JP2002215224A - Equipment maintenance/management support consulting system - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an equipment maintenance/management support consulting system devised so that a user is provided with equipment maintenance/ management for short, medium and long terms and with merits based on the accumulation of know-how and is encouraged for self-sustained by constructing a system capable of synergistically exhibiting merits of both a supporting center having expert technology about equipment maintenance/management and the user practically using the installed equipment. SOLUTION: A contract concerned with the support of equipment maintenance/management is made between the supporting center C and the user U. The center C is equipped with various data files and a main computer (1) and the user U is equipped with terminal equipment (2). Both the center C and user U mutually transmit/receive information through the main computer (1) and the terminal equipment (2) and share the information, the center C provides consulting for support to the user U and the user U is allowed to receive consulting from the center C and utilize the supporting information from the center C by his (or her) own capacity.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an equipment maintenance management support consulting system capable of sharing maintenance information in real time using a network and performing high quality equipment maintenance management.

[0002]

2. Description of the Related Art In the manufacturing industry, maintenance management of manufacturing equipment is indispensable. Therefore, for the equipment (including equipment and equipment) installed at the factory, normal maintenance (daily inspection, periodic inspection), handling of failures including initial failures, predictive management to prevent occurrence of abnormal situations in advance, It is necessary to manage the timing of replacement or repair, and to manage the environment associated with the operation of the equipment. It is also necessary to provide basic knowledge and skills for equipment management and to conduct operator training to enable daily inspections.

[0003] These managements are performed by the company where the equipment is actually installed, but depending on the size of the company, it is often the case that individual departments are in charge of individual departments and comprehensive management is often not performed. In many cases, when the equipment stopped operating or when an obvious abnormality was found, but not so far, the manufacturer of the equipment was requested to repair or replace the equipment.

[0004] Such ex post measures are burdensome for the company installing the equipment in terms of the cost required for repair, temporary stoppage of operation in the event of failure, etc., and in terms of safety and environmental problems. But it is a problem to be solved. However,
Despite the necessity of achieving both a reduction in manufacturing costs and stable operation, in practice there have been cases where sufficient measures have not been taken.

[0005] In order to solve these problems, it has been proposed to install a device for equipment maintenance management on the site where the equipment is actually installed.

For example, Japanese Unexamined Patent Publication No. Hei 5-185355 discloses that a production plan is received from a host computer, an operation prediction of the site equipment is performed based on the production plan, and an operation prediction value is obtained. Calculate the total operation value by adding the predicted operation value to the actual equipment operation value that was set, and compare whether the total operation value does not exceed the equipment maintenance deadline value registered in advance. Equipment maintenance management that outputs a maintenance request book to execute, prompts the host computer to replan to make a production plan that does not cause the production plant to stop due to equipment failure, and gives advance maintenance instructions and production planning support based on production maintenance prediction. An equipment maintenance management device provided with a computer is shown.

In Japanese Unexamined Patent Publication No. Hei 6-168168, a system diagram display means displays a system diagram of plant equipment corresponding to a system diagram number registered in advance on a request on a display device. The coordinate data of the range where each device is located and the corresponding equipment code are registered in the equipment coordinate data file in advance for each figure, and the target equipment extraction means performs the coordinate data corresponding to the equipment specified on the system diagram. The target equipment code is extracted from the system diagram number, and the equipment information extraction means searches for the equipment code, the equipment information, and the target equipment code, and outputs the relevant equipment information to a display device or the like. The drawing is retrieved from the optical disk device based on the drawing index information and retrieved and output to a display device or the like by using the related drawing number, the drawing index information and the target equipment code.備保 all management business support apparatus is shown.

Japanese Patent Application Laid-Open No. 7-49712 discloses a storage means for storing information necessary for equipment maintenance in a tree form for maintenance management, and for storing an operation status including stop / start and a failure status. An operation / failure state detection unit having operation state judgment / estimation means for judging and outputting an operation state including a stop / start and a failure state based on an operation state of a component required by the equipment; An information transmission unit for transmitting information; a storage unit for storing maintenance / inspection time of each component; an alarm unit for outputting failure information from the information transmission unit; and a unit for correcting the maintenance / inspection time of the component. An equipment maintenance management device provided with a maintenance management unit for performing correction management is shown.

