JP2021018626A - Facility abnormality treatment timing determination system, facility abnormality treatment timing determination method, and computer program - Google Patents

Abstract

To automatically determine timing of treatment for an operator to perform for abnormality of a facility for manufacturing an article.SOLUTION: A facility abnormality treatment timing determination system comprises: a post-treatment versus untreated time supposed number comparing section that determines whether or not a post-treatment supposed number is larger than an untreated time supposed number; a treatment timing determining section that determines treatment timing which is timing to be treated by an operator; and an outputting section that outputs the treatment timing together with treatment content. The treatment timing determining section determines that the operator should start treatment in spare time which is calculated from a difference between the post-treatment supposed number and a planned number when it is determined that the post-treatment supposed number is above the planned number in a first post-treatment supposed number versus planned number comparing section, and determines that the operator should immediately start the treatment when the post-treatment supposed number is not above the planned number in the first post-treatment supposed number versus planned number comparing section.SELECTED DRAWING: Figure 1

Description

The present invention relates to an equipment abnormality treatment timing determination system for automatically determining the timing of treatment to be performed by an operator for an abnormality in equipment for manufacturing a product.

Patent Document 1 (Japanese Unexamined Patent Publication No. 2019-21008) discloses an equipment element maintenance analysis system that determines and notifies the necessity of maintenance of equipment elements of manufacturing equipment for manufacturing a product. This equipment element maintenance analysis system calculates the error rate of the equipment element and determines that the equipment element whose error rate is equal to or higher than a predetermined value is required to be maintained, but does not determine the timing of maintenance.

Patent Document 2 (Japanese Unexamined Patent Publication No. 63-85862) discloses a schedule control system having a display means for displaying a schedule of staff work determined by the adjusting means. The adjusting means controls the operating speed of each device in order to shift the working time zone of the staff, but does not consider the spare time based on the relationship between the planned quantity and the assumed quantity of the product at that time.

Patent Document 3 (Japanese Unexamined Patent Publication No. 2011-39751) discloses an information processing apparatus that calculates the amount of consumption of moving parts of a production apparatus and determines whether or not maintenance is necessary and the time required for maintenance. This information processing device controls the production device so as to perform the second maintenance process for a time required less than or equal to the time required for the first maintenance during the first maintenance process, or performs maintenance processing for moving parts before executing a job. It decides to implement it, but does not consider the spare time based on the relationship between the planned quantity and the assumed quantity of the product.

Patent Document 4 (Japanese Unexamined Patent Publication No. 2014-164322) discloses a maintenance work timing determination device that determines and outputs the maintenance work timing of parts of equipment to be maintained. This maintenance work timing determination device determines the maintenance work timing based on the relationship between the cumulative operating time of parts and the maintenance work implementation rate. At that time, the relationship between the planned quantity and the estimated quantity of the product is determined. It does not take into account the time to spare.

Patent Document 5 (Japanese Unexamined Patent Publication No. 2018-32206) discloses a maintenance support device that selects a maintenance timing condition from a plurality of timing condition candidates based on the cost of performing maintenance. The cost is the sum of the maintenance cost and the trouble cost as described in paragraph 0024 of Patent Document 5. This maintenance support device does not specify the object of maintenance to the equipment that manufactures the product, and therefore, when selecting the timing conditions, the relationship between the planned quantity and the assumed quantity of the product when manufacturing the product It does not take into account the time to spare.

Patent Document 6 (Japanese Unexamined Patent Publication No. 2018-169684) discloses a business support device for construction machinery, which includes predicting the occurrence date of maintenance work on the construction machine and outputting a list of maintenance work. This sales support device calculates the date when maintenance work occurs based on various information such as the scheduled completion date of construction, but maintenance should be performed in consideration of the spare time for progress of construction until the scheduled completion date of construction. It does not determine the day. In the first place, this sales support device is intended for maintenance of construction machinery, not equipment for manufacturing products.

In Patent Document 7 (Japanese Unexamined Patent Publication No. 2014-21627), a first grace period until a failure occurs and / and a second grace period during which preventive maintenance can be postponed without a failure are estimated. A maintenance management device for a moving machine equipped with a grace period estimation unit is disclosed. These grace periods are, in short, the time until a failure occurs estimated based on past case data, and are determined based on the relationship between the planned quantity and the estimated quantity of the product in the case of manufacturing the product. It's not something.

Patent Document 8 (Japanese Unexamined Patent Publication No. 2018-13842) includes a consumable and deteriorated product management device provided with a margin determination unit for specifying a maintenance time and determining a margin for a consumable and deteriorated product of a vehicle that requires maintenance. It is disclosed. According to paragraph 0019 of Patent Document 8, the margin may be determined based on the travel history data, the maintenance execution history data, and the like, and the planned quantity and the assumed quantity of the product in the case of manufacturing the product. It is not determined based on the relationship of. In the first place, this consumable and deteriorated product management device is intended for maintenance of vehicles, not equipment for manufacturing products.

