70B. Hereinafter, when database groups50A,50B are not particularly distinguished, each of database groups50A,50B is referred to as a “database group50”. When provision permission databases70A,70B are not particularly distinguished, each of provision permission databases70A,70B is referred to as a “provision permission database70”.

Registration section10A, data analysis section11A, and inquiry and answer section12A are implemented by processor101(seeFIG.4) of server100A executing management program130. Database group50A, quality database60A, and provision permission database70A are implemented by memory102and storage103of server100A. Registration section10B, data analysis section11B, and inquiry and answer section12B are implemented by processor101of server100B executing management program130. Database group50B, quality database60B, and provision permission database70B are implemented by memory102and storage103of server100B.

FIG.8is a view illustrating an example of a database included in a database group. As illustrated inFIG.8, database group50includes BOM database51, BOP database52, a BOE database53, a first association database54, and a second association database55.

BOM database51indicates the hierarchical structure of at least one component constituting the product. For example, BOM database51of server100A indicates the hierarchical structure of at least one component constituting the motor. On the other hand, BOM database51of server100B indicates the hierarchical structure of at least one component constituting the housing.

BOP database52indicates the hierarchical structure of at least one process producing the product. BOE database53indicates a hierarchical structure of at least one facility producing the product.

First association database54indicates a correspondence relationship between each of at least one process producing the product and the component used in the process. Second association database55indicates a correspondence relationship between each of at least one process and the facility used in the process.

FIG.9is a view illustrating examples of a BOM database and a BOP database of the server inFIG.6. As illustrated inFIG.9, a BOM database MA of server100A illustrates the hierarchical structure of components “housing unit”, “end cap unit”, “rotor unit”, “housing”, “magnet”, “end bell”, “brush”, “coil”, “core”, and “shaft” that constitute the motor that is the product. A BOP database52A of server100A indicates the hierarchical structure of processes manufacturing the motor, namely, “housing unit assembly”, “end cap unit assembly”, “rotor unit assembly”, “motor assembly”, “fix housing”, “attach magnet”, “fix end bell”, “attach brush”, “fix shaft”, “fit core”, and “wind electric wire around core”.

A first association database54A associates the component indicated by BOM database51A with the process indicated by BOP database52A. For example, first association database54A associates the component “housing” with the process “fix housing” using the component “housing”. In this manner, BOM database51A and BOP database52A are correlated with each other by first association database54A.

FIG.10is a view illustrating examples of the BOP database and a BOE database of the server inFIG.6. As illustrated inFIG.10, a BOE database53A of server100A illustrates the hierarchical structure of facilities “station1”, “station2”, “station3”, “station4”, “fixing jig1”, “workbench1”, “fixing jig2”, “workbench2”, “fixing jig3”, “press fitting machine”, and “winding machine” that manufacture the motor that is the product.

A second association database55A associates the process indicated by BOP database52A with the facility indicated by BOE database53A. For example, second association database55A associates the process “fix housing” with the facilities “fixing jig1” and “workbench1” used in the process. In this manner, BOP database52A and BOE database53A are correlated with each other by second association database55A.

BOM database51includes, for each individual of each component, supply source data that associates the component serial number of the individual with third identification information identifying a supply source of the individual. Hereinafter, it is assumed that a “supplier number” is used as the third identification information.

FIG.11is a view illustrating a data item in of the BOM database of the server inFIG.6. As illustrated inFIG.11, BOM database51A includes supply source data56A configured by data items “supplier number” and “delivered component serial number”. Specifically, supply source data56A associates the supplier number “D0001A” of the supply source supplying the component “housing” of the component number “S6500” with the component serial numbers “HA4300” to “HA4600” identifying the individual of the component. Furthermore, supply source data56A associates the supplier number “D0023B” of the supply source supplying the component “housing” of the component number “S6501” with the component serial numbers “HB5000” to “HB5100” identifying the individual of the component.

Quality database60A inFIG.6associates the unit serial number (or product serial number) identifying the individual of the intermediate product (or product) manufactured by the process with the quality data set regarding the quality of the individual for each process of the control target of manufacturing controller200A. The quality data set includes the item data indicating each of a plurality of items.

