WO2013038785A1

WO2013038785A1 - Maintenance planning system, maintenance planning system server and maintenance planning system client terminal

Info

Publication number: WO2013038785A1
Application number: PCT/JP2012/067269
Authority: WO
Inventors: 聡菓子
Original assignee: 株式会社日立製作所
Priority date: 2011-09-14
Filing date: 2012-07-06
Publication date: 2013-03-21
Also published as: JP2013061819A

Abstract

In conventional maintenance planning, plan execution is inadequate, with no consideration of whether there are sufficient resources (maintenance personnel, equipment, parts) for doing advance maintenance, or of how to control conflicts between resources when maintaining multiple machines. In addition, plan fitness is inadequate, with no consideration of how an implementation schedule for maintenance done in response to a risk of failure of multiple parts will affect the operating ratio of the machinery said parts configure, sometimes resulting in a target operating ratio not being met, or in excessive maintenance cost being generated even if the target operating ratio is met. The invention is a maintenance planning system that creates multiple industrial machinery maintenance plans, said maintenance planning system being provided with: an input receiving process means that receives input of a target operating ratio for the industrial machinery and receives input of information related to a possessed resource needed to perform maintenance; a storage means that stores the information input from the input receiving process means; and a plan generation means that generates a maintenance plan such that the target operating ratio stored in the storage means is satisfied and the possessed resource is not exceeded.

Description

Maintenance planning system, maintenance planning system server, and maintenance planning system client terminal

The present invention relates to a maintenance planning system.

If a sudden failure occurs in an industrial machine and the operating rate falls, a great damage will occur. It is necessary to prevent sudden failures by performing appropriate pre-maintenance at an appropriate time, and it is important to create and adjust a maintenance plan for that purpose. In Japanese Patent No. 4416306, pre-maintenance recommendation information is generated with the time when the failure risk of each part is a predetermined value as the time when each part is replaced.

Japanese Patent No. 4416306

It is necessary to improve the reliability of industrial machines by performing appropriate advance maintenance on industrial machines. In the system of Patent Document 1, there are sufficient resources (maintenance personnel / equipment / parts) for performing pre-maintenance, and how to adjust the contention of resources when performing maintenance on multiple machines. Was not taken into account, and the feasibility of the plan was not sufficient.

In addition, it is not considered how the maintenance timing for the failure risk of multiple parts affects the operating rate of the machine itself, and it is excessive even if the target operating rate is satisfied, even if the target operating rate is satisfied Maintenance costs may occur, and the validity of the plan was not sufficient. An object of the present invention is to provide a maintenance plan system that provides a highly reliable industrial machine by ensuring the executability and validity of a maintenance plan and performing maintenance appropriately.

In order to solve the above problems, for example, the configuration described in the claims is adopted. The present application includes a plurality of means for solving the above-described problems. For example, a maintenance plan system for creating a maintenance plan for a plurality of industrial machines by a computer, which includes a target operating rate and maintenance of the industrial machine. An input acceptance processing means for accepting input of information relating to the possessed resources necessary to perform; a storage means for storing information input from the input acceptance processing means; satisfying a target operating rate stored in the storage means; and And a plan generating means for generating a maintenance plan so as not to exceed the possessed resources.

According to the present invention, it is possible to provide an industrial machine with high reliability by generating an appropriate maintenance plan having feasibility and validity. Problems, configurations, and effects other than those described above will be clarified by the following description of embodiments.

It is an example of the block diagram of this invention. It is an example (stand-alone system) of the utilization system of this invention. It is an example (client-server system) of the utilization system of this invention. It is an example of the data structure of this invention. It is an example of the screen regarding the input process reception part of this invention. It is an example of the screen regarding the target operating rate information storage part of this invention. It is an example of the screen regarding the possession resource information storage part of this invention. It is an example of the screen regarding the maintenance reference | standard information storage part of this invention. It is an example of the screen regarding the status information storage part classified by number machine of this invention. It is an example of the screen regarding the maintenance plan information storage part classified by number of this invention. It is an example of the screen regarding the output process part of this invention. It is an example of the processing flow regarding the input reception process part of this invention. It is an example of the processing flow regarding the plan production | generation procedure control processing part of this invention. It is an example of the processing flow regarding the plan choice production | generation part of this invention. It is an example of the processing flow regarding the optimal plan selection process part of this invention. It is an example of the input data regarding an example of the mathematical model which this invention handles. It is an example of the output data regarding an example of the mathematical model which this invention handles.

Hereinafter, examples will be described with reference to the drawings.

In this example, information on the target operating rate and owned resources is received from the input screen, input file, database or input communication data, and the maintenance cost is minimized so that the target operating rate is met and the owned resources are not exceeded. An example of a maintenance plan system that generates a maintenance plan to be converted will be described.