Japanese Unexamined Patent Publication No. 2019-21008 JP-A-63-85862 Japanese Unexamined Patent Publication No. 2011-39751 Japanese Unexamined Patent Publication No. 2014-164322 JP-A-2018-32206 Japanese Unexamined Patent Publication No. 2018-169684 JP-A-2014-21627 Japanese Unexamined Patent Publication No. 2018-13842

In equipment for manufacturing things, various abnormalities that require treatment by an operator may occur during the operation of the equipment. In order to eliminate the abnormality, it is necessary to search for the place where the abnormality occurs, investigate the cause, and take measures such as taking measures. When performing such procedures, it is often necessary to shut down the equipment during the procedure, resulting in a reduction in the expected quantity (ie, the estimated production quantity) compared to the case where the equipment continues to operate. It becomes. On the other hand, if the manufacturing capacity (that is, the manufacturing quantity per hour) is reduced due to an abnormality in the equipment, the manufacturing capacity can be expected to recover by taking measures, and an increase in the assumed quantity may be expected. Therefore, when deciding whether or not to take measures against an abnormality in the equipment, the inventors of the present application consider various conditions such as an estimate of the time required for the treatment and an estimated amount of recovery of the manufacturing capacity by the treatment. Therefore, we repeatedly examined a system for automatically determining which case is more advantageous for the assumed quantity.

In addition, when manufacturing products, it is common to set deadlines and planned quantities based on contracts with clients and their own business goals. Therefore, the inventors of the present application consider the deadline and the planned quantity in addition to the above-mentioned conditions when automatically deciding whether or not to take measures against the abnormality of the equipment. I came up with the idea that it is preferable to do so. By doing so, for example, if the equipment continues to operate as it is, the planned quantity could be achieved by the deadline, but it was not reached because the equipment was stopped and the measures were taken by mistake. Can be prevented. On the contrary, if measures are taken to eliminate the abnormality of the equipment, the manufacturing capacity can be recovered and the planned quantity can be achieved, but it is prevented that the production capacity is not reached because the abnormality is left unattended and the operation is continued by mistake. it can.

Furthermore, the inventors of the present application can also determine how much time is available before taking measures in order to achieve the planned quantity by the deadline when taking measures against an abnormality in the equipment. , I came to the idea that it is sometimes important. By doing so, for example, when an abnormality occurs in another equipment B while taking measures for an abnormality in one equipment A, and the same worker needs to take measures. Whether the treatment of the equipment A should be continued as it is or the treatment of the equipment A should be suspended and the treatment of the equipment B should be performed first can be accurately determined if the spare time of each treatment is known. In addition, the spare time information is also useful when determining whether or not it is necessary to call a worker urgently when an abnormality occurs in the equipment during the time when the worker is absent.

In view of the above problems, it is an object of the present invention to provide a system, a method, and a computer program for automatically determining the timing of actions to be taken by an operator in response to an abnormality in equipment for manufacturing a product. And.

In one aspect, the present invention provides an equipment abnormality treatment timing determination system for automatically determining the timing of treatment to be performed by an operator for an abnormality in equipment for manufacturing a product. In the equipment abnormality treatment timing determination system, for each of one or more status indicators related to equipment, the abnormality occurrence rate, which is the rate at which the status index indicates an abnormal value, exceeds the threshold value set in relation to the status index. It has an abnormality occurrence rate determination unit that determines whether or not it is present. The equipment abnormality treatment timing determination system further determines the treatment content, which is the content of the treatment to be performed by the operator when the abnormality occurrence rate determination unit determines that the abnormality occurrence rate exceeds the threshold value. Has. In the equipment abnormality treatment timing determination system, the estimated post-treatment quantity, which is the quantity of products estimated to be manufactured by a predetermined deadline, assuming that the worker immediately starts the treatment according to the treatment content, is further determined. It has a post-treatment vs. untreated estimated quantity comparison unit that determines whether or not it exceeds the untreated estimated quantity, which is the quantity of goods estimated to be manufactured by the deadline when no treatment is performed. The equipment abnormality treatment timing determination system further manufactures the estimated post-treatment quantity by the deadline when it is determined by the post-treatment vs. untreated estimated quantity comparison unit that the estimated post-treatment quantity exceeds the estimated untreated quantity. It has a first post-treatment assumed quantity vs. plan comparison unit that determines whether or not it exceeds the planned quantity, which is the quantity of goods set as the target. The equipment abnormality treatment timing determination system further has a treatment timing determination unit that determines the treatment timing, which is the timing at which the operator should start the treatment. The equipment abnormality treatment timing determination system further has an output unit that outputs the treatment timing together with the treatment content.

The treatment timing determination unit determines the margin time calculated from the difference between the post-treatment estimated quantity and the planned quantity when the first post-treatment estimated quantity vs. the plan comparison unit determines that the post-treatment estimated quantity exceeds the planned quantity. It is decided as the treatment timing that the worker should start the treatment within. The treatment timing determination unit determines that the operator should promptly start the treatment when the first post-treatment estimated quantity vs. planning comparison unit determines that the post-treatment estimated quantity does not exceed the planned quantity. To determine as.