Japanese Patent Application Laid-Open No. Hei 9-22432 discloses that running costs are collected from equipment including a plurality of devices, initial costs are input by an operator from an input device, and trends are obtained from the initial costs and the running costs, respectively, to evaluate LCC. The expected lifetime cost is determined by the function, the determined expected lifetime cost is compared with the target lifetime cost set in advance by the target setting function, and the result is displayed on the output device. An equipment maintenance management method and an equipment maintenance management system in which the optimal renewal time of equipment is determined from the estimated lifetime cost of the equipment.

[0010]

However, it is not easy for many small and medium-sized companies to introduce the systems and apparatuses described in the above publications in terms of equipment funds and human constraints. In addition, since the systems and devices described in the above publications have a limited scope of application, they only cover a part of the equipment maintenance management, and must manage all the equipment in the factory with limited personnel and cost. For small and medium-sized companies that have to work, it is hard to say that it is easy to use.

[0011] In addition, regardless of the size of a company, even if there are human resources who can use the above-mentioned system, it is better to outsource to a specialized company from the comprehensive viewpoint of corporate management. , May be advantageous in terms of total cost. However, the method of completely outsourcing to a specialized company may lose its own technology accumulation efforts and human resource development efforts related to equipment maintenance management, and in the long term it may not always be a plus for user companies .

[0012] Under such a background, the present invention provides a support center having specialized skills in equipment maintenance management and a user who actually deploys and uses equipment.
By creating a system that can mutually demonstrate the characteristics of each other, users can achieve short, medium, and long-term equipment maintenance management, and at the same time foster the benefits of users' accumulated know-how and motivation for independence. The purpose is to provide a devised equipment maintenance management support consulting system.

[0013]

An equipment maintenance management support consulting system according to the present invention comprises a support center C having specialized skills in equipment maintenance management and a user U who actually deploys and uses the equipment. A contract concerning facility maintenance management support is concluded between them. The support center C manages, calculates, searches, records, and outputs various data files necessary for facility maintenance management by linking these data files. Main computer for processing such as
(1) On the other hand, the user U has a terminal device capable of communicating with the main computer (1) of the support center C.
(2), and the support center C and the user U exchange information with each other via the main computer (1) -terminal device (2) and share the information,
The support center C provides consulting for support regarding facility maintenance management to the user U.
While receiving consulting from Support Center C,
It is characterized in that the support information from the support center C can be used by its own power.

[0014]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described below in detail.

<Organization> In the equipment maintenance management support consulting system of the present invention, first, a support center C having specialized skills for equipment maintenance management and a user U who actually deploys and uses the equipment are provided. A contract for facility maintenance management support will be concluded with. A contract is a contract or a membership.

The support center C may be a maker that supplies the main equipment, a company associated with the maker, or a third-party company independent of these companies. The equipment already installed usually spans multiple manufacturers,
There is also a desire to expand the options for purchasing equipment, so companies independent of the major equipment suppliers themselves are more likely to join users U, and the support center C is not restricted to specific manufacturers. It is possible to make full use of unique know-how and to provide support that is considered to be most suitable from the viewpoint of the user U.

In the consulting system of the present invention, it is particularly advantageous that the user U be a member of a member organization. With such a member organization, members can receive various services from the support center C and can provide continuous support, so that the system of the present invention can be operated more effectively. In other words, it is like building a relationship between the patient and the attending physician, and since the attending physician also accumulates a large number of cases and treatment cases, the diagnosis and the selection of a treatment based on it are improved by real-time information exchange. Become quick, accurate and targeted. That is, in the exchange between the support center C and the user U, know-how accumulates on both sides, and a cycle preferable for equipment maintenance management is formed.