FIG. 1 is an example of a block diagram of the maintenance planning system of the present invention. The maintenance plan system 10 stores an input reception processing unit 1000 that receives an instruction for generating a maintenance plan and a designation of a file used when generating the maintenance plan, and a target operating rate of one or more units in time series. A target operating rate information storage unit 1500, a retained resource information storage unit 1600 that stores in a time series the retained resource information including maintenance man-hours, equipment operation time, and the number of parts that can be used for maintenance. Maintenance including the failure probability of parts, pre-maintenance time, pre-maintenance cost, and recovery time and recovery cost when a part occurs without pre-maintenance, depending on the timing of pre-maintenance before the failure occurs Maintenance standard information storage unit 1700 for storing standard information, operation rate of each unit, main body accumulated operating time of each unit, or parts constituting each unit The unit-specific status information storage unit 1800 that stores unit-specific status information including the cumulative component usage time, a plan generation procedure control processing unit 1100 that controls the procedure for generating a maintenance plan, and a plan for generating maintenance plan options An option generation processing unit 1200, an optimal plan selection processing unit 1300 that selects an optimal plan that minimizes the cost from the above plan options, and a maintenance plan for each unit that indicates what kind of preliminary maintenance is to be performed at each unit A unit-specific maintenance plan information storage unit 1900 that stores information and an output processing unit 1400 that outputs unit-specific maintenance plan information are provided.

The maintenance planning system 10 of the present invention may be used as a stand-alone installation at the maintenance headquarters or maintenance sites in various places as shown in FIG. Further, as in the example shown in FIG. 3, the maintenance planning system server 10 is installed in the maintenance headquarters, and may be used from the client terminal 30 (40) not only at the maintenance headquarters but also at various maintenance sites via the network 20. . In addition, the maintenance planning system server 10 may be installed not at the maintenance headquarters but at a specific maintenance site and used from the client terminal 30 (40) at other maintenance sites via the network 20. The maintenance planning system server 10 may be installed in a data center that is not the maintenance headquarters or a specific maintenance site, and may be used via the network 20 from the client terminal 30 (40) at the maintenance headquarters or maintenance sites in various places. For example, information regarding the target operating rate and owned resources is input at the client terminal 30, and a maintenance plan based on the input information is generated at the maintenance plan system server 10, and the generated maintenance plan is sent to the client via the network 20. The data is transmitted to the terminal 30, and the maintenance plan is output and displayed at the client terminal 30.

The maintenance planning system 10 of the present invention includes, for example, a screen data structure Data 1050 relating to the input reception processing unit 1000, a data structure Data 1550 of the target operating rate information storage unit 1500, and data of the retained resource information storage unit 1600 as shown in FIG. Structure Data 1650, Data Structure Data 1750 of Maintenance Criteria Information Storage Unit 1700, Data Structure Data 1850 of Unit Status Information Storage Unit 1800, Data Structure Data 1950 of Unit Maintenance Plan Information Storage Unit 1900, Data Structure Data 1450 of Screen for Output Processing Unit 1400, have.

The data structure Data 1050 of the screen related to the input reception processing unit 1000 in FIG. As a key value, one target availability information file name, possession resource information file name, maintenance standard information file name, and in the variable length part, multiple units, status information file of each of the multiple units A data structure having a name and a maintenance plan information file name for each of the plurality of units. A specific data structure will be described below. The meaning of the data items will be described later in the screen and processing flow.

The data structure Data 1550 of the target operating rate information storage unit 1500 in FIG. 4 is, for example, variable length data, has the target operating rate information file name as a key value, has one customer and maintenance site, and has a variable length. Shows a data structure having a plurality of unit groups, a plurality of units belonging to the plurality of unit groups, a model of the unit, a calendar month of the unit group, and a target operating rate of the unit group in the calendar month. .

The data structure Data 1650 of the possessed resource information storage unit 1600 is, for example, variable length data, and has the possessed resource information file name as a key value. In the variable length portion, a plurality of calendar days, each of the plurality of calendar days Maintenance staff skills, maintenance staff skill hours of the maintenance staff skills held for each of the calendar days, equipment tools held for the calendar days, and equipment tools held for the calendar days 2 shows a data structure having the number of equipment tool man-hours, the parts held for each of the plurality of calendar days, and the number of parts of the parts held for each of the plurality of calendar days.

The data structure Data 1750 of the maintenance standard information storage unit 1700 in FIG. 4 is, for example, variable-length data, and has a maintenance standard information file name as a key value. , Parts pre-maintenance work for each unit group or model, parts pre-maintenance work contents of parts pre-maintenance work for each unit group or model, parts for each unit group or model Pre-maintenance of parts to perform pre-maintenance work, failure probability at the time of execution of parts pre-maintenance work to perform the parts pre-maintenance work for each unit group or model The parts required for maintenance at the time of performing the parts preliminary maintenance work Pre-maintenance time, parts pre-maintenance cost for performing maintenance at the time of the parts pre-maintenance work for performing the parts pre-maintenance work for each of the plurality of machine groups or models Perform the parts pre-maintenance work at the time of performing the parts pre-maintenance work.When the failure occurs without performing maintenance, perform the parts pre-maintenance work for the multiple units or models. Performs maintenance at the time when the parts pre-maintenance work is performed to perform the parts pre-maintenance work for each of the multiple units or models. Maintenance personnel skills required in case Carry out maintenance work at the time of performing the preliminary maintenance work for the relevant parts. The number of maintenance personnel skills required for the maintenance staff skills, the relevant multiple machine groups, or the relevant preliminary maintenance work for each model. Equipment tools required when performing maintenance at the time of parts preliminary maintenance work, required when performing maintenance at the time of the parts preliminary maintenance work that implements the parts preliminary maintenance work for each group of machines or models Equipment tool manhours of the equipment tool to be used, parts of the plurality of units or parts of the model, parts required for maintenance at the time of performing the parts preliminary maintenance work for each model, the plurality of units Perform maintenance at the time of performing the relevant parts preliminary maintenance work for each group or model. The data structure having the part quantity of the part required in the event is shown.

