A preferred embodiment of the present invention will be described with reference to
First, manufacturing equipments S, Xi, and Yj (i denotes an integer of 1 or larger) provided for the manufacturing line ML will be described. As shown in
Subscripts “i” show the order of processing equipments arranged downstream of the inserting equipment S as a reference. In the case of showing a plurality of processing equipments or generally the processing equipments, they are indicated with alphabet letters. Similarly, subscripts “j” indicate the order of measuring equipments arranged downstream of the inserting equipment S as a reference. In the case of showing a plurality of measuring equipments or generally the measuring equipments, they are indicated with alphabet letters.
The inserting equipment S inserts a work (an object to be manufactured) to the manufacturing line ML. Each time a work is inserted to the manufacturing line ML, the inserting equipment S generates a insert signal and transmits it to a marker controller 11 (marker inserting controller).
In the present embodiment, when a marker insert signal is received from the marker controller 11, the inserting equipment S inserts a marker in place of a work to the manufacturing line ML. The marker is used to divide measurement data to be obtained by the measuring equipments Yj. The details of the marker will be described later.
The processing equipment Xi processes a work. Specifically, the processing equipment Xi processes a conveyed work in a predetermined procedure and, as necessary, changes process parameters in accordance with an instruction of a site worker W. For example, by changing the process parameters such as bending, pressure, and temperature, quality characteristics such as external sizes of the work and operating characteristics can be adjusted.
The measuring equipment Yj measures a work. Specifically, the measuring equipment Yj measures quality characteristics such as external sizes and operating characteristics of the work conveyed, and transmits the measurement data together with measurement time to a data collector (data associating unit) 12.
Usually, a plurality of measurement items are measured by a single measuring equipment. In this case, a plurality of pieces of measurement data are generated for each work in a single measuring equipment. In the present embodiment, it is assumed that the plurality of pieces of measurement data are synchronized and perfectly associated with each other.
In the present embodiment, when a marker is conveyed, the measuring equipment Yj measures the marker in the same manner as the work, and transmits measurement data together with measurement time to the data collector 12.
The outline of the data display system 10 will now be described. As shown in
The data collector 12 collects the measurement data obtained by the measuring equipments Yj. When the data collector 12 detects a marker inserted from the inserting equipment S to the manufacturing line ML in accordance with an instruction of the marker controller 11, the data collector 12 generates section data as a set of a plurality of pieces of measurement data included between neighboring markers.
Next, the data collector 12 associates section data of different measuring equipments with each other by using the markers. The data collector 12 displays a plurality of pieces of section data associated with each other among the measuring equipments on the display device 17. Consequently, the site worker W can easily compare the section data associated with each other among the measuring equipments.
The data synchronizer 14 generates synchronous data as a set of a plurality of pieces of measurement data smaller than that of section data by using the section data. The synchronous data is associated with each other among different measuring equipments. The data synchronizer 14 displays a plurality of pieces of synchronous data associated with each other among measuring equipments or a statistical amount of the synchronous data on the data display device 17. Consequently, the site worker W can easily compare the synchronous data or the statistical amounts associated with each other among the measuring equipments with each other. The site worker W can easily grasp time transition of the synchronous data or the statistical amounts.
When the site worker W instructs a change in the manufacture parameters of a manufacturing equipment by the parameter input device 15, the data comparator 16 generates, as comparison data, a plurality of pieces of synchronous data associated with each other among the measuring equipments, which are pieces of synchronous data before and after the change or statistical amounts of the synchronous data pieces. The data comparator 16 displays the generated comparison data on the data display device 17. Consequently, the site worker W can easily compare the synchronous data pieces before and after the change or the statistical amounts of the synchronous data pieces with each other.
Next, the details of the various devices 11 to 17 included in the data display system 10 will be described.
First, the details of the marker controller 11 will be described. The marker controller 11 instructs the inserting equipment S to insert a marker. Concretely, on receipt of a work insert signal from the inserting equipment S, the marker controller 11 counts the number of works inserted and, every predetermined number of inserted works, transmits a marker insert signal that instructs insertion of a marker to the inserting equipment S. Since the number of works inserted between neighboring markers is constant, the number of elements (measurement data) included in section data generated by using the marker by the data collector 12 can be made almost constant. Thus, precision in association of the measurement data improves.
