JP2008090682A - Apparatus and method for providing module trouble information - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a module trouble information providing apparatus and its method which can support operation from the cause investigation of a trouble up to the execution of its countermeasures by providing a means for extracting a module or a component related to a fault on the basis of product trouble information generated in the market and presenting trouble information requiring countermeasures. <P>SOLUTION: Trouble information is collected in each module or each component which is a structural element of a product on the basis of product trouble information and product production result information which are generated in the market and a trouble occurrence rate and a trouble increase rate in each prescribed period is calculated in each module or each component and provided. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention makes it possible to clarify the quality of products by clarifying development issues and design issues from product planning to development stage based on information on defects and failures in the period from product planning to production stage and market distribution stage. The present invention relates to a module failure information providing apparatus and method for enhancing the module failure.

  When a product defect occurs in a mass-produced product, whether the product defect has continuously occurred in multiple products from the beginning of the sale to the current state, or many defects have occurred at the beginning of the sale Is the occurrence of defects in the current modules and parts replaced by product repairs performed to eliminate the defects that occurred, or the occurrence of defects was low at the start of sales, but gradually It is necessary to investigate whether the occurrence of defects is increasing.

  According to the prior art, defect information from customers is ranked in a time series for each product on the market, for example, by calculating a cumulative value of the number of occurrences and the amount of occurrence. By listing the priority countermeasure items that should be addressed at the top, calculating the cumulative value after the countermeasures have been implemented for the listed priority countermeasure items, and comparing with the cumulative value before the countermeasure, It is possible to verify whether or not there is a predetermined effect (see, for example, Patent Document 1).

JP 2001-109736 A

  In order to design and manufacture various products in a short period of time at a new product development site, first, a product is defined as a combination of a plurality of modules and parts. Next, there is an effort to standardize the function of each module and component to make it a required specification, design and produce the module and component according to the required specification, and make the product that realizes the necessary function by combining the module and component Has been done. As a result, by standardizing the connection (interface) specifications for each module and component, it is possible to replace modules with the same interface, and it is possible to shorten the design and manufacturing period by diverting modules designed and manufactured in the past. , It becomes possible to develop variations that meet the demands of various customers.

  However, even if each module or component is manufactured according to the standard interface specifications, there are combinations that are prone to malfunction and combinations that are not likely to occur depending on the combination of modules and components (note that combinations with low probability of malfunction) Is called a “combination with good compatibility”, and a combination with a high probability of malfunction is called a “combination with bad compatibility”).

  For example, interface specifications related to electrical signals often define allowable ranges such as voltage and frequency as rated values. However, the interface of each module is not exactly the same because there are matters that are not sufficiently defined in the interface specifications, such as the rising / falling speed of the signal voltage and noise characteristics. In addition, since it is impossible to test in advance whether all the combinations of modules work correctly in all situations, if a problem occurs due to the combination of modules, i.e., the condition between the modules is incompatible. There is a case.

  When considering the use of an existing module in new product development, it is necessary to examine whether a problem has occurred in the module to be used and whether a problem that has occurred in the past has been resolved.

  However, it is not possible to determine whether measures have been taken to eliminate defects that have occurred in the past by simply determining the number of occurrences and failure rates, and must track changes in the number of occurrences and changes in failure rates. Further, in product development, it is necessary to compare a plurality of modules and parts to be selected.

  Although it is possible to confirm the effect of countermeasures by comparing the cumulative number of occurrences of defects that occurred using the above-mentioned conventional technology for each fixed period, specify the modules and parts related to the problems that occurred, I do not have the means to provide.

  The object of the present invention is to provide a means for extracting a module or a part related to a failure on the basis of the failure information of a product that has occurred in the market and presenting the failure information that requires countermeasures. It is an object to provide a module defect information providing apparatus and method that supports the implementation of countermeasures.

The present invention reads out and obtains product configuration information from a storage unit that stores product configuration information including a product component and a module configured by a plurality of components of the product. Product configuration information collecting means for extracting and storing a combination of modules for each
Defect information and production results information is acquired from a storage unit that stores information on the components where a product defect has occurred and information related to the defect, as well as production result information indicating the results of producing the product. And, based on the acquired information, defect information collecting means for collecting and storing defect information for each component of the product,
The defect information for each component of the product is acquired from the defect information collecting means, and the defect increase for each predetermined period, indicating the defect occurrence rate for each predetermined period and the increasing tendency rate of the defect occurrence rate for each component of the product. A defect information extracting means for calculating a rate based on production performance information and defect information, and extracting defect information;
Defect information providing means for acquiring and providing defect information extracted by the defect information extracting means;
It is a module malfunction information provision apparatus characterized by including.

Further, in the present invention, the defect information extracting means is configured so that a defect occurs in a product from a setting date which is a date when the product is installed and a defect occurrence rate for each production date included in the production result information for each product configuration. It is the usage time until it occurs, and calculates the defect occurrence rate for each usage time of the product included in the defect information,
The defect increase rate is calculated for each production date of the product and for any given period.

Further, in the present invention, when the use time is not stored in the storage unit that stores the defect information, the defect information collection means is a product of the same model as the product that does not store the use time, For the product in which the usage time is stored, the sum of the usage time for each unit is divided by the total difference between the failure occurrence date and the installation date included in the failure information obtained for each unit. Calculate the average daily usage time,
Multiplying the difference between the failure occurrence date and the installation date for each unit by the calculated average daily usage time to calculate the estimated usage time of the product, and using the estimated usage time instead of the usage time Features.

In the present invention, when the storage unit that stores the defect information stores installation date missing information that is defect information that does not include the installation date, the defect information collecting means stores the defect information. Only the defect information including the same model and the installation date as the model included in the installation date missing information is acquired from the storing unit, and the difference between the installation date and the production date for each product from the acquired defect information. To calculate the average distribution period by dividing the total obtained by the total number of acquired defect information,
The estimated installation date of the product is calculated from the calculated average distribution period and the sum of the production dates included in the installation date missing information, and the estimated installation date is used instead of the installation date.