The data structure Data 1850 of the unit-specific status information storage unit 1800 in FIG. 4 is, for example, variable-length data, and has a unit-specific status information file name as a key value, one unit, and a variable-length portion. A plurality of calendar days, a main unit operating rate of the unit for each of the plurality of calendar days, a cumulative operating time of the main unit of the unit for each of the plurality of calendar days, a plurality of parts constituting the unit for the plurality of calendar days, The data structure which has the component accumulated use time of the said some components which comprise the said number machine for every said calendar day is shown.

The data structure Data 1950 of the maintenance plan information storage unit 1900 shown in FIG. 4 is, for example, variable-length data, has a maintenance plan information file name for each unit as a key value, has one unit, and has a variable length part. , Multiple implementation dates, multiple parts preliminary maintenance work to be performed on the multiple implementation dates, required maintenance personnel skills required for the multiple parts preliminary maintenance work to be performed on the multiple implementation dates, the multiple implementation dates The required maintenance staff skill man-hours of the required maintenance staff skill required in the plurality of parts preliminary maintenance work to be performed, the required equipment tool required in the plurality of parts preliminary maintenance work on the plurality of implementation dates, Required equipment tool man-hours of the required equipment tools required for the parts pre-maintenance work to be performed on multiple implementation dates Shows the data structure having the required parts required in the plurality of parts pre-maintenance work to be performed and the required parts quantity of the required parts required in the plurality of parts pre-maintenance work on the plurality of execution dates in .

The maintenance planning system 10 of the present invention includes screens as shown in FIGS. 5 to 11, for example. The data structure of the data handled on the screens of FIGS. 5 to 11 is as shown in FIG. The screens shown in FIGS. 5 to 11 will be specifically described below.

The maintenance planning system 10 of the present invention displays, for example, an input reception screen relating to the input reception processing unit 1000 as shown in FIG. The maintenance plan generation number column 1001 automatically includes key values for identifying when and which input file is used to generate the maintenance plan and which output file is stored. . For example, the key value includes the year, month, day, hour, second when the input reception screen is opened to generate the maintenance plan. In the target operating rate information column 1002, an input for specifying a file as to which file to use is received with respect to the target operating rate information that is an input file used when generating a maintenance plan. In the owned resource information column 1003, an input for specifying a file as to which file is to be used with respect to the owned resource information that is an input file used when generating a maintenance plan is accepted. In the maintenance standard information column 1004, an input for specifying a file as to which file is to be used for the maintenance standard information, which is an input file used when generating a maintenance plan, is accepted. For the unit 1006 selected in the unit selection column 1005, in the unit-specific status information column 1007, which file of the unit-specific status information is used for the unit-specific status information that is an input file used when generating the maintenance plan. Or accept the file specification input. For the unit 1006 selected in the unit selection column 1005, the unit-specific maintenance plan information column 1008 accepts an input for specifying a file as to which file is used as the output file of the generated maintenance plan. In response to pressing of a maintenance plan generation button 1009, an instruction to generate a maintenance plan using each file specified above is received. When a cancel button 1010 is pressed, a maintenance plan is not generated.

For example, the maintenance planning system 10 of the present invention performs registration / update of the target operating rate information stored in the target operating rate information storage unit 1500 on a screen as shown in FIG. In addition to the screen of FIG. 6, a data file may be imported. A target operating rate information file name column 1501 accepts an input of a file name for operating a record of the target operating rate information storage unit 1500. The file name may be designated by the user or may be automatically generated systematically as long as it is uniquely determined without duplication. The customer column 1502 accepts input of codes and names indicating customers such as owners and borrowers of machines to be maintained. When the maintenance planning system 10 is used in-house, the customer column 1502 can be omitted. A maintenance site column 1503 accepts input of a code or name indicating a place where the machine undergoes maintenance or a place where the machine is used. The machine group setting 1504 receives an input for setting which machine of which model belongs to which machine group when each machine of the machine is managed as a group. Here, in the example of FIG. 6, the screen corresponds to management as a group. However, the screen may be a screen that individually manages the units without performing management as a group. The target operating rate setting 1505 accepts an input for setting a target operating rate for each calendar month for each unit group. Here, in the example of FIG. 6, the screen corresponds to the setting for each calendar month. However, for example, the unit may be smaller than the calendar month in consideration of the contract contents with the customer and the business process of the company. However, it may be a unit larger than the calendar month. A registration / update button 1506 is a button for accepting an instruction to register / update the input accepted in each of the input fields in the target operating rate information storage unit 1500. When the cancel button 1010 is pressed, registration / update to the target operating rate information storage unit 1500 is not performed.

The maintenance planning system 10 according to the present invention performs registration / update of owned resource information stored in the owned resource information storage unit 1600 from a screen as shown in FIG. Data files other than the screen of FIG. 7 may be imported. The owned resource information file name column 1601 accepts an input of a file name for operating a record of the owned resource information storage unit 1600. The file name may be designated by the user or may be automatically generated systematically as long as it is uniquely determined without duplication.