FIG.12is a view illustrating an example of a quality database corresponding to a housing unit assembling process. A quality database60A_1inFIG.12associates the unit serial number with the item data indicating each of items “process number”, “worker name”, and “work start time stamp” for each individual of the housing unit. The item “process number” identifies the process in which the individual having the corresponding unit serial number is manufactured. The item “worker name” identifies the worker who manufactured the individual having the corresponding unit serial number. The item “work start time stamp” indicates the start time of the work on the individual having the corresponding unit serial number.

FIG.13is a view illustrating an example of the quality database corresponding to a motor inspection process. A quality database60A_2inFIG.13associates the product serial number with the item data indicating each of items “process number”, “worker name”, “work start time stamp”, and “quality determination result” for each individual of the motor. The item “quality determination result” indicates the quality of the individual having the corresponding product serial number.

Quality database60B inFIG.7associates a unit serial number (or product serial number) identifying the individual of the intermediate product or the product manufactured by the process with the quality data set regarding the quality of the individual for each process of the control target of manufacturing controller200B. The quality data set includes the item data indicating each of a plurality of items.FIG.14is a view illustrating an example of the quality database corresponding to a housing molding process. A quality database60B_1inFIG.14associates the product serial number with the item data indicating each of items “process number”, “worker name”, “work start time stamp”, “processing condition”, and “processing method” for each individual of the housing. The item “processing condition” indicates the processing condition when the individual having the corresponding product serial number is manufactured. The item “processing method” indicates the processing method when the individual having the corresponding product serial number is manufactured.

FIG.15is a diagram illustrating an example of the quality database corresponding to a housing inspection process. A quality database60B_2inFIG.15associates the product serial number with item data of each of items “process number”, “worker name”, “work start time stamp”, “measurement dimension”, and “distortion” for each individual of the housing. The item “measured dimension” indicates the dimension of the individual having the corresponding product serial number. The item “distortion” indicates a distortion amount of the individual with having corresponding product serial number.

Provision permission database70A inFIG.6indicates provision permission of each of the plurality of items indicated by quality database60A to a supply destination for the motor that is the product. Similarly, provision permission database70B in FIG.7indicates provision permission of each of the plurality of items indicated by quality database60B to the supply destination for the housing that is the product.

FIG.16is a view illustrating an example of a provision permission database inFIG.7. Provision permission database70B inFIG.16indicates items “measurement dimension”, “distortion”, as items that are permitted to be provided, and indicates items “processing condition”, “processing method”, as items that are not permitted to be provided.

Registration section10A inFIG.6registers the data in BOM database51A and BOP database52A included in database group50A and quality database60A. Registration section10B inFIG.7registers the data in BOM database51and BOP database52included in database group50B and quality database60B. Because the processing contents of registration sections10A,10B are similar, only the processing of registration section10A will be described below.

When manufacturing controller200A acquires at least one item data from each process, registration section10A registers the at least one item data in quality database60A corresponding to the process.

In addition, when manufacturing controller200A acquires the component serial number of the target component from each process, registration section10A registers the component serial number in the hierarchy of the target component in BOM database51A. Specifically, when manufacturing controller200A acquires the component serial number from each process, registration section10A specifies the target component to be used in the process using first association database54A. Then, registration section10A registers the component serial numbers in the hierarchy of the target components in the order acquired by manufacturing controller200A in BOM database51A.

Furthermore, when manufacturing controller200A acquires the serial number of the intermediate product or the product manufactured by the process from each process, registration section10A registers the serial number in the hierarchy of the process in the order acquired in BOP database52A.

Data analysis section11A illustrated inFIG.6performs data analysis using database group50A and quality database60A. Data analysis section11B inFIG.7performs data analysis using database group50B and quality database60B.

For example, data analysis section11A operates as a search section that searches the component serial number of each individual of at least one component constituting the target individual of the product using BOM database51A, BOP database52A, and first association database54A. In addition, data analysis section11A searches the facility used to manufacture the target individual using BOE database53A and second association database55A. Data analysis section11B also executes the similar search processing.

Inquiry and answer section12A inFIG.6transmits inquiry to another server100and transmits answer information about inquiry to another server100. Inquiry and answer section12B inFIG.7also transmits inquiry to another server100and transmits the answer information about inquiry to another server100.

