1. An evaluation system, comprising:

an index value collection unit that collects, for a lot of a produced product, an evaluation index value that is a value of an evaluation index predetermined for a production element of the product; and

an evaluation unit configured to derive a distribution of the evaluation index values for a plurality of the lots, and generate a public value for each of the lots based on a deviation of the evaluation index value from the distribution, the public value being a value for disclosing the evaluation index.

2. The evaluation system according to claim 1, wherein the evaluation portion generates a group public value for each of the production elements by grouping the public values of the plurality of evaluation indexes for each of the production elements, the group public value being the grouped public value.

3. The evaluation system according to claim 2, wherein the evaluation portion generates a hierarchical public value by setting an upper-level group public value as an upper-level hierarchy and setting the group public value of each of the production elements as a lower-level hierarchy, the upper-level group public value being a result of further grouping the group public values of the plurality of production elements, the hierarchical public value being the hierarchical group public value.

4. The evaluation system according to claim 3, wherein the evaluation portion generates at least one of the public value, the grouping public value, and the hierarchical public value in a radar map.

5. The evaluation system according to claim 3 or 4,

the evaluation system includes a quality value generation section that generates a quality value based on a quality evaluation index value that is a value of an evaluation index predetermined for the quality of the product, the quality value being an index value of a deviation from a distribution of the evaluation index predetermined for the quality of the product,

the evaluation section associates at least one of the public value, the packet public value, and the hierarchical public value with the quality value.

6. The evaluation system according to claim 5,

the index value collection unit collects the evaluation index value from a production management system that controls production equipment that produces the product,

the evaluation unit transmits the public value to a customer system managed by a customer of the product.

7. The evaluation system according to claim 6, wherein the quality value generation section transmits a scatter chart of the quality values and the public values to the demander system.

8. An evaluation method performed by an evaluation system, the evaluation method characterized by comprising:

collecting an evaluation index value for a lot of a produced product, the evaluation index value being a value of an evaluation index predetermined for a production element of the product;

deriving a distribution of the evaluation index values for a plurality of the batches; and

generating a public value for the lot based on a deviation of the evaluation index value from the distribution, the public value being a value for disclosing the evaluation index.

9. The evaluation method according to claim 8, further comprising:

generating a grouping public value for each of the production elements by grouping the public values of the plurality of evaluation indexes for each of the production elements, the grouping public value being the grouped public value.

10. The evaluation method according to claim 9, further comprising:

a hierarchical public value is generated by setting an upper-level grouping public value as an upper-level hierarchy and setting the grouping public value of each of the production elements as a lower-level hierarchy, the upper-level grouping public value being a result of further grouping the grouping public values of the plurality of production elements, the hierarchical public value being the grouping public value of the hierarchical layer.

11. The evaluation method according to claim 10, further comprising:

generating at least one of the public value, the grouping public value and the hierarchical public value in the form of a radar map.

12. The evaluation method according to claim 10 or 11, characterized in that the evaluation method further comprises:

generating a quality value, which is a value of an evaluation index predetermined for the quality of the product, based on a quality evaluation index value that is an index value of a deviation from a distribution of the evaluation index predetermined for the quality of the product; and

associating at least one of the public value, the packet public value, and the hierarchical public value with the quality value.

13. The evaluation method according to claim 12, further comprising:

collecting the evaluation index value from a production management system that controls production equipment that produces the product; and

sending the public value to a system of requesters managed by a requester of the product.

14. The evaluation method according to claim 13, further comprising:

sending a scatter plot of the quality values and the public values to the desirer system.

15. A non-transitory computer-readable storage medium storing one or more programs to be executed by a computer of an evaluation system, the one or more programs causing the computer to:

collecting an evaluation index value for a lot of a produced product, the evaluation index value being a value of an evaluation index predetermined for a production element of the product;

deriving a distribution of the evaluation index values for a plurality of the batches; and

generating a public value for the lot based on a deviation of the evaluation index value from the distribution, the public value being a value for disclosing the evaluation index.

16. The computer-readable non-transitory storage medium of claim 15, wherein the one or more programs cause the computer to:

generating a grouping public value for each of the production elements by grouping the public values of the plurality of evaluation indexes for each of the production elements, the grouping public value being the grouped public value.

17. The computer-readable non-transitory storage medium of claim 16, wherein the one or more programs cause the computer to:

a hierarchical public value is generated by setting an upper-level grouping public value as an upper-level hierarchy and setting the grouping public value of each of the production elements as a lower-level hierarchy, the upper-level grouping public value being a result of further grouping the grouping public values of the plurality of production elements, the hierarchical public value being the grouping public value of the hierarchical layer.

18. The computer-readable non-transitory storage medium of claim 17, wherein the one or more programs cause the computer to:

generating at least one of the public value, the grouping public value and the hierarchical public value in the form of a radar map.

19. The computer-readable non-transitory storage medium of claim 17 or 18, wherein the one or more programs cause the computer to:

generating a quality value, which is a value of an evaluation index predetermined for the quality of the product, based on a quality evaluation index value that is an index value of a deviation from a distribution of the evaluation index predetermined for the quality of the product; and

associating at least one of the public value, the packet public value, and the hierarchical public value with the quality value.

20. The computer-readable non-transitory storage medium of claim 19, wherein the one or more programs cause the computer to:

collecting the evaluation index value from a production management system that controls production equipment that produces the product; and

sending the public value to a system of requesters managed by a requester of the product.

Background

Conventionally, production systems such as process control systems have been constructed for production facilities such as factories and factories, and highly automated operations have been realized. In a conventional production system, conditions for production elements (elements for producing products) are set based on scientific techniques and production techniques established in a research institute. The quality of the product is guaranteed by maintaining the set conditions. Here, the raw Material (Material), equipment (Machine), process (Method), and Man (Man) are also sometimes referred to as "production four elements". In addition, the "production four elements" is sometimes referred to as "4M".