In one embodiment, the equipment abnormality treatment timing determination system plans the estimated post-treatment quantity when the estimated post-treatment vs. untreated quantity comparison unit determines that the estimated post-treatment quantity does not exceed the estimated untreated quantity. It also has a second post-treatment estimated quantity vs. plan comparison unit that determines if the quantity is exceeded. In one embodiment, when the equipment abnormality treatment timing determination system determines that the estimated post-treatment quantity exceeds the planned quantity in the second post-treatment assumption vs. plan comparison unit, the operator takes action according to the treatment content. It also has a post-treatment vs. untreated expected profit comparison unit that determines whether the expected post-treatment profit, which is the expected profit, exceeds the expected untreated profit, which is the expected profit when no treatment is performed. .. In one embodiment, the treatment timing determination unit further promptly causes the worker to take action when the post-treatment vs. untreated expected profit comparison unit determines that the post-treatment expected profit exceeds the untreated expected profit. Decide what to start as the treatment timing.

In one embodiment, the treatment content determination unit stores a judgment basis list having a judgment basis as an element and a work content list having a work content associated with the judgment basis as an element, which is determined for each state index. It has a storage unit and a judgment basis collation unit that extracts the one that matches the current situation from the judgment basis in the judgment basis list. In one embodiment, the treatment content determination unit determines the priority for each of the extracted judgment grounds when the judgment grounds extracted by the judgment grounds collation unit exists, and at least the judgments extracted based on the priority. One or more judgment grounds are selected from the grounds, and the work content corresponding to the selected judgment ground is determined as the treatment content. In one embodiment, the treatment content determination unit determines all the work contents in the work content list as the treatment content when the judgment basis extracted by the judgment basis collation unit does not exist.

In one embodiment, when the judgment grounds extracted by the judgment grounds collation unit exist, the treatment content determination unit estimates the effect of eliminating the cause of the judgment grounds for each of the extracted judgment grounds. At least one or more judgment grounds are selected from the judgment grounds extracted based on the priority and the estimated effect, and the work content corresponding to the selected judgment grounds is determined as the treatment content.

The present invention provides, in one aspect, a method for determining equipment abnormality treatment timing for automatically determining the timing of treatment to be performed by an operator for an abnormality in equipment for manufacturing a product. The present invention also provides, in one aspect, a computer program that can be executed on a computer system, including instructions for causing the computer to perform the steps of the equipment anomaly treatment timing determination method.

By using the equipment abnormality treatment timing determination system according to one aspect of the present invention, the necessity, content, and timing of the treatment to be taken by the operator for the equipment abnormality for manufacturing the product are automatically determined. To. At that time, according to the treatment content determined from the condition of the equipment, whether the production quantity can be improved by the deadline by taking the treatment, and if the treatment is performed, the planned quantity is achieved by the deadline. Judgment is made as to whether or not it is possible, and based on the result of the judgment, whether or not to take action, what to do, and how long it takes to start the action to achieve the planned quantity by the deadline. A decision is made as to whether there is time to spare or whether treatment should be started promptly. In one embodiment, a determination is also made as to whether or not the treatment is expected to improve profits, which is reflected in the determination of the necessity of the treatment.

In one embodiment, the appropriate treatment content is determined based on the priority for eliminating the cause of the abnormality and the effect estimated when the cause of the abnormality is eliminated.

It is a block diagram which shows the schematic structure of the equipment abnormality treatment timing determination system by one Embodiment of this invention. It is a figure which shows the schematic hardware configuration of the equipment abnormality treatment timing determination system by one Embodiment of this invention. It is a figure which shows the flow of the equipment abnormality treatment timing determination processing by 1st Embodiment of this invention. It is a figure which shows the flow of the abnormality collation processing in 1st Embodiment of this invention. It is a graph which shows each of the four patterns concerning the relationship between the estimated quantity at the time of untreatment, the estimated quantity after treatment, and the planned quantity. (1) indicates a case where the estimated quantity after treatment does not exceed the estimated quantity at the time of no treatment and the planned quantity is not achieved. (2) shows a case where the estimated quantity after treatment does not exceed the estimated quantity at the time of no treatment, but the planned quantity is achieved. (3) shows a case where the estimated quantity after treatment exceeds the estimated quantity at the time of no treatment but the planned quantity is not achieved. (4) shows a case where the estimated quantity after treatment exceeds the estimated quantity at the time of no treatment and the planned quantity is achieved. It is a figure which shows the example judgment basis list and work content list defined for each state index in 1st Embodiment of this invention. It is a figure which shows the flow of the equipment abnormality treatment timing determination processing by the 2nd Embodiment of this invention.

Hereinafter, embodiments of the equipment abnormality treatment timing determination system according to the present invention will be described with reference to the drawings.

