JP2004287785A - Facility maintenance managing system, facility maintenance managing method, facility maintenance managing program and recording medium having its program recorded thereon - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a facility maintenance managing system/method/program/recording medium for supporting the enhancement of the efficiency of a general task in a facility maintenance department to realize the stable operation/operation rate improvement and the maintenance task at the optimal costs of the facility. <P>SOLUTION: This facility maintenance managing system is configured to unitarily manage the regular maintenance, post-maintenance and modified maintenance of a producing facilities on the basis of a budget. This system is provided with: a storage means (hard disk device 20) for imparting ID to each of the elements of the respective management items of maintenance plan management 15, maintenance information management 16, budget/expense management 17, parts inventory management 18 and maintenance person in charge management 19 associated with the facility maintenance, and for dividing them for each management task information by associating them with the ID for storage; and a calculating means (control part 2) for calculating the maintenance period, parts inventory and maintenance person in charge. Then, the post-maintenance or modified maintenance is performed on the basis of the past maintenance results and budget spending results. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a facility maintenance management system, a facility maintenance management method, and a facility maintenance management program for efficiently managing a wide variety of facility maintenance information in a department that performs management and maintenance of production facilities in a factory or the like. And a recording medium on which an equipment maintenance management program is recorded.
[0002]
[Prior art]
As a conventional equipment maintenance management system, equipment maintenance management that performs maintenance work at the appropriate timing reflecting the failure status of each equipment and properly manages the inventory of maintenance products for a production line consisting of multiple equipment A system has been proposed (for example, see Patent Document 1).
[0003]
This equipment maintenance management system is an equipment maintenance management system for a production line consisting of a plurality of equipment. In each equipment, the period from the previous maintenance work to the next maintenance work is determined based on the past failure and wear conditions. Means for predicting the maintenance period that will be, and for each equipment, based on the production results up to now and the past operation status, predict the future operation status required to fulfill the predetermined production plan, Means for specifying a time at which the next maintenance work should be performed, based on the predicted maintenance period, the operating time from the previous maintenance work, and the predicted operation status, and the specified maintenance time. Based on the above, the maintenance work is urged for the facilities near the maintenance time, and for each facility, based on the specified maintenance time, the number of inventories and the delivery date of the maintenance items required for the maintenance work. There are, and is characterized in that it comprises a means for prompting the recruitment of conservation products missing.
[0004]
As another conventional technique, a total maintenance management device that supports maintenance work by outputting guide information of the maintenance work has been proposed (for example, see Patent Document 2).
[0005]
This comprehensive maintenance management device stores the storage quantity, storage timing, stock quantity, used quantity, usage time, stock location, etc. of various parts in a storage device, and at the same time, an inventory management device displayed on a display device, a plant abnormality or equipment failure. Occasionally, based on the signal sent from the plant observation device and the information stored in the storage device, the handling method of the failure location, the storage location of the repaired / replaced parts, the number of storage, the failure occurrence time, the failure history, the maintenance history, etc. Based on the failure countermeasure guide device displayed on the display device and the maintenance schedule for each device, the signals corresponding to the actual operation time, operation frequency, and failure / maintenance frequency sent from the plant observation device are input and processed. While modifying the above maintenance schedule, the maintenance / replacement time, maintenance / replacement history, operation history, failure history, parts storage location and number of parts A preventive maintenance guide device for displaying on a ray device, wherein signals are exchanged between the inventory management device, the failure countermeasure guide device, and the preventive maintenance guide device through the storage device, the arithmetic device, and the display control device. Things.
[0006]
[Patent Document 1]
JP 2001-92520 A
[Patent Document 2]
JP-A-60-233709
[0007]
[Problems to be solved by the invention]
In the equipment maintenance department, for example, in addition to the above, other than the above, routine inspection work, equipment maintenance work, routine work such as budget and expense management, etc. It covers a wide range of tasks, such as problem analysis through failure analysis, root causes of failures, improvement in processing capacity through improved maintenance, and reductions in repair and parts costs.
[0008]
However, it is difficult for the above-mentioned conventional technology to support such a wide range of equipment maintenance management work.
[0009]
In view of such problems of the prior art, the object of the present invention is to support the overall efficiency of operations in the equipment maintenance department, improve the stable operation and operation rate of equipment, and maintain equipment to lead to maintenance work at optimal cost. An object of the present invention is to provide a management system, a facility maintenance management method, a facility maintenance management program, and a recording medium on which the facility maintenance management program is recorded.
[0010]
[Means for Solving the Problems]
In order to achieve the above object, the equipment maintenance management system of the present invention is an equipment maintenance management system for centrally managing periodic maintenance, post-maintenance, and improvement maintenance of production equipment based on a budget. A storage unit that assigns an ID to each element of each management item of maintenance information management, budget / expense management, parts inventory management, and maintenance personnel management, and stores the divided management information in association with the ID; It is characterized by comprising a maintenance time, a parts inventory, and a calculating means for calculating a maintenance person, and performing post-maintenance or improved maintenance based on past maintenance results and budget consumption results.
[0011]
Here, the post-maintenance is to repair an unplanned failure that occurred during the operation of the equipment. In addition, improvement maintenance refers to the modification of equipment and parts for the purpose of improving the production capacity and stable operation of equipment.When a defect such as a shortage of production capacity or a decrease in the operating rate due to frequent or recurring failures occurs. Or when it may occur.
[0012]
According to the equipment maintenance management system of the present invention, information on a wide range of equipment maintenance management operations including not only periodic maintenance but also post-maintenance and improvement maintenance can be centrally managed by association based on individual management IDs. This makes it possible to reliably perform maintenance work in accordance with the determined facility management standards and budget.
[0013]
Further, the equipment maintenance management system of the present invention further comprises a first warning means for issuing a warning when the budget consumption result exceeds a predetermined threshold for each of the periodic maintenance, the post-maintenance, and the improvement maintenance. It may be.
