JP2004118698A - Failure maintenance management system and failure maintenance management method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To lead a worst facility to a best facility and to reduce the cost of maintenance by analysis and evaluation of each facility based on three parameters such as a latest date of failure, accumulated number of times of failure, and maintenance cost. <P>SOLUTION: After a failure occurs in one or more facilities, failure information including the date of the failure and the cost for the maintenance is input (S1); the input failure information is accumulated and a failure information database is created (S2); the failure information of each facility for a prescribed period is collected using the failure information database, and the latest date of failure, the accumulated number of times of failure, and the accumulated maintenance cost of each facility are calculated (S3); a reference value, which defines each rank for classification of the latest date of failure, the accumulated number of times of failure, and the accumulated maintenance cost, is set (S4); the latest date of failure, the accumulated number of times of failure, and the accumulated maintenance cost are classified into corresponding ranks for each facility based on the reference value (S5); and the result of the classification is output (S6). <P>COPYRIGHT: (C)2004,JPO

Description

[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a failure maintenance management system and a failure maintenance management method, and in particular, in a maintenance management of equipment, identifies a location to be maintained, quantitatively analyzes maintenance costs, and specifies a maintenance location and reduces maintenance costs. Therefore, the present invention relates to a failure maintenance management system and a failure maintenance management method for outputting the analysis result.
[0002]
[Prior art]
In a conventional failure maintenance management system, generally, a maintenance location is specified, a maintenance plan is created based on the location, and preventive maintenance and post-maintenance are performed, and the results are recorded and stored in a database.
[0003]
This type of conventional system analyzes the material degradation, corrosion tendency, etc. using “advanced analysis technology” as a means to quantitatively grasp the spots to be maintained and evaluates them quantitatively. Quantitative evaluation for failure of moving equipment is performed by failure mode effect analysis (for example, see Patent Document 1).
[0004]
[Patent Document 1]
JP-A-2002-123314 (page 3)
[0005]
This “advanced analysis technology” means: 1) Create a physical model of the danger of interpersonal risk, loss of function, and material deterioration of the equipment, and perform thermofluid analysis, structural analysis, vibration / noise analysis, etc. Guides the average time between failures and the remaining life of the material. 2) For accidents that could not be predicted due to functional loss and material deterioration, conduct a thermal fluid analysis, structural analysis, vibration / noise analysis, etc. to investigate the cause and feed it back as maintenance data. It is described in the publication.
[0006]
Further, in another conventional technique, a maintenance period is predicted and a time at which the next maintenance work is to be performed is specified based on a failure management database for collecting and managing past failure and wear conditions (for example, Patent Reference 2).
[0007]
[Patent Document 2]
Japanese Patent Application Laid-Open No. 2001-092520
[Problems to be solved by the invention]
In the prior art described in Patent Literature 1, when performing analysis, an “advanced analysis technique” by a person experienced in maintenance is required, and it is not possible to reliably specify a maintenance device by a simple method. There was a problem. In addition, since no consideration is given to the cost, there is a problem that it is not possible to specify a device for reducing the maintenance cost.
[0009]
Further, in the prior art described in Patent Document 2, the maintenance period can be predicted and the next maintenance work time can be specified based on the analysis result of the data of the failure management database, and the analysis for continuous operation is possible. However, on the other hand, there is a problem that the device cannot be specified from the viewpoint of reducing maintenance costs.
[0010]
The present invention has been made to solve such a problem, and analyzes and evaluates each facility with three parameters of the latest failure date, the total number of failures, and the maintenance cost as axes. It is an object of the present invention to provide a failure maintenance management system and a failure maintenance management method that can lead the worst equipment to the best equipment and reduce maintenance costs.