Japanese patent application laid-open No. 2016-. In the technique disclosed in japanese patent application laid-open No. 2016-177794, a lot of a manufacturing process is divided into a plurality of groups based on principal component scores generated based on process data, and the merits of the plurality of groups are determined based on product data. In addition, the product performance and the manufacturing performance are stabilized by determining an interfering factor that affects the quality of the stack.

However, in recent years, the product quality is more strictly demanded from producers by consumers of the products. For example, for an already-obtained product, it is required to suppress the product price and maintain the quality of the product in the past. On the other hand, fluctuations in production elements in production become significant. In the conventional production system, since a burden is mainly imposed on the "process" (actually, control such as process control) in the "four elements of production", fluctuation in product quality is controlled. However, the fluctuation of each production element tends to be large, and the influence on the quality of the product may not be controlled only by the "process".

Generally, in a sales contract between a requester of a product and a producer, delivery specifications of the product are often interchanged. The specifications defined by the delivery specifications are often values (capacity, weight, viscosity, transparency, composition ratio, and the like) that can be actually measured from the produced product (also by the product customer himself, if necessary). Hereinafter, these values (evaluation values) that can be measured from the produced product are referred to as "result evaluation values". On the other hand, the expectation of the customer for the product is not limited to the product specification (result evaluation value). For example, there is aging of the product, etc. (e.g., aging of viscosity after 5 years, transparency, etc.). Although aging and the like of a product can be confirmed to some extent by an accelerated test such as a thermal shock test by sampling, if the product is expected to be extremely high (for example, 99.9% transparency and the like of the product are maintained even after 5 years), the accelerated test by sampling cannot be handled (it is actually necessary to perform an accelerated test on the whole number, and the pressure generated by the accelerated test is applied to the product). As one method for expecting (guaranteeing) quality other than the result evaluation value of the product, there is a method for a product consumer to change the product without modification. This is based on the expectation that products of the same quality can be produced continuously if they are the same producer. However, the product demander cannot know the change in the production element of the product from the result evaluation value of the product. Therefore, the product demander may request the product producer to maintain the production factors of the product and further request the evaluation result. Hereinafter, an evaluation value of a change in a production element or the like that cannot be expressed by a product achievement evaluation value is referred to as a "process evaluation value". On the other hand, for the producer of the product, in a case where the process evaluation value of the product is faithfully provided to the consumer of the product, a possibility arises that other producers (competitors) imitate the production process based on the provided process evaluation value (know-how outflow). Further, it is possible to reduce the margin for the manufacturer to carry out the drilling work for reducing the production cost even when the manufacturing process is strictly disclosed (agreed) to the customer.

Disclosure of Invention

In order to solve the above problem, an evaluation system (1a) according to one embodiment of the present invention includes: an index value collection unit (10) that collects, for a batch of a produced product, an evaluation index value that is a value of an evaluation index predetermined for a production element of the product; and an evaluation unit (12a) that derives a distribution of the evaluation index values for a plurality of the lots, and generates a public value (101) for each of the lots on the basis of a deviation of the evaluation index value from the distribution, the public value (101) being a value for disclosing the evaluation index.

In the evaluation system (1b) according to one aspect of the present invention, the evaluation unit (12b) groups the public values of the plurality of evaluation indexes for each production element, thereby generating a group public value for each production element, the group public value being the grouped public value.

In addition, in an evaluation system (1c) according to one aspect of the present invention, an evaluation unit (12c) generates a hierarchical public value (102) by setting an upper-level group public value as an upper-level hierarchy and setting the group public value for each production element as a lower-level hierarchy, the upper-level group public value being a result of further grouping the group public values of the plurality of production elements, and the hierarchical public value (102) being the group public value that is hierarchically layered.

In the evaluation system according to one aspect of the present invention, the evaluation unit generates at least one of the public value, the grouping public value, and the hierarchical public value in the form of a radar map.

An evaluation system according to an aspect of the present invention includes a quality value generation unit (13) that generates a quality value (103) based on a quality evaluation index value that is an evaluation index predetermined for the quality of the product, the quality value (103) being an index value of a deviation from a distribution of the evaluation index predetermined for the quality of the product, and the evaluation unit associates at least one of the public value, the group public value, and the hierarchical public value with the quality value.

In the evaluation system according to an aspect of the present invention, the index value collection unit collects the evaluation index value from a production management system that controls a production facility that produces the product, and the evaluation unit transmits the public value to a customer system managed by a customer of the product.

In the evaluation system according to one aspect of the present invention, the quality value generation unit may transmit a scatter chart of the quality value and the public value to the customer system.

An evaluation method according to an aspect of the present invention is executed by an evaluation system, and includes: collecting an evaluation index value for a lot of a produced product, the evaluation index value being a value of an evaluation index predetermined for a production element of the product; deriving a distribution of the evaluation index values for a plurality of the batches; and generating a public value (101) for the lot based on a deviation of the evaluation index value from the distribution, the public value (101) being a value for disclosing the evaluation index.

In addition, the evaluation method according to an embodiment of the present invention further includes: generating a grouping public value for each of the production elements by grouping the public values of the plurality of evaluation indexes for each of the production elements, the grouping public value being the grouped public value.

In addition, the evaluation method according to an embodiment of the present invention further includes: a hierarchical public value is generated by setting an upper-level grouping public value as an upper-level hierarchy and setting the grouping public value of each of the production elements as a lower-level hierarchy, the upper-level grouping public value being a result of further grouping the grouping public values of the plurality of production elements, the hierarchical public value being the grouping public value of the hierarchical layer.

In addition, the evaluation method according to an embodiment of the present invention further includes: generating at least one of the public value, the grouping public value and the hierarchical public value in the form of a radar map.

In addition, the evaluation method according to an embodiment of the present invention further includes: generating a quality value, which is a value of an evaluation index predetermined for the quality of the product, based on a quality evaluation index value that is an index value of a deviation from a distribution of the evaluation index predetermined for the quality of the product; and associating at least one of the public value, the packet public value, and the hierarchical public value with the quality value.

In addition, the evaluation method according to an embodiment of the present invention further includes: collecting the evaluation index value from a production management system that controls production equipment that produces the product; and sending the public value to a system of desirers managed by a desirer of the product.