[0014]
According to the equipment maintenance management system of the present invention, a warning is issued when any of the budget consumption results of the regular maintenance, the post-maintenance, and the improvement maintenance exceeds a predetermined threshold in the middle of a period, so that the budget balance has been reduced. Can be surely grasped. As a result, since the budget redistribution and the like can be examined and executed at an early stage, it is possible to prevent a situation in which a necessary budget for maintenance work cannot be secured due to a shortage of the budget balance at the end of the term or the like as much as possible.
[0015]
Further, the equipment maintenance management system of the present invention may further include a second warning unit for prompting the improvement maintenance when the periodic maintenance or the post-maintenance occurs at a budget or more.
[0016]
Here, the fact that the maintenance cost exceeds the budget amount means, for example, that the performance of the relevant equipment is progressing, so that there is a possibility that some failure may occur before the next periodic maintenance time. Or, even if a failure does not occur, the condition of the equipment is not good, so that the original production capacity may not be exhibited. In such a case, it is preferable to carry out systematic improvement and maintenance on the equipment in advance and take a permanent measure, rather than taking a provisional measure after a more serious failure occurs.
[0017]
According to the equipment maintenance management system of the present invention, a warning is issued to urge the improvement maintenance of the equipment when a cost exceeding the budget amount is required in the periodic maintenance or the post-maintenance, so that the fact can be surely grasped. Improve the production capacity of the equipment by avoiding a situation where more serious breakdowns occur and hinder production by implementing improvement measures and implementing permanent countermeasures for the equipment at an early stage in accordance with this warning. Can be.
[0018]
Alternatively, in order to achieve the above object, the equipment maintenance management method of the present invention is an equipment maintenance management method for centrally managing periodic maintenance, post-maintenance, and improvement maintenance of production equipment based on a budget. A storage step in which an ID is assigned to each element of each management item of planning management, maintenance information management, budget / expense management, parts inventory management, and maintenance staff management, and divided and stored for each management work information in association with the ID. And a maintenance step, a parts inventory, and a calculation step of calculating a maintenance person, and perform post-maintenance or improvement maintenance based on past maintenance results and budget consumption results.
[0019]
According to the equipment maintenance management method of the present invention, information on a wide range of equipment maintenance management work including not only periodic maintenance but also post-maintenance and improvement maintenance can be centrally managed by association based on individual management IDs. This makes it possible to reliably perform maintenance work in accordance with the determined facility management standards and budget.
[0020]
Alternatively, to achieve the above object, a facility maintenance management program of the present invention causes a computer to execute the facility maintenance management method.
[0021]
According to the facility maintenance management program of the present invention, the facility maintenance management system of the present invention can be realized anywhere as long as there is a computer environment in which the program can be executed. Furthermore, if this equipment maintenance management program is executable by a general-purpose computer, it is not necessary to prepare a dedicated computer environment for realizing the equipment maintenance management system of the present invention, and the equipment maintenance management program of the present invention is not required. The usefulness of the management program increases.
[0022]
Alternatively, in order to achieve the above object, a recording medium on which the facility maintenance management program of the present invention is recorded is a computer-readable recording medium, wherein the facility maintenance management program is recorded.
[0023]
According to the recording medium storing the equipment maintenance management program of the present invention, the equipment maintenance management system of the present invention can be easily realized in various places and environments, and the versatility of the equipment maintenance management method of the present invention is improved. be able to.
[0024]
BEST MODE FOR CARRYING OUT THE INVENTION
Hereinafter, an embodiment in which the present invention is used for equipment maintenance management work in an equipment maintenance department of a production factory will be described with reference to the drawings. Here, all management work related to equipment maintenance, including daily inspections, shall be performed by this equipment maintenance department.
[0025]
<Overview of system configuration and management functions>
FIG. 1 is a configuration diagram of an equipment maintenance management system according to the present invention.
[0026]
As shown in FIG. 1, the equipment maintenance management system 1 controls the entire equipment maintenance management system 1 and also functions as a calculation unit, and a data input device for inputting data to the equipment maintenance management system 1. 3, a display device 4 for displaying information by the control unit 2, a printer 5 for outputting necessary information to paper or the like, and a computer 21 having a hard disk device 20 as storage means. I have.
[0027]
The hard disk device 20 includes a facility management reference information database 6, a maintenance plan information database 7, a daily inspection information database 8, a periodic maintenance information database 9, a post-maintenance information database 10, a parts inventory information database 11, an improved maintenance information database 12, a maintenance Nine databases of a staff information database 13 and a budget / expense information database 14 are stored.
[0028]
The equipment maintenance management system 1 can perform the following five managements.
[0029]
(1) Maintenance plan management
The maintenance plan management 15 calculates a scheduled maintenance execution scheduled date based on the maintenance execution cycle and the maintenance execution history, and outputs a periodic maintenance budget plan table together with the budget information. Details will be described later with reference to FIG.
[0030]
(2) Maintenance information management
The maintenance information management 16 determines the scheduled scheduled maintenance date based on the assumed scheduled maintenance date, parts inventory information, maintenance personnel information, production plan / work-in-progress information, outputs the scheduled maintenance schedule, and outputs the scheduled maintenance schedule. Register the execution history of Here, the term “parts” includes repair parts for repairing failures, consumable parts that need to be regularly replaced by the equipment manufacturer, and auxiliary materials such as tapes and lubricating oils.
[0031]
When performing post-maintenance, it is necessary to judge whether internal or external maintenance work is to be performed, call up the past response history, support the work of maintenance personnel, and register the details of the repairs performed.
[0032]
When improvement maintenance is carried out for aging and capacity enhancement of equipment, the items to be implemented are displayed to the workers, the improvement maintenance execution items are output, and the modification contents are registered.
[0033]
After each maintenance work, the date, cost, and parts used are registered. Details will be described later with reference to FIGS. 12, 14, and 15.
[0034]
(3) Budget and expense management
The budget / expense management 17 manages the budget and expenses of each facility. Details will be described later with reference to FIG.
[0035]
(4) Parts inventory management
The parts inventory management 18 manages the latest inventory number and inventory parts information for each part ID.
[0036]
(5) Maintenance personnel management
The maintenance clerk management 19 manages maintenance execution items that can be performed by each maintenance clerk.