[0011]
[Means for Solving the Problems]
The present invention is a failure maintenance management system that collects failure information from one or a plurality of management target facilities, and collects the failure information of the facilities to obtain a latest failure date, a cumulative number of failures, and a cumulative failure count for each of the facilities. A failure information summarizing means for obtaining a maintenance cost, and the latest failure date, the cumulative number of failures, and a predetermined reference value for the cumulative maintenance cost are combined. Classification means for classifying the cumulative maintenance cost with respect to the failure date and the cumulative number of failures.
[0012]
BEST MODE FOR CARRYING OUT THE INVENTION
Embodiment 1 FIG.
FIG. 1 shows an example of a system to which the fault maintenance management system of the present invention is applied. The example of FIG. 1 shows an example in which failure maintenance of each device installed in a plant is performed. As shown in FIG. 1, one or more facilities 1 (facilities A, B, C, D, and E) are provided in a plant to be managed. These facilities 1 are various things of various sizes, for example, air-conditioning facilities, substation facilities, power distribution facilities, escalator elevators, and the like. As shown in the figure, each of the facilities 1 includes a facility to which the facility management system 3 is connected via a communication network 4 such as an intranet or the Internet, and a facility to which the facility management system 3 is not connected. In the figure, the facilities A to C are connected to the facility management system 3 via the communication network 4, and the facilities D to E are not connected to the facility management system 3.
The facility management system 3 performs monitoring operations and operation control of each facility 1 connected via the communication network 4. In addition, inspection information is collected for the equipment 1 (equipment D to equipment E in FIG. 1) that is not connected to the equipment management system 3 using the mobile terminal 23 in the maintenance system 2. That is, for example, the inspection information and operation information of the equipments D to E in FIG. 1 are input and collected by the inspection worker using the mobile terminal 23 and transmitted (uploaded) to the central server 21. Alternatively, a method of outputting the inspection information, driving information, and the like input to the portable terminal 23 on paper and inputting the inspection information from the terminal 22 is also conceivable.
The failure information of each facility 1 is transmitted from the maintenance system 2 and the facility management system 3 to the failure maintenance management system 5 via a network.
[0013]
As shown in FIG. 1, the equipment management system 3 includes a system management terminal 31 for managing the equipment management system 3, a central server 32, and a plurality of terminals 33 for the operator to use for equipment monitoring and operation control. And they are interconnected. These are assumed to be connected by a bus or an intranet.
[0014]
Further, as shown in FIG. 1, the maintenance system 2 includes a central server 21, a terminal 22 connected to the central server 21, and various mobile terminals (mobile telephones, notebook personal computers, etc.) 23 owned by inspection workers. It is configured. As described above, the inspection worker uses the mobile terminal 23 to collect inspection information and operation information of the equipment 1 that is not connected to the communication network 4, and stores the inspection information and operation information and the like in the central server 21. accumulate.
[0015]
As shown in FIG. 1, the failure maintenance management system 5 includes a plurality of terminals 51 and a failure information database 52 that records failure information input from the equipment management system 3. It is connected to the.
[0016]
The overall operation of FIG. 1 will be briefly described. The equipment management system 3 transmits a control signal to each equipment 1 (equipment A to equipment C in the figure) via the communication network 4 to control the operation of each equipment 1 and communicate from each equipment 1. Information on the operating state, failure information, and the like is collected via the network 4 and recorded and stored. The operator refers to the collected information by using the terminal 33 and takes action when there is a problem or the like. Of the information, the failure information is transmitted to the failure maintenance management system 5 through a dedicated line or a predetermined communication network, and is recorded and stored in the failure information database 52. On the other hand, in the maintenance system 2, inspection of each facility 1 is performed by an inspection worker who owns the mobile terminal 23, inspection / failure information is transmitted from the mobile terminal 23 to the central server 21, and further, via the communication network 4. Then, the information is transmitted to the failure maintenance management system 5, where it is recorded and stored in the failure information database 52. In this way, the information transmitted from the equipment management system 3 and the plant system 2 and recorded and stored in the failure information database 52 is analyzed in the failure maintenance management system 5 by a predetermined computer program or the like. Reference is made to the operator by 51 or the like. Although FIG. 1 shows an example in which the maintenance system 2, the equipment management system 3, the failure maintenance management system 5, and the equipment 1 (equipment A to equipment C) are connected via a common communication network 4, However, the present invention is not limited to this case, and they may be connected via different communication networks, or some may be connected via a common communication network and the other via a separate communication network. Furthermore, they may be connected by a dedicated line instead of a communication network.