<Main computer (1), data file>
The support center C includes various data files necessary for equipment maintenance management, and a main computer (1) for linking these data files to perform processing such as management, calculation, search, recording, and output of various data. Equipped with

The data file on the side of the support center C includes at least: a client data file (11) related to client or member management;
Includes data analysis software (12) for judging overhaul and replacement timing, ・ Training-related information data file for training for human resource development (13), ・ Basic data file (14) as a ledger for equipment specifications To do.

The customer data file (11) contains the user U
Various information related to is input.

The data analysis software (12) is for predicting the timing of equipment replacement, such as regression analysis software.

In the training related information data file (13), various kinds of information related to training for human resource development related to job training such as operator training, human resource development, and morale improvement are prepared. Examples of the training software include skill improvement training such as software for early detection of equipment abnormalities and small repair in-house processing.

The basic data file (14) serves as a ledger for equipment, and can be searched from the type of equipment and various other viewpoints.

The data files may further include: a work plan data file (15) related to a work plan, a work and trouble history management data file (16) related to work and failure history management, and an existing work specification. Such construction specification data file (1
7) ・ Include a maintenance management plan data file (18) for maintenance management of existing equipment.

<Terminal (2)> On the other hand, the user U is equipped with a terminal (2) capable of communicating with the main computer (1) of the support center C. The terminal device (2) may be a personal computer or a portable communication device.

<Consulting> The support center C and the user U are connected to the main computer (1) -terminal device.
Exchange information with each other via (2) and share the information. The support center C provides the user U with consulting for support regarding facility maintenance management. The user U receives the consultation from the support center C and also uses the support center C by his / her own power.
To be able to use support information from

Various consultations are performed using the main computer (1) and data files of the support center C and the terminal device (2) of the user U. FIG. 1 is an explanatory diagram showing an outline of the consulting system of the present invention. The user U accesses the main computer (1) using the terminal device (2), requests the support center C for analysis as needed, and receives feedback. In simple cases or when the person in charge of the user U becomes skilled, only the person in charge of the user U can operate the data file of the main computer (1) to obtain necessary information such as analysis results.

Examples of the initial maintenance support include the following. (a) Investigation of the current status of equipment: Investigate the main equipment as an initial investigation and lay the foundation for chart making. (b) Main ledger maintenance: Support the creation of charts that are not left to the manufacturer but are tailored to the factory. (c) Simple inspection, checklist creation, guidance for inspection procedures: Support and guidance for checklist creation so that operators can perform periodic inspections. (d) Management advice based on regular reports: Find improvements from reports.

Examples of the facility consulting include the following. (a) Acceptance of consultation for daily equipment management: Troubles and various requests from user U are received by telephone, facsimile, e-mail, on the computer screen, etc., and expert staff answers. In the case of a telephone, it can be made toll free. For questions with simple and standard content, type by pressing the # button on a touch-phone for a telephone, or click an appropriate item on the screen for a computer screen. Automatic answering without human intervention) is also possible. (b) Improvement advice: If necessary, introduce a contractor and cooperate in calculating the estimate. (c) Information provision: Introduce maintenance technology-related news and examples from other companies. It can also provide information on related periodicals and major articles, relevant laws and regulations, and administrative jurisdiction. (d) Information on various seminars: Provide information useful not only for equipment but also for corporate management.

The operator training includes, for example, the following. (a) Equipment training: Acquisition of equipment components and basic knowledge. (b) Routine inspection procedure: Upgrading skills to enable equipment inspection. (c) Acquisition of equipment abnormality detection method: Acquisition of a point of judgment. (d) Selection of various training courses: Five courses each for machinery and electricity will be provided.

According to the equipment training of the above (a), for example, through the following steps, an operator who is strong in equipment is nurtured.・ The first stage: Detect defective parts and learn the improvement process.・ 2nd stage: Understand the mechanism and role of equipment.・ Phase 3: Know that product quality is built in equipment.・ Fourth stage: The trouble can be fixed by yourself.