[0037]
<Example of each database>
FIG. 2 shows an example of the equipment management reference information database 6, in which (a) shows the equipment management reference information 6a, and (b) shows the necessary parts information 6b for each maintenance execution item.
[0038]
As shown in FIG. 2A, in the facility management reference information 6a, a facility ID, a facility group ID, a maintenance execution item ID, a maintenance implementation content, and a periodic maintenance implementation cycle are recorded in advance for each equipment ID. Further, as shown in FIG. 2B, in the required parts information 6b for each maintenance execution item, a maintenance execution item ID and a part ID required for the work are recorded in advance for each maintenance execution item ID. When a plurality of parts are used for one maintenance execution item, recording is performed separately for each part in a plurality of records having a common maintenance execution item ID and different part IDs.
[0039]
Here, the ID is assigned to each unit to be managed for the object (equipment, parts, people, etc.) and information (budget, maintenance item, etc.). Used to uniquely identify the management unit of The same applies to various IDs in other databases described later.
[0040]
FIG. 3 is an example of the maintenance plan information database 7.
[0041]
As shown in FIG. 3, the maintenance plan information database 7 stores a maintenance plan ID, a facility ID, a maintenance execution item ID, an assumed scheduled maintenance execution date, and a budget ID to be allocated for each equipment ID and maintenance execution item ID. Record.
[0042]
Here, the periodic maintenance item is calculated by performing the periodic maintenance execution cycle of the equipment management standard information 6a (see FIG. 2A) of the equipment management standard information database 6 and the periodic maintenance of the periodic maintenance information database 9 (see FIG. 5). This is performed at regular intervals based on the implementation date. For example, if it is carried out at the end of each period, a periodic maintenance item scheduled to be carried out next year is calculated.
[0043]
FIG. 4 is an example of the daily inspection information database 8.
[0044]
As shown in FIG. 4, the daily inspection information database 8 records a daily inspection ID, a facility ID, a daily inspection execution date, a maintenance execution item ID, and a person in charge ID when a daily inspection of the equipment is performed.
[0045]
FIG. 5 is an example of the periodic maintenance information database 9.
[0046]
As shown in FIG. 5, the periodic maintenance information database 9 stores, for example, at the end of each month, based on the assumed scheduled maintenance execution date of the maintenance plan information database 7 (see FIG. 3), the maintenance execution item ID for the next month. The regular maintenance ID, maintenance plan ID, equipment ID, scheduled maintenance execution date, person in charge ID, and expense ID are registered.
[0047]
After the periodic maintenance is performed, the date of the periodic maintenance is recorded in the record having the corresponding maintenance execution item ID in the periodic maintenance information database 9.
[0048]
In other words, as for the scheduled maintenance date, the assumed scheduled maintenance date is determined at the end of each period, and when the scheduled scheduled maintenance date approaches, the operating status of the equipment and the status of maintenance personnel and parts possession are determined. Investigate and determine the scheduled date for scheduled maintenance. Then, when the regular maintenance is performed after a slight schedule adjustment, the regular maintenance execution date is recorded.
[0049]
FIG. 6 shows an example of the post-maintenance information database 10, in which (a) shows the post-maintenance information 10a and (b) shows the post-maintenance-specific used part information 10b.
[0050]
Here, the post-maintenance is to repair an unplanned failure that occurred during the operation of the equipment.
[0051]
When the post-maintenance is performed, as shown in FIG. 6A, the post-maintenance ID, the equipment ID, the fault occurrence date and time, the fault symptom, the fault classification, the fault occurrence status, and the fault cause are added to the post-maintenance information 10a. , Cause classification, response start date and time, response completion date and time, response content, permanent countermeasure, person in charge ID, and expense ID are recorded. As shown in FIG. 6B, the post-maintenance-specific used part information 10b records the post-maintenance ID and the part ID used for the work for each post-maintenance ID. When a plurality of components are used in one post-maintenance item, the recording is performed separately for each component in a plurality of records having a common post-maintenance ID and different component IDs.
[0052]
FIG. 7 shows an example of the parts inventory information database 11, in which (a) shows the parts inventory update history information 11a, and (b) shows the parts inventory information 11b.
[0053]
If the number of parts in stock increases or decreases due to exhaustion of parts in daily inspection, periodic maintenance, and post-maintenance or purchase of parts for stock replenishment, as shown in FIG. The part ID, the update date and time, the increase / decrease number, the update category, the post-maintenance ID, the periodic maintenance ID, and the expense ID are recorded in the inventory update history information 11a. Further, as shown in FIG. 7B, for the component stock information 11b, for each component ID, the component ID, the component name, the latest stock quantity, the last update date, the storage location, the proper stock quantity, the component classification, and the management Record the category, manufacturer, manufacturer model number, unit price, supplier, and equipment group ID.
[0054]
Here, the appropriate stock quantity is a quantity obtained by adding a safety quantity calculated in accordance with an equipment operation plan and a depreciation year to a predicted use quantity obtained by calculating an expected use quantity during the period based on past use results of parts.
[0055]
FIG. 8 is an example of the improved maintenance information database 12.
[0056]
Here, improvement maintenance refers to the renovation of equipment and parts for the purpose of improving the production capacity and stable operation of the equipment, causing problems such as a shortage of production capacity and a decrease in the operating rate due to frequent and recurring failures. It is implemented when or when there is a possibility that it will occur.
[0057]
When the improvement maintenance is performed, as shown in FIG. 8, the improvement maintenance ID, the equipment ID, the expense ID, the modification contents, and the execution date are recorded in the improvement maintenance information database 12.
[0058]
FIG. 9 is an example of the maintenance staff information database 13.
[0059]
As shown in FIG. 9, a person in charge ID, a name, a facility group ID, and an executable maintenance item ID are recorded in advance in the person in charge of maintenance information 13 for each person in charge ID. If the number of maintenance items that can be performed by the person in charge increases, the information is additionally registered as a new record.
[0060]
FIG. 10 shows an example of the budget / expense information database 14, in which (a) shows budget information 14a and (b) shows expense information 14b.