[0017]
Next, the operation of the failure maintenance management system 5 will be described in more detail with reference to FIG. First, in step S1 of FIG. 2, as described above, failure information is input from the equipment management system 3 and / or the maintenance system 2 and collected. As a collection method, as shown in FIG. 3, an input screen 300 as shown in FIG. 3A is displayed on the screen of the display device of the system management terminal 31 or the terminal 33 of the equipment management system 3, and the operator Is manually input, and the input fault information is transmitted to the fault maintenance management system 5. Alternatively, as shown in FIG. 3B, the central server 32 automatically acquires the failure information from each facility 1 and transmits it to the failure maintenance management system 5. In this case, the failure detection can be performed by using various sensors. Alternatively, a combination of FIGS. 3A and 3B may be used, that is, data automatically acquired by the central server 32 is displayed on the screen 300 of FIG. (For example, maintenance costs) may be manually input by an operator.
[0018]
Returning to the description of FIG. 2, in step S2 of FIG. 2, the failure information collected in step S1 is accumulated, and a failure information database 52 is created and recorded and stored. FIG. 4 shows an example of the failure information database 52. The failure information database 52 includes equipment numbers, equipment names, installation locations, failure dates, failure phenomena, failure causes, used parts, maintenance costs (parts), maintenance costs (labor costs), and the like.
[0019]
Next, in step S3 of FIG. 2, the failure information is totaled for each facility 1. As shown in FIG. 5 (a), the tabulation refers to extracting a past failure record for each device for a predetermined period from the failure information recorded and stored in the failure database 52, and obtaining the result in FIG. As shown in b), the latest failure date, the cumulative number of failures, and the cumulative maintenance cost are obtained. The cumulative maintenance cost includes a maintenance cost (parts) and a maintenance cost (labor cost). In addition, the user can appropriately set the totaling period, for example, for the past six months, for the past one year, and for the past five years (a default value may be set).
[0020]
Next, in step S4 of FIG. 2, as shown in FIG. 6, five steps are set for analyzing the latest failure date, five steps are set for analyzing the cumulative number of failures, and the accumulated maintenance amount is analyzed. Are separately set. In the example of FIG. 6, five stages of the latest failure date are set as follows: rank 5: less than one month, rank 4: one month to less than two months, rank 3: two to six months, less than six months, rank 2: six months to twelve Less than a month, rank 1: 12 months or more. Which of the five ranks the latest failure date obtained in step S3 corresponds to is determined in step S5 described later and used for analysis. In addition, five stages of the cumulative number of failures are set as follows: rank 5:10 or more, rank 4: 5 or more and less than 10, rank 3: 3 or more and less than 5 times, rank 2: 1 or more and less than 3 times, rank 1 : 0 or less. In addition, the five-stage setting of the accumulated maintenance amount is as follows: Rank 5: 1,000,000 yen or more, Rank 4: 500,000 yen or more and less than 1,000,000 yen, Rank 3: 300,000 yen or more and less than 500,000 yen, Rank 2: 100,000 yen or more It is set to be less than 300,000 yen and rank 1: less than 100,000 yen.
[0021]
Next, in step S5 of FIG. 2, the three parameters (the latest failure date, the cumulative number of failures, and the cumulative amount of maintenance) are classified into five stages for each facility. That is, using the example of FIG. 3B, assuming that the totaled date is 2002/08/30, the latest failure date (2002/06/30) is rank 4, and the cumulative failure count (20 times) is The facility is ranked 5 and the accumulated maintenance cost (2 million yen) is ranked 5. The facility is classified as "455" by a three-digit number in which these three ranks are arranged. As a result, each facility is classified into 5 patterns × 5 steps × 5 steps = 125 patterns obtained by combining the ranks. FIG. 7 is a graph showing these 125 patterns in three dimensions, and each cubic block in FIG. 7 corresponds to each of the 125 patterns. Each facility is classified into one of these 125 patterns, and a table as shown in FIG. 8 is created.