In addition, the evaluation method according to an embodiment of the present invention further includes: sending a scatter plot of the quality values and the public values to the desirer system.

A computer-readable non-transitory storage medium according to an aspect of the present invention stores a program executed by a computer of an evaluation system, the one or more programs causing the computer to: collecting an evaluation index value for a lot of a produced product, the evaluation index value being a value of an evaluation index predetermined for a production element of the product; deriving a distribution of the evaluation index values for a plurality of the batches; and generating a public value for the lot based on a deviation of the evaluation index value from the distribution, the public value being a value for disclosing the evaluation index.

In a computer-readable non-transitory storage medium according to an aspect of the present invention, the one or more programs cause the computer to: generating a grouping public value for each of the production elements by grouping the public values of the plurality of evaluation indexes for each of the production elements, the grouping public value being the grouped public value.

In a computer-readable non-transitory storage medium according to an aspect of the present invention, the one or more programs cause the computer to: a hierarchical public value is generated by setting an upper-level grouping public value as an upper-level hierarchy and setting the grouping public value of each of the production elements as a lower-level hierarchy, the upper-level grouping public value being a result of further grouping the grouping public values of the plurality of production elements, the hierarchical public value being the grouping public value of the hierarchical layer.

In a computer-readable non-transitory storage medium according to an aspect of the present invention, the one or more programs cause the computer to: generating at least one of the public value, the grouping public value and the hierarchical public value in the form of a radar map.

In a computer-readable non-transitory storage medium according to an aspect of the present invention, the one or more programs cause the computer to: generating a quality value, which is a value of an evaluation index predetermined for the quality of the product, based on a quality evaluation index value that is an index value of a deviation from a distribution of the evaluation index predetermined for the quality of the product; and associating at least one of the public value, the packet public value, and the hierarchical public value with the quality value.

In a computer-readable non-transitory storage medium according to an aspect of the present invention, the one or more programs cause the computer to: collecting the evaluation index value from a production management system that controls production equipment that produces the product; and sending the public value to a system of desirers managed by a desirer of the product.

According to the present invention, it is possible to prevent a recipe or the like for producing a product from flowing out to a third party while ensuring the reliability of a user of the product (without changing from the conventional product).

Further features and aspects of the present invention will become apparent from the detailed description of the embodiments given below with reference to the accompanying drawings.

Drawings

Fig. 1 is a diagram showing an example of the configuration of a production system in the first embodiment.

Fig. 2 is a diagram showing an example of the process evaluation index definition in the first embodiment.

Fig. 3 is a diagram showing an example of the configuration of the evaluation system in the first embodiment.

Fig. 4 is a diagram showing an example of the published value associated with the reaction time for each batch in the first embodiment.

Fig. 5 is a diagram showing an example of each disclosed value in the first embodiment.

Fig. 6 is a flowchart showing an example of the operation of the evaluation system in the first embodiment.

Fig. 7 is a diagram showing an example of the configuration of the production system in the second embodiment.

Fig. 8 is a diagram showing an example of the configuration of the evaluation system in the second embodiment.

Fig. 9 is a diagram showing an example of the definition of each evaluation index in the second embodiment.

Fig. 10 is a diagram showing an example of a packet public value in the second embodiment.

Fig. 11 is a diagram showing an example of hierarchical public values in the second embodiment.

Fig. 12 is a diagram showing an example of the configuration of the production system in the third embodiment.

Fig. 13 is a diagram showing an example of quality evaluation index definition in the third embodiment.

Fig. 14 is a diagram showing an example of the configuration of the evaluation system according to the third embodiment.

Fig. 15 is a diagram showing an example of quality values associated with the transparency of each lot in the third embodiment.

Fig. 16 is a diagram showing an example of the quality value in the third embodiment.

Fig. 17 is a diagram showing an example of a tree diagram of a group of hierarchical public values according to the third embodiment.

Fig. 18 is a diagram showing an example of a scatter diagram of groups of hierarchical public values and quality values in the third embodiment.

Detailed Description

The embodiments of the present invention will be described with reference to preferred embodiments. Those skilled in the art, having the benefit of the teachings of this invention, will be able to implement numerous alternative embodiments to the one described herein, and the invention is not limited to the preferred embodiments described herein.

One embodiment of the present invention provides an evaluation system, an evaluation method, and a computer-readable non-transitory storage medium that can ensure the reliability of a product requester (without changing from a conventional product) and prevent a production recipe and the like of a product from going outside a third party.

The evaluation system, the evaluation method, and the computer-readable non-transitory storage medium according to the embodiments of the present invention will be described in detail below with reference to the drawings. Hereinafter, an outline of embodiments of the present invention will be described first, and then details of each embodiment of the present invention will be described.

[ summary ]

In the embodiment of the present invention, even if a producer submits an evaluation result (process evaluation value) of fluctuation of production elements of a product to a customer, it is possible to prevent other producers from simulating a production process or the like based on the evaluation result.

In the device industry, the technology has matured over a long history, and stable work has been performed. In a conventional production method, predetermined production conditions are set for each production element based on chemical techniques and production techniques established in the institute, and a producer maintains the quality of a product by maintaining the production conditions.

Sometimes producers produce products as raw materials for finished products. For example, sometimes manufacturers produce films (resins) as raw materials of finished products, i.e., smart phones. Such a manufacturer purchases raw materials from a predetermined same raw material manufacturer in order to attach importance to the quality of a product, performs a predetermined same quality check on the product through a predetermined same production process, and provides the product to a customer, i.e., a customer, of the manufacturer in the supply chain of the manufacturing industry.

A demander, which is a customer of a producer, orders a required amount of a product from the producer. To produce a product, a manufacturer orders a required amount of raw materials from a raw material manufacturer and receives the raw materials before the delivery date. The manufacturer uses the received raw materials to produce the product, and delivers the product to the demander before the delivery date. In a conventional supply chain, the same producer often becomes a supplier based on years of business or past quality measures.