[0061]
As shown in FIG. 10A, at the end of each period, a budget ID, a facility group ID, a target month, a budget amount, and a budget category for the next period are recorded in the budget information 14a for each equipment group and target month. . Further, at the time when the occurrence of the expense is determined, as shown in FIG. 10B, the expense information 14b includes, for each expense ID, an expense ID, a budget ID, a facility ID, an expense date, an amount, an expense category, and a trader. Record the quotation, quote number, and expected cost acceptance date. Further, after the cost inspection is performed, the cost inspection date is recorded in the corresponding record in the expense information 14b.
[0062]
The method for determining the periodic maintenance budget will be described later with reference to FIG. The budget determination method for the post-maintenance and improvement maintenance is determined based on the past maintenance results, taking into account the equipment operation plan for the current term, the budget consumption results, and the degree of aging of the equipment. The expenditure results of the periodic maintenance, the post-maintenance, and the improvement maintenance are managed by the progress rate against the budget, and a warning is displayed when the progress rate exceeds a predetermined threshold because the progress rate exceeds a certain level (first warning means). For example, to encourage budget redistribution.
[0063]
<Maintenance plan management>
FIG. 11 is a flowchart showing a flow of processing performed by the maintenance plan management 15 in the present embodiment, and a diagram showing a flow of data to and from each database used.
[0064]
As shown in FIG. 11, the equipment maintenance management system 1 acquires the equipment ID and the periodic maintenance execution cycle for each maintenance execution item ID recorded in advance in the equipment management reference information 6 a, and acquires the equipment ID from the periodic maintenance information database 9. , The latest regular maintenance date for each maintenance execution item ID is acquired.
[0065]
By adding the periodic maintenance implementation cycle acquired from the facility management standard information 6a to the periodic maintenance implementation date acquired from the periodic maintenance information database 9, the next scheduled scheduled maintenance implementation date (periodic maintenance plan) is added to the control unit 2 (FIG. 1). (See step S11-1).
[0066]
For example, taking the equipment ID “APCVD01” as an example, in the equipment management reference information 6a, the record of the maintenance execution item ID “A00002” has a periodic maintenance execution cycle of “720 hours”. In the periodic maintenance information database 9, there is one record that satisfies the equipment ID “APCVD01” and the maintenance execution item ID “A00002”, and the periodic maintenance execution date “2002/5/4” of the record is the latest periodic maintenance execution date. It becomes. To the above, the above-mentioned periodic maintenance execution cycle “720 hours” is added. When the equipment is operating for 24 hours, 720 hours = 24 hours × 30 days, so “2002/5/4” is 30 days. Can be calculated as “2002/6/3” for the next scheduled scheduled maintenance date.
[0067]
Next, the calculation result in step S11-1 (described later with reference to FIG. 19) is displayed on the display device 4 (see FIG. 1) and output by the printer 5 (see FIG. 1) (step S11-2). ).
[0068]
Based on the information output in step S11-2, for the periodic maintenance execution items scheduled to be performed in the next term, together with the post-maintenance and improvement maintenance budgets, the budget information 14a is used for the budget ID, equipment group ID, target month of budget, budget Record the amount and budget category. In addition, the maintenance plan information database 7 records the maintenance plan ID, the equipment ID, the maintenance execution item ID, the assumed scheduled maintenance execution date, and the budget ID (step S11-3).
[0069]
Based on the information registered in step S11-3, the next term periodic maintenance execution plan (periodic maintenance budget plan table) and the maintenance execution budget for each budget category (see FIG. 10A for an example of the budget) are controlled. The data is tabulated by the unit 2 and displayed on the display device 4 and output by the printer 5 (step S11-4), and the process ends.
[0070]
<Maintenance information management>
FIG. 12 is a flowchart showing a flow of a process of periodic maintenance information management performed by the maintenance information management 16 in the present embodiment, and a diagram showing a data flow with each database used.
[0071]
As shown in FIG. 12, for example, at the end of each month, the equipment maintenance management system 1 uses the equipment ID, the maintenance execution item ID, the assumed period for the scheduled maintenance execution item (scheduled maintenance plan) scheduled to be executed in the next month from the maintenance plan information database 7. The controller 2 (see FIG. 1) searches for the scheduled maintenance execution date (step S12-1).
[0072]
Next, the search result in S12-1 is displayed on the display device 4 (see FIG. 1) and output by the printer 5 (see FIG. 1) (step S12-2).
[0073]
With respect to the information of the periodic maintenance plan displayed in step S12-2, the necessary inventory of parts is confirmed from the parts inventory information 11b, and the assumed maintenance plan is executed from the maintenance clerk information database 13 and the periodic maintenance information database 9. Confirm the availability of maintenance personnel who can work on the day. Further, it is confirmed from the production plan 31 and the production in-process information 32 that the maintenance execution facility is to be operated (whether or not there is an emergency product and whether or not a bottleneck has occurred) on the assumed scheduled maintenance execution date (step S12-3).
[0074]
Then, it is determined whether or not it is possible to perform the work on the assumed scheduled maintenance execution date displayed in step S12-2 (step S12-4).
[0075]
When the scheduled maintenance can be performed as scheduled (Yes in S12-4), the scheduled scheduled maintenance date is determined to determine the scheduled maintenance plan, and the scheduled maintenance information database 9 is checked for the scheduled maintenance ID, the maintenance plan ID, and the equipment. The ID, scheduled maintenance execution date, maintenance execution item ID, person in charge ID, and expense ID are recorded, and expense registration processing (described later with reference to FIG. 17) is performed on the expense information 14b (step S12). -6).
[0076]
If the scheduled maintenance cannot be performed as scheduled (No in S12-4), after the necessary parts are ordered and maintenance personnel are secured, the scheduled scheduled maintenance is corrected (step S12-5).
[0077]
Next, in step S12-6, the information on the periodic maintenance plan recorded in the periodic maintenance information database 9 (see FIG. 5A for an example of the recorded information) is displayed on the display device 4 and output by the printer 5. (Step S12-7).