[0022]
Next, in step S6, the table created in step S5 is displayed on the screen of the display device of the terminal 51 of the failure maintenance management system 5, and is printed as necessary.
[0023]
The operator can improve the worst equipment to the best equipment by performing the maintenance work with reference to the displayed or printed result in step S6. That is, the maintenance work plan is reviewed and measures for cost reduction are implemented based on the value of the analysis result based on the 125 patterns. A representative one of the 125 patterns will be briefly described.
555: Worst equipment: The worst equipment that has recently failed, has many failures, and requires a lot of maintenance costs.
→ Analyze the failure. Analyze detailed failure contents from equipment to component level, review inspection cycle, and in some cases, consider updating or changing equipment. <Messages on maintenance work> Reduction of follow-up measures by shortening the inspection cycle. Alternatively, maintenance costs can be reduced by replacing equipment or replacing equipment.
511: Caution equipment: Although it has recently failed, the number of failures is small and maintenance costs are not incurred.
→ A watch is needed because it may shift to the worst equipment in the future.
<Message about maintenance work> For a certain period of time, shorten the inspection cycle and check the status. After confirming that a recent failure was a catastrophic failure, change to a normal maintenance cycle.
155: Worst original equipment: Equipment that had been the worst equipment until recently, but after taking countermeasures, breakdowns have stopped.
→ Continue maintenance as it is and shift to the best equipment.
<Message about maintenance work> Continue normal inspection, analyze the contents again when a failure occurs, and review the inspection cycle.
551: Frequent failure equipment: Equipment that always occurs but is a minor failure and does not require much maintenance cost.
→ If the failure details are unavoidable, the system may be operated as it is. However, analyze the failure details, and review the inspection cycle and consider updating or changing equipment. <Messages on maintenance work> Reduction of post-operation by shortening the inspection cycle. Or reduce maintenance costs by replacing equipment.
111: Best equipment: Best equipment with few failures.
→ By continuing maintenance as it is, it can be operated without problems.
<Message about maintenance work> Regular inspection is continued. In some cases, the inspection cycle may be lengthened to reduce inspection costs.
[0024]
The table in FIG. 8 shows an example in which the equipment number, equipment name, installation location, latest failure date, cumulative number of failures, and cumulative maintenance cost of the equipment corresponding to each of the 125 patterns are described. If a simple message such as <message about maintenance work> is added, it becomes a reference for an operator who has little experience in maintenance management, and convenience is further improved.
[0025]
As described above, in the present embodiment, for each device, three parameters (latest failure date, cumulative failure frequency, cumulative maintenance amount) are ranked in five stages, and are classified and analyzed / evaluated into 125 patterns. By taking individual countermeasures for each facility, it is possible to not only identify maintenance points but also to reduce the overall maintenance costs, and to use the worst facilities that are expensive and have many failures, and that do not cost much and have few failures. It can lead to the best equipment.
Further, in the present embodiment, three parameters are shown in three dimensions, but it is also possible to adopt a configuration in which any two parameters are taken out of the three parameters and two-dimensional analysis is repeated. For example, if the analysis is divided into the latest failure date and the accumulated maintenance amount, and the accumulated failure frequency and the accumulated maintenance amount, the correspondence between the latest failure date or the accumulated failure number and the accumulated maintenance amount can be easily understood.