FIG. 1 is a block diagram showing a schematic configuration of an equipment abnormality treatment timing determination system 100 according to an embodiment of the present invention. When the equipment abnormality treatment timing determination system 100 determines that the treatment for the abnormality is necessary based on the information 151 of the state index related to the equipment P, the equipment abnormality treatment timing determination system 100 outputs the information 152 of the timing and the treatment content to start the treatment from the output unit 130. It can be output.

In one embodiment, the equipment abnormality treatment timing determination system 100 includes an abnormality occurrence rate determination unit 111, a treatment content determination unit 112, a post-treatment vs. untreated estimated quantity comparison unit 113, and a first post-treatment estimated quantity pair. It includes a plan comparison unit 114 and a treatment timing determination unit 115. In one embodiment, the treatment content determination unit 112 includes a list storage unit 121 for storing the determination basis list 122 and the work content list 123, and a determination basis collation unit 118. In one embodiment, the equipment abnormality treatment timing determination system 100 further includes a second post-treatment estimated quantity vs. plan comparison unit 116 and a post-treatment vs. untreated expected profit comparison unit 117.

FIG. 2 shows an exemplary computer hardware configuration of the equipment abnormality treatment timing determination system 100 according to an embodiment of the present invention. The equipment abnormality treatment timing determination system 100 includes a central processing unit (CPU), a storage device such as a RAM, ROM, and a hard disk drive (HDD) for storing various programs and data executed by the central processing unit, and these devices. Can be realized using a general-purpose computer having a bus that connects to each other. Further, the equipment abnormality treatment timing determination system 100 includes a drive device that inputs / outputs data to / from an external storage medium such as a CD-ROM or a DVD-ROM, and an input device such as a keyboard or a mouse, if necessary. And an output device such as a CRT, a liquid crystal display or a printer, and a communication interface for communicating with another computer or network may be connected.

FIG. 3 shows a processing flow 300 executed to determine the timing at which an abnormality should be treated in the equipment abnormality treatment timing determination system 100 according to the first embodiment of the present invention.

The processing flow 300 starts in step 301. The equipment abnormality treatment timing determination system 100 may be configured to start the flow 300 each time the equipment P receives the state index information 151. Alternatively, the equipment abnormality treatment timing determination system 100 is configured to repeatedly start the flow 300 so as to be executed periodically or continuously, and acquire the state index information 151 from the equipment P each time. You may.

The state index is an index showing the state of the equipment P, and can be appropriately determined according to the type of the equipment P. For example, when the equipment P is an RTP device, as illustrated in the leftmost column of FIG. 6, "sticking accuracy", "adhesion of foreign matter", "generation of air bubbles", and "generation of chipping / cracking" are Each can be used as a state index. The RTP method is a normal sheet having no defects from a strip-shaped optical film laminate in which a plurality of sheet-shaped optical films are supported on a strip-shaped release film via an adhesive layer in a manufacturing process of a liquid crystal display device or the like. This is a method of continuously manufacturing a liquid crystal display device by sequentially peeling only the morphological optical film together with the pressure-sensitive adhesive layer from the release film and bonding it to a rectangular panel via the pressure-sensitive adhesive layer. A continuous manufacturing system for a liquid crystal display device that realizes such a method is distinguished from a device that realizes a conventional individual sticking method in which a sheet of an optical film cut out in advance is stuck to a rectangular panel, and is distinguished from "continuous sticking" or "RTP (roll)". Two-panel) ”device. "RTP" and "Roll to Panel" are registered trademarks of Nitto Denko KK. In this case, the "sticking accuracy" is a state index indicating the error of the actual position of the optical film with respect to the target position on the panel when the optical film is stuck to the panel, and the "adhesion of foreign matter" is It is a state index related to the adhesion of foreign matter that can be detected on the panel with the optical film attached, and "generation of air bubbles" is a state index related to the air bubbles that can be detected on the optical film attached to the panel, and is "chip / crack". Can be a state indicator of chips and cracks that can be detected on the panel.

In step 302, for each of the state indicators, it is determined whether or not the abnormality occurrence rate, which is the rate at which the state index indicates an abnormal value, exceeds the threshold value determined in relation to the state index. Here, the outlier can be defined as a value indicating that the state of the equipment P represented by the state index is a factor for reducing the manufacturing capacity (that is, the manufacturing quantity per unit time). For example, in the case of an RTP device, an abnormal value of "sticking accuracy" can be defined as a value in which the position error exceeds a predetermined tolerance range. In this case, the panel to which the optical film is attached at a position exceeding the permissible error is a rejected product, and the yield is lowered, which is a factor of lowering the manufacturing capacity. Further, the abnormal value of "adhesion of foreign matter" can be defined as the detection of adhesion of foreign matter. The abnormality occurrence rate is the ratio of the number of times the state index shows an abnormal value based on the product manufactured by the equipment P and the nature of the state index, the number of times the abnormal value occurs per unit time, and the like. can do. If the abnormality occurrence rate exceeds the threshold value determined in relation to the state index (for example, the abnormal value is 5 times out of the last 100 times), the process proceeds to step 303. On the other hand, if the abnormality occurrence rate does not exceed the threshold value, it is determined that the treatment is not necessary at the present time, and the process proceeds to step 311 without outputting the information 152 of the treatment timing and the treatment content.