For example, inquiry and answer section12A specifies the supplier number corresponding to the component serial number searched by data analysis section11A based on BOM database51A. Then, inquiry and answer section12A transmits the inquiry about the quality of the individual indicated by the component serial number searched by data analysis section11A to server100(for example, server100B) of the component supplier indicated by the specified supplier number.

For example, inquiry and answer section12B generates the answer information in response to receiving the inquiry about the quality of the target individual from the supply destination of the housing that is the product, and transmits the generated answer information to the supply destination. Specifically, inquiry and answer section12B reads the quality data set of the target individual from quality database60B. Inquiry and answer section12B specifies at least one item permitted to be provided to the supply destination based on provision permission database70B. Inquiry and answer section12B extracts the item data corresponding to each of the specified at least one item from the read quality data set, and includes the extracted item data in the answer information.

FIG.17is a flowchart illustrating a flow of pre-processing. The pre-processing is executed before a production start of the product. The flowchart inFIG.17is executed in each information management system1.

First, a designer of the product produces a drawing of the product, and produces BOM database51based on the component number identifying each of at least one component constituting the product and a structure of the product (step S1).

Subsequently, the designer of the process produces BOP database52based on the design content (step S2), and produces BOE database53(step S3).

Furthermore, the designer of the process produces first association database54based on the design content (step S4) and produces second association database55(step S5).

The person in charge of product delivery produces provision permission database70indicating the provision permission of each of the plurality of items regarding the quality of the product to the supply destination based on the contract content with the supply destination of the product (step S6). Thus, the pre-processing ends.

<Flow of Information Management Processing after Production Start>

FIG.18is a flowchart illustrating a flow of information management processing. For example, the flowchart inFIG.18is executed for each lot. Hereinafter, it is assumed that the flowchart inFIG.18is executed for each lot.

As illustrated inFIG.18, processor101of server100registers the supply source data in BOM database51according to the delivery of the component used for the product of the target lot (step S11). In the supply source data, for each individual of the delivered components, the component serial number of the individual is associated with the supplier number identifying the supply source of the individual. For example, as illustrated inFIG.11, supply source data56A is registered in BOM database51A.

Subsequently, processor201of manufacturing controller200controls the operation of the facility installed in each process to start the production of the target lot (step S12).

Subsequently, processor201acquires the component serial number identifying the individual of the component used in the process from each process (step S13).

Subsequently, in step S14, in response to the acquisition of the component serial number from each process, processor101of server100specifies the target component used in the process using first association database54. Then, processor101registers the component serial numbers in the order acquired by manufacturing controller200in the hierarchy of the target components in BOM database51.

FIG.19is a view illustrating an example of the BOM database in which the component serial number of the used component is registered.FIG.19illustrates BOM database51A represented in a table format. As illustrated inFIG.19, BOM database51A includes a data item57A that registers the component serial number acquired from each process. The component serial numbers are registered in BOM database51A in the acquired order. For this reason, in the example ofFIG.19, it is understood that the component serial numbers “HA4353”, “HA4354”, “HB5018”, are acquired from the process in this order.

Each time the intermediate product or the product is manufactured in each process, processor201of manufacturing controller200acquires the serial number (the unit serial number or the product serial number) identifying the individual of the intermediate product or the product (step S15). Processor201outputs the serial number acquired from each process to server100.

In response to the acquisition of the serial number identifying the individual of the intermediate product or the product from each process, processor101of server100registers the serial number in the hierarchy of the process of BOP database52in the acquired order (step S16).

Processor201of manufacturing controller200acquires at least one item data regarding the quality of the intermediate product or the product manufactured by each process (step S17). Processor201outputs the item data acquired from each process to server100.

In response to the acquisition of at least one item data corresponding to each individual of the intermediate product or the product from each process, processor101of server100registers the at least one item data in quality database60corresponding to the process (step S18).

Processor101determines whether the production of the target lot is completed (step S19). For example, processor101may determine whether the production of the target lot is completed based on the production plan from the MES.

When the production of the target lot is not completed (NO in step S19), the information management processing returns to step S13.

When the production of the target lot is completed (YES in step S19), processor101determines whether a defective product exists based on quality database60(step S20). For example, based on quality database60A_2inFIG.13, processor101determines that the individual having the product serial number “MA0002” is the defective product. When the defective product does not exist (NO in step S20), the information management processing ends.