The demander avoids the delivery delay or poor quality of the product from affecting the demander by thus selecting a producer based on past practice and ordering the product from a plurality of producers selected based on past practice.

Production conditions for maintaining the quality of the produced product at a predetermined level are determined for each production element. For example, for each production element of "4M", the production conditions are determined in the following manner.

Production element "raw material": typically, the feedstock is composed of a plurality of components. The allowable ranges of the plurality of components are determined as production conditions.

Production element "plant": in the construction or repair of the equipment, a plant user or a plant engineer designs the equipment. The equipment is constructed or installed based on the design.

Production element "process": in the past, the conditions of raw materials and equipment were kept constant, and fluctuations in production factors were absorbed by the "process". In addition, in the conventional production process, real-time control using a sequential control logic, a PID (Proportional Integral derivative) control logic, or the like is performed to obtain a target result.

Production element "human": a person performs processing of a portion in the production facility that is difficult to automate. The processing of the portion difficult to automate refers to, for example, handling for coping with the occurrence of an abnormality, replacement of a production target, maintenance of production equipment, and the like.

The method and system for producing a product from a raw material using "4M" are sometimes collectively referred to as a "production management system". The entire system that provides the method and function of not changing 3M other than the "process" in "4M", or the entire system that provides the method and function of suppressing the change in the "process" may be referred to as a "process control system".

As examples of the peripheral environment of the current production industry, there are activation of global competition, wide fluctuation in the cost of energy or raw materials, reduction and aging of labor population, and diversification of supply chains independent of series. Due to such an environmental change, the following phenomena (1) to (4) start to occur in the production management system of the producer.

(1) The quality of the raw Material (Material) is becoming non-constant.

(2) The aging of the device (Machine) is aggravating.

(3) The manufacturer has not developed the trouble of working process (Method) for straight surface.

(4) People at a skilled level (Man) are reduced and producers lose know how to operate the plant.

That is, in the case where the producer uses equipment with a lot of deterioration in quality of raw materials and uses a person having few know-how for operating the equipment, the producer needs to provide differentiated products to consumers with higher quality than before.

Furthermore, the demander is strictly required to provide a high and uniform quality product as a producer of the downstream process of the supply chain. For example, in order for a producer to prove that the quality of a product has not changed from the conventional one (the conventional quality is maintained), a requester may request submission of a production process. In addition, for example, in the case of a raw material used by a producer, sometimes a demander instructs the producer not to use an inexpensive raw material.

Thus, it becomes necessary for the requester to impose strict ordering conditions on the producer. In order to meet the requirements of the demanders, all products should be inspected before the products are shipped. However, when the product destruction behavior is included in the necessary inspection items, the inspection of all the products cannot be performed, the production cost increases, and much time is taken until the product is shipped, so that there is a limit to the number of man-hours taken for the verification before the product is shipped. However, even if the quality is poor only once, there is a risk that the producer cannot obtain the next order from the customer.

Therefore, the producer is required to visualize the quality of the product. As a numeralization for visualizing the quality of a product, there are a numerical value (result evaluation value) related to the quality of a product provided to a customer and a numerical value (process evaluation value) related to a production process of a product provided to a customer. The result evaluation value is an evaluation value that can be measured from the product itself, such as a measurement value and fluctuation of the product provided to the customer. The process evaluation value is a value measured or managed in the production process. The process evaluation value is disclosed to the customer, thereby becoming a certificate for making the customer use the product with confidence. However, conventionally, from the viewpoint of preventing the flow of the know-how, etc., it has been avoided as much as possible to directly present the real process evaluation value (the value itself measured in the production process) to the customer.

In an embodiment of the present invention, an evaluation system collects, for each lot of a produced product (hereinafter referred to as "product lot"), an evaluation index value that is a value of an evaluation index (Key Performance Indicator) predetermined for a production element of the product. The evaluation index value may also be said to be a true process evaluation value. The evaluation system derives the distribution of the evaluation index values for a plurality of product batches. The evaluation system generates a value for disclosing the evaluation index for each product lot based on a deviation of the evaluation index value from a distribution center of the evaluation index value. Thus, in the embodiment of the present invention, even if a producer submits a process evaluation result for disclosing a value of an evaluation index as a production element of a product to a customer, another producer (competitor) cannot simulate a production process based on the process evaluation result.

[ first embodiment ]

Production system

Fig. 1 is a diagram showing an example of the configuration of a production system 100a according to the first embodiment. The production system 100a is a system for producing a product using a raw material. The production system 100a is managed by a producer (e.g., a raw material manufacturer). The production system 100a produces a product 301 using the raw material 300 based on the order information 201 acquired from the customer system 200. The production system 100a outputs a value for disclosing an evaluation index (hereinafter referred to as "disclosed value") and a product 301 to the requester system 200.

The public value 101 becomes a certificate for certifying that the product is produced in a usual (as usual) production process. Since the public value 101 is not an evaluation index value (for example, the temperature of a reactor in a production facility) itself, other producers cannot simulate a production process based on the public value 101. An evaluation index value is determined in advance for each production element of the product 301. The production elements are, for example, raw materials, equipment, processes, and people. Generally, each production element has a plurality of evaluation index values (e.g., origin, grade, viscosity, etc. of the raw material). However, in the description of the first embodiment, an example is shown in which one evaluation index value that is considered to have the most influence on the product quality is set for each production element (an example in which a plurality of evaluation index values are set for each production element is described later). In addition, in the case where the producer is, for example, a raw material manufacturer, the product 301 is a raw material produced in the production system 100 a.

System of needs

The demander system 200 is a system managed by a demander (repeat purchaser) of a product. The demander system 200 sends the order information 201 for the product 301 to the production system 100 a. In the case where the requester is, for example, a product manufacturer, the product 301 is a raw material of the finished product produced in the requester system 200. The requester system 200 takes the public value 101 and the product 301 from the production system 100 a.

Next, the configuration of the production system 100a will be explained.

The production system 100a includes an evaluation system 1a, a production facility 2, a talent management system 3, and a production management system 4 a. The production management system 4a includes a material management system 40, a process management system 41, and an equipment management system 42.