In step 303, the treatment content, which is the content of the treatment to be performed by the operator, is determined. Here, a specific example of the process of determining the treatment content will be described with reference to FIG. The process flow 400 for determining the treatment content starts in step 401. In step 402, a judgment basis corresponding to the state index and matching the current situation is extracted from the judgment basis list 122 stored in the list storage unit 121. For example, when the equipment P is an RTP device and the judgment basis list 620 illustrated in FIG. 6 is used, if the state index in which the abnormality occurrence rate exceeds the threshold value is "pasting accuracy", the judgment basis list 620 "The parameters have been changed most recently" "The original fabric has been replaced most recently" "The feed roller replacement time is near or past" "The sticking roller replacement time is near or past" Of the four grounds for judgment, the one that matches the current situation is extracted. The current situation can be recognized based on, for example, information 153 of the treatment input by the operator and work other than the treatment, information 154 that can be acquired from the equipment P, and the like.

Then, in step 403, it is determined whether or not the extracted judgment basis exists. If there is one or more extracted judgment grounds, the process proceeds to step 404. In step 404, for each of the extracted judgment grounds, the effect of eliminating the cause of the judgment grounds is estimated. Further, in step 405, the priority is determined for each of the extracted judgment grounds. After that, in step 406, one or more judgment grounds are selected from the extracted judgment grounds based on the priority and the estimated effect, and the work contents in the corresponding work contents list are determined as the treatment contents. To do. For example, when the judgment basis list 620 and the work content list 630 illustrated in FIG. 6 are used, the judgment basis selected for the state index of "pasting accuracy" is "the feed roller replacement time is near or past. If "", the corresponding work content "feed roller replacement" is determined as the treatment content.

On the other hand, in step 403, if there is no extracted judgment basis, the process proceeds to step 409. In step 409, all the judgment grounds corresponding to the state index are selected from the judgment grounds list 122. Then, the effect is not estimated and the priority is determined for each of the judgment grounds, and all the work contents corresponding to each of the judgment grounds are determined as the treatment contents. For example, when the equipment P is an RTP device and the judgment basis list 620 and the work content list 630 illustrated in FIG. 6 are used, the state index of "pasting accuracy" is "most recently changed". If none of "the most recent replacement of the original fabric", "the replacement time of the feed roller is near or past", and "the replacement time of the pasting roller is near or past" does not match the current situation, these All of "parameter correction", "parameter adjustment", "feed roller replacement", and "paste roller replacement" corresponding to each of the above are determined as the treatment contents.

Returning to FIG. 3, in step 304, assuming that the worker immediately starts the treatment according to the treatment content determined in step 303 (that is, the processing flow 400 for determining the treatment content), by a predetermined deadline. The estimated post-treatment quantity, which is the estimated quantity of goods to be manufactured, and the estimated untreated quantity, which is the quantity of goods estimated to be manufactured by the deadline without treatment, are compared. If it is determined that the estimated quantity after treatment does not exceed the estimated quantity at the time of no treatment, it is determined that the treatment should not be performed, and the process proceeds to step 311 without outputting the information 152 of the treatment timing and the treatment content.

On the other hand, if it is determined in step 304 that the estimated quantity after treatment exceeds the estimated quantity at the time of no treatment, the process proceeds to step 305. In step 305, the estimated post-treatment quantity is compared with the planned quantity, which is the quantity of the target product to be manufactured by the deadline. If it is determined that the estimated quantity after treatment exceeds the planned quantity, that is, if it is expected that the planned quantity can be achieved assuming that the treatment is started immediately, the treatment timing is set in step 306. It is determined that the worker should start the treatment within the margin calculated from the difference between the estimated quantity after the treatment and the planned quantity. On the other hand, when it is determined that the estimated quantity after treatment does not exceed the planned quantity, that is, when it is expected that the planned quantity cannot be achieved even if the treatment is started immediately, and there is no time to spare. In step 307, it is determined that the operator should start the treatment promptly as the treatment timing. In either case, in step 310, information 152 of the treatment timing and the treatment content is output and notified to the operator. The worker who is notified of the information 152 of the treatment timing and the treatment content performs the treatment for the abnormality of the equipment P, and records the treatment and the work information other than the treatment.

In step 311 the processing flow 300 ends.

The graphs (1) to (4) of FIG. 5 show four patterns relating to the relationship between the assumed quantity before treatment, the estimated quantity after treatment, and the planned quantity. In each graph, the horizontal axis represents time, tk represents the current time, and te represents the deadline. The vertical axis represents the production quantity, and p represents the planned quantity. The solid line A on the left side of the current tc represents the transition of the actual production quantity up to the present time. The solid line B on the right side of the current tc represents the transition of the production quantity estimated when no treatment is performed. The height of the solid line portion B at the deadline te represents the estimated quantity when untreated. The broken line part C represents the transition of the production quantity during the treatment estimated assuming that the treatment is started immediately. Since the operation of the equipment P is stopped during the treatment, the product is not manufactured, and therefore the broken line portion C becomes a horizontal line. The solid line part D represents the transition of the production quantity after the treatment estimated when the treatment is assumed to be performed immediately. The height of the solid line portion D at the deadline te represents the estimated quantity after treatment.

