JP2006004219A - Facility maintenance system - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To facilitate generation of an FMEA sheet and to provide a facility maintenance system by the FMEA sheet by fetching failure information online from a real-time database such as plant monitoring system, and automatically generating a failure database by an interface for inputting respective coping methods by selection. <P>SOLUTION: This system is adapted so that a maintenance function comprising specification of a facility maintenance position, preparation of a maintenance plan, and execution of preventive maintenance and follow-up maintenance can be added to the FMEA (failure mode and effects analysis) sheet. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to an equipment maintenance system using a failure mode and effects analysis (FMEA) sheet generated based on online information from a real-time database such as a process monitoring system.

  In general, an equipment maintenance system is used to identify maintenance points, create a maintenance plan based on them, and implement preventive maintenance and subsequent maintenance. The results are recorded and stored in a database and reused for subsequent maintenance management operations. Consists of a workflow. This maintenance site identification and maintenance planning are usually based on a rule of thumb, and there are technologies that use optimization tools for optimal planning maintenance, but apart from the process monitoring system, Since it is installed offline, labor is required to generate equipment management ledgers and reflect maintenance results. As a typical conventional technology, in an optimization system for plant equipment maintenance consisting of a specific process for equipment maintenance location, a maintenance plan planning process, preventive maintenance and post-maintenance implementation process, Analyzing material deterioration / corrosion tendency etc. with advanced technology and quantitatively evaluating it, as well as means for quantitatively evaluating the failure of moving equipment by functional failure mode effect analysis, quantifying the maintenance location based on the quantitative evaluation An equipment maintenance optimization system with means to identify failure and frequency of failure using the impact assessment method, and to assess (frequency * impact) as a risk. Yes (see, for example, Patent Document 1). As another conventional technique, when creating an FMEA sheet, predetermined data related to FMEA sheet creation is searched from a database, and the searched data is used as a candidate for data input by a user. New data that is not registered in the database receives input from the user, is reflected in the FMEA sheet being created, and is registered in the database. There is an FMEA system that uses predetermined data related to FMEA sheet creation as a failure mechanism, and decomposes the failure mechanism into a component specification that is a component specification and a component environment (stress) that is an environment in which the component is placed (for example, Patent Literature) 2).

JP 2002-123314 A Japanese Patent Laid-Open No. 2003-36278

  In conventional equipment maintenance systems, maintenance work is planned and implemented based on empirical rules only, and equipment maintenance is optimized by performing quantitative evaluation using functional failure mode effect analysis (FMEA). However, since it is an offline system that is independent of a real-time database such as an actual plant monitoring system, labor is required such as creation of equipment management ledger and reflection of maintenance results. Further, even when the FMEA sheet is generated, know-how is accumulated in an offline system, and there is a problem that a database must be generated manually.

  In addition, activities to ensure the implementation of the PDCA (Plan Do Check Action) cycle is important for maintenance management. However, as mentioned above, it takes a great deal of effort to build a foundation, and because it is offline, It was often not used gradually.

  The facility maintenance optimization system described in Patent Document 1 uses the FMEA method, but does not mention the creation method.

  The FMEA system described in Patent Document 2 has a structure in which FMEA can be easily created based on a database that has accumulated know-how. However, FMEA system accumulates online failure information from a real-time database such as a plant monitoring system. The system is not created and used for equipment maintenance.

  The present invention has been made to solve the above-described problems, and it captures failure information online from a real-time database such as a plant monitoring system, and an interface for easily inputting each coping method by a selection method. An object of the present invention is to provide a facility maintenance system using an FMEA sheet that can automatically generate a failure database and easily generate an FMEA sheet.

  In the facility maintenance system using the FMEA sheet according to the present invention, the location of the facility maintenance, the planning of the maintenance plan, the preventive maintenance and the subsequent maintenance are performed on the failure mode and effects analysis (FMEA) sheet. A maintenance function consisting of

  It also has a database in which various data used for FMEA (Functional Failure Mode Impact Analysis) sheet generation is registered, selects the device that is the target of FMEA sheet generation, extracts the failure mode of the device, and determines the failure mechanism of the failure mode. An FMEA sheet generation system that is a part of a maintenance management system used by a user to generate an FMEA sheet to be examined, and at the time of generation of an FMEA sheet, search means for searching predetermined data related to FMEA sheet generation from a database And data input candidate means for using data retrieved from the database as candidates for data input by the user, new data receiving means for accepting input from the user of new data not registered in the database, and generating new data New to reflect on FMEA sheet And over data reflecting unit is one and a new data registration means for registering a new data into the database.