The marker controller 11 transmits the marker insert signal also to the data collector 12. To facilitate generation of synchronous data by the data synchronizer 14 which will be described later, it is desired that the marker insert interval is an integral multiple of the number obtained by adding the number of works which are expected to be increased or decreased during processes to the number of pieces of measurement data in a set to be associated with each other.
The marker will now be described. A suitable marker is a marker which can be easily determined not a work in the measuring equipment Yj. For example, in the case where the measuring equipment Yj measures electric characteristics, a marker which can be easily determined on the basis of the electric characteristics is suitable. In the case where the measuring equipment Yj measures external size accuracy, a marker which can be determined on the basis of the external size accuracy is suitable. In the case where the measuring equipment Yj recognizes shape, a work having a unique shape is suitable as a marker.
A marker which is cheap and can be repeatedly used is suitable in terms of manufacturing cost. From the viewpoint of conveyance on the manufacturing line ML, a marker having the same shape as that of the work is suitable since the number of troubles at the time of operation is small. A nonstandard work such as non-conductive or heavy work is also suitable as a marker. In this case, a marker can be easily found in an inspection process and automatically removed from completed products.
For example, in the case where a work is an electronic component, an electronic component (dummy) designed so that two terminals which are normally conductive are nonconductive can be used as a marker. When the measuring equipment Yj examines whether the two terminals are conductive or not, whether the electronic component is a marker or not can be determined. Since the marker can be easily found in an inspection process and automatically removed as a nonstandard work, the marker does not go missing in products.
A work to which an identifier that can be detected in a non-contact manner such as a bar code or ID tag is attached can be used as a marker. In this case, however, a reader for reading the identifier has to be provided for the measuring equipment Yj.
A site worker may manually insert a marker every break between lots. In this case, however, the site worker may forget inserting a marker, or variations in time consumed for inserting a marker occurs, so that precision of associating measurement data obtained by different measurement equipments Yj deteriorates. Since the number of working processes of the site worker increases, the manufacture cost increases.
Usually, a marker is inserted every hundreds of works. In this case, since the interval between markers is wide, even if the markers are not discriminated from each other, it is not difficult to associate data with each other. However, in the case where markers are inserted more frequently (for example, every tens of works), identifiers for discriminating the markers from each other are preferably provided with the markers. Since markers are inserted in place of works, the larger the number of markers becomes relative to the number of works, the worse the production efficiency deteriorates.
For example, in the case where one marker is inserted every approximately 100 works is equivalent to the case where one defective occurs every approximately 100 works. Therefore, the production efficiency deteriorates by approximately 1%. On the other hand, in the case where one marker is inserted every approximately 1,000 works, deterioration in the production efficiency is only approximately 0.1%.
Although the marker controller 11 inserts a maker every predetermined number of inserted works in the present embodiment, it may insert a marker every predetermined period, or in accordance with other conditions, or at random. In the other cases, however, as described above, a constraint has to be added on the maker controller 11 such that a marker is inserted after approximately 100 works, desirably, hundreds of works are inserted.
Next, the data collector 12 will be described with reference to
The measurement data obtaining unit 21 obtains measurement data Cj obtained by the corresponding measuring equipment Yj. The measurement data obtaining unit 21 transmits the obtained measurement data Cj to the marker detector 22 and the section data generator 23.
The marker detector 22 detects a marker based on the measurement data Cj received from the measurement data obtaining unit 21. The marker detector 22 notifies the section data generator 23 of the fact that the marker is detected. A marker can be detected on the basis of the fact that, for example, received measurement data is out of specification.
The marker detector 22 receives a marker insertion signal from the marker controller 11 and, by using the received marker insert signal, checks whether the corresponding marker has arrived or not. A work can be prevented from being erroneously recognized as a marker, and a marker can be prevented from being erroneously recognized as a work.