The production facility 2 is provided with the necessary facilities for producing the product. Examples of necessary equipment include piping, valves, pumps, reactors, and vessels. The production apparatus 2 produces (manufactures) a product 301 using the raw material 300 based on the control of the production management system 4 a. The talent management system 3 outputs a value of an evaluation index (hereinafter referred to as "human evaluation index value") predetermined for a human (a talent engaged in the production of a product) to the evaluation system 1a via the production management system 4 a.

The production management system 4a controls the operation of the production apparatus 2 based on the order information 201. The material management system 40 generates a value of an evaluation index (hereinafter referred to as "material evaluation index value") predetermined for a material. The process management system 41 generates a value of an evaluation index (hereinafter referred to as "process evaluation index value") predetermined for a production process. The device management system 42 generates a value of an evaluation index (hereinafter referred to as "device evaluation index value") predetermined for a device. The production management system 4a may generate a value of an evaluation index (hereinafter referred to as "environmental evaluation index value") predetermined for the environment of the production facility.

Fig. 2 is a diagram showing an example of the process evaluation index value in the first embodiment. The process evaluation index value is a process evaluation value assumed to have the most influence on the quality of the product, and is, for example, one of the pre-reaction temperature, the temperature rise gradient, the reaction time, the reaction internal pressure, the cooling gradient, and the post-reaction temperature of the reactor (not shown) of the production facility 2.

The evaluation system 1a shown in fig. 1 collects evaluation index values of the respective production elements from the production management system 4a for each lot of the product 301. The evaluation system 1a generates the public value 101 for each lot of the product 301 as a certificate for certifying that the product is produced in a usual (as usual) production process. The evaluation system 1a sends the public value 101 to the demander system 200 for each batch of the product 301.

Next, a configuration example of the evaluation system 1a will be explained.

Fig. 3 is a diagram showing an example of the configuration of the evaluation system 1a according to the first embodiment. The evaluation system 1a includes an index value collection unit 10, an evaluation index storage unit 11a, and an evaluation unit 12 a. The evaluation unit 12a includes a public value generation unit 120.

The index value collection unit 10 collects a raw material evaluation index value, an equipment evaluation index value, a process evaluation index value, a human evaluation index value, and an environmental evaluation index value from the production management system 4a for each product lot. The index value collection unit 10 acquires the product lot number of the product 301 from the production management system 4a for each product lot. The index value collection unit 10 transmits the material evaluation index value, the equipment evaluation index value, the process evaluation index value, the human evaluation index value, the environmental evaluation index value, and the product lot number of the product 301 to the evaluation unit 12 a. The evaluation index storage unit 11a stores each evaluation index value. The evaluation index storage unit 11a outputs each evaluation index value to the public value generation unit 120.

The public value generating unit 120 acquires each evaluation index value of the past product lot from the evaluation index storage unit 11 a. The public value generation unit 120 acquires a material evaluation index value, a device evaluation index value, a process evaluation index value, a human evaluation index value, an environmental evaluation index value, and a product lot number of the product 301 of the production lot from the index value collection unit 10. The public value generation unit 120 compares each evaluation index value of a production lot with evaluation index values of a plurality of past product lots, and derives a distribution of the evaluation index values. The public value generating unit 120 generates a public value for each lot based on a deviation from the distribution of the evaluation index values. That is, the public value is a numerical value indicating at which position each evaluation index value, which is a process evaluation value of a currently-produced lot, is positioned with respect to the distribution of each evaluation index value of past product lots. Therefore, it is difficult for the demander to derive a true evaluation index value (process evaluation value) from the public value, and outflow of the production recipe and the like can be prevented. In addition, the public value is represented by, for example, an integer (score) from 1 to 5.

Fig. 4 is a diagram showing an example of the published value associated with the reaction time for each product lot in the first embodiment. The horizontal axis represents the deviation (distance from the distribution center of the reaction time) of the evaluation index value (for example, reaction time) of each product lot. The vertical axis represents the frequency of the product batches. The public value generating unit 120 generates a public value regarding the reaction time as an evaluation index of the current batch from the distribution (fluctuation) of the reaction times of the past product batches. For example, the closer the reaction time is to the center of the distribution, the higher the public value relating to the reaction time becomes. That is, the closer the public value is to 5 points (highest points) the more the reaction time is normal (same as usual), and the closer the public value is to 1 point (lowest points) the more the reaction time is different from normal.

The public value generation unit 120 may generate the public value based on comparison with a product lot (hereinafter, referred to as a "reference lot") determined to be more preferable among the past product lots, instead of the comparison with the distribution of the evaluation index values of the past product lots. For example, the Mahalanobis Distance (MD) may be derived as a public value by using the Mahalanobis Taguchi Method (MT Method) for a reference space composed of reference batches. The public value generating unit 120 may change the weight of the public value for each production element according to the importance of each production element.

Hereinafter, the public value relating to the raw material evaluation index is referred to as "raw material public value". The public value related to the equipment evaluation index is referred to as "equipment public value". The public value related to the process evaluation index is referred to as a "process public value". The public value related to the human evaluation index is referred to as a "human public value". The public value related to the environmental evaluation index is referred to as an "environmental public value".

Fig. 5 is a diagram showing an example of each disclosed value in the first embodiment. In fig. 5, a material public value, an equipment public value, a process public value, and a person public value are associated with each product lot number. The public values are generated, for example, in the form of radar maps. The public value generating unit 120 transmits at least one of the material public value, the equipment public value, the process public value, and the person public value, and the lot number of the product 301 to the customer system 200 according to the request of the customer. In addition, material public values, equipment public values, process public values, human public values, and environment public values may also be associated with each product lot number. The public value generating unit 120 may transmit the environment public value to the customer system 200.

Next, an operation example of the evaluation system 1a will be described.