Further, in the present invention, the defect information extraction means calculates a priority order for preferentially presenting a module or a part with a small change in the defect occurrence rate and the defect increase rate,
The defect information providing means displays the defect information along with the defect information on the occurrence of a module or component based on the calculated priority.

Further, in the present invention, the defect information extraction means sets a threshold value for the defect increase rate in advance, and sets a warning flag when the defect increase rate exceeds the threshold value,
The defect information providing means displays the warning flag together with defect information.

Further, in the present invention, the storage unit that stores the defect information includes replacement part information about a module or a part that has been replaced in order to solve the problem that has occurred,
The defect information collecting means acquires the replacement part information from the storage unit that stores the defect information, and further collects and stores defect information for each replaced module or part based on the acquired information.
The defect information extraction means acquires the defect information for each replacement part of the repaired product from the defect information collection means, and indicates the defect occurrence rate and the defect increase rate for each component of the product after replacement, production record information and defect information. Based on the above, it is calculated every predetermined period.

The present invention also reads and obtains product configuration information from a storage unit that stores product configuration information including a product component and a module configured by a plurality of components of the product. Product configuration information collection process that extracts and stores a combination of modules for each model
Defect information and production results information is acquired from a storage unit that stores information on the components where a product defect has occurred and information related to the defect, as well as production result information indicating the results of producing the product. And, based on the acquired information, a defect information collecting process for collecting and storing defect information for each component of the product,
Obtain defect information for each component of the product, calculate a defect increase rate indicating the defect occurrence rate and the rate of increase in the defect occurrence rate for each component of the product based on the production result information and the defect information, A defect information extraction process for extracting information;
A defect information providing step of acquiring and providing defect information extracted by the defect information extracting step;
A module failure information providing method characterized by including:

  According to the present invention, the module defect providing device includes product configuration information collecting means, defect information collecting means, defect information extracting means, and defect information providing means.

  First, the product configuration information collecting unit reads and acquires the product configuration information from the storage unit that stores the product configuration information, and extracts and stores the combination of modules for each product model from the product configuration information.

  Next, the defect information collecting means acquires defect information and production record information from a storage unit that stores defect information and production record information. Based on the acquired information, defect information is collected for each component of the product. Collect and remember.

  Further, the defect information extracting means acquires defect information for each component of the product from the defect information collecting means, and represents the ratio of the defect occurrence rate for each predetermined period and the increasing tendency of the defect occurrence rate for each component of the product. A defect increase rate for each predetermined period is calculated based on production performance information and defect information.

  Further, the defect information providing unit acquires and provides the defect information extracted by the defect information extracting unit.

  As described above, the present invention provides a means for extracting a module or a part related to a failure based on the failure information of a product generated in the market and presenting the failure information requiring a countermeasure, thereby determining the cause of the failure. Support from implementation to implementation of countermeasures.

  As a result, an increase in the failure rate is suppressed, and the user of the present apparatus can easily verify whether or not the problem that has occurred has been resolved, and the effectiveness of the countermeasure can be confirmed. In addition, it is possible to expect the effect of preventing the occurrence of defects by knowing in advance the failure information that occurs in the combination of modules and parts adopted in new development, and using it as a material for determining whether or not to adopt modules and parts. .

  Further, according to the present invention, the defect information extracting means detects a defect from the installation date that is the date of product installation and the defect occurrence rate for each product date included in the production performance information for each product configuration. Calculates the defect occurrence rate for each usage time of the product included in the defect information, and the defect increase rate for each production date of the product and for every fixed period. .

  As described above, by calculating the defect occurrence rate for each production date and usage time of the product and the defect increase rate for each production period and for any given period for the modules and parts employed in the new development, It is possible to easily estimate and determine a change in a failure occurring in a module or part, and it can be applied to quality control of a market product for the purpose of monitoring the quality of the market product and quickly responding to the failure.

  Further, according to the present invention, when the use time is not stored in the storage unit that stores the defect information, the defect information collection means is a product of the same model as the product that does not store the use time. For the product in which the usage time is stored, the sum of the usage time for each unit is divided by the sum of the difference between the failure occurrence date and the installation date included in the failure information obtained for each unit. Calculate the average daily usage time. Further, the estimated usage time of the product is calculated by multiplying the difference between the failure occurrence date and the installation date for each product not including the usage time information by the calculated average daily usage time, The estimated usage time is used instead of the usage time.

  As described above, even when the usage time is not obtained, the estimated usage time of the product can be calculated, so that it is possible to calculate the failure occurrence rate and the failure increase rate for each usage time.

  Further, according to the present invention, when the storage unit that stores the defect information stores installation date missing information that is defect information that does not include the installation date, the defect information collection unit stores the defect Only defect information including the same model and installation date as the model included in the installation date missing information is acquired from the storage unit that stores the information, and the installation date and the production date for each product are acquired from the acquired defect information. The average distribution period is calculated by calculating the difference between the two and calculating the sum of these, and dividing the obtained sum by the total number of the acquired defect information. Further, the estimated installation date of the product is calculated from the calculated average distribution period and the sum of the production dates included in the installation date missing information, and the estimated installation date is used instead of the installation date.

  As described above, even when the usage time and the installation date are not obtained, the estimated usage time of the product can be calculated, so that it is possible to calculate the failure occurrence rate and the failure increase rate for each usage time.

Further, according to the present invention, the defect information extraction means calculates a priority order for preferentially presenting modules and parts with a small change in the defect occurrence rate and the defect increase rate,
The defect information providing means displays the information together with the defect information on the occurrence of the module or component based on the calculated priority order.