The marker detector 22 may receive, in place of a marker insert signal from the marker controller 11, a marker detection signal indicating that a marker is detected, from the marker detector 22 for a measuring equipment which is neighboring on the upstream side and, by using the received marker detection signal, check whether the corresponding marker has arrived or not. In this case, in accordance with the arrangement order of the measuring equipments Yj, whether the corresponding marker has arrived or not can be determined. Further, the marker detector 22 for the last measuring equipment may transmit the marker detection signal to the marker controller 11. In this case, the marker controller 11 can detect that a marker has passed through all of the measuring equipments Yj and, after that, insert the next marker.
The section data generator 23 generates section data as a set of a plurality of pieces of measurement data included between the neighboring markers detected by the marker detector 22. The section data generator 23 transmits the section data to the section data associating unit 24.
Alternatively, markers may be detected by the measuring equipment Yj. In this case, it is sufficient to provide the marker detector 22 in the measuring equipment Yj. On detection of a marker, measuring equipment Yj transmits measurement data indicative of the marker to the data collector 12. On receipt of the measurement data indicative of the marker, the section data generator 23 in the data collector 12 generates the section data.
The section data associating unit 24 associates the section data received from the section data generators 23 corresponding to the measuring equipments Yj with each other. The section data associating unit 24 transmits the plurality of pieces of section data associated with each other among the measuring equipments Yj to the data synchronizer 14 and the data display device 17.
A concrete example of associating the section data with each other will be described with reference to
As shown in
Next, the line information storage 13 will be described. The line information storage 13 stores various information on the manufacturing line ML. In the present embodiment, the line information storage 13 stores dead times and the numbers of unprocessed works in each of the manufacturing equipments S, Xi, and Yj.
The dead time denotes a time period consumed between the completion of processing of a work in a manufacturing equipment and the start of processing of the work in the neighboring manufacturing equipment on the downstream side. The minimum dead time as the minimum value of the dead time denotes a time period always consumed between neighboring manufacturing equipments even if the process is performed most efficiently. In other words, before the lapse of the minimum dead time since a work is finished processing in a manufacturing equipment, the work is not to be processed by the neighboring manufacturing equipment on the downstream side.
On the other hand, the dead works denotes the dead works stored up in a manufacturing equipment. In a normal manufacturing equipment, in order to prevent unprocessed works from being excessively stored up and flooding onto the manufacturing line ML, when the dead works exceeds a threshold value, the manufacturing equipment neighboring on the upstream side is instructed to stop. Since the threshold value is the possible maximum value of the dead works, it is called the maximum dead works. That is, the number of works or markers existing between neighboring manufacturing equipments does not exceed the maximum dead works.
Therefore, the dead time and the dead works can be used as new parameters for improving accuracy of association of a set of measurement data with each other among different measuring equipments Yj.
In the present embodiment, the dead time and the dead works of each of the manufacturing equipments S, Xi, and Yj stored in the line information storage 13 are the values obtained by multiplying the dead time and the numbers of unprocessed works of one manufacturing equipment by, respectively, the dead times and the numbers of unprocessed works of all the other manufacturing equipments provided on the upstream side of the manufacturing equipment. In this case, the dead time and the dead works between different measuring equipments Yj can be obtained by subtracting the dead time and the dead works of the measuring equipments on the upstream side from the dead time and the dead works on the downstream side, respectively.
As shown in
Next, the data synchronizer 14 will be described with reference to
The section data obtaining unit 31 obtains section data {Dj(k)} associated with each other among the measuring equipments Yj from the data collector 12. The section data obtaining unit 31 transmits the obtained section data {Dj(k)} to the synchronous data generator 32.
By using the section data {Dj(k)} from the section data obtaining unit 31, the synchronous data generator 32 generates synchronous data {Ej(k)} associated with each other among different measuring equipments Yj, the synchronous data {Ej(k)} being a set of pieces of measurement data Cj that is smaller in number than the section data Dj. The synchronous data transmitter 33 transmits the generated synchronous data {Ej(k)} to the synchronous data transmitter 33.