When the defective product exists (YES in step S20), processor101executes data analysis (step S21). After step S21, the information management processing ends.

<Subroutine in Step S21>

FIG.20is a flowchart illustrating a flow of processing of a subroutine in step S21inFIG.18.

First, processor101of server100extracts the data regarding the defective product from various databases using the serial number of the defective product as a key (step S31). Specifically, processor101extracts the unit serial number of the intermediate product constituting the defective product, the quality data set corresponding to the defective product or the intermediate product constituting the defective product, the component serial number of the component constituting the defective product, the supplier number identifying the supply source of the component constituting the defective product, the process number identifying the process used for manufacturing the defective product, a facility number identifying the facility used for manufacturing the defective product, and the like.

For example, in the case of the example inFIG.1, the product serial number “MA00002” of the defective product is registered second in the hierarchy of the “motor assembling process” in BOP database52. Accordingly, processor101determines that the defective product is manufactured second. As a result, processor101specifies the housing unit having the unit serial number “00002” registered second in the hierarchy of the “housing unit assembling process” as the intermediate product constituting the defective product. Furthermore, the processor specifies the housing having a component serial number “HB5018” registered second in the hierarchy of “housing” in BOM database51as the component constituting the defective product.

Furthermore, processor101specifies the quality data set corresponding to the unit serial number “000002” of quality database60A_1inFIG.12as the quality data set regarding the quality of the intermediate product constituting the defective product. That is, processor101specifies the worker in charge of manufacturing the intermediate product constituting the defective product and the work start time.

Furthermore, processor101specifies the quality data set corresponding to the product serial number “MA00002” of quality database60A_2inFIG.13as the quality data set regarding the quality of the defective product. That is, processor101specifies the worker in charge of manufacturing the defective product and the work start time.

Furthermore, processor101specifies “D0023B” corresponding to the component serial number “HB5018” in supply source data56A included in BOM database51A inFIG.19as the supplier number identifying the supply source of the component constituting the defective product.

Subsequently, processor101provides the information extracted in step S31(step S32). Specifically, processor101generates a screen indicating the specified information, and causes display device140(seeFIG.4) to display the generated screen.

The production manager investigates the defect cause based on the provided information. As described above, the provided information includes information regarding the defective product, and the intermediate product and the component constituting the defective product. Accordingly, the production manager can easily investigate the defect cause.

FIG.21is a view illustrating a method of investigating a cause of a motor defect.FIG.21illustrates a tree structure of a plurality of possible causes that may be generated in the motor. The tree structure inFIG.21is previously constructed based on the structure of the motor, the investigation result of the past defect cause, and the like.

As illustrated inFIG.21, cause candidates of “decrease in torque of motor performance” include “electrical disconnection of coil”, “increase in gap between core and magnet”, “generation of seizure of bearing”, and “wear of bearing”. “Distortion of shape of housing” and “eccentricity of shaft due to positional deviation of the bearing” can be cited as the cause candidate of “increase in gap between core and magnet”. “Mistake in processing work of housing” can be cited as the cause candidate of “distortion of shape of housing”. “Application of impact load to shaft” can be cited as the cause candidate of “eccentricity of shaft due to positional displacement of bearing”. “Mistake in assembly work of rotor unit” and “mistake in work of inspection process” can be cited as the cause candidate of “application of impact load to shaft”.

The production manager may investigate the cause candidates located at the end of the tree structure inFIG.21. The production manager may check whether the cause candidates “electrical disconnection of coil”, “generation of seizure of bearing”, and “wear of bearing” surrounded by an alternate long and short dash line among the cause candidates located at the end are the defect cause by investigating the motor itself that is the product.

The production manager checks whether the cause candidates “mistake in assembling work of rotor unit” and “mistake in work in inspection process” among the cause candidates located at the end are the defect cause using the quality data set corresponding to each of the “rotor unit assembling process” and the “inspection process”. Specifically, the production manager can check whether the cause candidates “mistake in assembling work of rotor unit” and “mistake in work in inspection process” are the defect causes by inquiring the worker indicated by the quality data set.

The production manager cannot immediately check whether the cause candidate “mistake in processing operation of housing” among the cause candidates located at the end is the defect cause. Accordingly, the production manager inputs an inquiry instruction to the component supplier to server100.