Fig. 6 is a flowchart showing an example of the operation of the evaluation system 1a in the first embodiment. The index value collection unit 10 collects an evaluation index value of each production element from the production management system 4a for each produced product lot (step S101). The evaluation unit 12a derives a result of comparison between the evaluation index value of the current product lot and the distribution of the evaluation index values of the plurality of past product lots as a first public value (fluctuation public value) of the evaluation index value. For example, as shown in fig. 4, the evaluation unit 12a derives a comparison result of the distribution of values of the reaction times of the current product lot and the past product lots as a first public value of the reaction time (step S102). The evaluation unit 12a generates a second public value (deviation public value) as an evaluation index value based on a deviation "σ" of the evaluation index value of the current lot from the distribution center of the past product lot. For example, as shown in fig. 4, the evaluation unit 12a generates a score from 1 to 5 points as a second public value of the reaction time of the production lot based on the deviation "σ" of the distribution center of the values of the reaction time with respect to the past production lot (step S103). The evaluation unit 12a outputs the public value 101 including at least one of the first public value and the second public value to the customer system 200 (step S104).

As described above, the index value collection unit 10 collects, for each lot of the product 301 being produced, an evaluation index value that is a value of an evaluation index (for example, raw material, equipment, process, human, environment) predetermined for a production element of the product 301. The public value generation unit 120 derives a distribution of evaluation index values for a plurality of past product lots. The public value generation unit 120 generates the public value 101 based on a deviation of the evaluation index value of the current production lot from the distribution center of the evaluation index values of the plurality of past production lots.

Thus, in the first embodiment, even if the public value 101 is submitted to the customer as the evaluation result of the production process of the product 301, since the public value 101 is not the evaluation index value (process evaluation value) itself, it is possible to make it impossible for another producer to simulate the production process based on the public value 101. The customer can objectively evaluate the production process of the product 301 based on the public value 101.

[ second embodiment ]

The second embodiment differs from the first embodiment in that the evaluation unit includes a grouping unit and a hierarchical unit. In the second embodiment, differences from the first embodiment will be mainly described.

Hereinafter, the public value grouped by each production element is referred to as a "grouped public value". The packet public value of the hierarchical layer is referred to as a "hierarchical layer public value".

Fig. 7 is a diagram showing an example of the configuration of the production system 100b in the second embodiment. The production system 100b includes an evaluation system 1b, a production facility 2, a talent management system 3, and a production management system 4 b. The production management system 4b includes a material management system 40, a process management system 41, and an equipment management system 42.

The production system 100b produces the product 301 using the raw material 300 based on the order information 201 acquired from the demander system 200. The production system 100b outputs the hierarchical public value 102 and the product 301 to the demander system 200.

Next, a configuration example of the evaluation system 1b will be described.

Fig. 8 is a diagram showing an example of the configuration of the evaluation system 1b according to the second embodiment. The evaluation system 1b includes an index value collection unit 10, an evaluation index storage unit 11b, and an evaluation unit 12 b. The evaluation unit 12b includes a public value generation unit 120, a grouping unit 121, and a hierarchical unit 122.

The index value collection unit 10 collects one or more evaluation index values from each production element. In the first embodiment, one evaluation index is collected for each production element, but actually, in most cases, a plurality of evaluation index values to be targeted are provided for each production element.

Fig. 9 shows an example of a list of evaluation index values extracted for each production element. Hereinafter, the evaluation index values for each production element are collectively referred to as "evaluation index definition". Fig. 9 illustrates a raw material evaluation index definition, an equipment evaluation index definition, a process evaluation index definition, a human evaluation index definition, and an environmental evaluation index definition. For example, the raw material evaluation index is defined by the origin of the raw material, the grade of the raw material, the property a of the raw material, the property B of the raw material, and the storage period of the raw material. The content of the evaluation index definition may be determined by the producer itself or may be determined based on the instruction of the customer. Further, each evaluation index definition (an evaluation index selected for each production element) may be stored in the evaluation index storage unit.

The public value generating unit 120 in fig. 8 generates a public value for each evaluation index value collected by the index value collecting unit 10 (by the same method as in the first embodiment). The grouping unit 121 obtains the material public value, the equipment public value, the process public value, and the person public value, and the lot number of the product 301 from the public value generating unit 120. The grouping unit 121 groups the public values of the evaluation indexes for each production element based on the above-described definitions of the evaluation indexes, thereby generating a grouping public value for each production element.

Fig. 10 is a diagram showing an example of a packet public value in the second embodiment. A group public value for each production element is generated for a plurality of evaluation indices, for example in the form of radar maps. In fig. 10, the group public values of the production elements "steps" are generated as radar maps for the evaluation index "temperature before reaction", the evaluation index "temperature after reaction", the evaluation index "cooling slope", the evaluation index "internal pressure at reaction", the evaluation index "reaction time", and the evaluation index "temperature rising slope". In this example, the public value on the vertical axis of the radar chart shows that the public value is closer to 5 points (highest points) as usual (as usual), and is closer to 1 point (lowest points) as usual, but the public value may have another expression.

The grouped public values of each production element are summarized for the evaluation index predetermined as the operation condition. In fig. 10, as an example, the group public value of the production element "process", the group public value of the production element "raw material", the group public value of the production element "facility", and the group public value of the production element "person" are summarized for the environmental evaluation index "day time, air temperature, humidity, and week" as the operation condition. The grouping section 121 outputs the grouping public value and the product lot number to the hierarchy section 122.

The grouping unit 121 may transmit the grouping public value and the product lot number to the customer system 200. The grouping public value shown in fig. 10 may be displayed on a display device (not shown) of the requester system 200.

Fig. 11 is a diagram showing an example of hierarchical public values in the second embodiment. The hierarchy section 122 acquires a grouping public value from the grouping section 121 for each product lot. In fig. 11, the hierarchical portion 122 acquires, for each product lot, a group disclosure value of the production element "raw material", a group disclosure value of the production element "equipment", a group disclosure value of the production element "process", and a group disclosure value of the production element "person" from the grouping portion 121.