  In this way, the present invention has few occurrences of defects, or prioritizes modules or parts that have been resolved but have been resolved in the past, and information on defects that have occurred in the presented modules and parts is also included. It is possible to provide a device for presentation. Therefore, the user can determine whether or not a measure for solving a problem that occurred in the past is being implemented based on the result of tracking the transition of the number of occurrences and the change in the failure rate. In addition, since the user is displayed together with the defect information in accordance with the priority order based on the comparison result of the plurality of modules and parts to be selected, the user can select more appropriate modules and parts. Become.

  Further, according to the present invention, the defect information extracting means sets a threshold value for the defect increase rate in advance, sets a warning flag when the defect increase rate exceeds the threshold value, and the defect information providing means Is displayed together with defect information.

  As described above, when the failure increase rate exceeds a predetermined threshold value, a warning flag is displayed, so that more appropriate modules and components can be selected.

  Further, according to the present invention, the storage unit that stores the defect information includes replacement part information about a module or a part that has been replaced in order to eliminate the generated defect. The defect information collecting means acquires replacement part information from a storage unit that stores the defect information, and further collects and stores defect information for each replaced module or part based on the acquired information. The defect information extraction means acquires defect information for each replacement part of the repaired product from the defect information collection means, and calculates the defect occurrence rate and the defect increase rate for each component of the product after replacement based on the production result information and defect information. And calculated for each predetermined period.

  As described above, since the failure occurrence rate and the failure increase rate are calculated for each predetermined period for the modules and parts exchanged to eliminate the failure that has occurred, the user can determine whether or not the failure has been resolved. This makes it possible to easily verify the effectiveness of the measure.

  According to the present invention, the module defect providing method includes a product configuration information collecting step, a defect information collecting step, a defect information extracting step, and a defect information providing step.

  First, in the product configuration information collecting step, product configuration information is read and acquired from a storage unit that stores product configuration information including a product component and a module configured by a plurality of product components. The combination of modules is extracted and stored for each product model.

  Next, the defect information collection step includes a storage unit that stores defect information including information on a component in which a defect of the product has occurred and information related to the defect, and production record information indicating a record of producing the product. The defect information and the production result information are acquired, and the defect information is collected and stored for each component of the product based on the acquired information.

  In addition, the defect information extraction process acquires defect information for each component of the product, and calculates the defect occurrence rate and the increase rate of the defect occurrence rate for each component of the product, the production performance information and the defect information. To calculate defect information.

  Further, the defect information providing step acquires and provides the defect information extracted by the defect information extraction step.

  In this way, the present invention provides a means for extracting the modules and parts related to the failure based on the failure information of the product that has occurred in the market and presenting the failure information that requires countermeasures, thereby taking measures against the cause investigation. To prevent the failure rate from increasing. In addition, the user can easily verify whether or not the problem caused by the present invention has been resolved, and the effectiveness of the countermeasure can be confirmed. In addition, since the user can know in advance the failure information that occurs in the combination of modules and parts adopted in new development, the effect of preventing the occurrence of defects by using it as a material for determining whether modules or parts can be adopted Can also be expected.

The present invention will be described in more detail with reference to the accompanying drawings.
[First Embodiment]
FIG. 1 is a diagram showing a schematic configuration of functions of a module failure information providing apparatus 10 according to the first embodiment of the present invention. The module defect information providing apparatus 10 includes a product information collecting function 11 that is a product configuration information collecting unit, a defect information collecting function 12 that is a defect information collecting unit, a defect information extracting function 13 that is a defect information extracting unit, and a defect information providing unit. The defect information providing function 14 is included.

  The module defect information providing apparatus 10 stores product configuration information including product functions, parts that are components constituting the product to realize the functions, and modules configured by a plurality of components. Product configuration information database 15, defect information database 16 that stores defect information that indicates a defect of a product that has occurred, sales record database 17 that stores sales record information that represents the results of selling products, and production that represents the results of producing products A production performance database 18 for storing performance information is connected so that data communication is possible. Further, for example, a terminal device 19 such as a personal computer is connected so that data communication is possible.

  Product configuration information, defect information, production performance information, and sales performance information need only be stored in a storage unit that is a storage device such as a disk device, and is not necessarily a database. The communication path 20a, the communication path 20b, the communication path 20c, the communication path 20d, and the communication path 20e may be a communication path or a communication cable configured by, for example, a LAN (Local Area Network), an intranet, or the Internet, Hereinafter, these are collectively referred to as a communication path 20.

  The common module failure information management apparatus 10 includes, for example, a CPU (Central Processing Unit), a memory section including a semiconductor memory that stores a program to be executed by the CPU and information processed by the CPU, and a database via the communication path 20. And a communication unit that transmits / receives information to / from the CPU and transfers information to / from the CPU. Further, the user inputs information to the module defect information providing apparatus 10 from the terminal apparatus 19 such as a personal computer via the communication path 20e.

  The module combination information collecting function 11, the defect information collecting function 12, the defect information extracting function 13, and the defect information providing function 14 are functions realized by causing the CPU to execute a program stored in the memory unit.

  The product configuration information collection function 11 serving as product configuration information collection means has a product configuration information storage unit, and acquires and stores product configuration information. That is, when the product configuration information collection function 11 receives information from the terminal device 19 such as a personal computer via the communication path 20 e to instruct the module defect providing device 10 to start processing, the product configuration information collection function 11 receives the product from the product configuration information database 15. Product configuration information such as a module that is a structural unit that constitutes a module and a component that is a constituent element that constitutes the module is acquired and stored.