In the pattern (1), the estimated quantity after treatment does not exceed the estimated quantity at the time of no treatment and does not reach the planned quantity p. In this case, since it is determined in step 304 that the estimated quantity after treatment does not exceed the estimated quantity at the time of no treatment, the information 152 of the treatment timing and the treatment content is not output.

In the pattern (2), the estimated quantity after treatment does not exceed the estimated quantity at the time of no treatment, but reaches the planned quantity p. In this case as well, as in the pattern of (1), since it is determined in step 304 that the estimated quantity after treatment does not exceed the estimated quantity at the time of no treatment, the treatment timing and treatment content information 152 is not output. .. The pattern (1) and the pattern (2) can be distinguished from each other in the second embodiment of the present invention described later.

In the pattern (3), the estimated quantity after treatment exceeds the estimated quantity at the time of no treatment, but does not reach the planned quantity p. In this case, it is determined in step 304 that the estimated post-treatment quantity exceeds the assumed quantity at the time of no treatment, and in step 305 it is determined that the estimated post-treatment quantity does not exceed the planned quantity. Therefore, in step 307, the treatment timing is set. , It will be decided promptly that the worker should start the procedure.

In the pattern (4), the estimated quantity after treatment exceeds the estimated quantity at the time of no treatment and reaches the planned quantity p. In this case, it is determined in step 304 that the estimated post-treatment quantity exceeds the assumed quantity at the time of no treatment, and in step 305 it is determined that the estimated post-treatment quantity exceeds the planned quantity. Therefore, in step 306, the treatment timing is set. It is determined that the worker should start the treatment within the margin time calculated from the difference between the estimated quantity after the treatment and the planned quantity.

In the pattern (4), as an example, the margin time can be calculated as follows. The slope of the solid line B (ie, the estimated manufacturing capacity without treatment (ie, the production quantity per unit time)) and the slope of the solid D (ie, the estimated post-treatment manufacturing with treatment). The ability) is assumed to be constant, and the slope of the solid line portion B is b and the slope of the solid line portion D is d. Specifically, b can be the manufacturing capacity from the most recent point in time when the abnormality is considered to have already occurred to the present, and d can be the manufacturing capacity before the abnormality occurs, for example, shortly after the start of production. Can be the production capacity at the time when was stable. In general, the procedure can be performed to restore production capacity, thus d> b. Also, let ε be the difference between the estimated quantity after treatment and the planned quantity p. At this time, the margin time can be calculated as ε / (db). Assuming that the treatment is started at the end of this margin time, it is computationally confirmed that the expected production quantity at the deadline te matches the planned quantity p.

FIG. 7 shows a processing flow 700 executed to determine the timing at which an abnormality should be treated in the equipment abnormality treatment timing determination system 100 according to the second embodiment of the present invention. Each step of the processing flow 700 is the same as each step of the processing flow 300 according to the first embodiment described above, except for step 708 and step 709. Therefore, in the following, a part different from the first embodiment will be described with respect to the second embodiment.

If it is determined in step 704 that the estimated post-treatment quantity does not exceed the estimated untreated quantity (for example, in the cases of (1) and (2) of FIG. 5), in step 708, the estimated post-treatment quantity is used. It is compared with the planned quantity. When it is determined that the estimated quantity after treatment does not exceed the planned quantity (for example, in the case of (1) in FIG. 5), it is determined that the treatment should not be performed, and the treatment timing and treatment content information 152 is output. Without doing so, the process proceeds to step 711. On the other hand, when it is determined that the estimated quantity after the treatment exceeds the planned quantity (for example, in the case of (2) of FIG. 5), the profit expected when the worker takes the treatment according to the treatment content in step 709. The expected profit after treatment is compared with the expected profit at the time of untreatment, which is the profit expected when no treatment is performed. Here, the profit is, for example, a profit from achieving the planned quantity earlier than the deadline, a profit from manufacturing more products by the deadline, or a negative related to the procurement cost of parts caused by the replacement of parts. Possible positive and negative profits, such as the profits of the above, can be converted into, for example, an amount or points and totaled. If it is determined that the expected profit after the treatment does not exceed the expected profit at the time of no treatment, it is determined that the treatment should not be performed, and the process proceeds to step 711 without outputting the information 152 of the treatment timing and the treatment content. On the other hand, if it is determined that the expected profit after the treatment exceeds the expected profit at the time of no treatment, the process proceeds to step 707, and it is determined that the operator should promptly take the treatment as the treatment timing as in step 307. After that, in step 710, information 152 of the treatment timing and the treatment content is output, and the operator is notified. The worker who is notified of the information 152 of the treatment timing and the treatment content performs the treatment for the abnormality of the equipment P, and records the treatment and the work information other than the treatment.