The reason why the synchronous data Ej is generated is as follows. As described above, in order to prevent deterioration in production efficiency caused by insertion of a marker M, the marker M is usually inserted every hundreds of works. In this case, the number of pieces of measurement data Cj included in one piece of section data Dj is hundreds. On the other hand, in the present embodiment, the statistical amount of a set including a plurality of pieces of measurement data Cj is calculated and transition in the statistical amount is checked, thereby determining a change in the manufacturing process. Consequently, when the number of pieces of measurement data Cj included in the section data Dj is large, a change in the manufacturing process is easily overlooked. In the present embodiment, the synchronous data generator 32 generates the synchronous data. The details of generation of synchronous data will be described later.
The synchronous data transmitter 33 transmits the synchronous data {Ej(k)} from the synchronous data generator 32 to the data comparator 16 and the data display device 17. To display the synchronous data {Ej(k)} intelligibly, it is desired that the data synchronizer 14 calculates statistical amounts such as average value, standard deviation, average±(3× standard deviation), and the like from the measurement data Cj included in the synchronous data Ej(k) and transmits the calculated statistical amounts to the data display device 17.
The synchronous data Ej(k) is generated as follows. The data synchronizer 14 generates synchronous data made of a predetermined number of pieces of measurement data in time sequence from a plurality of pieces of measurement data obtained by the first measurement equipment Y1. While shifting the synchronous data by a predetermined number of pieces, the data synchronizer 14 sequentially generates synchronous data.
Next, the data synchronizer 14 generates synchronous data corresponding to the synchronous data generated with respect to the first measuring equipment Y1 for the second measuring equipment Y2. By repeating the generating process for the other measuring equipments Yj, synchronous data associated with each other among the different measuring equipments Yj is generated.
In the present embodiment, the synchronous data is generated by the following method. First, with respect to certain synchronous data of the first measuring equipment Y1, the ordinal ratio indicating the position in the number of all of measurement data pieces in the section data, of the measurement data piece existing in a predetermined position in all of the measurement data pieces is calculated. Next, synchronous data in which the measurement data corresponding to the calculated ordinal ratio is included in the predetermined position is generated with respect to corresponding section data in the second measuring equipment Y2. The synchronous data generating process is repeated for all of the synchronous data pieces of the first measuring equipment Y1. Examples of the predetermined position are the head, center, and end of the whole measurement data. In the present embodiment, the predetermined position is the center.
First, the synchronous data generator 32 generates, as the first synchronous data E1(1), synchronous data made of L pieces of measurement data C1 immediately after detection of the first marker M(1) in the first measuring equipment Y1 and, while shifting the synchronous data by L/2 pieces of the measurement data C1, sequentially generates the synchronous data E1. In such a manner, as shown in
Next, the synchronous data generator 32 calculates the ordinal number n2(p) at the head of the p-th synchronous data E2(p) in the second measuring equipment Y2 by using the following equation (1).
nj+1(p)=Tj+1(k)x(nj(k)−nj(p))−(1−Tj+1(k))xL/2+nj+1(k) (1)
nj(k) denotes the ordinal number of the k-th marker M(k) in the j-th measuring equipment Yj, and nj(p) denotes the ordinal number of the head of the p-th synchronous data Ej(p) in the j-th measuring equipment Yj. Tj+1(k) denotes the ratio of the number of works (measurement data) between the k-th and (k+1)-th markers M(k) and M(k+1) in the (j+1)-th measuring equipment Yj+1 to the number of works (measurement data) between the k-th and (k+1)-th markers M(k) and M(k+1) in the j-th measuring equipment Yj. Tj+1(k) is expressed by the following equation (2).
Tj+1(k)=(nj+1j(k+1)−nj+1(k))/(nj(k+1)−nj(k)) (2)
The p-th synchronous data E2(p) made of L pieces of measurement data C2 from the head ordinal number n2(p) calculated by using the equation (1) is generated.
In the example of
On the other hand, the number of works between the (k+1)-th marker M(k+1) and the (k+2)-th marker M(k+2) decreases by removal during conveyance from the first measuring equipment Y1 to the second measuring equipment Y2. Also in such a case, the interval between the ordinal numbers n2 at the heads in the neighboring synchronous data E2 in the second measuring equipment Y2 is narrowed by the equation (1). Therefore, the synchronous data E among the different measuring equipments Yj can be associated with each other with high precision.