  It also has a database for generating a database in which various data used for FMEA (Functional Failure Mode Impact Analysis) sheet generation are registered, and selects the FMEA sheet generation target device from a real-time database such as a process monitoring system. An FTA diagram generation system which is a part of a maintenance management system used by a user to generate an FTA (Fault Tree Analysis) diagram from the extracted data; At the time of FTA diagram generation, search means for searching predetermined data related to FTA diagram generation from the database, data input candidate means for using data searched from the database as candidates for data input by the user, and registration in the database New data from the user New data receiving means for receiving the force, new data reflecting means for reflecting the new data in the FTA diagram being generated, and new data registering means for registering the new data in the database.

  Further, a storage means for inputting a failure mode of the apparatus, a cause of the failure, a recovery measure and the like to a real-time database such as a process monitoring system and storing the input information in the database is provided.

  According to the present invention, an FTA diagram is automatically generated based on real-time database information of a process monitoring system, and an FTA diagram database is generated by deriving the true cause by daily improvement activities based on the FTA diagram. By automatically generating an FMEA diagram based on the figure database, deriving a countermeasure plan from daily improvement activities based on the FMEA diagram, generating an FMEA database, and using the FMEA countermeasure plan as a maintenance management index as it is, Even if a dedicated equipment maintenance system is not introduced, it can be operated as an equipment maintenance system closely related to daily work, and as a result, it can greatly contribute to improving the productivity of the target process.

Embodiment 1 FIG.
FIG. 1 is a system configuration diagram showing the overall configuration of an equipment maintenance system according to Embodiment 1 for carrying out the present invention.
As shown in FIG. 1, an FMEA sheet maintenance management system according to the first embodiment includes an FTA diagram creation system including an FTA (Fault Tree Analysis) diagram generation unit 2 and an FTA diagram database 6, and an FMEA sheet generation unit 3 And an FMEA sheet creation system including the FMEA database 7 and a maintenance system including the maintenance notification unit 4. Further, as a system that is the basis of the maintenance management system using the FMEA sheet, there is a process monitoring system including an apparatus stop information input unit 1, a real time database 5, and a failure occurrence database generation processing unit 8.

  Next, the operation of the maintenance management system using the FMEA sheet according to the first embodiment will be described with reference to FIGS.

  FIG. 2 shows an apparatus stop information input screen 10 executed on the process monitoring system. When a failure occurs in the signal for process monitoring, one item data is added to the real-time database 5 by the failure generation database generation processing 8 and notified on the monitoring screen. When the monitor selects the person in charge after troubleshooting the cause of the failure and displays the device stop information input screen 10, the occurrence time 11, the failure device 12, the failure phenomenon 13, the recovery time 17 and the person in charge name 18 are displayed on this screen. Displayed in advance. The failure mode 14 is a pull-down selection in the case of a failure already registered in the real-time database 5, and a direct input is performed in the case of a new failure. Similarly, for the treatment 16, pull-down selection is performed for a treatment that has already been registered in the real-time database 5, and direct input is performed for a new treatment. For cause 15, if the cause is known on the spot, it is directly entered. If it is not known, it is not necessary to enter here because the cause is investigated in the improvement activities to be implemented later. For other 19 items, memos are entered for reference items for improvement activities.

  FIG. 3 shows the FTA diagram generation unit 2 of the maintenance management system using the FMEA sheet according to the first embodiment. The FTA diagram 20 is generated by selecting the search range by specifying the device name 11 for which the FTA diagram 20 is to be generated and the calendar designation. Since the FTA diagram 20 is stored in the FTA diagram database 6, if the device name 11 and the search range selection by the calendar designation match, a search is performed from the real-time database 5 based on the past data (search means). The data retrieved from the database is used as a candidate for data input by the user (data input candidate means). If there is no corresponding data, a new FTA diagram 20 is generated from the real-time database 5. As described above, since the FTA diagram 20 is not always automatically generated, once it has been created in the FTA diagram database 6, it is added by the data input candidate means, and when there is no corresponding data, it is newly created (new Data receiving means, new data reflecting means and new data registering means). It is also possible to create an FTA diagram database manually in advance. The FTA diagram 20 shown in FIG. 3 is displayed in the form of a tree in the order of device name 11, failure mode 14, failure cause 15, action 16, and others 19 from the left. Then, in the improvement activities, for example, the non-input failure mode 22, the non-input failure cause 23, the non-input treatment 24, etc. are pursued based on the FTA FIG. At that time, if there are other 19 comments, it is very useful for pursuing the root cause, so it is important to input information as much as possible on the device stop information input screen 10.