The maintenance worker skill field 1602 accepts the input of the man-hour for each maintenance worker skill held at the maintenance site every calendar day. Here, maintenance engineer skills include, for example, the types of technicians such as electrical circuits, mechanics, and welding, the types of managers such as field supervisors and project managers, and the abilities and experiences of technicians and managers. Call. Here, the number of man-hours refers to, for example, a sum of times that maintenance personnel can operate for each maintenance technician skill. The equipment tool column 1603 accepts the input of the man-hours of the equipment tool held at the maintenance site for each calendar day. Here, the equipment tool refers to, for example, a crane or the like that is limited in quantity, highly shared, or effectively managed as a retained resource. Here, the number of man-hours refers to, for example, a sum of times when equipment tools that can be replaced with each other are treated as the same equipment tool and the equipment tools can be operated.

The parts column 1604 accepts the input of the quantity of parts held at the maintenance site for each calendar day. Here, the parts refer to, for example, individual parts, a unit in which parts are combined, a substitute machine, and the like. In the example of FIG. 7, the screen corresponds to the setting for each calendar date. However, for example, the unit may be smaller than the calendar date based on the contract details with the customer, the business process of the company, or the like. It may be a unit larger than a day. A registration / update button 1605 is a button for accepting an instruction to register / update the input accepted in each of the input fields in the owned resource information storage unit 1600. When the cancel button 1606 is pressed, registration / update to the owned resource information storage unit 1600 is not performed.

The maintenance planning system 10 of the present invention performs registration / update of maintenance standard information stored in the maintenance standard information storage unit 1700 from a screen as shown in FIG. Data files other than the screen shown in FIG. 8 may be imported. The maintenance standard information file name column 1701 accepts an input of a file name for operating a record in the maintenance standard information storage unit 1700. The file name may be designated by the user or may be automatically generated systematically as long as it is uniquely determined without duplication.

The maintenance target selection column 1702 accepts input of a plurality of maintenance target selections from the checkboxes for the machine group or model. The part pre-maintenance work column 1703 accepts input of selection of a plurality of parts pre-maintenance work to be performed on the maintenance object selected in the maintenance object selection field 1702. In addition, when a click is received on a character string such as a code or name indicating a component pre-maintenance operation in the component pre-maintenance operation column 1703, the character string is highlighted and a column of the content of the component pre-maintenance operation is displayed. In 1704, the input of the contents of the parts preliminary maintenance work is accepted. If the contents of the parts pre-maintenance work already exist, the contents of the parts pre-maintenance work are displayed and the content update input is accepted.

The setting field 1705 at the time when the parts preliminary maintenance work is performed receives an input of a setting of when the parts preliminary maintenance work is performed when the cumulative usage time of the parts is reached. Although the example of using the component cumulative usage time is shown in the screen of FIG. 8, the main body cumulative operation time may be used. Regarding the input of the setting of maintenance standard information at the time of execution of the parts preliminary maintenance work, the failure probability column 1706 accepts the input of the probability of failure of the parts at the time of execution, and the parts preliminary maintenance time column 1707 The input of the time required for the preliminary maintenance work is accepted, the input of the cost required for the parts preliminary maintenance work is received in the part preliminary maintenance cost column 1708, and the failure is detected without performing the part preliminary maintenance work in the recovery time column 1709. Accepts input of total downtime and repair time in case of occurrence, and input of total of opportunity loss cost and recovery cost in case of failure without performing relevant parts pre-maintenance work in recovery cost column 1710 As a required resource, in the maintenance staff skill column 1711, the maintenance required when the parts preliminary maintenance work is performed. The input of man-hours for each worker skill is accepted. In the equipment tool column 1712, the input of the man-hours of the equipment tool required when the relevant part pre-maintenance work is performed is accepted, and in the part field 1713, the relevant part pre-maintenance work is performed. Accept the input of the required quantity of parts.

The screen in FIG. 8 shows an example in which all requested resources are used at one point in time at the time of implementation and there is no subsequent time series data, but relatively large-scale maintenance that requires multiple days, etc. In the case of performing the above, a data structure or screen having time-series increments may be used. The registration / update button 1714 is a button for accepting an instruction to register / update the input accepted in each of the input fields in the maintenance reference information storage unit 1700. If a cancel button 1715 is pressed, registration / update to the maintenance standard information storage unit 1700 is not performed.

For example, the maintenance planning system 10 of the present invention performs registration / update of the unit-specific status information stored in the unit-specific status information storage unit 1700 from the screen as shown in FIG. Data files other than the screen of FIG. 9 may be imported. The unit-specific status information file name column 1801 accepts an input of a file name for operating a record in the unit-specific status information storage unit 1800. The file name may be designated by the user or may be automatically generated systematically as long as it is uniquely determined without duplication. The number field 1802 receives an input for designating which number status information is set. The main body operating rate column 1803 accepts the input of the operating rate of the main body of the relevant machine every calendar day. The column 1804 of the main body accumulated operation time receives the input of the accumulated operation time of the main body of the relevant machine for each calendar day. The part column 1805 accepts input of parts to be maintained among a plurality of parts constituting the relevant machine. The part accumulated use time column 1806 receives the input of the accumulated operation time of the part of the relevant machine for each calendar day. The registration / update button 1807 is a button for accepting an instruction to register / update the input accepted in each of the input fields in the unit-specific status information storage unit 1800. If a cancel button 1808 is pressed, registration / update to the unit-specific status information storage unit 1800 is not performed.