The method of generating the synchronous data Ej as shown in
Further, in the present embodiment, the synchronous data Ej associated with each other among the different measuring equipments Yj can be adjusted by using the minimum dead time and the dead works stored in the line information storage 13. Consequently, the head n2(p) of the synchronous data Ej calculated by using the equation (1) can be adjusted. Therefore, the synchronous data E can be associated with each other among the different measuring equipments Yj with high precision.
As shown in
Therefore, the synchronous data generator 32 determines whether the difference Δt2(p,1) satisfies the following equation or not.
Δt(yj+1)−Δt(yj)≦66 tj+1(p,q) (3)
where Δt(yj) is the minimum dead time in the j-th measuring equipment Yj, and Δtj(p,q) denotes the dead time in the q-th measurement data Cj in the p-th synchronous data Ej(p) with respect to the j-th measuring equipment Yj.
If the equation (3) is not satisfied, the measurement data C1 obtained at the time t1(p,l) by the first measuring equipment Y1 does not correspond to the measurement data C2 obtained at the time t2(p,1) by the second measuring equipment Y2 but corresponds to the measurement data C2 obtained after the time t2(p,1). It can be therefore understood that the p-th synchronous data E2(p) with respect to the second measuring equipment Y2 be shifted to the right.
As shown in
Therefore, the synchronous data generator 32 determines whether the difference Δn2(p,1) satisfies the following equation or not.
0≦Δnj+1(p,q)≦Δn(yj+1)−Δn(yj) (4)
where Δn(yj) denotes the maximum number of unused data pieces in the j-th measuring equipment Yj, and Δnj(p,q) denotes the number of unused measurement data pieces in the q-th measurement data Cj in the p-th synchronous data Ej(p) with respect to the j-th measuring equipment Yj.
If the equation (4) is not satisfied, the measurement data C1 obtained at the time t1(p,1) by the first measuring equipment Y1 does not correspond to the measurement data C2 obtained at the time t2(p,1) by the second measuring equipment Y2 but corresponds to the measurement data C2 obtained before the time t2(p,1). It can be therefore understood that the p-th synchronous data E2(p) with respect to the second measuring equipment Y2 be shifted to the left.
The process may be similarly performed with respect to intermediate or last measurement data Cj in the synchronous data Ej. Further, the process may be similarly performed with respect to all of the measurement data Cj in the synchronous data Ej. In this case, the measurement data Cj in the synchronous data Ej can be associated with each other among the different measuring equipments Yj.
In place of the minimum dead time and the maximum number of unused data pieces, an average dead time and an average number of unused data pieces can be used. In this case, precision of association further improves.
The method using the dead time is suitable for the manufacturing line ML in which, although the number of buffers between the manufacturing equipments is larger than the number of pieces of the measurement data Cj included in the synchronous data Ej, a long-time stop hardly occurs because of high operating rate of the manufacturing equipments. In this case, the dead time between the manufacturing equipments can be specified as the minimum dead time, so that precision of association improves.
The method using the above-described number of unused data pieces is suitable for the manufacturing line ML in which the number of buffers between the manufacturing equipments is not so large as compared with the number of pieces of the measurement data Cj included in the synchronous data Ej, but long-time stops frequently occur. In this case, the number of unused data pieces for the manufacturing equipments which stopped for a long time is specified as the maximum number of unused data pieces, so that precision of association improves.
In some cases, the same measurement item exists in measurement items of different measuring equipments Yj or, for example, measurement items such as the operating current and operating resistance are correlated. The measurement data Cj of the measurement items having such relations often changes in a related manner.
In the present embodiment, the synchronous data generator 32 determines whether association of the synchronous data Ej is proper or not by using measurement items which are related in the different measuring equipments Yj. In the case where the association is improper, it is sufficient to shift the synchronous data Ej in the past direction or the present direction so that the association becomes proper. Thus, the precision of the association can improve.