[0026]
In the present embodiment, the cumulative maintenance amount is the total amount of the maintenance cost (parts) and the maintenance cost (labor cost) generated after the failure, but is not limited to this case, and the total amount of the periodic inspection cost is also included. It may be. Alternatively, the total amount of the maintenance cost (parts and labor) and the periodic inspection cost may be used as the accumulated maintenance amount. Naturally, in step S1, information on the periodic inspection cost is input, and "periodic inspection cost" is added to the item of the database in step S2.
When the accumulated maintenance amounts are classified into maintenance costs and periodic inspection costs, ranks are set separately for each of the maintenance costs and the periodic inspection costs, and the maintenance costs and the periodic inspection costs are set for each facility. It is also possible to configure so that analysis is performed separately. With such a configuration, the composition ratio of the maintenance cost and the periodic inspection cost for each facility becomes clear, and the cost management becomes easier.
[0027]
Further, in the present embodiment, an example in which various plants are maintained and managed has been described. However, the present invention is not limited to the example shown in FIG. 1, and equipment such as buildings and stations may be maintained and managed.
[0028]
Further, in the present embodiment, an example in which each parameter is classified into five levels has been described. However, the present invention is not limited to this case, and three levels, ten levels, or any number of levels may be used. You may. Assuming that the latest failure date is k stages, the cumulative number of failures is m stages, and the rank of the cumulative maintenance cost is n stages, in the process of step S5, the patterns are classified into (k × m × n) patterns (however, k, m, and n are positive integers.)
Furthermore, according to the present embodiment, the introduction of the failure maintenance management system 5 allows the existing equipment 1 (equipment A to equipment C in FIG. 1) connected via the communication network 4 to be inspected. The operator can analyze failure information of the equipment 1 (equipment D to equipment E) from which information is collected using the mobile terminal 23, and the equipment 1 in both forms. Among the equipment, the equipment connected via the communication network and the equipment not connected and whose information is collected by the inspection worker using the mobile terminal 23 are classified according to the importance of the equipment, the equipment cost, and the like. Generally, it is done.
[0029]
【The invention's effect】
The present invention is a failure maintenance management system that collects failure information from one or a plurality of management target facilities, and collects the failure information of the facilities to obtain a latest failure date, a cumulative number of failures, and a cumulative failure count for each of the facilities. A failure information summarizing means for obtaining a maintenance cost, and the latest failure date, the cumulative number of failures, and a predetermined reference value for the cumulative maintenance cost are combined. Since the fault maintenance management system is provided with a classifying means for classifying the cumulative maintenance cost with respect to the failure date and the cumulative number of failures, the three parameters of the latest failure date, the total number of failures, and the maintenance cost are used as axes. By analyzing and evaluating each facility, the worst facility can be led to the best facility, and the maintenance cost can be reduced.
[Brief description of the drawings]
FIG. 1 is a diagram showing an example of a system to which a failure maintenance management system according to the present invention is applied.
FIG. 2 is a flowchart showing a processing flow of the failure maintenance management system of the present invention.
FIG. 3 is an explanatory diagram showing a method of inputting fault information input to the fault maintenance management system of the present invention.
FIG. 4 is an explanatory diagram showing a configuration of a fault information database generated in the fault maintenance management system of the present invention.
FIG. 5 is an explanatory diagram showing a method of counting fault information performed in the fault maintenance management system of the present invention.
FIG. 6 is an explanatory diagram showing an example of a reference value (set in five steps) for ranking three parameters of failure information in the failure maintenance management system of the present invention.
FIG. 7 is an explanatory diagram three-dimensionally showing the classification of devices based on the analysis result in the failure maintenance management system of the present invention.
FIG. 8 is an explanatory diagram showing a list of device classifications based on analysis results in the failure maintenance management system of the present invention.
[Explanation of symbols]
1 Equipment A, Equipment B, Equipment C, Equipment D, Equipment E, 2 Plant System, 3 Equipment Management System, 4a, 4b Communication Network, 5 Failure Maintenance Management System, 21, 32 Central Server, 23 Mobile Terminal, 22, 33 , 51 terminal, 31 system management terminal, 34, 53 HUB, 52 failure information database, 300 screens.