Although the first and second embodiments of the present invention have been described above, the present invention described in the claims is not limited to these embodiments, and various modifications can be made. , Those skilled in the art should be able to easily understand.

The worker of the equipment P can take a treatment for the abnormality of the equipment P based on the information 152 of the treatment timing and the treatment content output by the equipment abnormality treatment timing determination system 100 according to the embodiment of the present invention. When a margin time is specified as the treatment timing, the worker knows that the treatment should be started within the margin time in order to achieve the planned quantity, so that, for example, another work is prioritized. You can make a judgment such as. On the other hand, when it is specified that the treatment should be started promptly as the treatment timing, the worker should not have time to achieve the planned quantity and should start the treatment immediately if possible. I understand. It should be noted that it may take time for the worker to start the treatment in order to prepare for the treatment or move to the site, and it may be possible that the worker cannot start the treatment within the spare time or immediately. .. In such situations, workers also make decisions about appropriate actions, such as rushing preparations and movements, reporting the situation to the supervisor for instructions, and so on. The content information 152 can be useful.

100: Equipment abnormality treatment timing determination system 111: Abnormality occurrence rate determination unit 112: Treatment content determination unit 113: Post-treatment vs. untreated estimated quantity comparison unit 114: First post-treatment estimated quantity vs. plan comparison unit 115: Treatment timing Decision unit 116: Second post-treatment estimated quantity vs. plan comparison unit 117: Post-treatment body untreated expected profit comparison unit 118: Judgment basis collation unit 121: List storage unit 122: Judgment basis list 123: Work content list 130: Output unit 151: Status index information 152: Treatment timing and treatment content information 153: Worker treatment and work information 154: Information that can be acquired from equipment P

Claims (9)