Subsequently, processor101determines whether the inquiry instruction to the component supplier is input to input device150(step S33). When the inquiry instruction to the component supplier is not input (NO in step S33), step S21ends.

When the inquiry instruction to the component supplier is input (YES in step S33), processor101receives the input of the component of an inquiry target (step S34). For example, when there is a possibility that the cause candidate “error in processing operation of housing component” is the defect cause, the production manager inputs “housing” as the component of the inquiry target.

In response to the input, processor101specifies the component supplier of an inquiry destination (step S35). Specifically, processor101specifies the component serial number of the component of the inquiry target constituting the defective product.

For example, when the component of the inquiry target is “housing” and when the serial number of the defective product is “MA00002”, processor101specifies the component serial number “HB5018” based on BOM database51and BOP database52inFIG.1. Then, processor101specifies the component supplier identified by a supplier number “DB0023B” corresponding to the component serial number “HB5018” as the inquiry destination based on supply source data56A of BOM database51A inFIG.11. In the example of BOM database51A inFIG.11, the component having a component number “S6500” that is an authorized product and a component having a component number “S6501” that is a substitute exist as the component “housing”. The supplier number “DB0023B” corresponds to the component supplier that supplies the substitute. Accordingly, the component supplier that supplies the substitute is specified as the inquiry destination.

Subsequently, processor101generates an inquiry sentence and transmits the generated inquiry sentence to the inquiry destination (step S36). Processor101may generate the inquiry sentence in response to the input to input device150, or may generate the inquiry sentence by incorporating the component serial number of the inquiry target in a previously-produced fixed phrase.

Thereafter, processor101receives answer information from the inquiry destination (step S37). The received answer information is displayed on display device140. After step S37, step S21ends.

<Flow of Answer Processing>

FIG.22is a flowchart illustrating a flow of answer processing. As illustrated inFIG.22, processor101of server100determines whether an inquiry from another server100is received (step S41). When the inquiry is not received (NO in step S41), the answer processing returns to step S41.

When the inquiry is received (YES in step S41), processor101reads the quality data set corresponding to the individual having the serial number designated in the inquiry from quality database60(step S42). In step S42, processor101reads not only the quality data set corresponding to the same product serial number as the designated serial number but also the quality data set corresponding to the intermediate product constituting the product with the product serial number. The method for searching the unit serial number of the intermediate product constituting the product with the product serial number is as described above.

Subsequently, processor101specifies the item permitted to be provided to the supply destination based on the provision permission database70(step S43).

Processor101extracts, from the quality data set read in step S42, only item data permitted to be provided (step S44).

Processor101produces the answer information including the information indicated by the extracted item data, and transmits the answer information to the inquiry source (step S45). After step S45, the answer processing ends.

In the above description, server100includes BOM database51, BOP database52, BOE database53, quality database60, and provision permission database70. However, these databases may be distributed and located on different devices.

In the above description, as illustrated inFIG.19, BOM database51A includes data item57A, in which the component serial number of the used component is registered, separately from supply source data56A. In this case, the component serial number is redundantly registered in data item57A and supply source data56A Consequently, supply source data56A and data item57A may be combined.

FIG.23is a view illustrating a modification of the BOM database. BOM database51A inFIG.23includes data item57A in which the component serial number of the used component is registered and a data item58A in which the supplier number identifying the component supplier of the supply source of the used component is registered. In this case, the data registered in data items57A,58A constitutes supply source data59A that associates the component serial number of the individual with the supplier number identifying the supply source of the individual for each individual of the components.

When registering the component serial number of the used component in BOM database51A, processor101of server100also registers the supplier number identifying the component supplier of the supply source of the component in BOM database51A. Processor101may specify the supplier number corresponding to the used component by accessing the database in which a list of component serial numbers of components delivered from the component supplier is associated with the supplier number identifying the component supplier.

In the above description, it is assumed that BOP database52and quality database60are associated with each other on a one-to-one basis. However, in the company, a plurality of lines may be installed for one product. In this case, a plurality of quality databases60can be provided for each line. On the other hand, one BOP database52is provided in the company or the factory. In such a case, BOP database52is produced so as to indicate the hierarchical structure of processes for each line. That is, in BOP database52, the process number identifying each process identifies the line in which the process is installed and the process. Then, when the unit serial number (or product serial number) is acquired from a certain process of a certain line, the unit serial number (or product serial number) is registered in the hierarchy corresponding to the process of the line in BOP database52.