The relationship among the measurement items will be concretely described with reference to
In
As long as works having similar quality are measured by the same measuring equipment Yj, usually, the operating current and the operating resistance do not change so much. Therefore, the graph in the diagram is of an enlarged view of a specific region, and the inverse-proportional relation between the operating current and the operating resistance can approximate linear function.
Referring to
Concretely, the synchronous data generator 32 pre-stores the measurement items having correlation in different measuring equipments Yj and the range of the coefficient of correlation between the measurement items, calculates the correlation coefficient with respect to the average measurement value of the synchronous data Ej between the measurement items included between the markers M and, when the calculated correlation coefficient lies out of the range, determines that the association between the synchronous data Ej is improper. In this case, properness of the association is determined by using the average measurement value of the synchronous data Ej. Even if a work is added or taken during the operation, the influence on the average measurement value is low. Therefore, the influence on determination of the properness can be suppressed.
As described above, the synchronous data generator 32 determines properness of association of the synchronous data Ej by using the correlation between measurement items. In other words, when the association of the synchronous data Ej is proper, the correlation between other measurement items can be obtained. In the example of
Adjustment using the correlation coefficient is suitable for the case where a measurement value of measurement data included between the neighboring markers M changes. Therefore, the adjustment is suitable for the case where the number of pieces of measurement data included between the markers M is larger than the number of pieces of measurement data Cj in the synchronous data Ej (by approximately 30 to 100 times).
Next, the parameter input device 15 will be described. To change manufacturing parameters of a manufacturing equipment, the site worker W selects a manufacturing equipment and enters new manufacturing parameters to the parameter input device 15. The parameter input device 15 transmits manufacturing parameter data indicative of the inputted manufacturing parameters to the selected manufacturing equipment. Consequently, the manufacturing parameters of the manufacturing equipment which has received the manufacturing parameter data are changed. In the following, the manufacturing equipment whose manufacturing parameters are changed will be called a “changed equipment”.
The parameter input device 15 has an input device for receiving an input from the site worker W. Examples of the input device are a keyboard, a numeric keypad, a pointing device such as a mouse, and a touch panel. In the case of entering the manufacturing parameters by using a bar code, a bar code reader may be used as the parameter input device 15.
In the present embodiment, the parameter input device 15 obtains time when the site worker W enters the manufacturing parameters as manufacturing parameter change time and transmits the obtained change time and changed-equipment information indicative of the changed equipment selected by the site worker W to the data comparator 16. The changed equipment may transmit change time indicative of time when the manufacturing parameters are changed, and changed-equipment information indicative of the changed equipment to the data comparator 16.
The data comparator 16 will now be described with reference to
The synchronous data obtaining unit 42 obtains the synchronous data Ej from the data synchronizer 14. The synchronous data obtaining unit 42 transmits the obtained synchronous data Ej to the change time estimating unit 45.
The changed-equipment information obtaining unit 43 obtains changed-equipment information from the parameter input device 15. The changed-equipment information obtaining unit 43 transmits the obtained changed-equipment information to the line information storage 13. The line information storage 13 reads the average dead time and the average number of unused data pieces of the changed equipment and the average dead time and the average number of unused data pieces of the measuring equipment Yj positioned immediately next to the changed equipment on the downstream side, and transmits the read data to the change time estimating unit 45.
The change time information obtaining unit 44 obtains change time information from the parameter input device 15. The change time information obtaining unit 44 transmits the obtained change time information to the change time estimating unit 45.
The change time estimating unit 45 estimates change time as time when the measurement data Cj in each of the measuring equipments Yj changes in accordance with a change in the manufacturing parameters of the changed equipment. The change time estimating unit 45 transmits synchronous data before the estimated change time as synchronous data before a change, and synchronous data after the estimated change time as synchronous data after the change, to the comparison data generator 46. The process of estimating the change time will be described with reference to
First, the change time estimating unit 45 obtains the average dead time and the average number of unused data pieces of the first processing unit X1 and those of the first measuring equipment Y1 from the line information storage 13, and calculates the difference of the average dead time and the average number of unused data pieces. The difference corresponds to the average dead time and the average number of unused data pieces between the first processing equipment X1 and the first measuring equipment Y1.