The operator who returned to the site by the routine inspection procedure described in (b) above and the method for discovering equipment abnormalities described in (c) above decided from "the machine does not work" to "what is strange".
, And grasping the phenomenon that "this is a strange point"
The cause is clarified as "this is the possible cause", and if the cause can be clarified, it will be possible to respond and shift from the conventional post-maintenance to the preventive maintenance.

As for the curriculum of the above (d) for selecting various training courses, for example, five courses such as mechanical and electric are set as follows. An example of the standard program is “Maintenance Skills Training Course for Operators”. ・ Course A: Subject of Machinery, Training time: 10 hours ・ Course B: Rotary machinery and lubrication, Training time: 12 hours ・ C Course Subjects: rotating machinery and hydraulics, training time: 12 hours ・ D course Subjects: electricity and lubrication, training time: 12 hours ・ E course Subjects: electricity and hydraulics, training time: 12 hours training course.

[0034]

The present invention will be further described with reference to the following examples.

Embodiment An embodiment in which cost is reduced by reviewing the replacement cycle of a replacement part (liner) will be described. Initially, the replacement was periodically performed according to the current standard. From the accumulation (history) of the measurement data of the wear amount of the replacement part, the actual measurement data was analyzed by linear regression analysis or the like. Next, a review standard was created from the analysis results.

Table 1 shows the current standards for replacement parts (liners). Although the parts X, Y, and Z have different degrees of importance, they are periodically replaced every six months (twice a year), and the cost is 2 million yen each year.

[0037]

[Table 1]Current standards  Equipment name  Part X Part Y Part Z  Importance A BC Replacement cycle 6 months 6 months 6 months Failure history None None NoneService wear (mm) 7.00 7.00 7.00  Exchange cost (1,000 yen / time) 1,000 1,000 1,000 Number of exchanges (time / year) 2 2 2Annual repair costs (1,000 yen) 2,000 2,000 2,000

Table 2 below shows the history of the measurement results of the wear amount reduced by the wear of the parts X, Y and Z.

[0039]

[Table 2]History of measurement data  Equipment name  Part X Part Y Part Z  April 1 (updated) 0.00 0.00 0.00 May 1 measurement 1.20 0.60 1.10 June 1 measurement 1.80 1.20 1.80 July 1 measurement 2.40 2.40 3.10 August 1 measurement 4.00 3.50 3.50 September 1 measurement 4.10 4.60 5.10October 1 measurement 5.30 5.10 5.80  (Note) The numerical value is the amount of wear (mm).

FIG. 2 is a graph showing the measurement result of the wear amount of the replacement part in this embodiment, plotted with the measurement date on the horizontal axis and the wear amount on the vertical axis.

The measured data in Table 2 was analyzed by linear regression analysis, and the results of data analysis when a predicted value incorporating the safety factor was calculated are shown in Table 3.

[0042]

[Table 3]Data analysis results  Equipment name  Part X Part Y Part Z  November 1 predicted wear amount (mm) 6.10 6.14 6.79 Safety factor (importance classification) 1.20 1.10 1.00 November 1 predicted wear amount (mm) 7.32 6.76 6.79(Including safety factor)

The review criteria created from this analysis result are
It is shown in Table 4 below.

[0044]

[Table 4]Review criteria  Equipment name  Part X Part Y Part Z  Importance A B C Replacement cycle 6 months 7 months 7 months Failure history None None None Limit of wear (mm) 7.00 7.00 7.00 Replacement cost (1,000 yen / time) 1,000 1,000 1,000 Number of times of change (times / year) 2 1.71 1.71Annual repair costs (1,000 yen / year) 2,000 1,710 1,710

As shown in Table 4, according to this review standard,
Although the part X is the same as the current standard, the parts Y and Z have been replaced by six months instead of six months, and the annual repair cost for replacement is 2 million yen. The cost was reduced to 1,710,000 yen.

For the items (basic data) of the current standard, the support center C who has received the request usually inputs necessary items, and the user U who uses the equipment makes necessary corrections as necessary.

The data storage items are input by the user U, and the data is also fed back to the main computer (1).