  The defect information collection function unit 12 which is a defect information collecting unit has a defect information storage unit, collects defect information for each product configuration and product production result information, and calculates product usage time information. The defect information collection function 12 is connected to the defect information database 16, the production record database 17, and the sales record database 18 through communication paths 20a, 20b, and 20c, respectively. The defect information collection function 12 includes defect information from the defect information database 16, production numbers for each production date from the production result database 17, production dates for production of defective products, and sales numbers for each sale date from the sales result database 18. Respectively. Based on the acquired information, after collecting defect information for each component of the product, calculate the usage time until the defect occurs in the product, and store the product production date and product usage time in association with the defect that occurred. .

  The defect information extraction function 13 serving as defect information extraction means includes a defect occurrence rate and defect increase rate calculation unit and a priority calculation unit, and calculates a defect occurrence rate for each product configuration and a defect increase rate for each product configuration. Further, the priority order is calculated for modules and parts from those having a small change in failure occurrence rate and failure rate increase rate. That is, the defect information extraction function 13 acquires defect information, product production record information, and product usage time information associated with each product component from the defect information collection function unit 12, and the production date and use for each product component. A defect increase rate indicating a defect occurrence rate in time and an increasing tendency rate of the defect occurrence rate is calculated and stored for each product component.

  Further, the priority order is calculated and stored from modules and parts having a low failure occurrence rate and a failure increase rate.

  The defect information providing function unit 14 serving as defect information providing means has a defect information display unit for acquiring and providing defect information extracted by the defect information extracting function 13. When information on a target module or part is received from a terminal device (for example, a personal computer) connected via a communication path, the fault information extracted by the fault information extraction function 13 is acquired, and the target module or part is acquired. Based on the order of priority, the problem occurrence rate and the problem increase rate are low, and are transmitted to the terminal device 19 and displayed together with the defect information.

  FIG. 2 is a diagram showing details of the product configuration information stored in the product configuration information database 15 shown in FIG. In FIG. 2, “1) Model” column indicates the name of the product type, “2) Function” column indicates the function or role required to realize the required specifications of the product, and “3) Module” column. In the “4) Parts” column for each component of the product such as the main board, that is, for each configuration, management part identification information for each product that is attached to each component that is a component constituting the module, and “5” In the “) Part code” column, a unique in-house management code assigned to a component part is shown.

  In FIG. 2, for example, the function “power” and the function “analog” are shown for the model “AA”, and the module “AC adapter” and the module “inverter board” are shown for the function “power”. For the function “analog”, the module “sound” is shown. Furthermore, a component “AC adapter” is indicated for the module “AC adapter”, a component “IC101” and a component “IC102” are indicated for the module “inverter board”, and a component “AC adapter” is indicated. The part code “UADP-A1111WJP” is shown, and the part code “IC-PQ1011WJZZ” is shown for the part “IC101”.

  The product configuration information includes at least 1) model, 3) module, 4) part, and 5) part code.

  FIG. 3 is a diagram showing details of the defect information stored in the defect information database 16 shown in FIG. FIG. 3 shows an example of the content shown in the “example of content” column in association with the item number and the item shown in the “item” column. Each item will be described below in the order of item numbers. “1) ID” is a management defect identification information assigned to uniquely identify a defect. “2) Reception No.” is a number for the repair person to manage. “3) Date of reception. “4” “model” is the name indicating the type of product, “5) serial number” is a product-specific number assigned to uniquely identify the product, “6” ") Date of occurrence" is the date on which the defect occurred, "7) User declaration details" is the details of the content that the customer explained about the product defect, and "8) Symptom code" is the product defect The code representing the feature, “9) phenomenon name”, is a word representing the feature of the product defect, and corresponds to the phenomenon code on a one-to-one basis.

  FIG. 4 is a diagram illustrating an example of a failure phenomenon and a code in the market. In FIG. 4, “1) Phenomenon major category” column is a major category item of product defect characteristics, “2) Phenomenon during phenomenon” column is a middle category item of product defect characteristics, and “3) Phenomenon code”. In the column, codes representing the above-mentioned product failure characteristics are shown. “8) Phenomenon code” in FIG. 3 can be derived from “3) Phenomenon code” in FIG. 4, and “9) Phenomenon in FIG. The “name” can be derived from “2) Phenomenon during phenomenon” in FIG. In FIG. 4, for example, the phenomenon classification “power supply related” is repeated for the phenomenon classification “power does not turn on”, “power does not turn off”, “power turns off naturally”, and “power on / off” repeatedly. "," Short use time "," Charging failure "and" Other power supply related "are shown. Furthermore, the phenomenon code “1101” is assigned to the phenomenon category “power is not turned on”, the phenomenon code “1102” is assigned to the phenomenon category “power is not turned off”, and the phenomenon category “power is turned off naturally”. The phenomenon code “1103” is the phenomenon code “1104” for the phenomenon classification “repeating power ON / OFF”, the phenomenon code “1701” for the phenomenon classification “short use time”, The phenomenon code “1702” is shown for the phenomenon category “charge failure”, and the phenomenon code “1199” is shown for the phenomenon category “other power-related”.

  Referring to FIG. 3, “10) Phenomenon details” is the details of the contents of the defect confirmed by the repair person, “11) Installation date” is the date when the product was installed at the customer's place, and “12) Occurs. "Place" is the board or part where the failure occurred, "13) Part" is the part identification information for management in the product unit attached to each part which is a component constituting the module, and "14) Part code" Is a unique in-house management code assigned to a component part, “15) Cause code” is a code that indicates the characteristics of the cause estimated by the repair person, and “16) Cause” It is a word that expresses the characteristics of the cause estimated by the person in charge of repair, and corresponds to the cause code on a one-to-one basis. “17) Cause details” is the details of the cause estimated by the repair person, “18) Usage time” is the time the product was used, and “19) Repair contents” is the repair performed by the repair person. “20) Repair completion date” is the date of completion of repair.