The maintenance plan system 10 of the present invention refers to the maintenance plan information storage unit 1900 for each unit storing the maintenance plan generated by the maintenance plan system 10 on a screen as shown in FIG. In addition to the screen of FIG. 10, a data file exported may be referred to. The unit-specific maintenance plan information file name column 1901 accepts input of a file name for operating a record in the unit-specific maintenance plan information storage unit 1900. This file name is uniquely determined without duplication. The unit column 1902 indicates which unit status information is displayed. The execution time column 1903 indicates a calendar date for the parts preliminary maintenance work. The part pre-maintenance work column 1904 to be performed indicates a part pre-maintenance work to be performed on the calendar date. If there are multiple parts pre-maintenance operations to be performed on the calendar date, they are indicated with line feeds. A maintenance worker skill column 1905 indicates the total number of man-hours of maintenance personnel skills required to perform all of the parts preliminary maintenance work performed on the calendar date. The equipment tool column 1906 shows the total number of man-hours of the equipment tool required for performing all the parts preliminary maintenance work performed on the calendar date. The part column 1907 indicates the total value of the parts required to perform all of the parts preliminary maintenance work performed on the calendar date. When the close button 1908 is pressed, the screen in FIG. 10 is closed.

The maintenance planning system 10 of the present invention displays an output screen related to the output processing unit 1400 as shown in FIG. FIG. 11 is a screen for referring to the outline of the maintenance plan generation result. Maintenance plan generation No. Column 1401 shows the maintenance plan generation No. of the input screen related to the input reception processing unit 1000 shown in FIG. The key value is automatically entered so that it is possible to identify when and which input file is used to generate the maintenance plan and which output file is stored. The selection switch 1402 for displaying the time interval accepts an input for designating whether to display the summary of the maintenance plan generation result in the month or the day. For example, the selection button 1402 is displayed in the month by default. The display is switched so that the image is displayed daily.

The execution time column 1403 displays a calendar of the execution time in increments specified by the selection button 1402. The unit group column 1404 displays the unit group subjected to maintenance. The column of the average operating rate 1405 is the average operating rate of all units belonging to the relevant unit group, the total cost column 1406 is the total cost (parts pre-maintenance cost and recovery cost) of all units belonging to the relevant unit group, and the total resource usage rate Column 1407 displays the value divided by the maintenance resource possessing the maintenance resource required to perform the parts preliminary maintenance work for the entire machine belonging to the relevant machine group, in increments of the execution time designated by the selection button 1402 To do. The No. column 1408 displays all the units included in the No. group column 1404. The part pre-maintenance work column 1409 to be executed displays the part pre-maintenance work to be executed for the relevant machine in increments of the execution time designated by the selection button 1402. When the close button 1410 is pressed, the screen in FIG. 11 is closed.

The maintenance planning system 10 according to the present invention operates along a processing flow as shown in FIGS. This will be specifically described below.

FIG. 12 is an example of a processing flow related to the input reception processing unit 1000. In Step 1011, input of file specification of target operation rate information 1002, owned resource information 1003, maintenance reference information 1004, unit-specific status information 1007, and unit-specific maintenance plan information 1008 input from the input reception screen is received. Furthermore, when the input of the maintenance plan generation button 1009 is received in Step 1012, the signal for requesting generation of the specified file and the maintenance plan is transmitted to the plan generation procedure control processing unit 1100 in Step 1013.

FIG. 13 is an example of a processing flow related to the plan generation procedure control processing unit 1100. In Step 1111, when the maintenance plan generation request signal and the specified file name are received from the input reception processing unit 1000, in Step 1112, the target operating rate (average value of all units) for each calendar month from the target operating rate information storage unit 1500. The owned resource information for each calendar date is read from the owned resource information storage unit 1600, and the operation rate and accumulated component usage time of each unit on the latest calendar date are read from the specified file of the status information storage unit 1800 for each unit. In Step 1113, the procedure counter is set to the first calendar month of the maintenance plan generation target period. Using the procedure counter, steps 1114 to 1118 are performed within the range of the maintenance plan generation target period. In Step 1114, the plan option generation processing is requested by transmitting the designated file name received in Step 1111, each information read in Step 1112, and the value of the procedure counter to the plan option generation processing unit 1200. When the plan option generated from the plan option generation processing unit 1200 is received at Step 1115, the optimum plan selection is performed by transmitting the generated plan option information and the value of the procedure counter to the optimal plan selection processing unit 1300 at Step 1116. Request processing. When the optimum plan selection result is received from the optimum plan selection processing unit 1300 at Step 1117, the procedure counter is advanced to the next calendar month at Step 1118. If the procedure counter does not exceed the last calendar month of the target period in Step 1119, Step 1114 to Step 1118 are repeated. If the procedure counter exceeds the calendar month at the end of the target period in Step 1119, the generated maintenance plan is stored in the designated file of the maintenance plan information storage unit 1900 for each unit in Step 1120. In Step 1121, the maintenance plan generation result is transmitted to the output processing unit 1400.