It is an equipment abnormality treatment timing determination system for automatically determining the timing of actions to be taken by an operator in response to an abnormality in equipment for manufacturing products.
For each of the one or more state indicators related to the equipment, it is determined whether or not the abnormality occurrence rate, which is the rate at which the state index indicates an abnormal value, exceeds the threshold value set in relation to the state index. Abnormality occurrence rate judgment unit and
When the abnormality occurrence rate determination unit determines that the abnormality occurrence rate exceeds the threshold value, the treatment content determination unit determines the treatment content, which is the content of the treatment to be performed by the worker.
The estimated post-treatment quantity, which is the quantity of the product estimated to be manufactured by a predetermined deadline assuming that the worker immediately starts the treatment according to the treatment content, is the deadline when no treatment is performed. A post-treatment vs. untreated estimated quantity comparison unit that determines whether or not the quantity of the product estimated to be manufactured by the above is exceeded.
When the post-treatment vs. untreated estimated quantity comparison unit determines that the post-treatment estimated quantity exceeds the untreated estimated quantity, the post-treatment estimated quantity is set as a target for manufacturing by the deadline. The first post-treatment assumed quantity vs. plan comparison unit, which determines whether or not the quantity exceeds the planned quantity, which is the quantity of the above-mentioned product.
A treatment timing determination unit that determines the treatment timing, which is the timing at which the worker should start the treatment,
An output unit that outputs the treatment timing together with the treatment content,
Have,
The treatment timing determination unit
Within the margin time calculated from the difference between the estimated post-treatment quantity and the planned quantity when the estimated post-treatment quantity is determined by the plan comparison unit to exceed the planned quantity after the first treatment. It is determined as the treatment timing that the worker should start the treatment.
When the first post-treatment estimated quantity vs. plan comparison unit determines that the post-treatment estimated quantity does not exceed the planned quantity, the operator should promptly start the treatment as the treatment timing. decide,
Equipment abnormality treatment timing determination system.
When the post-treatment vs. untreated estimated quantity comparison unit determines that the post-treatment estimated quantity does not exceed the untreated estimated quantity, it is determined whether or not the post-treatment estimated quantity exceeds the planned quantity. , The second post-treatment estimated quantity vs. plan comparison section,
When the second post-treatment assumed vs. plan comparison unit determines that the post-treatment estimated quantity exceeds the planned quantity, the treatment is a profit expected when the worker takes the treatment according to the treatment content. The post-treatment vs. untreated expected profit comparison unit, which determines whether the post-treatment expected profit exceeds the untreated expected profit, which is the expected profit when no treatment is performed.
Have more
In the treatment timing determination unit, when the post-treatment vs. untreated assumed profit comparison unit determines that the post-treatment assumed profit exceeds the untreated assumed profit, the worker promptly takes action. The timing of the treatment is determined to be started.
The equipment abnormality treatment timing determination system according to claim 1.
The treatment content determination unit
A list storage unit that stores a judgment basis list having a judgment basis as an element and a work content list having a work content associated with the judgment basis as an element, which is determined for each state index.
From the judgment grounds in the judgment grounds list, the judgment grounds collation unit that extracts the one that matches the current situation,
Have,
When the judgment grounds extracted by the judgment ground collation unit exist, the priority is determined for each of the extracted judgment grounds, and at least one or more of the extracted judgment grounds based on the priority. The judgment basis of the above is selected, and the work content corresponding to the selected judgment basis is determined as the treatment content.
When the judgment basis extracted by the judgment basis collation unit does not exist, all the work contents in the work content list are determined as the action contents.
The equipment abnormality treatment timing determination system according to claim 1 or 2.
When the judgment grounds extracted by the judgment ground collation unit exist, the treatment content determination unit estimates the effect of eliminating the cause of the judgment grounds for each of the extracted judgment grounds, and at least the above-mentioned One or more judgment grounds are selected from the extracted judgment grounds based on the priority and the estimated effect, and the work content corresponding to the selected judgment grounds is determined as the treatment content.
The equipment abnormality treatment timing determination system according to claim 3.
This is a method for determining the timing of equipment abnormality treatment timing for automatically determining the timing of treatment to be performed by an operator for an abnormality in equipment for manufacturing a product.
For each of the one or more state indicators related to the equipment, it is determined whether or not the abnormality occurrence rate, which is the rate at which the state index indicates an abnormal value, exceeds the threshold value determined in relation to the state index. Abnormality occurrence rate determination process and
When it is determined in the abnormality occurrence rate determination step that the abnormality occurrence rate exceeds the threshold value, the treatment content determination step of determining the treatment content, which is the content of the treatment to be performed by the worker,
The estimated post-treatment quantity, which is the quantity of the product estimated to be manufactured by a predetermined deadline when it is assumed that the worker immediately starts the treatment according to the treatment content, is the deadline when no treatment is performed. A post-treatment vs. untreated estimated quantity comparison step, which determines whether or not the quantity of the product estimated to be manufactured by the above is exceeded.
When the post-treatment vs. untreated estimated quantity comparison unit determines that the post-treatment estimated quantity exceeds the untreated estimated quantity, the post-treatment estimated quantity is set as a target for manufacturing by the deadline. The first post-treatment assumed quantity vs. plan comparison step, which determines whether or not the quantity exceeds the planned quantity, which is the quantity of the above-mentioned product.
The treatment timing determination step of determining the treatment timing, which is the timing at which the worker should start the treatment,
Including
The treatment timing determination step is
Within the margin time calculated from the difference between the estimated post-treatment quantity and the planned quantity when the estimated post-treatment quantity is determined by the plan comparison unit to exceed the planned quantity after the first treatment. To determine that the worker should start the treatment as the treatment timing,
When the first post-treatment estimated quantity vs. plan comparison unit determines that the post-treatment estimated quantity does not exceed the planned quantity, the operator should promptly start the treatment as the treatment timing. To decide and
including,
Equipment abnormality treatment timing determination method.
When it is determined in the post-treatment vs. untreated estimated quantity comparison step that the post-treatment estimated quantity does not exceed the untreated estimated quantity, it is determined whether or not the post-treatment estimated quantity exceeds the planned quantity. , The second post-treatment estimated quantity vs. plan comparison process,
When it is determined in the second post-treatment assumed vs. planned comparison step that the post-treatment estimated quantity exceeds the planned quantity, the treatment is a profit expected when the worker takes the treatment according to the treatment content. A post-treatment vs. untreated expected profit comparison process that determines whether the post-treatment expected profit exceeds the untreated expected profit, which is the expected profit when no treatment is performed.
Including
In the treatment timing determination step, when it is determined in the post-treatment vs. untreated assumed profit comparison step that the post-treatment assumed profit exceeds the untreated assumed profit, the worker promptly takes action. Including determining what to start as the treatment timing.
The method for determining equipment abnormality treatment timing according to claim 5.
A judgment basis list having a judgment basis as an element and a work content list having a work content associated with the judgment basis as an element, which are determined for each state index, are prepared in advance.
The treatment content determination step is
Judgment basis collation process that extracts the one that matches the current situation from the judgment basis in the judgment basis list,
When the judgment grounds extracted in the judgment grounds collation step exist, the priority is determined for each of the extracted judgment grounds, and at least one or more of the extracted judgment grounds based on the priority. The step of selecting the judgment basis of the above and determining the work content corresponding to the selected judgment basis as the treatment content, and
When the judgment basis extracted in the judgment basis collation step does not exist, the step of determining all the work contents in the work content list as the treatment content, and
including,
The method for determining equipment abnormality treatment timing according to claim 5 or 6.
When the judgment grounds extracted in the judgment grounds collation step exist, the treatment content determination step estimates the effect of eliminating the cause of the judgment grounds for each of the extracted judgment grounds, and at least the above. It includes a step of selecting one or more judgment grounds from the extracted judgment grounds based on the priority and the effect, and determining the work content corresponding to the selected judgment grounds as the treatment content.
The method for determining equipment abnormality treatment timing according to claim 7.
A computer program that is executable on a computer system and comprises instructions for causing the computer system to perform the steps of the method according to any one of claims 4 to 8. program.

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