The data analysis item is the support center C,
Perform a high-level analysis by a specialist engineer and
Receives the analysis results. Alternatively, the analysis is automatically performed when the user U inputs a numerical value to the regression analysis software in the system prepared and registered and recorded by the support center C.

A series of processes and input data are also stored in the main computer (1), and are used for further accurate analysis thereafter. That is, as the user U inputs data and makes full use of it, the support center C and the user U cooperate with each other to improve accuracy and facilitate next use.

As a result, equipment failures can be prevented beforehand, so that not only accidental shutdown can be avoided, but also over-maintenance can be avoided, so that further cost reduction can be achieved.

At this time, the support center C sends the user U
Even if there is no request from the user, information about the time of equipment replacement can be sent to the user U when necessary, and a specialist is dispatched to the user U if necessary. The user U can also contact the support center C for any questions. Since such a system is employed, the user U naturally acquires the know-how of the equipment maintenance management without excessively burdening the user U.

If the user U executes the training software in a timely manner, participates in the training, or receives the actual training by dispatching the instructor from the support center C, the user U already has the raw experience. In addition to accumulating and motivating to learn, the effects of the training will be maximized.

[0053]

According to the facility maintenance management support consulting system of the present invention, both the support center C having specialized skills in facility maintenance management and the user U who actually deploys and uses the facilities are provided. Since the system is designed so that each user's characteristics can be synergistically exhibited, the user U can manage short, medium and long-term equipment maintenance, and the user U can accumulate know-how and motivate himself. Become like

Therefore, it is possible to prevent a failure from occurring, and it is possible to prevent repairs and replacements from being performed earlier than necessary in order to avoid a subsequent response, thereby preventing over-maintenance. As a result, it is possible to reduce costs and avoid unexpected equipment stoppages.

Since it is not necessary to hire a technical engineer or to create a facility-specific database for each user U's company, labor costs can be reduced. In addition, a higher level of equipment maintenance management can be achieved than when measures are taken for each company.

The user U who actually uses the equipment on the site under various conditions often has blind spots and know-how that the equipment manufacturer does not know. The know-how is also incorporated into the system, so that it can be applied to other places or taken over by other operators. In other words, even if the buried know-how or the operator using the know-how is not particularly conscious of this, the know-how on the site is utilized.

[Brief description of the drawings]

FIG. 1 is an explanatory diagram showing an outline of a consulting system of the present invention.

FIG. 2 shows a measurement result of a wear amount of a replacement part in the embodiment.
It is a graph plotting the number of elapsed months on the horizontal axis and the amount of wear on the vertical axis.

[Explanation of symbols]

 (1)… Main computer, (11)-(18)… Data file, (2)… Terminal device

Claims (2)

[Claims] An agreement between a support center C having specialized skills for facility maintenance management and a user U who actually deploys and uses facilities is provided for the facility maintenance management support. C is equipped with various data files necessary for equipment maintenance management and a main computer (1) for linking these data files to perform various data management, calculation, search, recording, output, etc. On the other hand, user U is the main computer of support center C
It is equipped with a terminal device (2) capable of communicating with (1), and the support center C and the user U exchange information with each other via the main computer (1) -terminal device (2) and exchange the information with each other. The information is shared, and the support center C provides the user U with consulting for the support regarding the equipment maintenance management. The user U receives the consultation from the support center C and also receives the support information from the support center C by his / her own power. A facility maintenance management support consulting system, characterized in that it can be used. 2. The data file of the support center C includes at least: a client data file for client or member management (11);
Includes data analysis software (12) for judging overhaul and replacement timing, ・ Training-related information data file for training for human resource development (13), ・ Basic data file (14) to be a ledger for equipment specifications・ If necessary, ・ Construction plan data file for construction planning (15) ・ Construction and failure history management data file for construction and failure history management (16) ・ Construction specification data file for existing construction specifications (15) 1
7) The consulting system according to claim 1, wherein the consulting system includes a maintenance management plan data file (18) for maintenance management of the existing equipment.