  In the example of the contents corresponding to each item shown in FIG. 3, the ID is “AA112234455”, the reception No. Is “X123456”, the reception date is “2005050110”, the model is “AA”, the serial number is “SH1334455”, the date of occurrence is “20050108”, and the user declaration content is “sudden screen “No longer appears.”, Phenomenon code is “1001”, phenomenon name is “Power does not turn on”, phenomenon details are “Even if you press the power button ...”, installation date is “20041225”, and the location is “Power supply unit”. Furthermore, the part is “IC101”, the part code is “IC-PQ1011WJZZ”, the cause code is “Z03”, the cause is “solder failure”, the cause details are “solder ...”, and the usage time is “102H” The repair contents are “power supply board replacement”, and the repair completion date is “20050112”.

  The defect information includes at least 1) ID, 4) model, 5) serial number, 6) date of occurrence, 11) installation date or 18) use time, and 13) part or 14) part code.

  FIG. 5 is a diagram showing details of the production result information stored in the production result database 17 shown in FIG.

  In FIG. 5, “1) Date of production” indicates the date when the product was produced, “2) Model” field indicates the name of the product type, and “3) Serial number” indicates the product uniquely. The product-specific number assigned for identification and the “4) Number of units produced” column show the number of products produced on the date of production.

  FIG. 5 shows, for example, the model “AA”, the start number “SH1331011” and the end number “SH1331450”, and the production number “350” in the production number for the production date “20051110”.

  FIG. 6 is a diagram showing the details of the sales record information stored in the sales record database 18 shown in FIG.

  In FIG. 6, “1) Date of sale” column indicates the date on which the product was sold, “2) Model” column indicates the name of the product type, and “3) Unit sales” column indicates that the product is sold. The number of products sold as of the year and month, “4) Production number” column indicates the product-specific number of the sold product.

  FIG. 6 shows, for example, the model “AA”, the number of units sold “285”, and the serial numbers “SH1331101, SH1331102,...” For the sales date “20051115”.

  FIG. 7 is a flowchart showing a processing procedure processed by the product configuration information storage unit of the product configuration information collection function 11 shown in FIG. When information for instructing the start of processing is input from the terminal device 19 such as a personal computer to the common module defect management device 10 via the communication path 20e, the process enters step S1.

  Information for instructing the start of processing includes modules and parts to be developed and examined, target usage time of modules and parts, a target period of defect occurrence rate, a target period of defect increase rate, and the like. When the information is input, the information is stored in a storage unit (not shown).

  In step S1, information on 1) model, 3) module, 4) component, and 5) component code is acquired from the product configuration information database 15 outside the apparatus.

  In step S2, the types of modules used and the parts constituting the modules are extracted for each product model.

In step S3, the product configuration information extracted in step S2 is stored.
FIG. 8 is a flowchart illustrating a processing procedure in which the defect information storage unit of the defect information collection function 12 illustrated in FIG. 1 collects defect information. After the processing of the flowchart of FIG. 7 showing the processing procedure to be processed by the product configuration information collection function 11, the process proceeds to step T1.

  In step T1, information on 1) model, 3) module, 4) component, and 5) component code is acquired from the product configuration information database 15 outside the apparatus.

  In addition, processing time can be shortened by acquiring these information from the structure information memorize | stored in FIG.7 S3.

  In step T2, next, defect information is acquired from the defect information database 16 outside the apparatus.

  In step T3, the ID, model, serial number, occurrence location, part or part code, installation date, and usage time are extracted from the acquired defect information.

  In step T4, the product configuration information acquired in step T1 is searched using the model and occurrence location, part or part code extracted in step T3 as keys, and the module to which the extracted part code belongs is specified.

  In step T5, the date of production is acquired from the production result database 17 using the model and serial number extracted in step T3 as keys.

  In step T6, the sales date and the number of units sold are acquired from the sales record database using the model extracted in step T3 as a key.

  In step T7, it is determined whether or not the usage time information has been extracted from the defect information database 16 in step T3. That is, if it is determined that “18) Usage time” in the defect information shown in FIG. 3 is blank and cannot be extracted, the process proceeds to step T8. If it is determined that there is usage time information and it has been extracted, the process proceeds to step T11.

  In step T8, it is determined whether or not the installation date has been extracted from the defect information database 16 in step T3. That is, if it is determined that “11) Installation date” in the defect information shown in FIG. 3 is blank and could not be extracted, the process proceeds to step T9. If it is determined that there is an installation date and it has been extracted, the process proceeds to step T10.

In step T9, first, an average distribution period is obtained, and an installation date is estimated from the production date and the average distribution period.
Only defect information including the same model and installation date as the model included in the defect information that does not include the installation date is acquired from the storage unit that stores the defect information.
Average distribution period (days) = W1 / W2
W1 is the total difference between the installation date and the production date for each product in the acquired defect information.
W2 is the total number of acquired defect information.
Estimated installation date = production date + average distribution period

Step T10 first obtains the average daily usage time of the product whose usage time is stored in the storage unit for storing the failure information among the corresponding models, and calculates the difference between the failure occurrence date and the installation date, and one Estimate the usage time from the average daily usage time. Here, when there is no installation date in the defect information, the estimated installation date calculated in step T9 is used.
Average daily usage time (hours) of products for which usage time is stored = W3 / W4
W3 is the total usage time of the corresponding model,
W4 is the sum total of (the date of failure of the corresponding model-installation date).
Estimated usage time (hours) = (Defect occurrence date-Installation date) x Average daily usage time of the model

  Step T11 associates defect information generated on modules and parts, production date, and usage time. Here, when there is no usage time in the defect information, the estimated usage time calculated in step T10 is used.

  FIG. 9 is a diagram illustrating an example in which a module and a defect information that has occurred are associated with each other on a model basis. Each item will be described below in the order of item numbers.