Next, the change time estimating unit 45 adds the calculated difference of the average dead time to the change time received from the change time information obtaining unit 44, thereby estimating change time t1(In) in the first measuring equipment Y1. Then, synchronous data (the p-th synchronous data E1(p) in the example of
With respect to the synchronous data Ej(p) of the another measuring equipment Yj associated with the synchronous data E1(p) of the first measuring equipment Y1, the change time estimating unit 45 estimates that the change time tj(In) exists between the measurement time of the Δnj(p,In)-th measurement data Cj from the head, which corresponds to above-mentioned number the Δn1(p,In), and the measurement time of the next measurement data Cj. Consequently, it can be estimated that the data from the head to the Δnj(p,In)-th data is the measurement data Cj before the change and the subsequent measurement data Cj is the measurement data Cj after the change.
The comparison data generator 46 obtains the synchronous data before the change and the synchronous data after the change from the change time estimating unit 45 and generates comparison data Fj indicative of the states before and after the change of the measurement data Cj. The comparison data may be time-series data of the measurement data Cj or statistical data of the measurement data Cj such as histogram. The comparison data generator 46 transmits the generated comparison data to the data display device 17.
Since the influence of the change in the manufacturing parameters does not usually reach measuring equipments upstream of the changed equipment, so that comparison data does not have to be generated. The statistical amount of the synchronous data may be used as comparison data. In this case, however, the details of data fluctuations before and after the change may not be easily referred to.
The data display device 17 will now be described with reference to
The data display device 17 has, although not shown, a display device such as a flat panel display such as a liquid crystal display or plasma display or a CRT, and a display controller for controlling the display device. Desirably, the data display device 17 has a switching unit for switching the graphs of the section data Dj, the synchronous data Ej, and the comparison data Fj in accordance with an instruction of the site worker W.
A concrete example in which the data display device 17 displays the comparison data Fj will be described with reference to
As time elapses from the change time, the influence on the measurement data Cj by factors other than the change in the manufacturing parameters increases. Therefore, by comparing measurement data Cj which is before and after the change and close to the center with each other, the measurement data Cj on which the influence of the factors other than the change in the manufacturing parameters is not exerted so much can be compared with each other.
When comparing the time-series data in a real time manner, it is usually the case that, while many pieces of data before the change as past information exist, only a small amount of data exists immediately after the change as future information.
On the other hand, the site worker W desires to know the result of the change in the manufacturing parameters as soon as possible. Consequently, a conventional data display device displays a sufficient amount of the measurement data Cj before the change and an insufficient amount of the measurement data Cj after the change. However, in a such display, the site worker W is sometimes influenced by the large amount of the measurement data Cj before the change, and erroneously grasps the state after the change.
In contrast, the data display device 17 of the present embodiment displays, as shown in
In the case of
As described above, the data comparator 16 estimates change time of another measuring equipment Yj on the basis of the change time in the measuring equipment Yj as a reference (the first measuring equipment Y1 in
In the data display device 17 of the present embodiment, as shown in
Also in the case of displaying histograms, it is desired that, in a manner similar to the case of displaying time-series data, frequencies of the histogram before the change and those after the change are set almost equal to each other, and that the measurement data Cj around the change time nj(In) is not displayed in the histograms.
Next, the operations in the data display system 10 having the above-described configuration will be described with reference to
When the marker reaches a measuring equipment Yj (S13), the data collector 12 divides a time series of the measurement data Cj obtained by the measuring equipments Yj every marker, thereby generating the section data Dj (S14). When the data collector 12 determines that the section data Dj to be synchronized (associated) with each other among different measuring equipments Yj exists (S15), the data synchronizer 14 obtains line information (the minimum dead time and the maximum number of unused data pieces) from the line information storage 13 and, by using the obtained line information, generates the synchronous data Ej from the section data Dj (S16).
When the site worker W tries to change the manufacturing parameters (S 17) and change time and a equipment to be changed are entered in the parameter input device 15 (S18), the data comparator 16 obtains the line information from the line information storage 13, by using the obtained line information and the synchronous data Ej, estimates the change time in each of the measuring equipments Yj, and generates comparison data with which the synchronous data Ej before and after the estimated change time is compared (S19).
