US-12619220-B2 - Production management system, production management method, and non-transitory computer readable medium

US12619220B2US 12619220 B2US12619220 B2US 12619220B2US-12619220-B2

Abstract

Provided is a production management system including: an operational data acquisition unit for acquiring operational data regarding a production element in a target production process as a target among a plurality of production processes for producing a product from a material; a quality data acquisition unit for acquiring quality data indicating quality of a target product; an analysis unit for analyzing the operational and quality data to estimate an influence, caused by an upstream product, on the quality of the target product, the upstream product being a product of an upstream production process and serving as a material in the target production process; and a feedback unit for outputting, based on an analysis result, feedback data for evaluating a production element in the upstream production process based on the quality of the target product in the upstream production process.

Inventors

Masato KATSUKI
Keiji Sato
Eiji TAYA
Tsutomu NIHO
Makoto Endo
Toshiya Yamashita
Akifumi INOMATA
Fumihiro Saito

Assignees

YOKOGAWA MANUFACTURING CORPORATION
YOKOGAWA ELECTRIC CORPORATION

Dates

Publication Date: 20260505
Application Date: 20210819
Priority Date: 20200910

Claims (19)

1 . A production management system comprising: at least one processor; an operational data acquisition unit that uses the at least one processor to acquire operational data regarding a production element in a target production process as a target among a plurality of production processes for producing a product from a material; a quality data acquisition unit that uses the at least one processor to acquire quality data indicating quality of a target product which is a product of the target production process; an analysis unit that uses the at least one processor to analyze the operational data and the quality data to estimate an influence, which is caused by an upstream product, on the quality of the target product, the upstream product being a product of an upstream production process which is an upstream process of the target production process and serving as a material in the target production process; a feedback unit that uses the at least one processor to output, on a basis of an analysis result, feedback data for evaluating a production element in the upstream production process on a basis of the quality of the target product in the upstream production process; a control information decision unit that uses the at least one processor to decide control information for controlling the production element in the target production process on the basis of the analysis result; and a control unit that uses the at least one processor to control the production element in the target production process on a basis of the control information decided by the control information decision unit; wherein the analysis unit uses the at least one processor to estimate the influence at least in part based on an analysis of similarity between instances of data of the acquired operational data corresponding to different lots of the target product.
2 . The production management system according to claim 1 , wherein the analysis unit uses the at least one processor to analyze a plurality of pieces of the operational data with which different pieces of the quality data are associated, to specify the upstream product that has caused deterioration in the quality of the target product.
3 . The production management system according to claim 2 , wherein the feedback unit uses the at least one processor to output information for identifying the upstream product specified by the analysis unit.
4 . The production management system according to claim 3 , wherein the feedback unit uses the at least one processor to output information for identifying a lot of the target product of which quality is estimated to no longer satisfy a predetermined standard due to the upstream product specified by the analysis unit.
5 . The production management system according to claim 3 , further comprising a lot management unit that uses the at least one processor to manage information for identifying a lot of the upstream product and information for identifying a lot of the target product in association with each other, wherein the feedback unit uses the at least one processor to output information for identifying a lot of the upstream product corresponding to a lot of the target product of which quality is estimated to no longer satisfy a predetermined standard due to the upstream product specified by the analysis unit.
6 . The production management system according to claim 3 , wherein the feedback unit uses the at least one processor to output information indicating a yield of the target product caused by the upstream product specified by the analysis unit.
7 . The production management system according to claim 3 , wherein the quality data acquisition unit uses the at least one processor to acquire, as the quality data, an evaluation result of the quality of the target product evaluated in the target production process.
8 . The production management system according to claim 2 , wherein the feedback unit uses the at least one processor to output information for identifying a lot of the target product of which quality is estimated to no longer satisfy a predetermined standard due to the upstream product specified by the analysis unit.
9 . The production management system according to claim 2 , further comprising a lot management unit that uses the at least one processor to manage information for identifying a lot of the upstream product and information for identifying a lot of the target product in association with each other, wherein the feedback unit uses the at least one processor to output information for identifying a lot of the upstream product corresponding to a lot of the target product of which quality is estimated to no longer satisfy a predetermined standard due to the upstream product specified by the analysis unit.
10 . The production management system according to claim 2 , wherein the feedback unit uses the at least one processor to output information indicating a yield of the target product caused by the upstream product specified by the analysis unit.
11 . The production management system according to claim 2 , wherein the quality data acquisition unit uses the at least one processor to acquire, as the quality data, an evaluation result of the quality of the target product evaluated in the target production process.
12 . The production management system according to claim 2 , wherein the quality data acquisition unit uses the at least one processor to acquire, as the quality data, feedback data for evaluating the production element in the target production process on a basis of quality of a downstream product in the target production process, the feedback data being output from a production management system configured to manage a downstream production process of producing the downstream product by using the target product as a material.
13 . The production management system according to claim 2 , wherein the analysis unit is further uses the at least one processor to estimate an influence, which is caused by an operation in the target production process, on the quality of the target product.
14 . The production management system according to claim 1 , wherein the quality data acquisition unit uses the at least one processor to acquire, as the quality data, an evaluation result of the quality of the target product evaluated in the target production process.
15 . The production management system according to claim 1 , wherein the quality data acquisition unit uses the at least one processor to acquire, as the quality data, feedback data for evaluating the production element in the target production process on a basis of quality of a downstream product in the target production process, the feedback data being output from a production management system configured to manage a downstream production process of producing the downstream product by using the target product as a material.
16 . The production management system according to claim 1 , wherein the analysis unit further uses the at least one processor to estimate an influence, which is caused by an operation in the target production process, on the quality of the target product.