  “1) Model” is a name indicating the type of product, “2” Module is a product unit such as a main board, and “3) Defect information ID” is used to uniquely identify the defect information that has occurred. The management identification number is the same as the ID stored in the defect information database 16 of FIG. “4) Phenomenon code” is a code that represents the feature of a product defect, and is the same as the phenomenon code stored in the defect information database 16 of FIG. “5) Part” is a component identification information for management in a product unit attached to each part which is a component constituting the module, and “6) Part code” is attached to the part which is a component. Unique internal management code, “7) Production date” is the date when the product was produced, “8) Usage time” is the time the product was used, and “9) Occurrence date” is the product The date when the defect occurred, “10) Installation date” is the date when the product was installed at the customer's place.

  Examples of contents corresponding to the items shown in FIG. 9 are: “AA” for the model, “AC adapter” for the module, “AA112234455” for the defect information ID, “1101” for the phenomenon code, The “AC adapter”, the part code is “UADP-A1111WJP”, the production date is “20050822”, the usage time is “130 hours”, the occurrence date is “20051220”, and the installation date is “20051029”.

  Referring to FIG. 8, in step T12, the defect information associated with the module and the part in step T11 is stored in the defect information storage unit as defect collection information.

  FIG. 10 is a flowchart showing a processing procedure in which the defect occurrence rate and defect increase rate calculation unit of the defect information extraction function 13 shown in FIG. 1 calculates the defect occurrence rate and the defect increase rate for each product configuration. After the processing of the flowchart of FIG. 8 showing the processing procedure processed by the defect information collection function 12 is completed, the process proceeds to step U1.

  In step U1, a module or component to be developed or examined, a target usage time of the module or component, a target period of the defect occurrence rate, a target period of the defect increase rate, and the like are acquired from a storage unit (not shown).

  Step U2 classifies defects occurring in each module or component based on the defect information acquired from the defect information collection function 12.

  FIG. 11 is a diagram illustrating an example in which defects occurring in units of modules and parts are classified. Each item will be described below in the order of item numbers. “1) Module” is a unit of the product such as the main board, “2) Model” column indicates the name of the product type, and “3) Defect information ID” uniquely identifies the defect information that has occurred. Is the same as the ID of the defect information database 16 in FIG. “4) Part” is a part identification information for management in units of products attached to each part which is a component constituting the module, and “5) Part code” is attached to the part which is a component. A unique in-house management code, “6) Production date” is the date when the product was produced, and “7) Usage time” is the time when the product was used.

  The example of the contents corresponding to each item shown in FIG. 11 is that the module is “AC adapter”, the model is “AA”, the defect information ID is “AA112234455”, the part is “AC adapter”, and the part code is “UADP-A1111WJP”, the production date is “20051122”, and the usage time is “130 hours”.

  Referring to FIG. 10, step U3 totals the number of occurrences of defects that occurred every production date and every use time for the defect information classified at step U2. In addition, the usage time is categorized and tabulated as an arbitrarily set time width, for example, less than 10 hours, 10 hours to less than 100 hours, and so on. Moreover, the defect information extraction function 13 can graph the above-mentioned total result.

  FIG. 12 is a diagram showing an example in which the number of trouble occurrences counted in step U3 is represented in a graph for a certain module. In this example, the number of occurrences for each usage time on each day for 14 days is shown, and the usage time is classified into less than 10 hours, 10 hours to less than 100 hours,. Each phenomenon code is color-coded.

  Referring to FIG. 10, in step U4, the actual production quantity by production date is obtained from the production achievement database using the “model” key in FIG. 11 aggregated in step U2.

In step U5, the defect occurrence rate for each production date and use time is calculated using the number of occurrences of defects for each production date and usage time collected in step U3 and the actual number of productions acquired in step U4.
Defect occurrence rate (PPM) = W5 / W6 × 10 ⁶
W5 is the number of occurrences and W6 is the actual number of production.

  FIG. 13 is a diagram illustrating an example in which a failure occurrence rate is calculated for each production date and each usage time in module units. Each item will be described below in the order of item numbers. “1) Module” is a structural unit of a product such as a main board, “2) Production date” is a date when the product is produced, “3) Usage time” is a time when the product is used, “4” ) “Problem occurrence rate” is the ratio of the number of occurrences of failure divided by the actual number of units produced, and the unit is PPM.

  Examples of contents corresponding to the items shown in FIG. 13 are “AC adapter” for the module, “20051122” for the production date, “less than 10 hours”, and “20 PPM” for the occurrence rate.

  FIG. 14 is a diagram illustrating an example in which the defect information extraction function 13 represents a defect occurrence rate calculated in step U5 in a graph for a certain module. In this example, the failure occurrence rate at each usage time for each month from April to September is shown, and the colors are classified by phenomenon code.

Referring to FIG. 10, in step U6, in the defect occurrence rate calculated in step U5, as the defect increase rate indicating the rate of increase in the defect occurrence rate, for example, the defect occurrence rate for the past year for the past year A ratio between the defect occurrence rate in an arbitrary fixed period and the defect occurrence rate in a past fixed period from the arbitrary fixed period, such as the defect occurrence rate and the current month defect occurrence rate with respect to the defect occurrence rate of the previous month, is calculated.
Defect increase rate (%) = (W7 / W8) × 100
Note that W7 is an occurrence rate in an arbitrary fixed period, and W8 is an occurrence rate in a past fixed period.

  FIG. 15 is a diagram showing an example in which the defect information extraction function 13 for a module calculates the defect increase rate of the defect occurrence rate for each month from April to September with respect to the same month of the previous year as a graph. It is.

Step U7 stores the failure occurrence rate and failure increase rate of the module or component.
FIG. 16 is a flowchart showing a processing procedure in which the priority order calculation unit of the defect information collection function 13 shown in FIG. After the processing of the flowchart of FIG. 10 showing the processing procedure for the failure information extraction function 13 to calculate the failure occurrence rate and the failure increase rate, the process proceeds to step V1.