[0078]
After the periodic maintenance, the date of the periodic maintenance is recorded in the periodic maintenance information database 9 and the expense information 14b of the budget / expense information database 14 is revised. Further, the number of used parts is recorded in the part inventory update history information 11a of the parts inventory information database 11 as an increase / decrease number of records having the part ID of the part (step S12-8), and the process ends. .
[0079]
FIG. 13 is a diagram showing the association of management items between databases used in the periodic maintenance information management of the maintenance plan management 15 and the maintenance information management 16 in the present embodiment.
[0080]
As shown in FIG. 13, the maintenance execution item ID of the equipment management reference information 6 a of the equipment management reference information database 6 is associated with the maintenance execution item ID of the periodic maintenance information database 9. As for the items of the periodic maintenance information database 9, the maintenance plan ID is associated with the maintenance plan ID of the maintenance plan information database 7, and the maintenance execution item ID is the maintenance execution item ID and the maintenance staff information of the necessary parts information 6b for each maintenance execution item. The expense ID is associated with the expense ID of the expense information 14 b of the budget / expense information database 14. The budget ID of the maintenance plan information database 7 is associated with the budget ID of the budget information 14a of the budget / expense information database 14. The component ID of the required component information 6b for each maintenance execution item is associated with the component ID of the component inventory information 11b of the component inventory information database 11.
[0081]
By performing the association by these IDs, for example, when carrying out periodic maintenance of a certain facility, the current stock quantity of necessary parts is checked (described later with reference to FIG. 20), and a list of operable maintenance personnel is extracted. (Described later with reference to FIG. 21).
[0082]
FIG. 14 is a flowchart showing a flow of post-maintenance information management processing performed by the maintenance information management 16 in the present embodiment, and a diagram showing a data flow with each database used.
[0083]
As shown in FIG. 14, when an equipment failure occurs, the equipment maintenance management system 1 searches the post-maintenance information 10a for correspondence data of past identical equipment and similar failures. When there is past similar failure handling data, the time required for the post-maintenance work is counted by the control unit 2 (see FIG. 1) (step S14-1), and the counting result (to be described later with reference to FIG. 22). ) Is displayed on the display device 4 (see FIG. 1) (step S14-2).
[0084]
Based on the information displayed in step S14-2, the production plan 31, and the production in-process information 32, the urgency of troubleshooting and the status of securing maintenance personnel are checked (step S14-3), and whether to deal with the company or not It is determined whether or not a request is made to deal with the failure (step S14-4).
[0085]
When the in-house response is performed (Yes in S14-4), a past post-maintenance record is searched from the post-maintenance information 10a using the equipment ID and the failure symptom as search keys (step S14-5), and the search result is displayed on the display device 4. It is displayed (step S14-6). The maintenance person performs repair with reference to the search results displayed on the display device 4.
[0086]
By performing the repair based on the displayed information, the maintenance technician can compensate for the lack of repair experience and perform the repair, and the maintenance technician of the maintenance technician is promoted.
[0087]
The repair content is recorded in the post-maintenance information 10a, and the used part ID and quantity are recorded in the parts inventory update history information 11a (step S14-7).
[0088]
If there is no in-house repair record, shortage of in-house maintenance staff, repair is urgent, and in-house response takes time to repair, request an external response (No in S14-4) and step S14. Proceed to -7.
[0089]
Thereafter, it is determined whether or not the repair has been completed in the post-maintenance performed (step S14-8). If the repair has not been completed, the process returns to step S14-4, and it is determined whether or not in-house response is possible. The steps after S14-4 are executed again.
[0090]
When the failure handling is completed, an expense registration process (described later with reference to FIG. 17) is performed on the expense information 14b (step S14-9), and the process ends.
[0091]
FIG. 15 is a flowchart showing a flow of processing of improved maintenance information management performed by the maintenance information management 16 in the present embodiment, and a diagram showing a data flow with each database used.
[0092]
Here, as mentioned above, improvement maintenance refers to renovation of equipment and parts for the purpose of improving production capacity and stable operation of equipment, as described above. Implemented when a problem occurs or is likely to occur.
[0093]
As shown in FIG. 15, the equipment maintenance management system 1 compiles the number of failure occurrences, equipment downtime, and expenses by equipment, failure classification, failure cause from the post-maintenance information 10a and the expense information 14b (step S15-1), the totaling result (described later with reference to FIG. 23) is displayed on the display device 4 (see FIG. 1), and output by the printer 5 (see FIG. 1) (step S15-2).
[0094]
Here, the equipment stop time is obtained by calculating the time difference between the response start date and time and the response completion date and time.
[0095]
Based on the output information, the equipment ID for which improvement maintenance needs to be performed and the contents of the improvement maintenance are determined, and improvement maintenance such as failure analysis, permanent measures, and equipment modification is performed (step S15-3).
[0096]
The contents of the implemented improvement maintenance are recorded in the improvement maintenance information database 12, and the expense information is recorded in the expense information 14b of the budget / expense information database 14 (step S15-4), and the process is terminated.
[0097]
FIG. 16 is a diagram showing the association of management items between databases used in post-maintenance information management and improved maintenance information management of the maintenance information management 16 in the present embodiment.
[0098]
As shown in FIG. 16, the post-maintenance ID of the post-maintenance information 10a in the post-maintenance information database 10 is associated with the post-maintenance ID of the used part information by post-maintenance information 10b. The component ID of the post-maintenance-specific used component information 10b is associated with the component ID of the component inventory update history information 11a of the component inventory information database 11, and is also associated with the component ID of the component inventory information 11b. The post-maintenance information 10a, the parts inventory update history information 11a, and each expense ID of the improved maintenance information database 12 are all associated with the expense ID of the expense information 14b of the budget / expense information database 14. The budget ID of the expense information 14b is associated with the budget ID of the budget information 14a.
[0099]
Based on these associations, for example, in carrying out the improvement maintenance, the failure handling cost in the past which is the most expensive is extracted by totaling the failure handling costs for each failure category for a certain facility (see FIG. 23). (Described later), and it is possible to carry out improvement and maintenance by focusing on items having a greater effect of reducing repair costs.