In addition, BOM database51is also produced so as to indicate the hierarchical structure of components for each line. That is, in BOM database51, the component number identifying each component identifies the line in which the component is used and the component. Then, when the component serial number is acquired from a certain process of a certain line, the component serial number is registered in the hierarchy corresponding to the component of the line in BOM database51.

Thus, the component constituting the target individual of the product manufactured in each line can be specified even when BOM database51and BOP database52are associated with quality database60on a one-to-many basis.

As described above, the embodiment includes the following disclosure.

An information management system (1,1A,1B) including:a BOM database (51,51A) configured to indicate a hierarchical structure of at least one component constituting a product;a BOP database (52,52A) configured to indicate a hierarchical structure of at least one process producing the product;a quality database (60,60A,60B) configured to associate first identification information identifying an individual of an intermediate product or the product manufactured by the process with a quality data set regarding quality of the individual for each of the at least one process;an acquisition section (21A,21B,201) configured to acquire second identification information identifying an individual of a target component used in the process in the at least one component, and the first identification information corresponding to the intermediate product or the product manufactured in the process according to work order of the process from each of the at least one process; anda registration section (10A,10B,101),wherein the registration section (10A,10B,101)registers the second identification information in a hierarchy of the target component of the BOM database (51,51A) in the order acquired by the acquisition sectionin response to the acquisition of the second identification information from each of the at least one process, andregisters the first identification information in a hierarchy of the process of the BOP database (52,52A) in the order acquired by the acquisition section in response to the acquisition of the first identification information from each of the at least one process.

The information management system (1,1A,1B) described in configuration 1, further including a search section (11A,11B,101) configured to search the second identification information of each individual of the at least one component constituting a target individual of the product using the BOM database (51,51A) and the BOP database (52,52A).

The information management system (1,1A,1B) described in configuration 2, further including an inquiry section (12A,12B,101) configured to specify third identification information corresponding to the second identification information searched by the search section (11A,11B,101) based on the BOM database (51,51A), and transmit inquiry about quality of the individual indicated by the second identification information searched by the search section to a supply source indicated by the specified third identification information,wherein the BOM database (51,51A) includes, for each individual of the at least one component, supply source data (56A,59A) that associates the second identification information of the individual with the third identification information identifying the supply source of the individual.

The information management system (1,1A,1B) described in any one of configurations 1 to 3, further including:a provision permission database (70A,70B) configured to indicate provision permission of each of the plurality of items to a supply destination of the product; andan answer section (12A,12B,101) configured to generate answer information in response to receiving an inquiry about the quality of the target individual of the product from the supply destination, and transmit the generated answer information to the supply destination,wherein the quality data set includes item data indicating each of a plurality of items, andthe answer section (12A,12B,101)reads the quality data set of the target individual from the quality database,specifies at least one item that can be provided based on the provision permission database (70A,70B),extracts the item data corresponding to each of the specified at least one item from the read quality data set, andincludes the extracted item data in the answer information.

An information management method in which a BOM database (51,51A) indicating a hierarchical structure of at least one component constituting a product, a BOP database (52,52A) indicating a hierarchical structure of at least one process producing the product, and a quality database (60,60A,60B) associating first identification information identifying an individual of an intermediate product or the product manufactured by the process with a quality data set regarding quality of the individual for each of the at least one process are used,the information management method including:(S13, S15) acquiring second identification information identifying an individual of a target component used in the process in the at least one component, and the first identification information corresponding to the intermediate product or the product manufactured in the process according to work order of the process from each of the at least one process;(S14) registering the second identification information in a hierarchy of the target component in the BOM database (51,51A) in the acquired order in response to the acquisition of the second identification information from each of the at least one process; and(S16) registering the first identification information in a hierarchy of the process of the BOP database (52,52A) in the acquired order in response to the acquisition of the first identification information from each of the at least one process.

Although the embodiment of the present invention has been described, it should be considered that the disclosed embodiment is an example in all respects and not restrictive. The scope of the present invention is indicated by the claims, and it is intended that all modifications within the meaning and scope of the claims are included in the present invention.