FIG. 14 is an example of a processing flow related to the plan option generation processing unit 1200. When the information of the designated file and the value of the procedure counter are received from the plan generation procedure control processing unit 1100 in Step 1211, the main body operation rate 1803 of each unit on the latest calendar date from the designated file in the unit status information storage unit 1800 in Step 1212. And the accumulated component usage time 1806 (according to necessity, the accumulated operation time 1804 of the main unit), the main unit operation rate and the accumulated component usage time of each unit on all calendar days belonging to the calendar month indicated by the procedure counter (if necessary) Main unit cumulative operating time) is calculated. For example, the main unit operating rate 1803 of each unit before performing the parts pre-maintenance work is based on the simple assumption that the date of the most recent calendar date applies in advance. ) Is calculated. In Step 1213, for every calendar day belonging to the calendar month indicated by the procedure counter, from the maintenance standard information storage unit 1700, the part failure probability, the parts pre-maintenance time, and the parts pre-order according to the calculated part cumulative use time of each unit The maintenance cost, the recovery time, the recovery cost, the required maintenance personnel, the required equipment, and the required parts are read, and, for example, a plan option is generated using a mathematical model as will be described later with Expressions 1 to 8. Here, the generation of the plan option means that, in addition to the extraction of the plan option that satisfies the formula 2, the constraint functions of the formula 3 to the formula 8 are satisfied when the plan is selected from the plan options that satisfy the formula 2. Comprehensively calculating whether the value of the expression 1 that is the evaluation result when the plan is selected from the choices of the plan that satisfies the expression 2 is determined. This is a process for preparing the optimum plan selection processing unit 1300 to select a plan that minimizes the cost from the generated plan options. In Step 1214, the plan option generated above is transmitted to the plan generation procedure control processing unit 1100.

FIG. 15 is an example of a processing flow related to the optimum plan selection processing unit 1300. In Step 1311, when the plan option information and the procedure counter value are received from the plan generation procedure control processing unit 1100, in Step 1312, the target operating rate (average value of all units) is not reduced in the calendar month indicated by the procedure counter. Plans that can be selected in the calendar month indicated by the procedure counter, because the maintenance staff does not fall below the required maintenance staff, the owned equipment does not fall below the required equipment, and the owned parts do not fall below the required parts on each calendar day belonging to the calendar month. One option is selected for each unit or not applicable, and the optimum plan is selected from the plan options using the mixed integer programming method with the aim of minimizing the maintenance cost in the calendar month. In step 1313, the cumulative use time of parts on the calendar date of the plan option for the selected plan option is set to 0, and thereafter, the cumulative use time of parts on each calendar date until the end of the procedure counter is recalculated. In Step 1314, for the selected plan option, the part of the requested part used in the plan option is subtracted from the held parts on each calendar date after the calendar date of the plan option. This process is for responding to a decrease in the number of parts each time it is used, unlike maintenance personnel and equipment tools. In Step 1315, the decision variable selection result is transmitted to the plan generation procedure control processing unit 1100.

Such a maintenance plan system 10 generates a maintenance plan by, for example, solving a mathematical model shown below by a mixed integer programming method. The mathematical model shown in this example is based on the premise that parts maintenance is not performed more than once a month, the target operating rate is managed in calendar month increments, one unit group, and one model. However, for example, the frequency of parts pre-maintenance is increased from once a month, the target operating rate is managed in larger or smaller increments than the calendar month, the number of units is increased to 2 or more, the number of models You may use a mathematical model that increases to 2 or more.

Hereinafter, an example of a mathematical model based on the above will be described. For parametric variables, m is calendar month, d is calendar day, g is machine, h is pre-maintenance of parts, M is the set of calendar months m in the maintenance period, Dm is the set of calendar days d included in calendar month m, Gm A set of unit g at the site in calendar month m, a set of parts pre-maintenance h to be carried out on site in calendar month m, an average operating rate 1505 for all units that target ARMm in calendar month m, and a calendar date for GRDgd Requested maintenance personnel 1711 for performing part pre-maintenance h at the d unit g operating rate 1803, DSdgh for the calendar unit d g unit cumulative usage time 1806, DEdgh for the calendar unit d g The required equipment tool 1712 for performing the parts pre-maintenance h at time 1806, the DPdgh is the required part 1713 for performing the parts pre-maintenance h at the part accumulated use time 1806 of the calendar date d Owned maintenance personnel 1602 secured on day d, owned equipment tool 1603 secured on calendar date d, SPd retained parts 1604 secured on calendar date d, TRdgh on calendar date d The part failure probability 1706 when the part pre-maintenance h is not performed in the part cumulative use time 1806, the part pre-maintenance cost 1708 when the part pre-maintenance h is performed in the part cumulative use time 1806 of the unit g of the calendar date d RCdgh is recovery cost 1710 when a failure occurs without performing parts pre-maintenance h at the part accumulated use time 1806 of calendar date d, and HLdgh is parts pre-maintenance h at parts accumulated use time 1806 of calendar day d Pre-maintenance time of parts 1707 when carrying out the operation, RLdgh is the cumulative use time of parts 1806 of calendar machine d on calendar day d Recovery time 1709 at the time of the failure without carrying the parts pre-maintenance h, to.

For the decision variable, let Xdgh be the judgment value (1 if it is implemented, 0 if it is not implemented) 1904, which is whether or not to perform the parts pre-maintenance h for the machine g on the calendar date d.