The hierarchy section 122 further groups the grouped public values of the plurality of production elements. Hereinafter, the grouping of the group public values of the plurality of production elements is referred to as "upper group public value". In fig. 11, upper-level group public values are generated as a radar map for the group public value of the production element "raw material", the group public value of the production element "device", the group public value of the production element "process", and the group public value of the production element "person". The hierarchy section 122 generates the hierarchy public value 102 by setting the upper layer grouping public value as an upper layer hierarchy and setting the grouping public value for each production element as a lower layer hierarchy.

The hierarchical public values 102 are generated for a plurality of production elements, for example in the form of hierarchical radar maps. In fig. 11, as an example, a hierarchical public value 102 is generated as a radar map of a hierarchy for a production element "raw material", a production element "equipment", a production element "process", and a production element "person". For example, the vertical axes (0 to 4) in the radar chart may be determined based on the balance of public values of the production elements. The hierarchy layer portion 122 sends the hierarchy public value 102 and the product lot number to the requestor system 200. The hierarchical public value 102 is displayed on a display device (not shown) of the system 200.

The evaluation unit 12c may receive a signal of a click operation as a signal of an operation (drill-down) for lowering the hierarchy of the evaluation index value and further refining the item of the evaluation index value. In a state where the hierarchical public value shown in fig. 11 is displayed on a display device (not shown) and the radar chart of the group public value of the production element "material" is not displayed, the evaluation unit 12c may display the radar chart of the group public value of the production element "material" when, for example, a click operation is performed on a region displayed as "material" in the upper-level group public value.

As described above, the grouping unit 121 groups the public values of the plurality of evaluation indexes for each production element to generate a grouping public value for each production element. The hierarchy section 122 generates the hierarchy public value 102 by setting an upper layer grouping public value as an upper layer hierarchy and setting a grouping public value for each production element as a lower layer hierarchy.

Thus, in the second embodiment, even if the producer submits the group public value or the hierarchical public value 102 to the customer as the evaluation result of the production element of the product, since the group public value or the hierarchical public value 102 is not the evaluation index value itself, it is possible to make it impossible for another producer to simulate the production process based on the group public value or the hierarchical public value 102. The hierarchical portion 122 can display an evaluation index, which is an obstacle factor causing fluctuation in product quality, on a display device (not shown) in an easily understandable manner using a radar map. The hierarchical portion 122 can display an evaluation index, which is an obstacle factor for generating fluctuation in product quality, on a display device (not shown) in an easily understandable manner, based on the drill-down process for the hierarchical public value.

[ third embodiment ]

The third embodiment differs from the second embodiment in that the production management system includes a quality management system, and the evaluation system includes a quality value generation unit. In the third embodiment, points different from the second embodiment will be mainly described.

Fig. 12 is a diagram showing an example of the configuration of a production system 100c according to the third embodiment. The production system 100c includes an evaluation system 1c, a production facility 2, a talent management system 3, and a production management system 4 c. The production management system 4c includes a material management system 40, a process management system 41, an equipment management system 42, and a quality management system 43. The quality management system 43 generates a result evaluation value (hereinafter referred to as "quality evaluation index value") predetermined for the quality of the product.

Fig. 13 is a diagram showing an example in which a plurality of predetermined achievement evaluation values are defined as quality evaluation index definitions of constituent items in the third embodiment. In fig. 13, as an example, the quality evaluation indexes are defined as transparency, tear strength, flexibility, surface roughness, and glossiness. The production management system 4c transmits the quality evaluation index value to the evaluation system 1 c. The quality evaluation index definition may be stored in an evaluation index storage unit described later.

Next, a configuration example of the evaluation system 1c will be described.

Fig. 14 is a diagram showing an example of the configuration of the evaluation system 1c according to the third embodiment. The evaluation system 1c includes an index value collection unit 10, an evaluation index storage unit 11c, an evaluation unit 12c, and a quality value generation unit 13.

The index value collection unit 10 collects a raw material evaluation index value, an equipment evaluation index value, a process evaluation index value, a human evaluation index value, an environmental evaluation index value, and a quality evaluation index value as a result evaluation value from the production management system 4c for each product lot. The index value collection unit 10 acquires the product lot number of the product 301 from the production management system 4 c. The index value collection unit 10 transmits the material evaluation index value, the equipment evaluation index value, the process evaluation index value, the human evaluation index value, the environmental evaluation index value, and the product lot number of the product 301 to the evaluation unit 12 c. The index value collection unit 10 transmits the quality evaluation index value of each quality evaluation index and the product lot number of the product 301 to the quality value generation unit 13.

The quality value generation unit 13 acquires the quality evaluation index value and the product lot number of the product 301 from the index value collection unit 10. The quality value generation unit 13 acquires the quality evaluation index definition from the evaluation index storage unit 11 c. The quality value generation unit 13 generates an index value (hereinafter referred to as "quality value") of a deviation from a distribution of evaluation indexes predetermined for the quality of a product, based on a quality evaluation index value of each quality evaluation index.

Fig. 15 is a diagram showing an example of quality values associated with the transparencies of a plurality of product lots in the third embodiment. The horizontal axis represents the distribution of transparency for multiple product batches. The vertical axis represents the frequency of the product batches. The public value generation unit 120 derives a quality value related to the transparency as an evaluation index for each product lot. The closer the transparency is to the distribution center of the transparency, the higher the public value relating to the transparency becomes. That is, the more common (as usual) transparency, the closer the public value becomes to 5 points (highest points). The more the transparency is different from the usual one, the closer the public value relating to the transparency becomes to 1 point (lowest point).

The quality value generation unit 13 may generate the quality value not based on the comparison with the distribution of the quality values of the past product batches but based on the comparison with a product batch (hereinafter, referred to as a reference batch) determined to be more preferable among the past product batches. The quality value generation unit 13 may derive the mahalanobis distance as the quality value by using the mahalanobis mouth method for the reference space formed by the reference batch, for example. The quality value generation unit 13 may change the weight of the quality value for each evaluation index according to the importance of the evaluation index.