The data display device 17 selects and displays at least one of the section data Dj from the data collector 12, the synchronous data Ej from the data synchronizer 14, and the comparison data Fj from the data comparator 16 (S20). After that, the operations in the data display system 10 are finished.
The present invention is not limited to the foregoing embodiments but can be variously modified in the scope of claims. Embodiments obtained by combining technical means properly modified within the scope of claims are also included in the technical scope of the present invention.
For example, although the marker M is inserted from the upstream end of the manufacturing line ML in the above embodiment, the marker M may be inserted from some midpoint of the manufacturing line ML. A marker can be inserted from any place as long as the place is upstream of, for example, a measuring equipment Yj to be associated.
In the foregoing embodiment, the synchronous data Ej disposed evenly with respect to the section data Dj is generated, the synchronous data Ej is associated with each other among the measuring equipments, and the association is adjusted by using the dead time, the number of unused data pieces, and the correlation coefficient.
Alternatively, the adjustment of the association can be also performed by using at least one of the dead time, the number of unused data pieces, and the correlation coefficient.
It is also possible to generate the synchronous data Ej by using at least one of the dead time, the number of unused data pieces, and the correlation coefficient without using the marker M, and associate the synchronous data Ej with each other among different measuring equipments Yj.
For example, by using the average dead time and the average number of unused data pieces, the synchronous data Ej associated with each other among the measuring equipments Yj can be generated. The generated synchronous data Ej can be adjusted by using the correlation coefficient. It is also possible to determine the range of the synchronous data Ej associated with each other among the measuring equipments Yj by using the minimum dead time and the maximum number of unused data pieces and adjust the synchronous data Ej by using the correlation coefficient while shifting the head of the synchronous data Ej in the determined range.
Further, the measurement data Cj in different measuring equipments Yj can be associated with each other by using at least one of the average dead time, the average number of unused data pieces, and the correlation coefficient without using the marker M.
Finally, each of the devices in the data display system 10, particularly, the data collector 12, the data synchronizer 14, the data comparator 16, and the data display device 17 may be constructed by a hardware logic or by software by using a CPU as follows.
The data display system 10 includes a CPU (Central Processing Unit) for executing an instruction of a control program realizing the functions, a ROM (Read Only Memory) storing the program, a RAM (Random Access Memory) on which the program is expanded, and a storage (recording medium) such as a memory storing the program and various data. The object of the present invention can be also realized in a manner such that a recording medium is supplied to the data display system 10, the recording medium computer-readably recording a program code of the control program (executable program, intermediate code program, or source program) of the data display system 10 as software realizing the above-described functions, and the computer (or CPU or MPU) reads and executes the program code recorded on the recording medium.
Examples of the recording medium are tapes such as a magnetic tape and a cassette tape, disks including magnetic disks such as a floppy (registered trademark) disk and a hard disk and optical discs such as CR-ROM, MO, MD, DVD, and CD-R, cards such as an IC card (including a memory card), and optical cards, and semiconductor memories such as mask ROM, EPROM, EEPROM, and flash ROM.
The data display system 10 may be constructed such that it can be connected to a communication network, and the program code may be supplied via the communication network. The communication network is not limited and, for example, the Internet, intranet, extranet, LAN, ISDN, VAN, CATV communication network, virtual private network, telephone network, mobile communication network, satellite communication network, and the like can be used. A transmission medium as a component of the communication network is not limited. For example, wired transmission such as IEEE1394, USB, power-line carrier, cable TV line, telephone line, and ADSL line or wireless transmission such as infrared rays of IrDA or remote controller, Bluetooth (registered trademark), 802.11 wireless network, HDR, cellular phone network, satellite line, terrestrial digital network, and the like can be also used. The present invention can be also realized in a mode of a computer data signal buried in a carrier wave, as an embodiment of the program code in electronic transmission.
The data associating apparatus and the data display apparatus according to the present invention can be applied not only to a manufacturing line but also to an apparatus for monitoring and controlling various processes of, for example, a home electric appliance.
Number | Date | Country | Kind |
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P2006-159085 | Jun 2006 | JP | national |