[0100]
<Budget and expense management>
FIG. 17 is a flowchart showing the flow of processing performed by the budget / expense management 17 in the present embodiment, and a diagram showing the flow of data to and from each database used.
[0101]
As shown in FIG. 17, the equipment maintenance management system 1 uses the budget information 14a to check at the end of each term whether or not the budget of the equipment group ID to be registered has already been registered (step S17-1).
[0102]
If the budget has not been registered (No in S17-1), the budget amount for the next term is recorded in the budget information 14a for each equipment group ID, each month, and each budget category (step S17-2).
[0103]
The next term budget plan is displayed on the display device 4 (see FIG. 1) and output by the printer 5 (see FIG. 1) (step S17-3).
[0104]
If the budget has been registered (Yes in S17-1), the next term budget plan is displayed on the display device 4 and output by the printer 5 (step S17-3).
[0105]
Further, when an expense is generated during the period, that is, when a group of facilities in which maintenance work involving the cost occurs is determined, the expense ID, the budget ID, the facility ID, the cost generation date, the amount, The expense class, the business partner, the quote number, and the scheduled cost inspection date are provisionally registered and approved by the administrator (step S17-4).
[0106]
The temporary expense registration information is displayed on the display device 4 and output by the printer 5 (step S17-5), and stored together with the estimate until the maintenance work is completed.
[0107]
After the maintenance work is completed, if necessary, the expense information registered in step S17-4 is corrected to the determined content, and the cost acceptance date is recorded in the corresponding record of the expense information 14b, and the acceptance process is executed (step S17). -6), end the process.
[0108]
FIG. 18 is a diagram showing the association of management items between databases used in the budget / expense management 17 in the present embodiment.
[0109]
As shown in FIG. 18, the budget ID of the maintenance plan information database 7 and the budget ID of the expense information 14b of the budget / expense information database 14 are respectively associated with the budget ID of the budget information 14a. The maintenance plan ID of the maintenance plan information database 7 is associated with the maintenance plan ID of the periodic maintenance information database 9. Each expense ID of the periodic maintenance information database 9, the post-maintenance information 10a, the improved maintenance information database 12, and the parts inventory update history information 11a is associated with the expense ID of the expense information 14b.
[0110]
With these associations, for example, it is possible to total the costs incurred in all maintenance work for a certain facility, and to calculate how much maintenance work is costly (expenses for post-maintenance for each facility) An example will be described later with reference to FIG. 23).
[0111]
When the total amount of the expenditure of the expenses of the periodic maintenance and the post-maintenance for each equipment group is equal to or larger than the budget amount of the budget information 14a (see FIG. 10A), A warning display (second warning means) may be performed so as to urge the improvement of production capacity or improvement maintenance for permanent measures.
[0112]
<Example of display / output>
FIG. 19 shows a calculation result example 33 of the scheduled next scheduled maintenance date according to the present embodiment.
[0113]
As shown in FIG. 19, the calculation result example 33 includes the equipment ID, the maintenance execution item ID, the maintenance execution content, the periodic maintenance execution date, the periodic maintenance execution cycle, and the next scheduled scheduled maintenance execution date. As already described with reference to FIG. 11, the calculation result example 33 is calculated according to the flowchart of FIG. For example, in the maintenance execution content "1 month inspection" determined by the equipment ID "APCVD01" and the maintenance execution item ID "A00002", the periodic maintenance implementation date is "2002/5/4" and the periodic maintenance implementation cycle is 720 hours. The scheduled next scheduled maintenance date is “2002/6/3”.
[0114]
FIG. 20 is an extraction example 34 of the required parts stock quantity for each maintenance execution item according to the present embodiment.
[0115]
As shown in FIG. 20, the extraction example 34 includes a facility ID, a maintenance execution item ID, a maintenance execution content, a part ID, a part name, and the latest stock quantity. Here, the maintenance execution item ID of the periodic maintenance information database 9 is associated with the maintenance execution item ID of the equipment management standard information 6a and the maintenance execution item ID of the required component information 6b for each maintenance execution item. Further, the component ID of the required component information 6b for each maintenance execution item is associated with the component ID of the component stock information 11b.
[0116]
For each equipment ID and maintenance execution item ID recorded in the periodic maintenance information database 9, the maintenance execution content is obtained from the equipment management reference information 6 a by associating with the maintenance execution item ID of the periodic maintenance information database 9. The part ID is obtained from the required part information 6b for each maintenance execution item by associating the item ID. Further, the part name and the latest stock quantity can be obtained from the part stock information 11b by associating the necessary part information 6b for each maintenance execution item with the part ID.
[0117]
The extraction example 34 is obtained by such an extraction process. For example, in the maintenance execution content "1 month inspection" determined by the equipment ID "APCVD01" and the maintenance execution item ID "A00002", one of the necessary component IDs is "PT00003" and the component name is "O-ring". The latest inventory of parts is two.
[0118]
FIG. 21 shows an example 35 of extracting workable persons by maintenance execution item according to the present embodiment.
[0119]
As illustrated in FIG. 21, the extraction example 35 includes a facility ID, a maintenance execution item ID, a maintenance execution content, a person in charge ID, and a name. Here, the maintenance execution item ID of the periodic maintenance information database 9 is associated with the maintenance execution item ID of the equipment management standard information 6a, and the person ID of the periodic maintenance information database 9 is the person ID of the maintenance person information database 13. Associated with
[0120]
The maintenance execution content is obtained from the equipment management reference information 6a by associating the equipment ID and the maintenance execution item ID recorded in the periodic maintenance information database 9 with the maintenance execution item ID of the periodic maintenance information database 9. Further, the person in charge and the name are obtained from the person in charge of maintenance information 13 by associating the person with person in charge in the regular maintenance information database 9.
[0121]
Extraction Example 35 is obtained by such an extraction process. For example, in the maintenance execution content "one month inspection" determined by the equipment ID "APCVD01" and the maintenance execution item ID "A00002", one of the personnel IDs is "MM00001" and the name of the person in charge is "Mr. A". It is.