  FIG. 4 shows the FMEA sheet generating unit 3 of the maintenance management system using the FMEA sheet according to the first embodiment. The FMEA sheet 30 is generated by selecting the search range of the device name 11 for which the FMEA sheet 30 is to be generated. Since the FMEA sheet 30 is stored in the FMEA database 7, if there is a database with the device name 11, a search from the FTA diagram database 6 is performed based on the past data (search means), and the FMEA sheet 30 is searched from the database. The data is set as a candidate for data input by the user (data input candidate means). If there is a difference here, it is reflected, but if there is no corresponding data, a new FMEA sheet 30 is generated from the FMEA database 7. Thus, since the FMEA sheet 30 is not always automatically generated, once it is created in the FMEA database 7, it is added by the data input candidate means, and if there is no corresponding data, it is newly generated (new data Receiving means, new data reflecting means and new data registering means). It is also possible to create an FMEA database manually in advance. Since the ordinary FMEA sheet 30 is difficult to use as a maintenance management system and as an improvement activity, the item name of the ordinary FMEA sheet is replaced with a form like the FMEA sheet 30 of the first embodiment, and finally the maintenance management is performed. The FMEA sheet 30 is added with data 39. The device name 11, the failure mode 14, the failure cause 15, the treatment 16, and the person in charge 18 in FIG. 20 correspond to the items on the FMEA sheet 30 as they are. In the improvement activities, severity 32 from the impact range 31, frequency 33 from the treatment 16, detection 35 from the current management index 34, priority 36 from the severity 32, frequency 33 and detection 35, Each of them is calculated, and a countermeasure plan 37 is examined from the failure mode 14 having a high priority 36. For example, if a failure has occurred due to a part that has been replaced once every 30 days, an appropriate replacement cycle is derived and the maintenance management data 39 is generated. The implementation status of the examination can be confirmed in the treatment status 38.

  FIG. 5 shows the maintenance notification unit 4 of the maintenance management system using the FMEA sheet according to the first embodiment. Based on the maintenance data 39 generated by the FMEA sheet generator 3, the operation status of each device is monitored, the operation signals are integrated, and maintenance information 40 such as the replacement time is displayed on the process monitoring system, thereby maintaining maintenance. Operate as a system.

  As described above, the facility maintenance system using the FMEA sheet according to the first embodiment not only automatically generates FTA diagrams and FMEA sheets according to the actual plant in a lump, but also unknowingly in the improvement activities. As a result, the system will be reviewed and enhanced, and the results will be used as maintenance management.

It is a system configuration figure showing the whole equipment maintenance system composition in Embodiment 1 of this invention. The apparatus stop information input screen figure in the process monitoring system of the equipment maintenance system in Embodiment 1 of this invention is shown. The FTA figure of the equipment maintenance system in Embodiment 1 of this invention is shown. The FMEA sheet figure of the equipment maintenance system in Embodiment 1 of this invention is shown. The maintenance notice screen figure of the equipment maintenance system in Embodiment 1 of this invention is shown.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Device stop information input part 2 FTA figure production | generation part 3 FMEA sheet | seat production | generation part 4 Maintenance notification part 5 Real-time database of a process monitoring system 6 FTA figure database of FTA figure creation system 7 FMEA database of FMEA sheet creation system 8 Database generation at the time of failure occurrence Processing part

Claims (4)

In equipment maintenance systems where equipment maintenance points are identified, maintenance plans are created, preventive maintenance and post-maintenance are carried out,
An FMEA sheet characterized by the addition of a maintenance function consisting of identification of equipment maintenance points, planning of maintenance plans, preventive maintenance and subsequent maintenance to the Failure Mode and Effects Analysis (FMEA) sheet The equipment maintenance system used. FMEA (Functional Failure Mode Impact Analysis) A database in which various data used for sheet generation is registered, a device that is an FMEA sheet generation target is selected, a failure mode of the device is extracted, and a failure mechanism of the failure mode is determined. An FMEA sheet generation system that is part of a maintenance management system used by a user to generate an FMEA sheet to consider,
Search means for searching predetermined data related to FMEA sheet generation from the database at the time of generation of the FMEA sheet;
Data input candidate means for setting data retrieved from the database as a candidate for data input by a user;
New data receiving means for receiving input from the user of new data not registered in the database;
New data reflecting means for reflecting the new data on the FMEA sheet being generated;
An equipment maintenance system comprising: new data registration means for registering the new data in the database. A database for generating a database in which various data used for FMEA (functional failure mode effect analysis) sheet generation are registered is selected, and a device that is an FMEA sheet generation target is selected from a real time database such as a process monitoring system, In the FTA diagram generation system which is a part of the maintenance management system used by the user to generate the FTA (Fault Tree Analysis) diagram from the extracted data, means for extracting the failure mode, failure cause, and recovery measure of the device There,
Search means for searching predetermined data related to FTA diagram generation from the database at the time of generation of the FTA diagram;
Data input candidate means for setting data retrieved from the database as a candidate for data input by a user;
New data receiving means for receiving input from the user of new data not registered in the database;
New data reflecting means for reflecting the new data in the FTA diagram being generated;
An equipment maintenance system comprising: new data registration means for registering the new data in the database.   4. A storage means for inputting a failure mode, a failure cause, a recovery procedure, etc. of an apparatus to a real-time database such as a process monitoring system and storing the input information in the database. The equipment maintenance system in any one of.

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