For the objective function, the overall cost 1406 (COSTm shown in Equation 1) in calendar month m belonging to the maintenance period M is denoted as minCOSTm, and the objective function is defined as minCOSTm.

For the constraint function, a constraint function that can be used to select whether or not to perform the part pre-maintenance h for the machine g on the calendar date d, and the part pre-maintenance h for the machine g can be performed in the calendar month. Constraint function to m once, constraint function that the total time required for parts pre-maintenance h to be performed for machine g on calendar day d is not more than 24 hours, and equation 5 is targeted for calendar month m Requirement maintenance staff 1711 of all parts preliminary maintenance h that is executed in all machines g on calendar day d, the constraint function that does not fall below the average availability factor 1505 of all the machines , A constraint function in which all the parts pre-maintenance h required equipment 1712 to be executed on all machines g on the calendar date d does not exceed the possessed equipment 1906, and an equation 8 on the calendar date d In Unit g Hodokosuru request parts 1713 of all of the parts pre-maintenance h constraints function that does not exceed the holding parts 1907, to.

FIG. 16 shows an example of input data and FIG. 17 shows an example of output data regarding the example of the mathematical model shown above. The data for a month in which the number of maintenance days per month is 5 days on the document space will be described. Note that the number of maintenance target days per month of the maintenance planning system 10 of the present invention is normally assumed to be all days belonging to the month (31 days, 30 days, etc.). Depending on various situations, such as when the break is about to reach the middle of the month, the number of days may be less than the total number of days belonging to the month (such as 5 days).

For the input data in FIG. 16, for example, the target average operating rate ARMm is a value obtained by dividing the value input from the column 1505 on the screen as shown in FIG. 6 by 100 (0.77 if 77.0%), for example, owned maintenance The personnel SSd, the owned equipment tool SEd, and the owned component SPd are values input from the

fields

1602, 1603, and 1604 of the screen as shown in FIG. 7, for example, the component failure probability TRdgh, the component preliminary maintenance time HLdgh, and the component preliminary The maintenance cost HCdgh, the recovery time RLdgh, the recovery cost RCdgh, the required maintenance personnel DSdgh, the required equipment tool DEdgh, and the required component DPdgh are 1706, 1707, 1708, 1709, 1710, 1711 at the point 1705 on the screen as shown in FIG. It is assumed that the values input from the

columns

1712 and 1713 are shifted to the time of the component cumulative usage time 1806 on the screen as shown in FIG.

In the output data of FIG. 17, the judgment value Xdgh of whether or not to perform the parts pre-maintenance so that the total cost COSTm of Expression 1 is the minimum and the restrictions of Expressions 2 to 8 are satisfied is the maintenance value of the present invention. The result calculated by the planning system 10 using the input data of FIG. 16 is entered. Parts pre-maintenance is not performed at the timing when the value is 0, but parts pre-maintenance is performed at the timing when the value is 1. The parts pre-maintenance to be performed is output, for example, in the field 1904 of the screen as shown in FIG. The minimum overall cost minCOSTm at this time is output, for example, in the column 1406 of the screen as shown in FIG.

As shown in Fig. 17, it can be seen that the Xdgh data satisfies the constraints of Equation 2 and Equation 3. Further, it can be seen that the constraints of Equations 4 to 8 satisfy the constraints because all the left sides are 0 or more. Note that the data related to the constraint is, for example, a value obtained by multiplying the value obtained by dividing the requested resource by the possessed resource by 100 in the column of the total resource usage rate 1407 in FIG. Outputs to log or message box or not.

As described above, according to this example, based on the capacity of limited resources (maintenance personnel, equipment, parts) and the target operating rate (the target operating rate of a group of multiple industrial machines or a single industrial machine) Thus, it is possible to provide a maintenance plan generated so as to minimize the maintenance cost. In addition, by executing the generated maintenance plan, it is possible to maintain and enhance the reliability of the entire plurality of industrial machines under appropriate resources.

In the above embodiment, the maintenance plan generated so as to minimize the maintenance cost is provided. However, the objective function can be a function other than the cost, and the present invention minimizes the maintenance cost. Should not be limited to things. For example, it is possible to set the objective function to maximize the operation rate, and to limit the cost and the resources held.

In addition, this invention is not limited to the above-mentioned Example, Various modifications are included. For example, the above-described embodiments have been described in detail for easy understanding of the present invention, and are not necessarily limited to those having all the configurations described. Further, a part of the configuration of one embodiment can be replaced with the configuration of another embodiment, and the configuration of another embodiment can be added to the configuration of one embodiment. Further, it is possible to add, delete, and replace other configurations for a part of the configuration of each embodiment.

In addition, each of the above-described configurations, functions, processing units, processing means, and the like may be realized by hardware by designing a part or all of them with, for example, an integrated circuit. Each of the above-described configurations, functions, and the like may be realized by software by interpreting and executing a program that realizes each function by the processor. Information such as programs, tables, and files for realizing each function can be stored in a recording device such as a memory, a hard disk, an SSD (Solid State Drive), or a recording medium such as an IC card, an SD card, or a DVD.

Also, the control lines and information lines indicate what is considered necessary for the explanation, and not all the control lines and information lines on the product are necessarily shown. Actually, it may be considered that almost all the components are connected to each other.