Fig. 16 is a diagram showing an example of the quality value in the third embodiment. The quality value generation unit 13 generates quality values by grouping (clustering) the quality evaluation index values of the plurality of quality evaluation indexes. In fig. 16, as an example, the quality value generation unit 13 generates a quality value including a quality evaluation index value related to transparency, a quality evaluation index value related to tear strength, a quality evaluation index value related to softness, a quality evaluation index value related to surface roughness, and a quality evaluation index value related to glossiness for each product lot. The quality value generation unit 13 generates a quality value in the form of a radar map, for example. In the present example, the quality value on the vertical axis of the radar chart indicates that the quality value becomes closer to 5 points (highest points) as usual (as usual) and 1 point (lowest points) as usual, but the quality value may be expressed in other ways. The quality value generation section 13 transmits the quality value 103 to the demander system 200.

Fig. 17 is a diagram showing an example of a tree representation of the public value and the quality value of the evaluation index value in the third embodiment. The quality value generation unit 13 may associate the public value of the process evaluation item and the quality value of the result evaluation item with the product lot number and transmit them to the customer system 200 in order to prove that the product evaluation value cannot be shown, such as to suppress the deterioration of the transparency. In fig. 17, for example, the public value of the raw material/production area is 3, which is different from the conventional value. To cope with this, the temperature is raised at a slightly different rate (disclosure value of 4) from the usual one. As a result, the transparency in the intermediate step becomes the same as usual (disclosure value of 5). In addition, the stirring device has a distribution slightly different from that of the conventional stirring device (the public value is 4, for example, the stirring speed is slightly fluctuated), but the same operator as the conventional stirring device operates the stirring device (the public value is 5), so that the product has the same transparency distribution (the quality value is 5) as the conventional stirring device. By providing these values to the customer, the customer can be trusted with the same product lot.

Fig. 18 is a diagram showing an example of a scatter diagram of public values as process evaluation indexes and quality values as result evaluation indexes in the third embodiment. The horizontal axis represents the quality value of the achievement evaluation index associated with a plurality of product lot numbers. The vertical axis represents the published values of the process evaluation index associated with a plurality of product lot numbers. The quality value generation unit 13 may transmit a scatter chart of the quality values and the public values to the customer system 200. As an example, fig. 18 shows that a plurality of past product lots are distributed in 5 clusters of a to E. In addition, the dotted square frame indicates the allowable range, and in this example, indicates that all the product lots are within the allowable range. Here, for example, it may be indicated at which position (star in the figure) the lot currently in production (or the production lot currently shipped) is distributed. In addition, when a reference batch is provided, the reference batch may be explicitly indicated. As described above, the quality value generation unit has a function of associating the public value of the process evaluation index of the product lot with the quality value of the result evaluation index and providing the associated value to the customer.

In addition, the quality control system 43 shown in fig. 12 may determine which group the lot of the product 301 under production belongs to by using a scatter chart during production of the product 301. In this case, the quality control system 43 may set the horizontal axis of fig. 18 as, for example, the public value Z of the process evaluation index. If the state of the lot currently in production is located at the position of the star mark, the post-process can be adjusted to be closer to the cluster D as the reference lot.

The quality value generation section 13 transmits the quality value 103 and the product lot number to the demander system 200. The quality value generation unit 13 outputs the product lot number to the evaluation unit 12 c. The evaluation unit 12c associates the product lot number with the hierarchical public value 102.

As described above, the quality value generation unit 13 generates the quality value 103 based on the quality evaluation index value. The quality value generation section 13 transmits the quality value 103 and the product lot number to the demander system 200. The evaluation portion 12c associates at least one of the public value 101, the packet public value, and the hierarchical public value 102 with the quality value 103. The evaluation unit 12c transmits at least one of the public value, the grouping public value, and the hierarchical public value, and the product lot number to the customer system 200.

Thus, in the third embodiment, even if the producer submits the hierarchical public value 102, which is the evaluation result of the fluctuation of the production elements of the product 301, to the customer, the hierarchical public value 102 is not the evaluation index value (the value of the process management point) itself, and therefore, it is possible to make it impossible for another producer to simulate the production process based on the hierarchical public value 102. In addition, since the user can know the information relating the hierarchical public value 102 and the quality value as the result evaluation index, the user can receive the product 301 with confidence.

Although the embodiments of the present invention have been described in detail with reference to the drawings, the specific configurations are not limited to the embodiments, and may be designed within a range not departing from the gist of the present invention.

A processor such as a CPU (Central Processing Unit) executes a program stored in the storage Unit, thereby implementing a part or all of the functional units of the production system and the customer system in software. That is, a part or all of the functions of each functional unit of the evaluation system are realized by software cooperating with hardware resources. The evaluation system of the production system may also be realized by cloud computing.

The program may be stored in a computer-readable storage medium. Examples of the computer-readable storage medium include a removable medium such as a flexible disk, a magneto-optical disk, a ROM (Read Only Memory), a CD-ROM (Compact disk Read Only Memory), and a non-transitory storage medium such as a storage device built in a computer system, for example. The program may also be received via a communication line.

In addition, a part or all of the functional units of the evaluation system may be realized by hardware. For example, the present invention can be realized by an electronic Circuit (electronic Circuit or Circuit) such as an LSI (Large Scale Integration Circuit), an ASIC (Application Specific Integrated Circuit), a PLD (Programmable Logic Device), or an FPGA (Field Programmable Gate Array).

The terms "front, rear, up, down, right, left, vertical, horizontal, row, column" and the like in the present specification denote directions, and mean the above-mentioned directions in the device of the present invention. Therefore, the above words in the description of the invention should be interpreted relatively in the device of the invention.

The term "form" is used when it is configured to perform a function of the present invention, or when it indicates a structure, an element, or a part of a device.

Furthermore, words expressed as "functionally defined" in the claims are intended to include all structures that can be used to perform the functions encompassed by the present invention.

The term "unit" is used to indicate a component, a unit, hardware, a part of software programmed to perform a desired function. Typical examples of hardware are, but not limited to, devices and circuits.

The preferred embodiments of the present invention have been described above, but the present invention is not limited to these embodiments. Additions, omissions, substitutions, and other changes in the structure can be made without departing from the spirit of the invention. The invention is to be defined not by the preceding description but only by the scope of the appended claims.