[0122]
FIG. 22 shows an example 36 of the total of similar past repair times according to the present embodiment.
[0123]
As shown in FIG. 22, the counting example 36 includes a post-maintenance ID, a facility ID, a failure symptom, a response start date and time, a response completion date and time, a response content, and a repair time. As already described with reference to FIG. 14, the counting example 36 is calculated according to the flowchart of FIG. When an equipment failure occurs, the corresponding data of the same equipment and similar failure in the past is retrieved from the post-maintenance information 10a (see FIG. 6A) of the post-maintenance information database 10. If there is past similar failure correspondence data, those records are extracted, and the repair time is determined by the control unit 2 (see FIG. 1) by the time difference between the correspondence start date and time and the completion date and time of each extracted record. Is calculated. Further, the control unit 2 calculates the average value of the repair time of each extracted record.
[0124]
The counting example 36 and the average repair time 36a are obtained in such a process. For example, if there are four extracted records and the repair times are 3: 00: 0, 4: 00: 00: 00, 3:20:00, and 2: 30: 0, the average repair time is 3:12:30. It becomes.
[0125]
FIG. 23 shows an example 37 of totaling the number of failure occurrences, the stop time, and the post-maintenance cost for each facility according to the present embodiment.
[0126]
As shown in FIG. 23, the tabulation example 37 includes a facility ID, a failure category, a failure cause, the number of failure occurrences, a facility downtime, and a post-maintenance cost. Here, the expense ID of the post-maintenance information 10a is associated with the expense ID of the expense information 14b.
[0127]
First, all records recorded in the post-maintenance information 10a are classified by equipment ID, failure category, and failure cause. The control unit 2 (see FIG. 1) counts the number of records for each combination of the equipment ID, the failure category, and the failure cause, and the count result corresponds to the number of failure occurrences. Further, the equipment downtime is calculated from the time difference between the corresponding start date and time and the corresponding completion date and time of each record recorded in the post-maintenance information 10a, and the equipment downtime is totaled for each combination of the equipment ID, the failure category and the failure cause. . Also, by associating the expense ID of the post-maintenance information 10a with the expense ID of the expense information 14b, the post-maintenance cost corresponding to each record recorded in the post-maintenance information 10a is obtained from the amount of the expense information 14b, The post-maintenance costs are tabulated for each combination of failure category and failure cause.
[0128]
The counting example 37 is obtained in such a process. For example, in the combination of the equipment ID “APCVD02”, the failure category “transport system”, and the failure cause “bearing in the motor”, the number of failure occurrences is 43, the total value of the equipment downtime is 246: 53: 00, and the post-maintenance is performed. The total value of the expenses is 352,000.
[0129]
<Program and recording medium>
The equipment maintenance management system of the present invention described above is realized by an equipment maintenance management program that causes the computer 21 (see FIG. 1) to execute equipment maintenance management processing. The computer 21 may be a general-purpose computer such as a personal computer or a workstation, but is not limited thereto.
[0130]
Thus, the equipment maintenance management system of the present invention can be realized anywhere as long as there is a computer environment in which the equipment maintenance management program can be executed.
[0131]
If the equipment maintenance management program is executable by a general-purpose computer, it is not necessary to prepare a dedicated computer environment for realizing the equipment maintenance management system of the present invention. Existing computers and the like can be used effectively, and when computers are not used as the equipment maintenance management system of the present invention, they can be used for other purposes. If the computer is a system capable of multi-task operation, the utility of the present invention is high, for example, it can be used for other purposes while being used as the equipment maintenance management system of the present invention.
[0132]
Further, such a facility maintenance management program may be recorded on a computer-readable recording medium. The recording medium may be a program medium itself, such as a memory, for example, a ROM, or a computer reading device may be provided as an external storage device, in which a storage medium, for example, a CD-ROM or a DVD-ROM may be provided. It may be a program medium that can be read by inserting a ROM or the like.
[0133]
In any case, the recorded program may be configured to be accessed and executed by a microprocessor. Alternatively, the program may be read first, the read program is loaded into a computer program storage area, and the program is executed. It is assumed that the loading program is stored in advance.
[0134]
Here, the program medium is a recording medium configured to be separable from the main body, such as a tape system such as a magnetic tape or a cassette tape, a magnetic disk system such as an FD (flexible disk) or an HD (hard disk), or a CD-ROM. / MO / MD / DVD, etc., and carries a fixed program including a card system such as an IC card / memory card / optical card, or a semiconductor memory such as a mask ROM / EPROM / EEPROM / flash ROM. It may be a medium.
[0135]
Thereby, the facility maintenance management system of the present invention can be easily realized in various places and environments, and the versatility of the facility maintenance management method of the present invention can be enhanced.
[0136]
Further, in the present invention, when the system configuration is connectable to a communication network including the Internet, the medium may carry the program in a fluid manner so that the program is downloaded from the communication network. When such a program is downloaded from a communication network, the download program may be built in advance or installed from another recording medium. The content recorded on the recording medium is not limited to a program, but may be data.
[0137]
This makes it easy to implement the equipment maintenance management system of the present invention in various places and environments without the need for a physical recording medium, and further enhances the versatility of the equipment maintenance management method of the present invention. it can.
[0138]
As described above, the present invention has been described based on the above-described embodiment. However, various modifications are possible within the scope of the present invention, and these are not excluded from the scope of the present invention.
[0139]
【The invention's effect】
As described above in detail, according to the equipment maintenance management system and the equipment maintenance management method of the present invention, information on a wide range of equipment maintenance management operations including not only periodic maintenance but also post-maintenance and improvement maintenance is based on the individual management ID. Centralized management can be performed by association. This makes it possible to reliably perform maintenance work in accordance with the determined facility management standards and budget.
[0140]
By accumulating and reusing maintenance work know-how in the database, it is possible to promote maintenance workers to be multi-skilled and improve their skills. Alternatively, if budgets and expenses are carefully managed in consideration of the occurrence of costs and the timing of acceptance for all maintenance work, accurate budget progress rates can be grasped, equipment repair costs, and cost reductions for parts costs can be reduced. Can be implemented.