Claims (9)

A failure maintenance management system for collecting failure information from one or a plurality of equipment to be managed,
A failure information totaling unit that aggregates the failure information of the equipment, and obtains a latest failure date, an accumulated failure frequency and an accumulated maintenance cost for each equipment;
Based on a combination reference value obtained by combining a predetermined reference value for the latest failure date, the cumulative number of failures and the cumulative maintenance cost, the cumulative maintenance for the latest failure date and the cumulative failure number for each of the facilities. A fault maintenance management system comprising: a classifying means for classifying costs. Failure information input means for inputting failure information including the date and time when the failure occurred and the cost for maintenance when a failure occurred in any of the one or more managed facilities;
Database creation means for creating a failure information database by accumulating the input failure information,
Using the failure information database, the failure information for each piece of equipment for a predetermined period of time, the latest failure date for each piece of equipment, the cumulative number of failures and failure information aggregation means to determine the cumulative maintenance cost,
Reference value setting means for setting a reference value defining each rank for ranking the latest failure date, the cumulative number of failures and the cumulative maintenance cost,
Based on the reference value, for each equipment, the latest failure date, the cumulative number of failures and the cumulative maintenance cost, classification means to classify the corresponding rank,
And a result output unit for outputting the classification result. The reference value setting means sets a separate reference value for each of the latest failure date, the cumulative number of failures, and the cumulative maintenance cost,
The classification means separately ranks the latest failure date, the cumulative number of failures, and the cumulative maintenance cost using the different reference values, and displays a three-digit number in which three rank values are arranged. The failure maintenance management system according to claim 2, wherein the equipment is classified using the equipment. The rank of the latest failure date is k levels,
The cumulative failure frequency rank is m stages,
The cumulative maintenance cost rank is n stages,
Where k, m and n are positive integers,
Then
The fault maintenance management system according to claim 2, wherein the classification unit classifies the facilities into (k × m × n) patterns. The failure maintenance management system according to claim 2, wherein the cumulative maintenance cost includes a part price and a labor cost used for the subsequent maintenance. The fault maintenance management system according to claim 2, wherein the cumulative maintenance cost includes a periodic inspection cost. The cumulative maintenance cost includes a maintenance cost including a part price and a labor cost used for the subsequent maintenance, and a periodic inspection cost,
The reference value setting means sets the reference value regarding the cumulative maintenance cost separately for each of the maintenance cost and the periodic inspection cost,
The said classification means classifies the said accumulated maintenance cost according to the said rank prescribed | regulated to the said maintenance cost and the said periodic inspection cost for every said equipment, The Claim 2 characterized by the above-mentioned. The failure maintenance management system described in the above. The reference value setting means sets a separate reference value for each of the latest failure date, the cumulative number of failures, and the cumulative maintenance cost,
The classification means ranks the latest failure date, the cumulative number of failures, and the cumulative maintenance cost separately using the separate reference values, and calculates the latest failure date, the cumulative failure frequency, and the cumulative maintenance cost. The fault maintenance management system according to any one of claims 2 to 7, wherein the equipment is classified using a number in which values of a plurality of ranks are arranged. A failure information input step in which, when a failure occurs in any of the one or more managed facilities, failure information including the date and time when the failure occurred and the cost required for maintenance is input;
A database creation step of creating the failure information database by accumulating the input failure information,
Using the failure information database, aggregating the failure information for each of the equipment for a predetermined period, and a failure information aggregation step of obtaining the latest failure date, the cumulative number of failures, and the cumulative maintenance cost for each equipment;
A reference value setting step of setting a reference value that defines each rank for ranking the latest failure date, the cumulative number of failures, and the cumulative maintenance cost;
Based on the reference value, for each equipment, the latest failure date, the cumulative number of failures and the cumulative maintenance cost, a classification step of classifying the corresponding rank,
And a result output step of outputting the classification result.

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