  Step V1 obtains the calculated failure occurrence rate and failure increase rate of the module or component from the failure occurrence rate and failure increase rate calculation unit.

  In step V2, points that are proportional to the rank are set in order from the modules having the lowest defect occurrence rate for each module or component. For example, 1st place is 1 point, 2nd place is 2 points, 3rd place is 3 points ...

  In step V3, points are set in order from the smallest failure increase rate in the same manner as in step V2 for the acquired failure increase rate for each module or component. Note that a threshold value may be set in advance for the defect increase rate, and a warning flag may be set if the defect increase rate exceeds the threshold value.

  In step V4, the points set in step V2 and step V3 are added together, and the order of display from the modules and components having few points is set. In addition, when the order of only the defect occurrence rate or the defect increase rate is required, the rank is set from the modules or parts having few points without adding the points.

  Step V5 stores the order determined in step V4 together with the defect collection information acquired from the defect information collection function 12. When the warning flag is set, the flag is stored together with the rank as a flag indicating that the defect increase rate exceeds the threshold.

  The defect information display unit of the defect information providing function 14 in FIG. 1 acquires the defect information extracted by the defect information collecting function 13, that is, the defect occurrence rate by product configuration, the increase rate of the defect occurrence rate, and the priority order.

  At the start of processing, among the modules and parts specified in the terminal device 19, the modules and parts with a low failure occurrence rate and a failure increase rate are determined according to the order set by the priority order calculation unit of the failure information extraction function 13. It is displayed on the display of the terminal device 19. In addition, other defect information such as a component, a component code, and a phenomenon of a failure occurring in the target period is also displayed.

  FIG. 17 is a diagram illustrating an example in which the module “AC adapter” is displayed on the display of the terminal device 19 in accordance with the priority order set from the calculation results of the defect occurrence rate and the defect increase rate. In this example, when the module is an AC adapter, the modules are displayed in the order in which they are set in the AC adapter that is a component constituting the AC adapter. Further, in this example, the phenomenon name corresponding to the phenomenon code is also output from the defect information collection function 12 for reference. Each item will be described below in the order of item numbers.

  “1) Module” is a structural unit of a product such as a main board, etc. “2) Parts” is management part identification information for each product attached to each part that is a component constituting the module, “3) “Part code” is a unique internal management code assigned to the component component, and “4) Order” is the priority of modules and parts set from the one with the lowest occurrence rate and increase rate. The rank, “5) Flag” is a flag indicating that the defect increase rate exceeds the threshold value, and “1” is displayed when it exceeds the threshold value. “6) Phenomenon code” is a code that represents the feature of a product defect, and is the same as the phenomenon code stored in the defect information database 16 of FIG. “9) Phenomenon name” is a word that represents a feature of a product defect, and corresponds to the phenomenon code on a one-to-one basis.

  The example of the contents corresponding to each item shown in FIG. 17 is that the module is “AC adapter”, the part is “AC adapter”, the part code is “UADP-A1111WJP”, the rank is “1”, and the flag is “ “None”, the phenomenon codes are “1101” and “1103”, the phenomenon name “1101” is the phenomenon name “the power is not turned on”, and the phenomenon code “1103” is the phenomenon name “ "The power turns off naturally."

  In addition, information as shown in the graph of the number of fault occurrences in FIG. 12, the example of calculating the fault occurrence rate in FIG. 13, the graph of the fault occurrence rate in FIG. 14, and the fault increase rate graph in FIG. It is also possible to display on the display.

  In the present embodiment, the defect information providing function 14 transmits the defect information to the terminal device 19 connected via the communication path 20 and displays it on the display. However, the module information management apparatus 10 includes a display unit. Thus, it is possible to display the defect information on the display of the module information management apparatus 10.

  According to the present invention, when selecting a module or a part, not only the number of occurrences of defects, but also a module and parts with a low defect occurrence rate and a failure increase rate, that is, with a low occurrence of defects and stable can be easily selected. Therefore, it is possible to confirm the contents of the troubles occurring in advance, and it is easy to examine the assumed troubles in advance, and it is possible to improve the quality in product development.

[Second Embodiment]
In the second embodiment, the defect information database 16 also stores replacement part information about modules and parts that have been replaced in order to eliminate a problem that has occurred.

  The defect information collection function 12 collects and stores defect information for each replaced module or component from the defect information database 16.

  The defect information extraction function 13 acquires the defect information for each replacement part of the repaired product from the defect information collection function 12, and determines the defect occurrence rate and the defect increase rate for each component of the product after the replacement in the first embodiment. Calculate in the same way as the form.

  The defect information providing function 14 acquires the defect occurrence rate, the increase rate of the defect occurrence rate and the priority for the replaced module or part from the defect information collecting function 13, and the phenomenon of the defect that occurred in the target period according to the priority order. In addition, other defect information such as a phenomenon code is transmitted to the terminal device 19 and displayed on the display of the terminal device 19.

  As described above, since the failure occurrence rate and the failure increase rate are calculated every predetermined period for the modules and parts exchanged to eliminate the failure that has occurred, whether or not the failure that has occurred has been resolved. Verification is possible easily.