[0141]
Further, according to the equipment maintenance management program of the present invention, the equipment maintenance management system of the present invention can be realized anywhere as long as there is a computer environment in which the program can be executed. Furthermore, if this equipment maintenance management program is executable by a general-purpose computer, it is not necessary to prepare a dedicated computer environment for realizing the equipment maintenance management system of the present invention, and the equipment maintenance management program of the present invention is not required. The usefulness of the management program increases.
[0142]
Further, according to the recording medium storing the equipment maintenance management program of the present invention, the equipment maintenance management system of the present invention can be easily realized in various places and environments, and the versatility of the equipment maintenance management method of the present invention is improved. Can be increased.
[Brief description of the drawings]
FIG. 1 is a configuration diagram of an equipment maintenance management system according to the present invention.
FIG. 2 is an example of an equipment management reference information database, in which (a) shows equipment management reference information and (b) shows necessary parts information for each maintenance execution item.
FIG. 3 is an example of a maintenance plan information database.
FIG. 4 is an example of a daily inspection information database.
FIG. 5 is an example of a periodic maintenance information database.
FIG. 6 is an example of a post-maintenance information database, where (a) shows post-maintenance information and (b) shows used part information by post-maintenance.
FIG. 7 is an example of a parts inventory information database, wherein (a) shows parts inventory update history information, and (b) shows parts inventory information.
FIG. 8 is an example of an improved maintenance information database.
FIG. 9 is an example of a maintenance staff information database.
FIG. 10 is an example of a budget / expense information database, where (a) shows budget information and (b) shows expense information.
FIG. 11 is a flowchart showing a flow of processing performed in the maintenance plan management according to the present embodiment, and a diagram showing a data flow with each database used.
FIG. 12 is a flowchart showing a flow of a process of periodic maintenance information management performed in the maintenance information management according to the present embodiment, and a diagram showing a data flow with each database used.
FIG. 13 is a diagram showing the association of management items between databases used in regular maintenance information management for maintenance plan management and maintenance information management in the present embodiment.
FIG. 14 is a flowchart showing a flow of a post-maintenance information management process performed in the maintenance information management according to the present embodiment, and a diagram showing a data flow with each database used.
FIG. 15 is a flowchart showing a flow of a process of improved maintenance information management performed in the maintenance information management according to the present embodiment, and a diagram showing a data flow with each database used.
FIG. 16 is a diagram showing association of management items between databases used in post-maintenance information management and improved maintenance information management of maintenance information management in the present embodiment.
FIG. 17 is a flowchart showing a flow of processing performed in budget / expense management according to the present embodiment, and a diagram showing a data flow with each database used.
FIG. 18 is a diagram showing the association of management items between databases used in budget / expense management in the present embodiment.
FIG. 19 is an example of a calculation result of a scheduled next scheduled maintenance date according to the embodiment;
FIG. 20 is an example of extraction of the required parts stock quantity for each maintenance execution item according to the present embodiment.
FIG. 21 is an example of extracting workable persons by maintenance execution item according to the present embodiment.
FIG. 22 is an example of a total of similar past failure repair times according to the present embodiment.
FIG. 23 is an example of tabulation of the number of failure occurrences, downtime, and post-maintenance costs for each facility according to the present embodiment.
[Explanation of symbols]
1 Equipment maintenance management system
2 control unit
3 Data input device
4 Display device
5 Printer
6 Equipment management standard information database
6a Equipment management standard information
6b Required parts information for each maintenance item
7 Maintenance plan information database
8 Daily inspection information database
9 Periodic maintenance information database
10 Ex-post maintenance information database
10a Post maintenance information
10b Used parts information by post-maintenance
11 Parts inventory information database
11a Parts inventory update history information
11b Parts inventory information
12 Improved maintenance information database
13 Maintenance person information database
14 Budget and Expense Information Database
14a Budget Information
14b Expense information
15 Maintenance plan management
16 Maintenance Information Management
17 Budget and expense management
18 Parts Inventory Management
19 Maintenance personnel management
20 Hard disk drive
21 Computer
31 Production Planning
32 Production in process information
33 Example of calculation results (the next scheduled scheduled maintenance date)
34 Example of extraction (necessary parts stock for each maintenance item)
35 Extraction Example (Workable Persons by Maintenance Item)
36 Example of aggregation (Past similar failure repair time)
36a Average repair time
37 Aggregation examples (number of failures by facility, downtime, post-maintenance costs)

Claims (6)

An equipment maintenance management system that centrally manages periodic maintenance, post-maintenance, and improvement maintenance of production equipment based on a budget.
An ID is assigned to each element of each management item of maintenance plan management, maintenance information management, budget / expense management, parts inventory management, maintenance personnel management related to equipment maintenance, and divided into management work information in association with the ID. Storage means for storing
A calculation means for calculating a maintenance time, a parts inventory, and a maintenance person,
An equipment maintenance management system that performs post-maintenance or improvement maintenance based on past maintenance results and budget consumption results. 2. The equipment maintenance management system according to claim 1, further comprising: a first warning unit that issues a warning when a budget consumption result exceeds a predetermined threshold for each of the periodic maintenance, the post-maintenance, and the improvement maintenance. 3. . The equipment maintenance management system according to claim 1, further comprising a second warning unit that prompts the improvement maintenance when the cost of the periodic maintenance or the post-maintenance is greater than a budget amount. An equipment maintenance management method that centrally manages periodic maintenance, post-maintenance, and improvement maintenance of production equipment based on a budget.
An ID is assigned to each element of each management item of maintenance plan management, maintenance information management, budget / expense management, parts inventory management, maintenance personnel management related to equipment maintenance, and divided into management work information in association with the ID. A storage step for storing
A calculation step for calculating a maintenance time, a parts inventory, and a maintenance person,
A facility maintenance management method characterized by performing post-maintenance or improvement maintenance based on past maintenance results and budget consumption results. A facility maintenance management program for causing a computer to execute the facility maintenance management method according to claim 4. A computer-readable recording medium on which the facility maintenance management program according to claim 5 is recorded.

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