DESCRIPTION OF SYMBOLS 10 Maintenance plan system 1000 Input reception process part 1100 Plan generation | occurrence | production procedure control process part 1200 Plan option generation process part 1300 Optimal plan selection process part 1400 Output process part 1500 Target operation rate information storage part 1600 Owned resource information storage part 1700 Maintenance reference information storage Unit 1800-specific status information storage unit 1900-specific maintenance plan information storage unit 20 Network 30 Client terminal

Claims

A maintenance planning system for creating a maintenance plan for a plurality of industrial machines by a computer,
Input acceptance processing means for accepting input of information related to the target operating rate of industrial machinery and resources required for maintenance;
Storage means for storing information input from the input reception processing means;
A plan generation means for generating a maintenance plan so as to satisfy the target operating rate stored in the storage means and not exceed the possessed resources;
A maintenance planning system comprising:
The maintenance planning system according to claim 1,
The input reception processing means further receives information on maintenance standards including maintenance work costs generated during maintenance work and recovery costs in the case of failure without maintenance,
The storage means stores information on the maintenance standard including maintenance work cost and recovery cost,
The said plan production | generation means produces | generates the maintenance plan which minimizes the total cost of the maintenance work cost stored in the said storage means, and a recovery cost, The maintenance plan system characterized by the above-mentioned.
The maintenance planning system according to claim 1,
A server and a client terminal;
The input reception processing means is provided in the client terminal,
The storage means and the plan generation means are provided in the server,
The server and the client terminal are connected to each other via a network.
The maintenance planning system according to claim 2,
An output means for outputting a display screen for input / output is provided.
In the display screen, comprising a screen for inputting the target operating rate, a screen for inputting the owned resource, and a screen for inputting information on the maintenance criteria,
The said display screen is provided with the screen which displays the maintenance plan produced | generated in the said plan production | generation means with the information regarding an average operating rate and cost, The maintenance plan system characterized by the above-mentioned.
2. The maintenance planning system according to claim 1, wherein when inputting the target operating rate, a plurality of industrial machines are managed as one unit group, and the target operating rate is input for each unit group.
A maintenance planning system for creating a maintenance plan for a plurality of industrial machines by a computer,
An input reception processing unit that receives the target operating rate of industrial machines, information on owned resources, maintenance standard information, and status information for each unit from an input screen, an input file, a database, or input communication data;
A target availability information storage unit for storing the target availability of multiple units in time series;
A possessed resource information storage unit that memorizes retained resource information including maintenance man-hours that can be used for maintenance, equipment operation time, and quantity of parts in time series,
The part failure probability, pre-maintenance time, pre-maintenance cost, and recovery time and cost when a part fails without pre-maintenance change depending on the timing of pre-maintenance before the part failure occurs. A maintenance standard information storage unit for storing maintenance standard information including;
Unit-specific status information storage unit that stores unit-specific status information including the operation rate of each unit, the main unit cumulative operating time of each unit, or the cumulative usage time of each part that makes up each unit,
A plan generation procedure control processing unit for controlling a procedure for generating a maintenance plan;
A plan option generation processing unit that reads information stored in the unit-specific status information storage unit and the maintenance reference information storage unit according to the procedure in the plan generation procedure control processing unit, and generates a maintenance plan option using a mathematical model; ,
Optimum that satisfies the target operating rate stored in the target operating rate information storage unit and selects the optimal plan that minimizes the cost from the plan options within the range of the stored resources stored in the stored resource information storage unit A plan selection processing unit;
A maintenance plan information storage unit for each unit that stores maintenance plan information for each unit based on the optimal plan selected in the optimal plan selection processing unit, and what kind of advance maintenance is performed for each unit at which timing;
A maintenance plan system comprising an output processing unit for outputting the maintenance plan information for each unit.
A maintenance plan system server for creating a maintenance plan for a plurality of industrial machines,
Storage means for storing information input from a client terminal that accepts input of information on a target operating rate of an industrial machine and information on owned resources required for maintenance;
A plan generation means for generating a maintenance plan so as to satisfy the target operating rate stored in the storage means and not exceed the possessed resources;
A maintenance planning system server comprising:
The maintenance planning system server according to claim 7,
The client terminal further receives information on maintenance standards including maintenance work costs generated during maintenance work and recovery costs in the case of failure without maintenance,
The storage means stores information on the maintenance standard including maintenance work cost and recovery cost,
The maintenance plan system server, wherein the plan generation unit generates a maintenance plan that minimizes the total cost of the maintenance work cost and the recovery cost stored in the storage unit.
A maintenance plan system client terminal that inputs and outputs information to a maintenance plan system server that creates maintenance plans for a plurality of industrial machines,
Input acceptance processing means for accepting input of information related to the target operating rate of industrial machinery and resources required for maintenance;
Output processing means for outputting information from the maintenance planning system server,
The system server transmits a maintenance plan generated so as to satisfy the target operating rate input from the input reception processing unit and not exceed the possessed resource to the maintenance plan system client terminal, and the output processing unit includes: A maintenance plan system client terminal that outputs the generated maintenance plan.
A maintenance planning system client terminal according to claim 9,
The input reception processing means further receives information on maintenance standards including maintenance work costs generated during maintenance work and recovery costs in the case of failure without maintenance,
The maintenance plan system server generates a maintenance plan that minimizes the total cost of the maintenance work cost and the recovery cost, and the output processing means outputs the generated maintenance plan. Planning system client terminal.