It is a figure which shows the structure of the outline of the function of the module malfunction information provision apparatus 10 which is one Embodiment of this invention. It is a figure which shows the detail of the product structure information memorize | stored in the product structure information database. It is a figure which shows the detail of the defect information memorize | stored in the defect information database 16. FIG. It is a figure which shows an example of the malfunction phenomenon and code | symbol in a market. It is a figure which shows the detail of the production performance information memorize | stored in the production performance database. It is a figure which shows the detail of the sales performance information memorize | stored in the sales performance database. 6 is a flowchart showing a processing procedure processed by a product configuration information storage unit of the product configuration information collection function 11; It is a flowchart which shows the process sequence which the defect information storage part of the defect information collection function 12 collects defect information. It is a figure which shows the example which linked | related the defect information which generate | occur | produced with the module in the model unit. It is a flowchart which shows the process sequence in which the malfunction occurrence rate and malfunction increase rate calculation part of the malfunction information extraction function 13 calculates the malfunction occurrence rate and malfunction increase rate according to product composition. It is a figure which shows the example which classified the malfunction which generate | occur | produced in the module or component unit. It is the figure which showed the example which represented the total number of malfunction occurrence about a module on the graph. It is a figure which shows the example which calculated the malfunction occurrence rate for every production day and every usage time in the module unit. It is the figure which showed the example which represented the malfunction occurrence rate calculated about a certain module on the graph. It is the figure which showed the example which represented on the graph the result of having calculated the malfunction increase rate with respect to the same month the previous year of the malfunction occurrence rate for every month from April to September. It is a flowchart which shows the process sequence which the priority order calculation part of the malfunction information collection function 13 performs prioritization. It is the figure which showed the example displayed on the display of the terminal device 19 about the module "AC adapter" according to the priority set from the calculation result of a malfunction occurrence rate and a malfunction increase rate.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 Module defect information provision apparatus 11 Product structure information collection function 12 Defect information collection function 13 Defect information extraction function 14 Defect information provision function 15 Product structure information database 16 Defect information database 17 Production performance database 18 Sales performance database 19 Terminal device

Claims (8)

Product configuration information is read out and acquired from a storage unit that stores product configuration information including a product component and a module configured by a plurality of components of the product. Product configuration information collecting means for extracting and storing a combination of
Defect information and production results information is acquired from a storage unit that stores information on the components where a product defect has occurred and information related to the defect, as well as production result information indicating the results of producing the product. And, based on the acquired information, defect information collecting means for collecting and storing defect information for each component of the product,
The defect information for each component of the product is acquired from the defect information collecting means, and the defect increase for each predetermined period, indicating the defect occurrence rate for each predetermined period and the increasing tendency rate of the defect occurrence rate for each component of the product. A defect information extracting means for calculating a rate based on production performance information and defect information, and extracting defect information;
Defect information providing means for acquiring and providing defect information extracted by the defect information extracting means;
A module defect information providing apparatus comprising: The defect information extraction means includes, for each product configuration, the defect occurrence rate for each production date of the product included in the production performance information and the usage time from the installation date, which is the date of product installation, to the occurrence of the defect in the product. And calculating the defect occurrence rate for each usage time of the product included in the defect information,
2. The module failure information providing apparatus according to claim 1, wherein a failure increase rate is calculated for each production date of the product and for each predetermined period. When the use time is not stored in the storage unit that stores the defect information, the defect information collection means stores the use time among products of the same model as the product that does not store the use time. The average usage time per day is calculated by dividing the total usage time for each product by the sum of the difference between the failure occurrence date and the installation date included in the failure information obtained for each device. To calculate
Multiplying the difference between the failure occurrence date and the installation date for each unit by the calculated average daily usage time to calculate the estimated usage time of the product, and using the estimated usage time instead of the usage time The module failure information providing apparatus according to claim 1 or 2, characterized in that In the storage unit that stores the defect information, when the installation date missing information that is the defect information that does not include the installation date is stored, the defect information collection unit, from the storage unit that stores the defect information, Obtain only the defect information including the same model and installation date as the model included in the installation date missing information, and calculate the difference between the installation date and the production date for each product from the acquired defect information Calculate the average distribution period by calculating the total sum and dividing the total obtained by the total number of the acquired defect information.
The estimated installation date is calculated from the calculated average distribution period and the sum of the production dates included in the installation date missing information, and the estimated installation date is used instead of the installation date. Module defect information providing device. The defect information extraction means calculates a priority order for preferentially presenting a module or a part with a small change in the defect occurrence rate and the defect increase rate;
5. The module failure according to claim 1, wherein the failure information providing means displays the failure information providing means together with failure information on occurrence of a module or a component based on the calculated priority. Information providing device. The defect information extracting means sets a threshold value for the defect increase rate in advance, and sets a warning flag when the defect increase rate exceeds the threshold value,
The module defect information providing apparatus according to claim 1, wherein the defect information providing unit displays the warning flag together with the defect information. The storage unit that stores the defect information includes replacement part information about a module or a part that has been replaced in order to solve the problem that has occurred,
The defect information collecting means acquires the replacement part information from the storage unit that stores the defect information, and further collects and stores defect information for each replaced module or part based on the acquired information.
The defect information extraction means acquires the defect information for each replacement part of the repaired product from the defect information collection means, and indicates the defect occurrence rate and the defect increase rate for each component of the product after replacement, production record information and defect information. The module failure information providing apparatus according to any one of claims 1 to 6, wherein the module malfunction information is calculated for each predetermined period. Product configuration information is read and acquired from a storage unit that stores product configuration information including a product component and a module configured by a plurality of components of the product, and the module is determined for each product model from the product configuration information. A product configuration information collection process for extracting and storing combinations of
Defect information and production results information is acquired from a storage unit that stores information on the components where a product defect has occurred and information related to the defect, as well as production result information indicating the results of producing the product. And, based on the acquired information, a defect information collecting process for collecting and storing defect information for each component of the product,
The defect information for each component of the product is acquired, and the defect increase rate for each predetermined period representing the defect occurrence rate for each predetermined period and the increasing tendency rate of the defect occurrence rate for each product configuration, the production result information A defect information extraction step for calculating the defect information and extracting the defect information;
A defect information providing step of acquiring and providing defect information extracted by the defect information extracting step;
A module defect information providing method comprising:

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