17 . The production management system according to claim 1 , wherein the analysis of similarity includes using a Mahalanobis distance in determining the similarity of operational data between the lots.
18 . A production management method comprising: acquiring operational data regarding a production element in a target production process as a target among a plurality of production processes for producing a product from a material; acquiring quality data indicating quality of a target product which is a product of the target production process; analyzing the operational data and the quality data to estimate an influence, which is caused by an upstream product, on the quality of the target product, the upstream product being a product of an upstream production process which is an upstream process of the target production process and serving as a material in the target production process; outputting, on a basis of an analysis result, feedback data for evaluating a production element in the upstream production process on a basis of the quality of the target product in the upstream production process; deciding control information for controlling the production element in the target production process on the basis of the analysis result; and controlling the production element in the target production process on a basis of the decided control information; wherein the analyzing includes estimating the influence at least in part based on an analysis of similarity between instances of data of the acquired operational data corresponding to different lots of the target product.
19 . A non-transitory computer readable medium having recorded thereon a production management program that, when executed by a computer, causes the computer to function as: an operational data acquisition unit configured to acquire operational data regarding a production element in a target production process as a target among a plurality of production processes for producing a product from a material; a quality data acquisition unit configured to acquire quality data indicating quality of a target product which is a product of the target production process; an analysis unit configured to analyze the operational data and the quality data to estimate an influence, which is caused by an upstream product, on the quality of the target product, the upstream product being a product of an upstream production process which is an upstream process of the target production process and serving as a material in the target production process; a feedback unit configured to output, on a basis of an analysis result, feedback data for evaluating a production element in the upstream production process on a basis of the quality of the target product in the upstream production process; a control information decision unit configured to decide control information for controlling the production element in the target production process on the basis of the analysis result; and a control unit configured to control the production element in the target production process on a basis of the control information decided by the control information decision unit; wherein the analysis unit uses the at least one processor to estimate the influence at least in part based on an analysis of similarity between instances of data of the acquired operational data corresponding to different lots of the target product.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS This application is a National Stage Entry of International Application No. PCT/JP2021/030315 filed on Aug. 19, 2021, which claims priority to Japanese Patent Application No. 2020-152340 filed on Sep. 10, 2020, the contents of each of which are hereby incorporated by reference in their entirety. BACKGROUND 1. Technical Field The present invention relates to a production management system, a production management method, and a non-transitory computer readable medium. 2. Related Art In the Patent Document 1, “a manufacturing process analyzing method for specifying an inhibiting factor causing a variation of product performance and for stabilizing the product performance” is described. CITATION LIST Patent Document Patent Document 1: Japanese Patent Application Publication No. 2016-177794 General Disclosure Item 1 A first aspect of the present invention provides a production management system. The production management system may include an operational data acquisition unit configured to acquire operational data regarding a production element in a target production process as a target among a plurality of production processes for producing a product from a material. The production management system may include a quality data acquisition unit configured to acquire quality data indicating quality of a target product which is a product of the target production process. The production management system may include an analysis unit configured to analyze the operational data and the quality data to estimate an influence, which is caused by an upstream product, on the quality of the target product, the upstream product being a product of an upstream production process which is an upstream process of the target production process and serving as a material in the target production process. The production management system may include a feedback unit configured to output, on a basis of an analysis result, feedback data for evaluating a production element in the upstream production process on a basis of the quality of the target product in the upstream production process. Item 2 The analysis unit may be configured to analyze a plurality of pieces of the operational data with which different pieces of the quality data are associated, to specify the upstream product that has caused deterioration in the quality of the target product. Item 3 The feedback unit may be configured to output information for identifying the upstream product specified by the analysis unit. Item 4 The feedback unit may be configured to output information for identifying a lot of the target product of which quality is estimated to no longer satisfy a predetermined standard due to the upstream product specified by the analysis unit. Item 5 The production management system may further include a lot management unit configured to manage information for identifying a lot of the upstream product and information for identifying a lot of the target product in association with each other. The feedback unit may be configured to output information for identifying a lot of the upstream product corresponding to a lot of the target product of which quality is estimated to no longer satisfy a predetermined standard due to the upstream product specified by the analysis unit. Item 6 The feedback unit may be configured to output information indicating a yield of the target product caused by the upstream product specified by the analysis unit. Item 7 The quality data acquisition unit may be configured to acquire, as the quality data, an evaluation result of the quality of the target product evaluated in the target production process. Item 8 The quality data acquisition unit may be configured to acquire, as the quality data, feedback data for evaluating the production element in the target production process on a basis of quality of a downstream product in the target production process, the feedback data being output from a production management system configured to manage a downstream production process of producing the downstream product by using the target product as a material. Item 9 The analysis unit may be further configured to estimate an influence, which is caused by an operation in the target production process, on the quality of the target product. Item 10 The production management system may further include a control information decision unit configured to decide control information for controlling the production element in the target production process on the basis of the analysis result. Item 11 The production management system may further include a control unit configured to control the production element in the target production process on a basis of the control information decided by the control information decision unit. Item 12 A second aspect of the present invention provides a production management method. The production management method may include acquiring operational data regarding a production element in